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)
Introduction
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
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 Options100
Engine Synchronization Throttle Control101
Throttle Control Location Transfer102
Pump Solenoid103
Water in Fuel (WIF) Sensor103
Engine Control Unit (ECU)105
Controller Area Network (CAN)106
Cruise Control Operation107
Intake Air Heater Operation107
Engine Protection108
Derate Programs108
Multiple Torque Curve Selection109
Governor Droop Mode Selection109
Engine Control Unit (ECU) Self-Diagnosis110
Diagnostics113
Observable Diagnostics and Tests119
About This Group of the Manual119
E1 – Engine Cranks/Won’t Start120
E1 – Engine Cranks/Won’t Start Diagnostic Procedure120
E2 – Engine Misfires/Runs Irregularly126
E2 – Engine Misfires/Runs Irregularly Diagnostic Procedure126
E3 – Engine Does Not Develop Full Power132
E3 – Engine Does Not Develop Full Power Diagnostic Procedure132
E4 – Engine Emits Excessive White Exhaust Smoke137
E4 – Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure137
E5 – Engine Emits Excessive Black Or Gray Smoke140
E5 – Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure140
E6 – Engine Will Not Crank143
E7 – Engine Idles Poorly143
E8 – Abnormal Engine Noise144
E9 – Analog Throttle (B) Does Not Respond146
F1 – Fuel Supply System Check Diagnostic Procedure147
F2 – Excessive Fuel Consumption150
F3 – Fuel in Oil150
F5 – Fuel Injection Nozzle Check151
D1 – ECU Does Not Communicate with the DST or SERVICE ADVISOR154
D1 – ECU Does Not Communicate With the DST orSERVICE ADVISOR™155
D1 – ECU Does Not Communicate with the DST or SERVICE ADVISOR™ Diagnostic Procedure155
D2 – Diagnostic Gauge Does Not Communicate With ECU158
D2 – Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure159
A1 – Intake Air Heater Check164
A1 – Intake Air Heater Check – Continued165
A1 – Intake Air Heater Check166
A1 – Intake Air Heater Check Diagnostic Procedure166
Check Fuel Supply Quality168
Test for Fuel Drain Back169
Test for Air in Fuel170
Check Fuel Supply Pressure171
Bench Test Fuel Supply Pump172
Bleed the Fuel System174
Test for Cylinder Misfire (Engine Running)177
Trouble Code Diagnostics and Tests179
About this Group of the Manual179
Electrical Concepts179
Using a Digital Multimeter180
Electrical Circuit Malfunctions180
Troubleshooting Circuit Malfunctions183
Engine Configuration Data Parameters on Diagnostic Gauge188
Viewing Active DTCs on Diagnostic Gauge190
Viewing Stored DTCs on Diagnostic Gauge190
Clearing Stored DTCs on Diagnostic Gauge191
Blinking DTCs192
Data Parameter Description194
Engine Test Instructions – Excavator Torque Curve Change Test197
Reprogramming Engine Control Unit (ECU)197
Diagnostic Trouble Codes (DTCs)198
Listing of Diagnostic Trouble Codes (DTCs) on ECU200
Diagnostic Procedure204
Intermittent Fault Diagnostics205
T1 – Multi-state Throttle Input High206
T1 – Multi-State Throttle Input High Diagnostic Procedure207
T2 – Multi-state Throttle Input Low210
T2 – Multi-State Throttle Input Low Diagnostic Procedure211
T3 – Analog Throttle (A) Input High214
T3 – Analog Throttle (A) Input High Diagnostic Procedure215
T4 – Analog Throttle (A) Input Low218
T4 – Analog Throttle (A) Input Low Diagnostic Procedure219
T5 – Analog Throttle (B) Input High222
T5 – Analog Throttle (B) Input High Diagnostic Procedure223
T6 – Analog Throttle (B) Input Low226
T6 – Analog Throttle (B) Input Low Diagnostic Procedure227
T7 – CAN Throttle Invalid230
T7 – CAN Throttle Invalid Diagnostic Procedure231
T11 – Excavator Throttle Reference Voltage High234
T11 – Excavator Throttle Reference Voltage High Diagnostic Procedure235
T12 – Excavator Throttle Reference Voltage Low238
T12 – Excavator Throttle Reference Voltage Low Diagnostic Procedure239
T13 – Excavator Throttle Ground Voltage High242
T13 – Excavator Throttle Ground Voltage High Diagnostic Procedure243
T14 – Excavator Throttle Ground Voltage Low246
T14 – Excavator Throttle Ground Voltage Low Diagnostic Procedure247
T15 – Excavator Throttle Input Voltage High250
T15 – Excavator Throttle Input Voltage High251
T15 – Excavator Throttle Input Voltage High Diagnostic Procedure251
T16 – Excavator Throttle Input Voltage Low254
T16 – Excavator Throttle Input Voltage Low Diagnostic Procedure255
T17 – Analog Throttle (C) Input High258
T17 – Analog Throttle (C) Input High Diagnostic Procedure259
T18 – Analog Throttle (C) Input Low262
T18 – Analog Throttle (C) Input Low Diagnostic Procedure263
T19 – Throttle Not Calibrated Properly265
T20 – Throttle Input Voltage Below Lower Calibration Limit266
T21 – Throttle Calibration Aborted267
T22 – Analog Throttle (A) Input Voltage Out of Range268
T23 – Multi-state Throttle Input Voltage Out of Range269
00002803 — Throttle Voltage High270
00002804 — Throttle Voltage Low270
00002903 — Throttle Voltage High271
00002904 — Throttle Voltage Low272
00002914 — Throttle Voltage Out of Range272
00008431 — Vehicle Speed Mismatch274
00008431 Vehicle Speed Mismatch Diagnostic Procedure275
00009103 — Throttle Voltage High277
00009104 — Throttle Voltage Low278
00009107 — Throttle Calibration Invalid278
00009110 — Throttle Voltage Low279
00009113 — Throttle Calibration Aborted279
00009114 — Throttle Voltage Out of Range280
00009700 — Water in Fuel Continuously Detected280
Water in Fuel Continuously Detected Diagnostic Procedure282
00009703 — Water in Fuel Signal Voltage High284
00009703 Water In Fuel Signal Voltage High Diagnostic Procedure285
00009704 — Water in Fuel Signal Voltage Low288
00009704 Water In Fuel Signal Voltage Low Diagnostic Procedure289
00009716 — Water in Fuel Detected292
00009716 Water In Fuel Detected Diagnostic Procedure293
00009731 — Water in Fuel Detected (750J Crawler Only)294
Water in Fuel Detected (750J Crawler Only) Diagnostic Procedure295
00010001 — Engine Oil Pressure Extremely Low298
00010001 Engine Oil Pressure Extremely Low Diagnostic Procedure300
00010003 — Engine Oil Pressure Input Voltage High302
00010003 Engine Oil Pressure Input Voltage High Diagnostic Procedure303
00010004 — Engine Oil Pressure Input Voltage Low306
00010004 Engine Oil Pressure Input Voltage Low Diagnostic Procedure308
00010016 – Engine Oil Pressure High, Moderately Severe Level312
00010016 — Engine Oil Pressure High, Moderately Severe Level Incorrect Reading Diagnostic Procedure312
Electrical Test313
00010018 — Engine Oil Pressure Moderately Low314
00010018 Engine Oil Pressure Moderately Low Diagnostic Procedure315
00010503 — Manifold Air Temperature Input Voltage High316
00010503 Manifold Air Temperature Input Voltage High Diagnostic Procedure317
00010504 — Manifold Air Temperature Input Voltage Low320
00010504 Manifold Air Temperature Input Voltage Low Diagnostic Procedure321
00010516 — Manifold Air Temperature Moderately High324
00010516 Manifold Air Temperature Moderately High Diagnostic Procedure325
00011000 — Engine Coolant Temperature Extremely High326
00011000 Engine Coolant Temperature Extremely High Diagnostic Procedure327
00011003 — Engine Coolant Temperature Input Voltage High328
00011003 Engine Coolant Temperature Input Voltage High Diagnostic Procedure329
00011004 — Engine Coolant Temperature Input Voltage Low332
00011004 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure333
00011015 — Engine Coolant Temperature High Least Severe336
00011015 Engine Coolant Temperature High Least Severe Diagnostic Procedure337
00011016 — Engine Coolant Temperature Moderately High338
00011016 Engine Coolant Temperature Moderately High Diagnostic Procedure339
00011100 — Loss of Coolant Temperature Extremely High340
00011100 Loss of Coolant Temperature Extremely High Diagnostic Procedure341
00011103 — Loss of Coolant Temperature Input Voltage High344
00011103 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure345
00011104 — Loss of Coolant Temperature Input Voltage Low348
00011104 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure349
00015817 — ECU Power Down Error352
00015817 ECU Power Down Error Diagnostic Procedure353
00016002 — Wheel Speed Input Noise356
00016002 Wheel Speed Input Noise Diagnostic Procedure357
00017103 — Ambient Air Temperature Input Voltage Out Of Range High (750J Crawlers only)359
00017103 AAT Input Voltage Out Of Range High Diagnostic Procedure (750J Crawlers only) 360
00017104 — Ambient Air Temperature Input Voltage Out Of Range Low (750J Crawlers Only)363
00017104 Ambient Air Temperature Input Voltage Out Of Range Low Diagnostic Procedure364
00017403 — Fuel Temperature Input Voltage High366
00017403 Fuel Temperature Input Voltage High Diagnostic Procedure367
00017404 — Fuel Temperature Input Voltage Low370
00017404 Fuel Temperature Input Voltage Low Diagnostic Procedure371
00017416 — Fuel Temperature High Moderately Severe374
00017416 Fuel Temperature High Moderately Severe Diagnostic Procedure375
00018900 — Engine Speed Derate377
00019000 — Engine Overspeed Extreme378
00019001 — Engine Speed Below Normal Operational Range, Most Severe Level (OEM Marine Only)379
00019001 — Engine Speed Below Normal Operational Range, Most Severe Level380
00019001 Engine Speed Below Normal Operational Range, Most Severe Level Diagnostic Procedure380
00019016 — Engine Overspeed Moderate382
00019018 — Engine Speed Below Normal Operational Range, Moderately Severe Level (OEM Marine Only)383
00052309 — Current Gear Selection Invalid or Not Received (J-series Loaders Only)384
00062003 — Sensor Supply Voltage High386
00062003 Sensor Supply Voltage High Diagnostic Procedure387
00062004 — Sensor Supply Voltage Low390
00062004 Sensor Supply Voltage Low Diagnostic Procedure391
00062913 — ECU Error394
00062913 ECU Error Diagnostic Procedure394
00063702 — Crank Position Input Noise396
00063702 Crank Position Input Noise Diagnostic Procedure397
00063710 — Crank Position Input Pattern Error400
00063710 Crank Position Input Pattern Error Diagnostic Procedure401
00063913 — CAN Bus Error404
00063913 CAN Bus Error Diagnostic Procedure405
00064402 — External Speed Command Input (OEM, Marine Only)407
00072903 — Inlet Air Heater Signal High408
00072903 Inlet Air Heater Signal High Diagnostic Procedure409
00072905 — Inlet Air Heater Signal Low412
00072905 Inlet Air Heater Signal Low Diagnostic Procedure413
00089809 — Vehicle Speed or Torque Message Invalid415
00097031 — Auxiliary Engine Shutdown Switch Active416
00097131 — External Engine Derate Switch Active417
00106909 — Tire Size Invalid418
00106909 — Tire Size Invalid419
00106909 Tire Size Invalid Diagnostic Procedure419
00106931 — Tire Size Error422
00106931 Tire Size Error Diagnostic Procedure423
00107600 — Pump Control Valve Closure Too Long424
00107600 Pump Control Valve Closure Too Long Diagnostic Procedure425
00107601 — Pump Control Valve Closure Too Short428
00107601 Pump Control Valve Closure Too Short Diagnostic Procedure429
00107603 — Pump Solenoid Current High432
00107603 Pump Solenoid Current High Diagnostic Procedure433
00107605 — Pump Solenoid Circuit Open436
00107605 Pump Solenoid Circuit Open Diagnostic Procedure437
00107606 — Pump Solenoid Circuit Severely Shorted440
00107607 — Pump Control Valve Closure Not Detected444
00107607 Pump Control Valve Closure Not Detected Diagnostic Procedure445
00107610 — Pump Solenoid Circuit Moderately Shorted448
00107610 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure449
00107613 — Pump Current Decay Time Invalid452
00107613 Pump Current Decay Time Invalid Diagnostic Procedure453
00107903 — Sensor Supply Voltage High456
00107903 Sensor Supply Voltage High Diagnostic Procedure457
00107904 — Sensor Supply Voltage Low460
00107904 Sensor Supply Voltage Low Diagnostic Procedure461
00110931 — Engine Protection Shutdown Warning464
00111031 — Engine Protection Shutdown465
00156802 — Torque Curve Selection Invalid or Missing (750J Crawler Only)466
00156931 — Fuel Derate468
00200006 — Internal ECU Failure469
00200013 — Security Violation470
Tools and Other Materials471
Electronic Fuel/Control System Repair Tools and Other Materials473
Fuel System Repair and Adjustment Essential Tools473
Fuel System Repair and Adjustment Service Equipment and Tools475
Fuel System Repair and Adjustment Other Materials476
Control System Repair and Adjustment Essential Tools477
Control System Repair and Adjustment Other Materials482
Diagnostic Service Tools483
ic Fuel System Diagnostic Tools483
Specifications487
Repair Specifications489
Unified Inch Bolt and Screw Torque Values489
Metric Bolt and Screw Torque Values490
General OEM Engine Specifications491
Electronic Fuel System Repair and Adjustment Specifications492
Electronic Engine Control Repair and Adjustment Specifications494
Diagnostic Specifications495
Group 150/160 Electronic Fuel System Diagnostic Specifications495
Application Specifications497
Backhoes – Sensor Specifications500
Backhoes – Torque Curve Selection501
Backhoes – Governor Mode Selection501
Backhoes – ECU Terminal Identification502
Crawlers – Sensor Specifications504
Crawlers – Torque Curve Selection506
Crawlers – Governor Mode Selection506
Crawlers – ECU Terminal Identification507
Excavators – Sensor Specifications508
Excavators – Torque Curve Selection509
Excavators – Governor Mode Selection509
Excavators – ECU Terminal Identification510
Forwarders – Sensor Specifications512
Forwarders – Torque Curve Selection514
Forwarders – Governor Mode Selection514
Forwarders – ECU Terminal Identification515
Harvesters – Sensor Specifications516
Harvesters – Torque Curve Selection517
Harvesters – Governor Mode Selection517
Harvesters – ECU Terminal Identification518
OEM Engines – Sensor Specifications520
OEM Engines – Torque Curve Selection522
OEM Engines – Governor Mode Selection With OC03038 Software or Later523
OEM Engines – Governor Mode Selection With OC03033 Software or Earlier524
OEM Engines – ECU Terminal Identification525
OEM Engines – Electronic Control System Wiring Diagram – Base ECUs526
OEM Engines – Electronic Control System Wiring Diagram – Extended ECUs (Early)527
OEM Engines – Electronic Control System Wiring Diagram – Extended ECUs (Later)528
OEM Engines – 45L & 68L Instrument Panel/Engine Start Components Electrical Wiring Diagram529
Skidders – Sensor Specifications530
Skidders – Torque Curve Selection532
Skidders – Governor Mode Selection532
Skidders – ECU Terminal Identification533
Telehandlers – Sensor Specifications534
Telehandlers – Torque Curve Selection536
Telehandlers – Governor Mode Selection536
Telehandlers – ECU Terminal Identification537
Tractors – Sensor Specifications538
Tractors – Torque Curve Selection540
Tractors – Governor Mode Selection540
Tractors – ECU Terminal Identification541
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