John Deere POWERTECH 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel System With Stanadyne DE10 Pump Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere POWERTECH 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel System With Stanadyne DE10 Pump Technical Manual – PDF DOWNLOAD
For complete service information also see:
POWERTECHâ 4.5 L and 6.8 L Diesel
Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104
Alternators and Starter Motors. . . . . . . . . . . CTM77
OEM Engine Accessories . . . . . . CTM67 (English Only)
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 (CTM331) covers only Level 12 Electronic Fuel System with the Stanadyne DE10 injection pump. It is one of five volumes on 4.5 L and 6.8 L engines.
The following four companion manuals cover the base engine, mechanical fuel system, level 4 electronic fuel system and level 1 electronic fuel system 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 Systems with
Delphi (Lucas) DP201 Pump
- Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
TABLE OF CONTENTS:
John Deere POWERTECH 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel System With Stanadyne DE10 Pump Technical Manual – PDF DOWNLOAD
Contents……………………………………………………………………………………………… 5
General Information………………………………………………………………………………… 7
Safety………………………………………………………………………………………… 9
Handle Fluids Safely—Avoid Fires……………………………………………………………… 9
Handle Starting Fluid Safely…………………………………………………………………. 9
Prepare for Emergencies……………………………………………………………………… 9
Avoid High-Pressure Fluids…………………………………………………………………… 10
Wear Protective Clothing…………………………………………………………………….. 10
Service Machines Safely……………………………………………………………………… 11
Work In Ventilated Area……………………………………………………………………… 11
Work in Clean Area………………………………………………………………………….. 11
Remove Paint Before Welding or Heating………………………………………………………… 12
Avoid Heating Near Pressurized Fluid Lines…………………………………………………….. 12
Illuminate Work Area Safely………………………………………………………………….. 13
Construct Dealer-Made Tools Safely……………………………………………………………. 13
Practice Safe Maintenance……………………………………………………………………. 14
Use Proper Tools……………………………………………………………………………. 14
Dispose of Waste Properly……………………………………………………………………. 15
Live With Safety……………………………………………………………………………. 15
Engine Identification…………………………………………………………………………… 17
Engine Model Designation…………………………………………………………………….. 17
Engine Serial Number Plate Information………………………………………………………… 18
OEM Engine Option Code Label…………………………………………………………………. 19
Information Relative to Emissions Regulations………………………………………………….. 19
Engine Application Charts……………………………………………………………………. 20
Fuels…………………………………………………………………………………………. 23
Lubricants and Coolant………………………………………………………………………. 23
Diesel Fuel………………………………………………………………………………… 23
Bio-Diesel Fuel…………………………………………………………………………….. 24
Testing Diesel Fuel…………………………………………………………………………. 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 Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base………………….. 30
Fuel Pre-Filter/Water Bowl Assembly (Optional)…………………………………………………. 33
Final Fuel Filter Assembly…………………………………………………………………… 34
Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl…………………………………… 35
Remove Fuel Supply Pump……………………………………………………………………… 37
Install Fuel Supply Pump…………………………………………………………………….. 38
Injection Pump Static Timing…………………………………………………………………. 38
Remove Injection Pump……………………………………………………………………….. 39
Inspect Injection Pump Drive Gear ID and Shaft OD………………………………………………. 41
Install Injection Pump………………………………………………………………………. 41
Remove Fuel Injection Nozzles………………………………………………………………… 44
Clean Fuel Injection Nozzle Bore……………………………………………………………… 46
Clean Fuel Injection Nozzles…………………………………………………………………. 46
Fuel Injection Nozzle Test…………………………………………………………………… 47
Disassemble Fuel Injection Nozzles……………………………………………………………. 50
Adjust Fuel Injection Nozzle…………………………………………………………………. 51
Install Seals on Fuel Injection Nozzle………………………………………………………… 52
Install Fuel Injection Nozzles……………………………………………………………….. 53
Bleed the Fuel System……………………………………………………………………….. 54
Electrical Engine Control Repair and Adjustment……………………………………………………. 57
Engine Control Unit (ECU)……………………………………………………………………. 57
Remove and Install Engine Coolant Temperature Sensor……………………………………………. 58
Remove and Install Loss of Coolant Temperature Sensor…………………………………………… 58
Replace Crankshaft Position Sensor……………………………………………………………. 59
Remove and Install Oil Pressure Sensor………………………………………………………… 59
Remove and Install Manifold Air Temperature Sensor……………………………………………… 60
Remove and Install Fuel Temperature Sensor…………………………………………………….. 60
Remove and Install Fuel Heater……………………………………………………………….. 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
Theory of Operation………………………………………………………………………………… 79
Electronic Fuel System Operation…………………………………………………………………. 81
About this Group……………………………………………………………………………. 81
Fuel System Operation……………………………………………………………………….. 82
Fuel Supply Pump Operation…………………………………………………………………… 84
Final Fuel Filter Operation………………………………………………………………….. 85
Fuel Injection Pump Operation………………………………………………………………… 86
Fuel Injection Nozzle Operation………………………………………………………………. 88
Electronic Control System Operation………………………………………………………………. 89
About This Group……………………………………………………………………………. 89
Electronic Control System Terminology…………………………………………………………. 90
Electronic Control System Operation…………………………………………………………… 91
Monitoring Engine Parameters…………………………………………………………………. 91
Electronic Control System Overview……………………………………………………………. 92
Measuring Temperature……………………………………………………………………….. 93
Measuring Pressure………………………………………………………………………….. 95
Measuring Throttle Position………………………………………………………………….. 96
Measuring Engine Speed………………………………………………………………………. 99
Marine Throttle Control Options……………………………………………………………….100
Engine Synchronization Throttle Control………………………………………………………..101
Throttle Control Location Transfer…………………………………………………………….102
Pump Solenoid……………………………………………………………………………….103
Water in Fuel (WIF) Sensor……………………………………………………………………103
Engine Control Unit (ECU)…………………………………………………………………….105
Controller Area Network (CAN)…………………………………………………………………106
Cruise Control Operation……………………………………………………………………..107
Intake Air Heater Operation…………………………………………………………………..107
Engine Protection……………………………………………………………………………108
Derate Programs……………………………………………………………………………..108
Multiple Torque Curve Selection……………………………………………………………….109
Governor Droop Mode Selection…………………………………………………………………109
Engine Control Unit (ECU) Self-Diagnosis……………………………………………………….110
Diagnostics………………………………………………………………………………………..113
Observable Diagnostics and Tests………………………………………………………………….119
About This Group of the Manual………………………………………………………………..119
E1 – Engine Cranks/Won’t Start………………………………………………………………..120
E1 – Engine Cranks/Won’t Start Diagnostic Procedure……………………………………………..120
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E2 – Engine Misfires/Runs Irregularly………………………………………………………….126
E2 – Engine Misfires/Runs Irregularly Diagnostic Procedure……………………………………….126
…………………………………………………………………………………………..126
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E3 – Engine Does Not Develop Full Power………………………………………………………..132
E3 – Engine Does Not Develop Full Power Diagnostic Procedure……………………………………..132
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E4 – Engine Emits Excessive White Exhaust Smoke…………………………………………………137
E4 – Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure………………………………137
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E5 – Engine Emits Excessive Black Or Gray Smoke…………………………………………………140
E5 – Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure………………………………140
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E6 – Engine Will Not Crank……………………………………………………………………143
E7 – Engine Idles Poorly……………………………………………………………………..143
E8 – Abnormal Engine Noise……………………………………………………………………144
E9 – Analog Throttle (B) Does Not Respond………………………………………………………146
………………………………………………………………………………………….147
F1 – Fuel Supply System Check Diagnostic Procedure………………………………………………147
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F2 – Excessive Fuel Consumption……………………………………………………………….150
F3 – Fuel in Oil…………………………………………………………………………….150
F5 – Fuel Injection Nozzle Check………………………………………………………………151
D1 – ECU Does Not Communicate with the DST or SERVICE ADVISOR…………………………………….154
D1 – ECU Does Not Communicate With the DST orSERVICE ADVISOR™…………………………………….155
D1 – ECU Does Not Communicate with the DST or SERVICE ADVISOR™ Diagnostic Procedure…………………155
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D2 – Diagnostic Gauge Does Not Communicate With ECU……………………………………………..158
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D2 – Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure…………………………..159
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A1 – Intake Air Heater Check………………………………………………………………….164
A1 – Intake Air Heater Check – Continued……………………………………………………….165
A1 – Intake Air Heater Check………………………………………………………………….166
A1 – Intake Air Heater Check Diagnostic Procedure……………………………………………….166
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Check Fuel Supply Quality…………………………………………………………………….168
Test for Fuel Drain Back……………………………………………………………………..169
Test for Air in Fuel…………………………………………………………………………170
Check Fuel Supply Pressure……………………………………………………………………171
Bench Test Fuel Supply Pump…………………………………………………………………..172
Bleed the Fuel System………………………………………………………………………..174
Test for Cylinder Misfire (Engine Running)……………………………………………………..177
Trouble Code Diagnostics and Tests………………………………………………………………..179
About this Group of the Manual………………………………………………………………..179
Electrical Concepts………………………………………………………………………….179
Using a Digital Multimeter……………………………………………………………………180
Electrical Circuit Malfunctions……………………………………………………………….180
Troubleshooting Circuit Malfunctions…………………………………………………………..183
Engine Configuration Data Parameters on Diagnostic Gauge…………………………………………188
Viewing Active DTCs on Diagnostic Gauge………………………………………………………..190
Viewing Stored DTCs on Diagnostic Gauge………………………………………………………..190
Clearing Stored DTCs on Diagnostic Gauge……………………………………………………….191
Blinking DTCs……………………………………………………………………………….192
Data Parameter Description……………………………………………………………………194
Engine Test Instructions – Excavator Torque Curve Change Test…………………………………….197
Reprogramming Engine Control Unit (ECU)………………………………………………………..197
Diagnostic Trouble Codes (DTCs)……………………………………………………………….198
Listing of Diagnostic Trouble Codes (DTCs) on ECU……………………………………………….200
Diagnostic Procedure…………………………………………………………………………204
Intermittent Fault Diagnostics………………………………………………………………..205
T1 – Multi-state Throttle Input High…………………………………………………………..206
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T1 – Multi-State Throttle Input High Diagnostic Procedure………………………………………..207
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T2 – Multi-state Throttle Input Low……………………………………………………………210
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T2 – Multi-State Throttle Input Low Diagnostic Procedure…………………………………………211
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T3 – Analog Throttle (A) Input High……………………………………………………………214
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T3 – Analog Throttle (A) Input High Diagnostic Procedure…………………………………………215
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T4 – Analog Throttle (A) Input Low…………………………………………………………….218
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T4 – Analog Throttle (A) Input Low Diagnostic Procedure………………………………………….219
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T5 – Analog Throttle (B) Input High……………………………………………………………222
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T5 – Analog Throttle (B) Input High Diagnostic Procedure…………………………………………223
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T6 – Analog Throttle (B) Input Low…………………………………………………………….226
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T6 – Analog Throttle (B) Input Low Diagnostic Procedure………………………………………….227
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T7 – CAN Throttle Invalid…………………………………………………………………….230
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T7 – CAN Throttle Invalid Diagnostic Procedure………………………………………………….231
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T11 – Excavator Throttle Reference Voltage High…………………………………………………234
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T11 – Excavator Throttle Reference Voltage High Diagnostic Procedure………………………………235
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T12 – Excavator Throttle Reference Voltage Low………………………………………………….238
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T12 – Excavator Throttle Reference Voltage Low Diagnostic Procedure……………………………….239
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T13 – Excavator Throttle Ground Voltage High……………………………………………………242
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T13 – Excavator Throttle Ground Voltage High Diagnostic Procedure…………………………………243
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T14 – Excavator Throttle Ground Voltage Low…………………………………………………….246
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T14 – Excavator Throttle Ground Voltage Low Diagnostic Procedure………………………………….247
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T15 – Excavator Throttle Input Voltage High…………………………………………………….250
T15 – Excavator Throttle Input Voltage High…………………………………………………….251
T15 – Excavator Throttle Input Voltage High Diagnostic Procedure………………………………….251
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T16 – Excavator Throttle Input Voltage Low……………………………………………………..254
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T16 – Excavator Throttle Input Voltage Low Diagnostic Procedure…………………………………..255
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T17 – Analog Throttle (C) Input High…………………………………………………………..258
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T17 – Analog Throttle (C) Input High Diagnostic Procedure………………………………………..259
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T18 – Analog Throttle (C) Input Low……………………………………………………………262
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T18 – Analog Throttle (C) Input Low Diagnostic Procedure…………………………………………263
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T19 – Throttle Not Calibrated Properly…………………………………………………………265
T20 – Throttle Input Voltage Below Lower Calibration Limit……………………………………….266
T21 – Throttle Calibration Aborted…………………………………………………………….267
T22 – Analog Throttle (A) Input Voltage Out of Range…………………………………………….268
T23 – Multi-state Throttle Input Voltage Out of Range……………………………………………269
000028.03 — Throttle Voltage High……………………………………………………………..270
000028.04 — Throttle Voltage Low………………………………………………………………270
000029.03 — Throttle Voltage High……………………………………………………………..271
000029.04 — Throttle Voltage Low………………………………………………………………272
000029.14 — Throttle Voltage Out of Range………………………………………………………272
000084.31 — Vehicle Speed Mismatch…………………………………………………………….274
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000084.31 Vehicle Speed Mismatch Diagnostic Procedure……………………………………………275
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000091.03 — Throttle Voltage High……………………………………………………………..277
000091.04 — Throttle Voltage Low………………………………………………………………278
000091.07 — Throttle Calibration Invalid……………………………………………………….278
000091.10 — Throttle Voltage Low………………………………………………………………279
000091.13 — Throttle Calibration Aborted……………………………………………………….279
000091.14 — Throttle Voltage Out of Range………………………………………………………280
000097.00 — Water in Fuel Continuously Detected…………………………………………………280
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Water in Fuel Continuously Detected Diagnostic Procedure…………………………………………282
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000097.03 — Water in Fuel Signal Voltage High…………………………………………………..284
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000097.03 Water In Fuel Signal Voltage High Diagnostic Procedure………………………………….285
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000097.04 — Water in Fuel Signal Voltage Low……………………………………………………288
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000097.04 Water In Fuel Signal Voltage Low Diagnostic Procedure…………………………………..289
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000097.16 — Water in Fuel Detected…………………………………………………………….292
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000097.16 Water In Fuel Detected Diagnostic Procedure……………………………………………293
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000097.31 — Water in Fuel Detected (750J Crawler Only)…………………………………………..294
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Water in Fuel Detected (750J Crawler Only) Diagnostic Procedure…………………………………..295
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000100.01 — Engine Oil Pressure Extremely Low…………………………………………………..298
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000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure………………………………….300
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000100.03 — Engine Oil Pressure Input Voltage High………………………………………………302
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000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure……………………………..303
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000100.04 — Engine Oil Pressure Input Voltage Low……………………………………………….306
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000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure………………………………308
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000100.16 – Engine Oil Pressure High, Moderately Severe Level…………………………………….312
000100.16 — Engine Oil Pressure High, Moderately Severe Level Incorrect Reading Diagnostic Procedure….312
Electrical Test……………………………………………………………………………..313
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000100.18 — Engine Oil Pressure Moderately Low………………………………………………….314
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000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure…………………………………315
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000105.03 — Manifold Air Temperature Input Voltage High………………………………………….316
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000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure…………………………317
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000105.04 — Manifold Air Temperature Input Voltage Low…………………………………………..320
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000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure………………………….321
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000105.16 — Manifold Air Temperature Moderately High…………………………………………….324
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000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure……………………………325
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000110.00 — Engine Coolant Temperature Extremely High……………………………………………326
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000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure…………………………..327
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000110.03 — Engine Coolant Temperature Input Voltage High………………………………………..328
………………………………………………………………………………………….329
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure……………………….329
…………………………………………………………………………………………..329
…………………………………………………………………………………………..329
…………………………………………………………………………………………..330
…………………………………………………………………………………………..330
000110.04 — Engine Coolant Temperature Input Voltage Low…………………………………………332
………………………………………………………………………………………….333
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure………………………..333
…………………………………………………………………………………………..333
…………………………………………………………………………………………..333
…………………………………………………………………………………………..334
000110.15 — Engine Coolant Temperature High Least Severe…………………………………………336
………………………………………………………………………………………….337
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure………………………..337
…………………………………………………………………………………………..337
…………………………………………………………………………………………..337
000110.16 — Engine Coolant Temperature Moderately High…………………………………………..338
………………………………………………………………………………………….339
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure………………………….339
…………………………………………………………………………………………..339
…………………………………………………………………………………………..339
000111.00 — Loss of Coolant Temperature Extremely High…………………………………………..340
………………………………………………………………………………………….341
000111.00 Loss of Coolant Temperature Extremely High Diagnostic Procedure………………………….341
…………………………………………………………………………………………..341
…………………………………………………………………………………………..342
000111.03 — Loss of Coolant Temperature Input Voltage High……………………………………….344
………………………………………………………………………………………….345
000111.03 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure………………………345
…………………………………………………………………………………………..345
…………………………………………………………………………………………..345
…………………………………………………………………………………………..346
…………………………………………………………………………………………..346
000111.04 — Loss of Coolant Temperature Input Voltage Low………………………………………..348
………………………………………………………………………………………….349
000111.04 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure……………………….349
…………………………………………………………………………………………..349
…………………………………………………………………………………………..349
…………………………………………………………………………………………..350
000158.17 — ECU Power Down Error………………………………………………………………352
………………………………………………………………………………………….353
000158.17 ECU Power Down Error Diagnostic Procedure……………………………………………..353
…………………………………………………………………………………………..353
…………………………………………………………………………………………..353
…………………………………………………………………………………………..354
000160.02 — Wheel Speed Input Noise……………………………………………………………356
………………………………………………………………………………………….357
000160.02 Wheel Speed Input Noise Diagnostic Procedure…………………………………………..357
…………………………………………………………………………………………..357
…………………………………………………………………………………………..357
…………………………………………………………………………………………..358
…………………………………………………………………………………………..358
…………………………………………………………………………………………..358
000171.03 — Ambient Air Temperature Input Voltage Out Of Range High (750J Crawlers only)…………….359
………………………………………………………………………………………….360
000171.03 AAT Input Voltage Out Of Range High Diagnostic Procedure (750J Crawlers only) …………….360
…………………………………………………………………………………………..360
…………………………………………………………………………………………..360
…………………………………………………………………………………………..361
…………………………………………………………………………………………..361
…………………………………………………………………………………………..361
…………………………………………………………………………………………..362
…………………………………………………………………………………………..362
000171.04 — Ambient Air Temperature Input Voltage Out Of Range Low (750J Crawlers Only)……………..363
………………………………………………………………………………………….364
000171.04 Ambient Air Temperature Input Voltage Out Of Range Low Diagnostic Procedure……………….364
…………………………………………………………………………………………..364
…………………………………………………………………………………………..364
…………………………………………………………………………………………..365
…………………………………………………………………………………………..365
…………………………………………………………………………………………..365
000174.03 — Fuel Temperature Input Voltage High…………………………………………………366
………………………………………………………………………………………….367
000174.03 Fuel Temperature Input Voltage High Diagnostic Procedure………………………………..367
…………………………………………………………………………………………..367
…………………………………………………………………………………………..367
…………………………………………………………………………………………..368
…………………………………………………………………………………………..368
000174.04 — Fuel Temperature Input Voltage Low………………………………………………….370
………………………………………………………………………………………….371
000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedure…………………………………371
…………………………………………………………………………………………..371
…………………………………………………………………………………………..371
…………………………………………………………………………………………..372
000174.16 — Fuel Temperature High Moderately Severe……………………………………………..374
………………………………………………………………………………………….375
000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure…………………………….375
…………………………………………………………………………………………..375
…………………………………………………………………………………………..375
…………………………………………………………………………………………..376
…………………………………………………………………………………………..376
000189.00 — Engine Speed Derate……………………………………………………………….377
000190.00 — Engine Overspeed Extreme…………………………………………………………..378
000190.01 — Engine Speed Below Normal Operational Range, Most Severe Level (OEM Marine Only)…………379
000190.01 — Engine Speed Below Normal Operational Range, Most Severe Level…………………………380
000190.01 Engine Speed Below Normal Operational Range, Most Severe Level Diagnostic Procedure………..380
…………………………………………………………………………………………..380
…………………………………………………………………………………………..380
…………………………………………………………………………………………..381
000190.16 — Engine Overspeed Moderate………………………………………………………….382
000190.18 — Engine Speed Below Normal Operational Range, Moderately Severe Level (OEM Marine Only)……383
000523.09 — Current Gear Selection Invalid or Not Received (J-series Loaders Only)………………….384
000620.03 — Sensor Supply Voltage High…………………………………………………………386
………………………………………………………………………………………….387
000620.03 Sensor Supply Voltage High Diagnostic Procedure………………………………………..387
…………………………………………………………………………………………..387
…………………………………………………………………………………………..387
…………………………………………………………………………………………..388
000620.04 — Sensor Supply Voltage Low………………………………………………………….390
………………………………………………………………………………………….391
000620.04 Sensor Supply Voltage Low Diagnostic Procedure…………………………………………391
…………………………………………………………………………………………..391
…………………………………………………………………………………………..391
…………………………………………………………………………………………..392
…………………………………………………………………………………………..392
000629.13 — ECU Error………………………………………………………………………..394
000629.13 ECU Error Diagnostic Procedure……………………………………………………….394
…………………………………………………………………………………………..394
000637.02 — Crank Position Input Noise…………………………………………………………396
………………………………………………………………………………………….397
000637.02 Crank Position Input Noise Diagnostic Procedure………………………………………..397
…………………………………………………………………………………………..397
…………………………………………………………………………………………..397
…………………………………………………………………………………………..398
000637.10 — Crank Position Input Pattern Error………………………………………………….400
………………………………………………………………………………………….401
000637.10 Crank Position Input Pattern Error Diagnostic Procedure…………………………………401
…………………………………………………………………………………………..401
…………………………………………………………………………………………..401
…………………………………………………………………………………………..402
…………………………………………………………………………………………..402
…………………………………………………………………………………………..402
…………………………………………………………………………………………..403
…………………………………………………………………………………………..403
…………………………………………………………………………………………..403
000639.13 — CAN Bus Error…………………………………………………………………….404
………………………………………………………………………………………….405
000639.13 CAN Bus Error Diagnostic Procedure……………………………………………………405
…………………………………………………………………………………………..405
…………………………………………………………………………………………..405
…………………………………………………………………………………………..406
…………………………………………………………………………………………..406
000644.02 — External Speed Command Input (OEM, Marine Only)………………………………………407
000729.03 — Inlet Air Heater Signal High……………………………………………………….408
………………………………………………………………………………………….409
000729.03 Inlet Air Heater Signal High Diagnostic Procedure………………………………………409
…………………………………………………………………………………………..409
…………………………………………………………………………………………..409
…………………………………………………………………………………………..410
…………………………………………………………………………………………..410
000729.05 — Inlet Air Heater Signal Low………………………………………………………..412
………………………………………………………………………………………….413
000729.05 Inlet Air Heater Signal Low Diagnostic Procedure……………………………………….413
…………………………………………………………………………………………..413
…………………………………………………………………………………………..413
…………………………………………………………………………………………..414
…………………………………………………………………………………………..414
…………………………………………………………………………………………..414
000898.09 — Vehicle Speed or Torque Message Invalid……………………………………………..415
000970.31 — Auxiliary Engine Shutdown Switch Active……………………………………………..416
000971.31 — External Engine Derate Switch Active………………………………………………..417
001069.09 — Tire Size Invalid…………………………………………………………………418
001069.09 — Tire Size Invalid…………………………………………………………………419
001069.09 Tire Size Invalid Diagnostic Procedure………………………………………………..419
…………………………………………………………………………………………..419
…………………………………………………………………………………………..419
…………………………………………………………………………………………..420
…………………………………………………………………………………………..420
…………………………………………………………………………………………..420
001069.31 — Tire Size Error…………………………………………………………………..422
………………………………………………………………………………………….423
001069.31 Tire Size Error Diagnostic Procedure………………………………………………….423
…………………………………………………………………………………………..423
…………………………………………………………………………………………..423
001076.00 — Pump Control Valve Closure Too Long…………………………………………………424
………………………………………………………………………………………….425
001076.00 Pump Control Valve Closure Too Long Diagnostic Procedure………………………………..425
…………………………………………………………………………………………..425
…………………………………………………………………………………………..425
…………………………………………………………………………………………..426
001076.01 — Pump Control Valve Closure Too Short………………………………………………..428
………………………………………………………………………………………….429
001076.01 Pump Control Valve Closure Too Short Diagnostic Procedure……………………………….429
…………………………………………………………………………………………..429
…………………………………………………………………………………………..429
…………………………………………………………………………………………..430
001076.03 — Pump Solenoid Current High…………………………………………………………432
………………………………………………………………………………………….433
001076.03 Pump Solenoid Current High Diagnostic Procedure………………………………………..433
…………………………………………………………………………………………..433
…………………………………………………………………………………………..433
…………………………………………………………………………………………..434
…………………………………………………………………………………………..434
…………………………………………………………………………………………..434
001076.05 — Pump Solenoid Circuit Open…………………………………………………………436
………………………………………………………………………………………….437
001076.05 Pump Solenoid Circuit Open Diagnostic Procedure………………………………………..437
…………………………………………………………………………………………..437
…………………………………………………………………………………………..437
…………………………………………………………………………………………..438
…………………………………………………………………………………………..438
…………………………………………………………………………………………..438
…………………………………………………………………………………………..438
001076.06 — Pump Solenoid Circuit Severely Shorted………………………………………………440
………………………………………………………………………………………….441
001076.06 Pump Solenoid Circuit Severely Shorted Diagnostic Procedure……………………………..441
…………………………………………………………………………………………..441
…………………………………………………………………………………………..441
…………………………………………………………………………………………..442
…………………………………………………………………………………………..442
…………………………………………………………………………………………..442
001076.07 — Pump Control Valve Closure Not Detected……………………………………………..444
………………………………………………………………………………………….445
001076.07 Pump Control Valve Closure Not Detected Diagnostic Procedure…………………………….445
…………………………………………………………………………………………..445
…………………………………………………………………………………………..445
…………………………………………………………………………………………..446
001076.10 — Pump Solenoid Circuit Moderately Shorted…………………………………………….448
………………………………………………………………………………………….449
001076.10 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure……………………………449
…………………………………………………………………………………………..449
…………………………………………………………………………………………..449
…………………………………………………………………………………………..450
…………………………………………………………………………………………..450
…………………………………………………………………………………………..450
001076.13 — Pump Current Decay Time Invalid…………………………………………………….452
………………………………………………………………………………………….453
001076.13 Pump Current Decay Time Invalid Diagnostic Procedure……………………………………453
…………………………………………………………………………………………..453
…………………………………………………………………………………………..453
…………………………………………………………………………………………..454
…………………………………………………………………………………………..454
…………………………………………………………………………………………..454
001079.03 — Sensor Supply Voltage High…………………………………………………………456
………………………………………………………………………………………….457
001079.03 Sensor Supply Voltage High Diagnostic Procedure………………………………………..457
…………………………………………………………………………………………..457
…………………………………………………………………………………………..457
…………………………………………………………………………………………..458
001079.04 — Sensor Supply Voltage Low………………………………………………………….460
………………………………………………………………………………………….461
001079.04 Sensor Supply Voltage Low Diagnostic Procedure…………………………………………461
…………………………………………………………………………………………..461
…………………………………………………………………………………………..461
…………………………………………………………………………………………..462
…………………………………………………………………………………………..462
001109.31 — Engine Protection Shutdown Warning………………………………………………….464
001110.31 — Engine Protection Shutdown…………………………………………………………465
001568.02 — Torque Curve Selection Invalid or Missing (750J Crawler Only)………………………….466
001569.31 — Fuel Derate………………………………………………………………………468
002000.06 — Internal ECU Failure………………………………………………………………469
002000.13 — Security Violation………………………………………………………………..470
Tools and Other Materials……………………………………………………………………………471
Electronic Fuel/Control System Repair Tools and Other Materials………………………………………473
Fuel System Repair and Adjustment Essential Tools……………………………………………….473
Fuel System Repair and Adjustment Service Equipment and Tools…………………………………….475
Fuel System Repair and Adjustment Other Materials……………………………………………….476
Control System Repair and Adjustment Essential Tools…………………………………………….477
Control System Repair and Adjustment Other Materials…………………………………………….482
Diagnostic Service Tools…………………………………………………………………………483
ic Fuel System Diagnostic Tools……………………………………………………………….483
Specifications……………………………………………………………………………………..487
Repair Specifications……………………………………………………………………………489
Unified Inch Bolt and Screw Torque Values………………………………………………………489
Metric Bolt and Screw Torque Values……………………………………………………………490
General OEM Engine Specifications……………………………………………………………..491
Electronic Fuel System Repair and Adjustment Specifications………………………………………492
Electronic Engine Control Repair and Adjustment Specifications……………………………………494
Diagnostic Specifications………………………………………………………………………..495
Group 150/160 Electronic Fuel System Diagnostic Specifications……………………………………495
Application Specifications……………………………………………………………………497
Backhoes – Sensor Specifications………………………………………………………………500
Backhoes – Torque Curve Selection……………………………………………………………..501
Backhoes – Governor Mode Selection…………………………………………………………….501
Backhoes – ECU Terminal Identification…………………………………………………………502
Crawlers – Sensor Specifications………………………………………………………………504
Crawlers – Torque Curve Selection……………………………………………………………..506
Crawlers – Governor Mode Selection…………………………………………………………….506
Crawlers – ECU Terminal Identification…………………………………………………………507
Excavators – Sensor Specifications…………………………………………………………….508
Excavators – Torque Curve Selection……………………………………………………………509
Excavators – Governor Mode Selection…………………………………………………………..509
Excavators – ECU Terminal Identification……………………………………………………….510
Forwarders – Sensor Specifications…………………………………………………………….512
Forwarders – Torque Curve Selection……………………………………………………………514
Forwarders – Governor Mode Selection…………………………………………………………..514
Forwarders – ECU Terminal Identification……………………………………………………….515
Harvesters – Sensor Specifications…………………………………………………………….516
Harvesters – Torque Curve Selection……………………………………………………………517
Harvesters – Governor Mode Selection…………………………………………………………..517
Harvesters – ECU Terminal Identification……………………………………………………….518
OEM Engines – Sensor Specifications……………………………………………………………520
OEM Engines – Torque Curve Selection…………………………………………………………..522
OEM Engines – Governor Mode Selection With OC03038 Software or Later………………………………523
OEM Engines – Governor Mode Selection With OC03033 Software or Earlier…………………………….524
OEM Engines – ECU Terminal Identification………………………………………………………525
OEM Engines – Electronic Control System Wiring Diagram – Base ECUs………………………………..526
OEM Engines – Electronic Control System Wiring Diagram – Extended ECUs (Early)……………………..527
OEM Engines – Electronic Control System Wiring Diagram – Extended ECUs (Later)……………………..528
OEM Engines – 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring Diagram…………529
Skidders – Sensor Specifications………………………………………………………………530
Skidders – Torque Curve Selection……………………………………………………………..532
Skidders – Governor Mode Selection…………………………………………………………….532
Skidders – ECU Terminal Identification…………………………………………………………533
Telehandlers – Sensor Specifications…………………………………………………………..534
Telehandlers – Torque Curve Selection………………………………………………………….536
Telehandlers – Governor Mode Selection…………………………………………………………536
Telehandlers – ECU Terminal Identification……………………………………………………..537
Tractors – Sensor Specifications………………………………………………………………538
Tractors – Torque Curve Selection……………………………………………………………..540
Tractors – Governor Mode Selection…………………………………………………………….540
Tractors – ECU Terminal Identification…………………………………………………………541
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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S.V