JD-CTM220-21JAN04 John Deere 4.5 L and 6.8 L PowerTech Diesel engines - Level 11 Electronic Fuel System With Denso HPCR techn...
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John Deere 4.5 L and 6.8 L PowerTech Diesel engines - Level 11 Electronic Fuel System With Denso HPCR technical manual (CTM220)

JD-CTM220-21JAN04
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Format: PDF

Pages: 676

File size: 4.50 MB

Language: English

Models: CTM220, PowerTech 4.5 L & 6.8 L Diesel Engines — Level 11 Electronic Fuel System With Denso HPCR

JD-CTM220-21JAN04-EN-preview.pdf - 424.46KB
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Table of Contents for JD-CTM220-21JAN04-EN manual

  • CTM220 21JAN04 (ENGLISH)
  • POWERTECH 4.5L & 6.8L Diesel Engines Level 11 Electronic Fuel System With Denso HPCR
  • Introduction
    • Forward
  • Contents
  • General
    • Contents
    • Safety
    • Handle Fluids Safely-Avoid Fires
    • Handle Starting Fluid Safely
    • Service Cooling System Safely
    • Prevent Battery Explosions
    • Prepare for Emergencies
    • Handling Batteries Safely
    • Avoid High-Pressure Fluids
    • Wear Protective Clothing
    • Service Machines Safely
    • Work In Ventilated Area
    • Work in Clean Area
    • Remove Paint Before Welding or Heating
    • Avoid Heating Near Pressurized Fluid Lines
    • Illuminate Work Area Safely
    • Use Proper Lifting Equipment
    • Construct Dealer-Made Tools Safely
    • Practice Safe Maintenance
    • Use Proper Tools
    • Dispose of Waste Properly
    • Live With Safety
    • Engine Identification
    • Engine Model Designation
    • Engine Serial Number Plate Information
    • OEM Engine Option Code Label
    • Information Relative to Emissions Regulations
    • Engine Application Charts
    • Fuels, Lubricants, and Coolant
    • Lubricants and Coolant
    • Diesel Fuel
    • Bio-Diesel Fuel
    • Dieselscan Fuel Analysis
    • Lubricity of Diesel Fuel
  • Repair and Adjustments
    • Contents
    • Electronic Fuel System Repair and Adjustments
    • Fuel System General Information
    • Relieve Fuel System Pressure
    • Remove and Install Pre-Filter/Water Bowl Base
    • Replace Pre-Filter Element
    • Remove and Install Final Fuel Filter/Water Bowl Base
    • Replace Final Fuel Filter Element
    • Remove Fuel Transfer Pump
    • Install Fuel Transfer Pump
    • Remove and Install High Pressure Fuel Pump
    • Remove and Install High Pressure Fuel Pump Inlet Filter
    • Remove and Install High Pressure Common Rail
    • Remove and Install Flow Dampers
    • Remove and Install Pressure Limiter
    • Remove Electronic Injectors (EIs)
    • Clean Electronic Injector (EI) Bore
    • Clean Electronic Injector (EI) Orifice
    • Clean Electronic Injector (EI) Body
    • Inspect Electronic Injector (EI) Body
    • Install Electronic Injectors (EIs)
    • Remove and Install Leak-off Lines
    • Electronic Engine Control Repair and Adjustment
    • Engine Control Unit (ECU)
    • Fuel System Sensors
    • Remove and Install Engine Coolant Temperature (ECT) Sensor
    • Remove and Install Fuel Temperature Sensor
    • Remove and Install Manifold Air Temperature (MAT) Sensor
    • Remove and Install Oil Pressure Sensor
    • Remove and Install Fuel Rail Pressure Sensor
    • Remove and Install Crank Position Sensor
    • Remove and Install Pump Position Sensor
    • Remove and Install Glow Plugs
    • Connectors
    • Use Electrical Insulating Compound
    • Using High-Pressure Washer
    • Connector
    • Repair WEATHERPACK
    • Remove Blade Terminals from Connector Body
    • Repair (Pull Type) METRI-PACK
    • Connectors
    • Repair (Push Type) METRI-PACK
    • Connectors
    • Repair DEUTSCH
    • Repair AMP Connector
    • Repair SUMITOMO
    • Connectors
    • Repair YAZAKI
  • Theory Of Operation
    • Contents
    • Electronic Fuel System Operation
    • About This Group
    • Fuel System Operation
    • Pre-filter Operation
    • Fuel Transfer Pump Operation
    • Final Fuel Filter Operation
    • High Pressure Fuel Pump Operation
    • High Pressure Common Rail (HPCR) Operation
    • Electronic Injector (EI) Operation
    • Electronic Control System Operation
    • About This Group
    • Electronic Control System Terminology
    • Electronic Control System Operation
    • Electronic Control System Overview
    • Monitoring Engine Parameters
    • Measuring Temperature
    • Measuring Pressure
    • Measuring Throttle Position
    • Measuring Engine Speed
    • Pump Control Valve (PCV)
    • Water in Fuel (WIF) Sensor
    • Electronic Injector (EI) Wiring Harness Connector
    • Engine Control Unit (ECU)
    • Controlled Area Network (CAN)
    • Glow Plug Operation
    • Cruise Control Operation
    • Engine Protection
    • Derate Programs
    • Multiple Torque Curve Selection
    • Governor Droop Mode Selection
    • Engine Control Unit (ECU) Self-Diagnosis
  • Diagnostics
    • Contents
    • Observable Diagnostics and Tests
    • About This Group
    • E1 Engine Cranks/Won't Start
    • E2 Engine Misfires/Runs Irregularly
    • E3 Engine Does Not Develop Full Power
    • E4 Engine Emits Excessive White Exhaust Smoke
    • E5 Engine Emits Excessive Black Or Gray Exhaust Smoke
    • E6 Engine Will Not Crank
    • E7 Engine Idles Poorly
    • E8 Abnormal Engine Noise
    • E9 Analog Throttle (A) Does Not Respond
    • E10 Analog Throttle (B) Does Not Respond
    • F1 Fuel Supply System Check
    • F2 Excessive Fuel Consumption
    • F3 Fuel in Oil
    • D1 ECU Does Not Communicate with DST or SERVICE ADVISOR
    • D2 Diagnostic Gauge Does Not Communicate With ECU
    • A2 Glow Plug Check
    • Check Fuel Supply Quality
    • Test for Air in Fuel
    • Check Fuel Supply Pressure
    • Check for Restricted Fuel Leak-off Line
    • Bleed the Fuel System
    • Check and Adjust High Pressure Fuel Pump Static Timing
    • Trouble Code Diagnostics and Tests
    • About This Group
    • Electrical Concepts
    • Using a Digital Multimeter
    • Electrical Circuit Malfunctions
    • Troubleshooting Circuit Malfunctions
    • Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR
    • Blinking DTCs
    • Engine Configuration Data Parameters on Diagnostic Gauge
    • Viewing Active DTCs on Diagnostic Gauge
    • Viewing Stored DTCs on Diagnostic Gauge
    • Clearing Stored DTCs on Diagnostic Gauge
    • Data Parameter Description
    • Engine Test Instructions-Cylinder Misfire Test
    • Engine Test Instructions-Compression Test
    • Engine Test Instructions- Cylinder Cutout Test
    • Engine Test Instructions- Tractor Torque Curve Change Test
    • Reprogramming Engine Control Unit (ECU)
    • Downloading Payload File For DST
    • Reprogramming Engine Control Unit (ECU) With DST
    • Downloading Payload File For SERVICE ADVISOR
    • Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR
    • Diagnostic Trouble Codes (DTCs)
    • Listing of Diagnostic Trouble Codes (DTCs) on ECU
    • Diagnostic Procedure
    • Intermittent Fault Diagnostics
    • T1 Multi-state Throttle Input High
    • T2 Multi-state Throttle Input Low
    • T3 Analog Throttle (A) Input High
    • T4 Analog Throttle (A) Input Low
    • T5 Analog Throttle (B) Input High
    • T6 Analog Throttle (B) Input Low
    • T7 CAN Throttle Invalid
    • T17 Analog Throttle (C) Input High
    • T18 Analog Throttle (C) Input Low
    • T22 Analog Throttle (A) Input Voltage Out of Range
    • 000028.03 - Throttle Voltage High
    • 000028.04 - Throttle Voltage Low
    • 000029.03 - Throttle Voltage High
    • 000029.04 - Throttle Voltage Low
    • 000084.31 - Vehicle Speed Mismatch
    • 000091.03 - Throttle Voltage High
    • 000091.04 - Throttle Voltage Low
    • 000091.09 - Throttle Invalid
    • 000091.14 - Throttle Voltage Out of Range
    • 000094.03 - Fuel Rail Pressure Input Voltage High
    • 000094.04 Fuel Rail Pressure Input Voltage Low
    • 000094.04 - Fuel Rail Pressure Input Voltage Low
    • 000094.10 - Fuel Rail Pressure Loss Detected
    • 000094.13 - Fuel Rail Pressure Higher Than Expected
    • 000094.17 - Fuel Rail Pressure Not Developed
    • 000097.00 - Water in Fuel Continuously Detected
    • 000097.03 - Water in Fuel Signal Voltage High
    • 000097.04 - Water in Fuel Signal Voltage Low
    • 000097.16 - Water in Fuel Detected
    • 000100.01 - Engine Oil Pressure Extremely Low
    • 000100.03 - Engine Oil Pressure Input Voltage High
    • 000100.04 - Engine Oil Pressure Input Voltage Low
    • 000100.18 - Engine Oil Pressure Moderately Low
    • 000105.00 - Manifold Air Temperature Extremely High
    • 000105.03 - Manifold Air Temperature Input Voltage High
    • 000105.04 - Manifold Air Temperature Input Voltage Low
    • 000105.16 - Manifold Air Temperature Moderately High
    • 000107.00 - Air Filter Differential Pressure
    • 000110.00 - Engine Coolant Temperature Extremely High
    • 000110.03 - Engine Coolant Temperature Input Voltage High
    • 000110.04 - Engine Coolant Temperature Input Voltage Low
    • 000110.15 - Engine Coolant Temperature High Least Severe
    • 000110.16 - Engine Coolant Temperature Moderately High
    • 000111.01 - Engine Coolant Level Low
    • 000158.17 - ECU Power Down Error
    • 000160.02 - Wheel Speed Input Noise
    • 000174.00 - Fuel Temperature High Most Severe
    • 000174.03 - Fuel Temperature Input Voltage High
    • 000174.04 - Fuel Temperature Input Voltage Low
    • 000174.16 - Fuel Temperature High Moderately Severe
    • 000189.00 - Engine Speed Derate
    • 000190.00 - Engine Overspeed Extreme
    • 000190.16 - Engine Overspeed Moderate
    • 000237.02 - Vehicle Identification Number Invalid
    • 000237.13 - Vehicle Identification Option Code Invalid
    • 000237.31 - Vehicle Model Number Invalid
    • 000611.03 - Electronic Injector Wiring Shorted To Power Source
    • 000611.04 - Electronic Injector Wiring Shorted To Ground
    • 000620.03 - Sensor Supply 2 Voltage High
    • 000620.04 - Sensor Supply 2 Voltage Low
    • 000627.01 - Electronic Injector Supply Voltage Problem
    • 000629.13 - ECU Error
    • 000636.02 - Pump Position Sensor Input Noise
    • 000636.08 - Pump Position Sensor Input Missing
    • 000636.10 - Pump Position Sensor Input Pattern Error
    • 000637.02 - Crank Position Input Noise
    • 000637.07 - Crank Position/Pump Position Timing Moderately Out of Sync
    • 000637.08 - Crank Position Input Missing
    • 000637.10 - Crank Position Input Pattern Error
    • 000639.13 - CAN Bus Error
    • 000651.05 - Cylinder #1 EI Circuit Open
    • 000651.06 - Cylinder #1 EI Circuit Shorted
    • 000651.07 - Cylinder #1 EI Mechanical Failure
    • 000652.05 - Cylinder #2 EI Circuit Open
    • 000652.06 - Cylinder #2 EI Circuit Shorted
    • 000652.07 - Cylinder #2 EI Mechanical Failure
    • 000653.05 - Cylinder #3 EI Circuit Open
    • 000653.06 - Cylinder #3 EI Circuit Shorted
    • 000653.07 - Cylinder #3 EI Mechanical Failure
    • 000654.05 - Cylinder #4 EI Circuit Open
    • 000654.06 - Cylinder #4 EI Circuit Shorted
    • 000654.07 - Cylinder #4 EI Mechanical Failure
    • 000655.05 - Cylinder #5 EI Circuit Open
    • 000655.06 - Cylinder #5 EI Circuit Shorted
    • 000655.07 - Cylinder #5 EI Mechanical Failure
    • 000656.05 - Cylinder #6 EI Circuit Open
    • 000656.06 - Cylinder #6 EI Circuit Shorted
    • 000656.07 - Cylinder #6 EI Mechanical Failure
    • 000676.03 - Glow Plug Relay Voltage High
    • 000676.05 - Glow Plug Relay Voltage Low
    • 000898.09 - Vehicle Speed or Torque Message Invalid
    • 000970.31 - Engine Shutdown Auxiliary Request
    • 000971.31 - External Fuel Derate Switch Active
    • 001069.09 - Tire Size Invalid
    • 001069.31 - Tire Size Error
    • 001079.03 - Sensor Supply 1 Voltage High
    • 001079.04 - Sensor Supply 1 Voltage Low
    • 001080.03 - Fuel Rail Pressure Sensor Supply Voltage High
    • 001080.04 - Fuel Rail Pressure Sensor Supply Voltage Low
    • 001109.31 - Engine Protection Shutdown Warning
    • 001110.31 - Engine Protection Shutdown
    • 001347.03 - Pump Control Valve Current High
    • 001347.05 - Pump Control Valve Current Mismatch
    • 001347.07 - Fuel Rail Pressure Control Error
    • 001347.10 - Pump Control Valve Fuel Flow Not Detected
    • 001568.02 - Torque Curve Selection Invalid
    • 001569.31 - Fuel Derate
    • 001639.01 - Fan Speed Input Missing
    • 001639.16 - Fan Speed Higher Than Expected
    • 001639.18 - Fan Speed Lower Than Expected
    • 002000.13 - Security Violation
    • 002005.09 - ACU Signal Missing
    • 002049.09 - CAB Signal Missing
    • 002071.09 - CCU Signal Missing
  • Tools
    • Contents
    • Control System Repair Tools and Other Materials
    • Electronic Fuel System Repair and Adjustment Essential Tools
    • Fuel System Repair and Adjustment Other Materials
    • Electronic Engine Control Repair Tools
    • Control Repair and Adjustment Other Materials
    • Diagnostic Service Tools
    • Electronic Fuel/Control System Diagnostic Tools
  • Specifications
    • Contents
    • Repair Specifications
    • Unified Inch Bolt and Cap Screw Torque Values
    • Metric Bolt and Cap Screw Torque Values
    • Electronic Fuel System Repair and Adjustment Specifications
    • Electronic Engine Control Repair and Adjustment Specifications
    • Diagnostic Specifications
    • Fuel System Diagnostic Specifications
    • Application Specifications
    • Combines Sensor Specifications
    • Combines Torque Curve Selection
    • Combines Governor Mode Selection
    • Combines ECU Terminal Identification
    • Loaders Sensor Specifications
    • Loaders Torque Curve Selection
    • Loaders Governor Mode Selection
    • Loaders ECU Terminal Identification
    • Motor Graders Sensor Specifications
    • Motor Graders Torque Curve Selection
    • Motor Graders Governor Mode Selection
    • Motor Graders ECU Terminal Identification
    • OEM Engines Sensor Specifications
    • OEM Engines Torque Curve Selection
    • OEM Engines Governor Mode Selection
    • OEM Engines ECU Terminal Identification
    • B01
    • B02
    • B03
    • X03 B04
    • B07
    • B08
    • B06
    • X03
    • X08
    • X14
    • X01
    • F02
    • S1
    • X02
    • S3
    • X03
    • N01
    • S2
    • X05
    • X04
    • 6020 Tractors Sensor Specifications
    • 6020 Tractors Torque Curve Selection
    • 6020 Tractors Governor Mode Selection
    • 6020 Tractors ECU Terminal Identification
    • Tractors 7720 7820 Series Sensor Specifications
    • Tractors 7720 7820 Series Torque Curve Selection
    • Tractors 7720 7820 Series Governor Mode Selection
    • Tractors 7720 7820 Series ECU Terminal Identification
  • Index
Language
English
Document type
Technical manual
Machinery type
engine
JD-CTM220-21JAN04-EN-preview.pdf - 424.46KB

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