John Deere Powertech 4.5L & 6.8L Diesel Engines Level 1 Electronic Fuel With Delphi DP201 Pump Technical Manual – PDF DOWNLOAD
FILE DETAILS:
John Deere Powertech 4.5L & 6.8L Diesel Engines Level 1 Electronic Fuel With Delphi DP201 Pump Technical Manual – PDF DOWNLOAD
Language : English
Pages : 268
Downloadable : Yes
File Type : PDF
Size: 4.07 MB
TABLE OF CONTENTS:
John Deere Powertech 4.5L & 6.8L Diesel Engines Level 1 Electronic Fuel With Delphi DP201 Pump Technical Manual – PDF DOWNLOAD
CTM284 22JUL15
Contents 3
General 5
Safety 7
Handle Fluids Safely — Avoid Fires 7
Handle Starting Fluid Safely 7
Service Cooling System Safely 7
Prevent Battery Explosions 8
Prepare for Emergencies 8
Handling Batteries Safely 8
Avoid High-Pressure Fluids 9
Wear Protective Clothing 10
Service Machines Safely 10
Work In Ventilated Area 10
Work in Clean Area 11
Remove Paint Before Welding or Heating 11
Avoid Heating Near Pressurized Fluid Lines 11
Illuminate Work Area Safely 12
Use Proper Lifting Equipment 12
Construct Dealer-Made Tools Safely 12
Practice Safe Maintenance 13
Use Proper Tools 13
Dispose of Waste Properly 14
Live With Safety 14
Engine Identification 15
Engine Model Designation 15
Engine Serial Number Plate Information 16
Engine Application Chart 17
Fuels 19
Lubricants and Coolant 19
Diesel Fuel 19
Diesel Fuel Additive Products 19
Bio-Diesel Fuel 20
Lubricity of Diesel Fuel 20
Repair and Adjustments 21
Electronic Fuel System Repair and Adjustments 23
Fuel System — General Information 23
Relieve Fuel System Pressure 23
Remove and Install Final Fuel Filter/Water Separator Base 23
Final Fuel Filter Assembly 25
Replace Final Fuel Filter/Water Separator 26
Remove Fuel Injection Pump 27
Repair Fuel Injection Pump 29
Install Fuel Injection Pump 29
Fuel Injection Pump Timing 31
Remove Fuel Injection Nozzles 32
Clean Fuel Injection Nozzle Bore 33
Clean Fuel Injection Nozzles 33
Diagnose Fuel Injection Nozzle Malfunction 34
Test Fuel Injection Nozzles 35
Disassemble Fuel Injection Nozzles 38
Inspect and Clean Fuel Injection Nozzle Body 40
Inspect and Clean Valve and Valve Seat 41
Inspect Valve Adjusting Mechanism 42
Assemble Fuel Injection Nozzles 43
Adjust Fuel Injection Nozzles 43
Install Seals on Fuel Injection Nozzle 46
Install Fuel Injection Nozzles 47
Electrical Engine Control Repair and Adjustment 49
Engine Control Unit (ECU) 49
Remove and Install Engine Coolant Temperature Sensor 49
Replace Engine Speed Sensor 50
Connectors 50
Use Electrical Insulating Compound 50
Using High-Pressure Washer 50
Repair Weather Pack ™ Connector 51
Remove Connector Body from Blade Terminals 52
Repair (Pull Type) Metri-Pack ® Connectors 53
Repair (Push Type) Metri-Pack ® Connectors 54
Repair Deutsch ® Connectors 56
Repair ECU Connector 58
Repair Fuel Injection Pump Connector 59
Theory of Operation 61
Electronic Fuel System Operation 63
About this Group 63
Fuel System Operation 63
Fuel Transfer Pump Operation 64
Final Fuel Filter/Water Separator Operation 65
Fuel Injection Pump Operation 66
Fuel Injection Nozzle Operation 68
Electrical Control System Operation 69
Electronic Control System Overview 69
Electronic Control System Terminology 70
Electronic Control System Operation 70
Monitoring Engine Parameters 71
Measuring Temperature 71
Measuring Throttle Position 71
Measuring Engine Speed 71
Engine Control Unit (ECU) 72
Controller Area Network (CAN) 73
Cruise Control Operation 73
Governor Droop Mode Selection 73
Engine Control Unit (ECU) Self-Diagnosis 74
Diagnostics 77
Observable Diagnostics and Tests 79
About this Group of the Manual 79
E1 – Engine Cranks/Won’t Start 80
E1 – Engine Cranks/Won’t Start Diagnostic Procedure 80
E2 – Engine Misfires/Runs Irregularly 84
E2 – Engine Misfires/Runs Irregularly Diagnostic Procedure 84
E3 – Engine Does Not Develop Full Power 88
E3 – Engine Does Not Develop Full Power Diagnostic Procedure 88
E4 – Engine Emits Excessive White Exhaust Smoke 93
E4 – Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure 93
E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke 96
E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedure 96
E6 – Engine Will Not Crank 98
E7 – Engine Idles Poorly 98
E8 – Abnormal Engine Noise 99
F1 – Fuel Supply System Check102
F1 – Fuel Supply System Check103
F1 – Fuel Supply System Check Diagnostic Procedure103
F2 – Excessive Fuel Consumption105
F3 – Fuel in Oil105
F4 – Excessive Fuel Filter Replacement105
Excessive Fuel Filter Replacement105
D1 – ECU Does Not Communicate With DST or Service ADVISOR ™108
D1 – ECU Does Not Communicate With DST or Service ADVISOR ™109
D1 – ECU Does Not Communicate With DST or SERVICE ADVISORSERVICE ADVISOR is a trademark of Deere & Company™ Diagnostic Procedure109
Using TIME TRAC ® as a Tachometer112
Check and Adjust Injection Pump Dynamic Timing112
Check Cold Start Switch Operation117
Check Cold Start Advance System Operation117
Check Light Load Advance Operation118
Test Fuel Shut-Off Solenoid118
Check Fuel Transfer Pump118
Check Fuel Supply Quality119
Test for Fuel Drain Back120
Test for Air in Fuel121
Check Fuel Supply Pressure122
Bleed the Fuel System122
Test for Cylinder Misfire (Engine Running)124
Test Fuel Injection Nozzles (Engine Running)124
Trouble Code Diagnostics and Tests125
About this Group of the Manual125
Electrical Concepts125
Using a Digital Multimeter125
Electrical Circuit Malfunctions126
Troubleshooting Circuit Malfunctions128
Connecting to Diagnostic Scan Tool (DST) or Service ADVISOR ™132
Data Parameter Description134
Engine Control Unit (ECU) — Donating this Engines’ ECU to be Used Elsewhere135
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU136
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU137
Engine Control Unit (ECU) — Reprogramming Current ECU138
Engine Control Unit (ECU) — Reprogramming Instructions139
Diagnostic Trouble Codes (DTCs)140
Listing of Diagnostic Trouble Codes (DTCs) on ECU142
Diagnostic Procedure143
Intermittent Fault Diagnostics144
00002803 — Analog Throttle (C) Input High146
00002803 — Analog Throttle (C) Input High147
00002803 Analog Throttle (C) Input High Diagnostic Procedure147
00002804 — Analog Throttle (C) Input Low150
00002804 — Analog Throttle (C) Input Low151
00002804 Analog Throttle (C) Input Low Diagnostic Procedure151
00002903 — Analog Throttle (B) Input High154
00002903 — Analog Throttle (B) Input High155
00002903 Analog Throttle (B) Input High Diagnostic Procedure155
00002904 — Analog Throttle (B) Input Low158
00002904 — Analog Throttle (B) Input Low159
00002904 Analog Throttle (B) Input Low Diagostic Procedure159
00009103 — Analog Throttle (A) Input High162
00009103 — Analog Throttle (A) Input High163
00009103 Analog Throttle (A) Input High Diagnostic Procedure163
00009104 — Analog Throttle (A) Input Low166
00009104 — Analog Throttle (A) Input Low167
00009104 – Analog Throttle (A) Input Low Diagnostic Procedure167
00009107 — Throttle Not Calibrated Properly170
00009113 — Throttle Calibration Aborted171
00011003 — Engine Coolant Temperature Input Voltage High172
00011003 — Engine Coolant Temperature Input Voltage High173
00011003 Engine Coolant Temperature Input Voltage High Diagnostic Procedure173
00011004 — Engine Coolant Temperature Input Voltage Low176
00011004 — Engine Coolant Temperature Input Voltage Low177
00011004 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure177
00019000 — Engine Overspeed179
00019002 — Engine Speed Input Noise180
00019002 — Engine Speed Input Noise181
00019002 Engine Speed Input Noise Diagnostic Procedure181
00062904 — ECU Unswitched Power Missing184
00062904 — ECU Unswitched Power Missing185
00062904 ECU Unswitched Power Missing Diagnostic Procedure185
00063913 — CAN Error186
00063913 — CAN Error – Continued187
00063913 CAN Error Diagnostic Procedure187
00081002 — Calculated Vehicle Speed Input Signal Noise190
00081002 — Calculated Vehicle Speed Input Signal Noise191
00081002 Vehicle Speed Input Signal Noise Diagnostic Procedure191
00093102 — Pump Current Instability194
00093102 — Pump Current Instability195
00093102 Pump Current Instability Diagnostic Procedure195
00093103 — Pump Current Feedback Input Voltage High198
00093103 — Pump Current Feedback Input Voltage High199
00093103 Pump Current Feedback Input Voltage High Diagnostic Procedure199
00093104 — Pump Current Feedback Input Voltage Low200
00093104 — Pump Current Feedback Input Voltage Low201
00093104 Pump Current Feedback Input Voltage Low Diagnostic Procedure201
00093115 — Pump Current Measurement Error (Engine OFF)202
00093115 — Pump Current Measurement Error (Engine OFF)203
00093115 Pump Current Measurement Error (Engine OFF) Diagnostic Procedure203
00093131 — Pump Current Not Controllable206
00093131 — Pump Current Not Controllable207
00093131 Pump Current Not Controllable Diagnostic Procedure207
00104102 — Start Signal Missing210
00104102 — Start Signal Missing211
00104102 Start Signal Missing Diagnostic Procedure211
00104103 — Start Signal Always Active214
00104103 — Start Signal Always Active215
00104103 Start Signal Always Active Diagnostic Procedure215
00106902 — Tire Size Error218
00106902 — Tire Size Error219
00106902 Tire Size Error Diagnostic Procedure219
00107903 — Sensor Supply Voltage High220
00107903 — Sensor Supply Voltage High221
00107903 Sensor Supply Voltage High Diagnostic Procedure221
00107904 — Sensor Supply Voltage Low222
00107904 — Sensor Supply Voltage Low223
00107904 Sensor Supply Voltage Low Diagnostic Procedure223
00200013 — Security Violation225
Tools and Other Materials227
Electronic Fuel/Control System Repair Tools and Other Materials229
Fuel System Repair and Adjustment Essential Tools229
Fuel System Repair and Adjustment Service Equipment and Tools231
Fuel System Repair and Adjustment Other Materials232
Control System Repair and Adjustment Essential Tools234
Control Repair and Adjustment Other Materials236
Diagnostic Service Tools237
Engine Diagnostics and Testing Procedure Tools237
Specifications241
Repair Specifications243
Electronic Fuel System Repair and Adjustment Specifications243
Electrical Engine Control Repair and Adjustment Specifications244
Diagnostic Specifications245
Fuel Injection Pump Specifications (Agricultural Applications)245
Fuel Injection Pump Specifications (OEM)248
Fuel System Diagnostic Specifications259
Torque Curve Selection259
Governor Droop Mode Selection259
Electronic Control System Wiring Diagram for 6010 Series Tractors260
Electronic Control System Wiring Diagram for 6020 and 7020 Series Tractors262
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V