Download Electronic Fuel System With Stanadyne DE10 Pump PDF

TitleElectronic Fuel System With Stanadyne DE10 Pump
TagsInternal Combustion Engine Fuel Injection Diesel Fuel Motor Oil Biodiesel
File Size11.8 MB
Total Pages510
Table of Contents
                            Contents
	General Information
		Safety
			Handle Fluids Safely—Avoid Fires
			Handle Starting Fluid Safely
			Prepare for Emergencies
			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
			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
		Fuels
			Lubricants and Coolant
			Diesel Fuel
			Bio-Diesel Fuel
			Testing Diesel Fuel
			Lubricity of Diesel Fuel
	Repair and Adjustments
		Electronic Fuel System Repair and Adjustments
			Fuel System—General Information
			Relieve Fuel System Pressure
			Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filte
			Fuel Pre-Filter/Water Bowl Assembly (Optional)
			Final Fuel Filter Assembly
			Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl
			Remove Fuel Supply Pump
			Install Fuel Supply Pump
			Injection Pump Static Timing
			Remove Injection Pump
			Inspect Injection Pump Drive Gear ID and Shaft OD
			Install Injection Pump
			Remove Fuel Injection Nozzles
			Clean Fuel Injection Nozzle Bore
			Clean Fuel Injection Nozzles
			Fuel Injection Nozzle Test
			Disassemble Fuel Injection Nozzles
			Adjust Fuel Injection Nozzle
			Install Seals on Fuel Injection Nozzle
			Install Fuel Injection Nozzles
			Bleed the Fuel System
		Electrical Engine Control Repair and Adjustment
			Engine Control Unit (ECU)
			Remove and Install Engine Coolant Temperature Sensor
			Remove and Install Loss of Coolant Temperature Sensor
			Replace Crankshaft Position Sensor
			Remove and Install Oil Pressure Sensor
			Remove and Install Manifold Air Temperature Sensor
			Remove and Install Fuel Temperature Sensor
			Remove and Install Fuel Heater
			Connectors
			Use Electrical Insulating Compound
			Using High-Pressure Washer
			Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electri
			Remove Blade Terminals from Connector Body
			Repair (Pull Type) METRI-PACKMETRI-PACK is a trademark of Delph
			Repair (Push Type) METRI-PACKMETRI-PACK is a trademark of Delph
			Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company™ Connec
			Repair AMP Connector
	Theory of Operation
		Electronic Fuel System Operation
			About this Group
			Fuel System Operation
			Fuel Supply Pump Operation
			Final Fuel Filter Operation
			Fuel Injection Pump Operation
			Fuel Injection Nozzle Operation
		Electronic Control System Operation
			About This Group
			Electronic Control System Terminology
			Electronic Control System Operation
			Monitoring Engine Parameters
			Electronic Control System Overview
			Measuring Temperature
			Measuring Pressure
			Measuring Throttle Position
			Measuring Engine Speed
			Marine Throttle Control Options
			Engine Synchronization Throttle Control
			Throttle Control Location Transfer
			Pump Solenoid
			Water in Fuel (WIF) Sensor
			Engine Control Unit (ECU)
			Controller Area Network (CAN)
			Cruise Control Operation
			Intake Air Heater Operation
			Engine Protection
			Derate Programs
			Multiple Torque Curve Selection
			Governor Droop Mode Selection
			Engine Control Unit (ECU) Self-Diagnosis
	Diagnostics
		Observable Diagnostics and Tests
			About This Group of the Manual
			E1 - Engine Cranks/Won't Start
				E1 - Engine Cranks/Won't Start Diagnostic Procedure
			E2 - Engine Misfires/Runs Irregularly
				E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
			E3 - Engine Does Not Develop Full Power
				E3 - Engine Does Not Develop Full Power Diagnostic Procedure
			E4 - Engine Emits Excessive White Exhaust Smoke
				E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Proce
			E5 - Engine Emits Excessive Black Or Gray Smoke
				E5 - Engine Emits Excessive Black Or Gray Smoke Diagnostic Proce
			E6 - Engine Will Not Crank
			E7 - Engine Idles Poorly
			E8 - Abnormal Engine Noise
			E9 - Analog Throttle (B) Does Not Respond
			F1 - Fuel Supply System Check
				F1 - Fuel Supply System Check Diagnostic Procedure
			F2 - Excessive Fuel Consumption
			F3 - Fuel in Oil
			F5 - Fuel Injection Nozzle Check
			D1 - ECU Does Not Communicate with the DST or SERVICE ADVISOR
			D1 - ECU Does Not Communicate With the DST orSERVICE ADVISORSERV
				D1 - ECU Does Not Communicate with the DST or SERVICE ADVISORSER
			D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With
			D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With
				D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With
			D3 - Diagnostic Gauge (Later Model) Does Not Communicate With EC
			D3 - Diagnostic Gauge (Later Model) Does Not Communicate With EC
				D3 - Diagnostic Gauge (Later Model) Does Not Communicate With EC
			A1 - Intake Air Heater Check
			A1 - Intake Air Heater Check - Continued
			A1 - Intake Air Heater Check
				A1 - Intake Air Heater Check Diagnostic Procedure
			Check Fuel Supply Quality
			Test for Fuel Drain Back
			Test for Air in Fuel
			Check Fuel Supply Pressure
			Bench Test Fuel Supply Pump
			Bleed the Fuel System
			Test for Cylinder Misfire (Engine Running)
		Trouble Code Diagnostics and Tests
			About this Group of the Manual
			Electrical Concepts
			Using a Digital Multimeter
			Electrical Circuit Malfunctions
			Troubleshooting Circuit Malfunctions
			Connecting to Diagnostic Scan Tool (DST) or Service ADVISOR
			Viewing Active DTCs on Diagnostic Gauge (Earlier Model)
			Viewing Stored DTCs on Diagnostic Gauge (Earlier Model)
			Clearing Stored DTCs on Diagnostic Gauge (Earlier Model)
			Engine Configuration Parameters on Diagnostic Gauge (Earlier Mod
			Viewing Active DTCs on Diagnostic Gauge (Later Model)
			Viewing Stored DTCs on Diagnostic Gauge (Later Model)
			Clearing Stored DTCs on Diagnostic Gauge (Later Model)
			Blinking DTCs
			Data Parameter Description
			Engine Test Instructions - Excavator Torque Curve Change Test
			Reprogramming Engine Control Unit (ECU)
			Diagnostic Trouble Codes (DTCs)
			Listing of Diagnostic Trouble Codes (DTCs) on ECU
			Diagnostic Procedure
			Intermittent Fault Diagnostics
			T1 - Multi-state Throttle Input High
			T1 - Multi-state Throttle Input High
				T1 - Multi-State Throttle Input High Diagnostic Procedure
			T2 - Multi-state Throttle Input Low
			T2 - Multi-state Throttle Input Low
				T2 - Multi-State Throttle Input Low Diagnostic Procedure
			T3 - Analog Throttle (A) Input High
			T3 - Analog Throttle (A) Input High
				T3 - Analog Throttle (A) Input High Diagnostic Procedure
			T4 - Analog Throttle (A) Input Low
			T4 - Analog Throttle (A) Input Low
				T4 - Analog Throttle (A) Input Low Diagnostic Procedure
			T5 - Analog Throttle (B) Input High
			T5 - Analog Throttle (B) Input High
				T5 - Analog Throttle (B) Input High Diagnostic Procedure
			T6 - Analog Throttle (B) Input Low
			T6 - Analog Throttle (B) Input Low
				T6 - Analog Throttle (B) Input Low Diagnostic Procedure
			T7 - CAN Throttle Invalid
			T7 - CAN Throttle Invalid
				T7 - CAN Throttle Invalid Diagnostic Procedure
			T11 - Excavator Throttle Reference Voltage High
			T11 - Excavator Throttle Reference Voltage High
				T11 - Excavator Throttle Reference Voltage High Diagnostic Proce
			T12 - Excavator Throttle Reference Voltage Low
			T12 - Excavator Throttle Reference Voltage Low
				T12 - Excavator Throttle Reference Voltage Low Diagnostic Proced
			T13 - Excavator Throttle Ground Voltage High
			T13 - Excavator Throttle Ground Voltage High
				T13 - Excavator Throttle Ground Voltage High Diagnostic Procedur
			T14 - Excavator Throttle Ground Voltage Low
			T14 - Excavator Throttle Ground Voltage Low
				T14 - Excavator Throttle Ground Voltage Low Diagnostic Procedure
			T15 - Excavator Throttle Input Voltage High
			T15 - Excavator Throttle Input Voltage High
				T15 - Excavator Throttle Input Voltage High Diagnostic Procedure
			T16 - Excavator Throttle Input Voltage Low
			T16 - Excavator Throttle Input Voltage Low
				T16 - Excavator Throttle Input Voltage Low Diagnostic Procedure
			T17 - Analog Throttle (C) Input High
			T17 - Analog Throttle (C) Input High
				T17 - Analog Throttle (C) Input High Diagnostic Procedure
			T18 - Analog Throttle (C) Input Low
			T18 - Analog Throttle (C) Input Low
				T18 - Analog Throttle (C) Input Low Diagnostic Procedure
			T19 - Throttle Not Calibrated Properly
			T20 - Throttle Input Voltage Below Lower Calibration Limit
			T21 - Throttle Calibration Aborted
			T22 - Analog Throttle (A) Input Voltage Out of Range
			T23 - Multi-state Throttle 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
			000029.14 — Throttle Voltage Out of Range
			000084.31 — Vehicle Speed Mismatch
			000084.31 — Vehicle Speed Mismatch
				000084.31 Vehicle Speed Mismatch Diagnostic Procedure
			000091.03 — Throttle Voltage High
			000091.04 — Throttle Voltage Low
			000091.07 — Throttle Calibration Invalid
			000091.09 — Throttle CAN message Missing
			000091.10 — Throttle Voltage Low
			000091.13 — Throttle Calibration Aborted
			000091.14 — Throttle Voltage Out of Range
			000094.01 — Fuel Pressure Extremely Low
			000094.01 — Fuel Pressure Extremely Low
				000094.01 Fuel Pressure Extremely Low Diagnostic Procedure
			000094.03 — Fuel Pressure Input Voltage High
			000094.03 — Fuel Pressure Input Voltage High
				000094.03 Fuel Pressure Input Voltage High Diagnostic Procedure
			000094.04 — Fuel Pressure Input Voltage Low
			000094.04 — Fuel Pressure Input Voltage Low
				000094.04 Fuel Pressure Input Voltage Low Diagnostic Procedure
			000094.18 — Fuel Pressure Moderately Low
			000094.18 — Fuel Pressure Moderately Low
			000097.00 — Water in Fuel Continuously Detected
			000097.00 — Water in Fuel Continuously Detected Diagnostic Proce
				Water in Fuel Continuously Detected Diagnostic Procedure
			000097.03 — Water in Fuel Signal Voltage High
			000097.03 — Water in Fuel Signal Voltage High
				000097.03 Water In Fuel Signal Voltage High Diagnostic Procedure
			000097.04 — Water in Fuel Signal Voltage Low
			000097.04 — Water in Fuel Signal Voltage Low
				000097.04 Water In Fuel Signal Voltage Low Diagnostic Procedure
			000097.16 — Water in Fuel Detected
			000097.16 — Water in Fuel Detected
				000097.16 Water In Fuel Detected Diagnostic Procedure
			000097.31 — Water in Fuel Detected (750J Crawler Only)
			000097.31 — Water in Fuel Detected (750J Crawler Only)
				Water in Fuel Detected (750J Crawler Only) Diagnostic Procedure
			000100.01 — Engine Oil Pressure Extremely Low
			000100.01 — Engine Oil Pressure Extremely Low
				000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure
			000100.03 — Engine Oil Pressure Input Voltage High
			000100.03 — Engine Oil Pressure Input Voltage High
				000100.03 Engine Oil Pressure Input Voltage High Diagnostic Proc
			000100.04 — Engine Oil Pressure Input Voltage Low
			000100.04 — Engine Oil Pressure Input Voltage Low
				000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Proce
			000100.16 - Engine Oil Pressure High, Moderately Severe Level
			000100.16 — Engine Oil Pressure High, Moderately Severe Level In
				Electrical Test
			000100.18 — Engine Oil Pressure Moderately Low
			000100.18 — Engine Oil Pressure Moderately Low
				000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedur
			000100.31 — Engine Oil Pressure Detected with Engine Stopped
			000100.31 — Engine Oil Pressure Detected with Engine Stopped
				000100.31 Engine Oil Pressure Detected with Engine Stopped Diagn
			000105.00 — Manifold Air Temperature Extremely High
			000105.00 — Manifold Air Temperature Extremely High
				000105.00 Manifold Air Temperature Extremely High Diagnostic Pro
			000105.03 — Manifold Air Temperature Input Voltage High
			000105.03 — Manifold Air Temperature Input Voltage High
				000105.03 Manifold Air Temperature Input Voltage High Diagnostic
			000105.04 — Manifold Air Temperature Input Voltage Low
			000105.04 — Manifold Air Temperature Input Voltage Low
				000105.04 Manifold Air Temperature Input Voltage Low Diagnostic
			000105.16 — Manifold Air Temperature Moderately High
			000105.16 — Manifold Air Temperature Moderately High
				000105.16 Manifold Air Temperature Moderately High Diagnostic Pr
			000107.00 — Air Filter Restriction Switch Activated
			000107.00 — Air Filter Restriction Switch Activated
				000107.00 Air Filter Restriction Switch Diagnostic Procedure
			000110.00 — Engine Coolant Temperature Extremely High
			000110.00 — Engine Coolant Temperature Extremely High
				000110.00 Engine Coolant Temperature Extremely High Diagnostic P
			000110.03 — Engine Coolant Temperature Input Voltage High
			000110.03 — Engine Coolant Temperature Input Voltage High
				000110.03 Engine Coolant Temperature Input Voltage High Diagnost
			000110.04 — Engine Coolant Temperature Input Voltage Low
			000110.04 — Engine Coolant Temperature Input Voltage Low
				000110.04 Engine Coolant Temperature Input Voltage Low Diagnosti
			000110.15 — Engine Coolant Temperature High Least Severe
			000110.15 — Engine Coolant Temperature High Least Severe
				000110.15 Engine Coolant Temperature High Least Severe Diagnosti
			000110.16 — Engine Coolant Temperature Moderately High
			000110.16 — Engine Coolant Temperature Moderately High
				000110.16 Engine Coolant Temperature Moderately High Diagnostic
			000111.00 — Loss of Coolant Temperature Extremely High
			000111.00 — Loss of Coolant Temperature Extremely High
				000111.00 Loss of Coolant Temperature Extremely High Diagnostic
			000111.03 — Loss of Coolant Temperature Input Voltage High
			000111.03 — Loss of Coolant Temperature Input Voltage High
				000111.03 Loss of Coolant Temperature Input Voltage High Diagnos
			000111.04 — Loss of Coolant Temperature Input Voltage Low
			000111.04 — Loss of Coolant Temperature Input Voltage Low
				000111.04 Loss of Coolant Temperature Input Voltage Low Diagnost
			000158.17 — ECU Power Down Error
			000158.17 — ECU Power Down Error
				000158.17 ECU Power Down Error Diagnostic Procedure
			000160.02 — Wheel Speed Input Noise
			000160.02 — Wheel Speed Input Noise
				000160.02 Wheel Speed Input Noise Diagnostic Procedure
			000171.03 — Ambient Air Temperature Input Voltage Out Of Range H
			000171.03 — Ambient Air Temperature Input Voltage Out Of Range H
				000171.03 AAT Input Voltage Out Of Range High Diagnostic Procedu
			000171.04 — Ambient Air Temperature Input Voltage Out Of Range L
			000171.04 — Ambient Air Temperature Input Voltage Out Of Range L
				000171.04 Ambient Air Temperature Input Voltage Out Of Range Low
			000174.00 — Fuel Temperature Extremely High
			000174.00 — Fuel Temperature Extremely High
				000174.00 Fuel Temperature Extremely High Diagnostic Procedure
			000174.03 — Fuel Temperature Input Voltage High
			000174.03 — Fuel Temperature Input Voltage High
				000174.03 Fuel Temperature Input Voltage High Diagnostic Procedu
			000174.04 — Fuel Temperature Input Voltage Low
			000174.04 — Fuel Temperature Input Voltage Low
				000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedur
			000174.16 — Fuel Temperature High Moderately Severe
			000174.16 — Fuel Temperature High Moderately Severe
				000174.16 Fuel Temperature High Moderately Severe Diagnostic Pro
			000189.00 — Engine Speed Derate
			000190.00 — Engine Overspeed Extreme
			000190.01 — Engine Speed Below Normal Operational Range, Most Se
			000190.01 — Engine Speed Below Normal Operational Range, Most Se
				000190.01 Engine Speed Below Normal Operational Range, Most Seve
			000190.16 — Engine Overspeed Moderate
			000190.18 — Engine Speed Below Normal Operational Range, Moderat
			000523.09 — Current Gear Selection Invalid or Not Received (J-se
			000620.03 — Sensor Supply Voltage High
			000620.03 — Sensor Supply Voltage High
				000620.03 Sensor Supply Voltage High Diagnostic Procedure
			000620.04 — Sensor Supply Voltage Low
			000620.04 — Sensor Supply Voltage Low
				000620.04 Sensor Supply Voltage Low Diagnostic Procedure
			000629.13 — ECU Error
				000629.13 ECU Error Diagnostic Procedure
			000637.02 — Crank Position Input Noise
			000637.02 — Crank Position Input Noise
				000637.02 Crank Position Input Noise Diagnostic Procedure
			000637.08 — Crank Position Input Missing
			000637.08 — Crank Position Input Missing
				000637.08 Crank Position Input Missing Diagnostic Procedure
			000637.10 — Crank Position Input Pattern Error
			000637.10 — Crank Position Input Pattern Error
				000637.10 Crank Position Input Pattern Error Diagnostic Procedur
			000639.13 — CAN Bus Error
			000639.13 — CAN Bus Error
				000639.13 CAN Bus Error Diagnostic Procedure
			000644.02 — External Speed Command Input (OEM, Marine Only)
			000729.03 — Inlet Air Heater Signal High
			000729.03 — Inlet Air Heater Signal High
				000729.03 Inlet Air Heater Signal High Diagnostic Procedure
			000729.05 — Inlet Air Heater Signal Low
			000729.05 — Inlet Air Heater Signal Low
				000729.05 Inlet Air Heater Signal Low Diagnostic Procedure
			000898.09 — Vehicle Speed or Torque Message Invalid
			000970.31 — Auxiliary Engine Shutdown Switch Active
			000971.31 — External Engine Derate Switch Active
			001069.09 — Tire Size Invalid
			001069.09 — Tire Size Invalid
				001069.09 Tire Size Invalid Diagnostic Procedure
			001069.31 — Tire Size Error
			001069.31 — Tire Size Error
				001069.31 Tire Size Error Diagnostic Procedure
			001076.00 — Pump Control Valve Closure Too Long
			001076.00 — Pump Control Valve Closure Too Long
				001076.00 Pump Control Valve Closure Too Long Diagnostic Procedu
			001076.01 — Pump Control Valve Closure Too Short
			001076.01 — Pump Control Valve Closure Too Short
				001076.01 Pump Control Valve Closure Too Short Diagnostic Proced
			001076.03 — Pump Solenoid Current High
			001076.03 — Pump Solenoid Current High
				001076.03 Pump Solenoid Current High Diagnostic Procedure
			001076.05 — Pump Solenoid Circuit Open
			001076.05 — Pump Solenoid Circuit Open
				001076.05 Pump Solenoid Circuit Open Diagnostic Procedure
			001076.06 — Pump Solenoid Circuit Severely Shorted
			001076.06 — Pump Solenoid Circuit Severely Shorted
				001076.06 Pump Solenoid Circuit Severely Shorted Diagnostic Proc
			001076.07 — Pump Control Valve Closure Not Detected
			001076.07 — Pump Control Valve Closure Not Detected
				001076.07 Pump Control Valve Closure Not Detected Diagnostic Pro
			001076.10 — Pump Solenoid Circuit Moderately Shorted
			001076.10 — Pump Solenoid Circuit Moderately Shorted
				001076.10 Pump Solenoid Circuit Moderately Shorted Diagnostic Pr
			001076.13 — Pump Current Decay Time Invalid
			001076.13 — Pump Current Decay Time Invalid
				001076.13 Pump Current Decay Time Invalid Diagnostic Procedure
			001079.03 — Sensor Supply Voltage High
			001079.03 — Sensor Supply Voltage High
				001079.03 Sensor Supply Voltage High Diagnostic Procedure
			001079.04 — Sensor Supply Voltage Low
			001079.04 — Sensor Supply Voltage Low
				001079.04 Sensor Supply Voltage Low Diagnostic Procedure
			001109.31 — Engine Protection Shutdown Warning
			001110.31 — Engine Protection Shutdown
			001568.02 — Torque Curve Selection Invalid or Missing (750J Craw
			001569.31 — Fuel Derate
			002000.06 — Internal ECU Failure
				002000.06 Pump or ECU Failure Diagnostic Procedure
			002006.06 — Internal ECU Failure
				002006.06 Pump or ECU Failure Diagnostic Procedure
			002000.13 — Security Violation
	Tools and Other Materials
		Electronic Fuel/Control System Repair Tools and Other Materials
			Fuel System Repair and Adjustment Essential Tools
			Fuel System Repair and Adjustment Service Equipment and Tools
			Fuel System Repair and Adjustment Other Materials
			Control System Repair and Adjustment Essential Tools
			Control System Repair and Adjustment Other Materials
		Diagnostic Service Tools
			ic Fuel System Diagnostic Tools
	Specifications
		Repair Specifications
			Unified Inch Bolt and Screw Torque Values
			Metric Bolt and Screw Torque Values
			General OEM Engine Specifications
			Electronic Fuel System Repair and Adjustment Specifications
			Electronic Engine Control Repair and Adjustment Specifications
		Diagnostic Specifications
			Group 150/160 Electronic Fuel System Diagnostic Specifications
			Application Specifications
			Backhoes - Sensor Specifications
			Backhoes - Torque Curve Selection
			Backhoes - Governor Mode Selection
			Backhoes - ECU Terminal Identification
			Crawlers - Sensor Specifications
			Crawlers - Torque Curve Selection
			Crawlers - Governor Mode Selection
			Crawlers - ECU Terminal Identification
			Excavators - Sensor Specifications
			Excavators - Torque Curve Selection
			Excavators - Governor Mode Selection
			Excavators - ECU Terminal Identification
			Forwarders - Sensor Specifications
			Forwarders - Torque Curve Selection
			Forwarders - Governor Mode Selection
			Forwarders - ECU Terminal Identification
			Harvesters - Sensor Specifications
			Harvesters - Torque Curve Selection
			Harvesters - Governor Mode Selection
			Harvesters - ECU Terminal Identification
			OEM Engines - Sensor Specifications
			OEM Engines - Torque Curve Selection
			OEM Engines - Governor Mode Selection With OC03038 Software or L
			OEM Engines - Governor Mode Selection With OC03033 Software or E
			OEM Engines - ECU Terminal Identification
			OEM Engines - Electronic Control System Wiring Diagram - Base EC
			OEM Engines - Electronic Control System Wiring Diagram - Extende
			OEM Engines - Electronic Control System Wiring Diagram - Extende
			OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Componen
			Skidders - Sensor Specifications
			Skidders - Torque Curve Selection
			Skidders - Governor Mode Selection
			Skidders - ECU Terminal Identification
			Telehandlers - Sensor Specifications
			Telehandlers - Torque Curve Selection
			Telehandlers - Governor Mode Selection
			Telehandlers - ECU Terminal Identification
			Tractors - Sensor Specifications
			Tractors - Torque Curve Selection
			Tractors - Governor Mode Selection
			Tractors - ECU Terminal Identification
Page Number
	Section 01
		Group 000
		Group 001
		Group 002
	Section 02
		Group 090
		Group 110
	Section 03
		Group 130
		Group 140
	Section 04
		Group 150
		Group 160
	Section 05
		Group 170
		Group 180
	Section 06
		Group 200
		Group 210
                        
Document Text Contents
Page 1

COMPONENT TECHNICAL MANUAL
PowerTech 4.5L and 6.8L Diesel
Engines—Level 12 Electronic Fuel

System with DE10 Pump
CTM331 15FEB11 (ENGLISH)

PowerTech™ 4.5L and
6.8L Diesel Engines

Level 12 Electronic
Fuel System With

Stanadyne DE10 Pump

For complete service information also see:

PowerTech 4.5L and 6.8L Diesel
Engines—Base Engine ...................................... CTM104
Alternators and Starter Motors ......................... CTM77
OEM Engine Accessories .................................. CTM67
Application List ................................................... CTM106819

John Deere Power Systems
LITHO IN U.S.A.

Page 2

Introduction

OUO1080,00001FE ­19­15FEB11­1/1

PU00210,00004DF ­19­15FEB11­1/1

Foreword

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 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. There are
four companion manuals which cover the base engine,
mechanical fuel system, level 4 electronic fuel system
and level 1 electronic fuel system repair, operation and
diagnostics:

Other manuals may 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.

This is the safety­alert symbol. When you see this
symbol on the machine or in this manual, be alert to the
potential for personal injury.

Use this component technical manual in conjunction with
the machine technical manual. An application
listing in Section 01, Group 001 identifies
product­model/component type­model relationship.
See the machine technical manual for information on
component removal and installation, and gaining access
to the components.

Information is organized in sections and groups for the
various components requiring service instruction. Section
05 summarizes all applicable essential tools, service
equipment and tools, other materials needed to do the
job, and service parts kits. Section 06 summarizes all
specifications, wear tolerances, and torque values.

Before beginning diagnosis or repair on an engine, clean
the engine.

This manual contains SI Metric units of measure followed
immediately by the U.S. customary units of measure.
Most hardware on these engines is metric sized.

Some components of this engine may be serviced without
removing the engine from the machine. Refer to the
specific machine technical manual for information on
components that can be serviced without removing the
engine from the machine and for engine removal and
installation procedures.

Read each block of material completely before performing
service to check for differences in procedures or
specifications. Follow only the procedures that apply to
the engine model number you are working on. If only
one procedure is given, that procedure applies to all the
engines in the manual.

CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects and other reproductive harm.

Record of Changes
Publication and Translation Date

Section / Group Block Title Comment Update Date

CTM331 (15FEB11) 4.5L and 6.8L Level 12 Electronic Fuel System
022311

PN=2

Page 255

Trouble Code Diagnostics and Tests

RG40854,0000115 ­19­23SEP05­1/8

RG40854,0000115 ­19­23SEP05­2/8

RG40854,0000115 ­19­23SEP05­3/8

RG40854,0000115 ­19­23SEP05­4/8

Continued on next page RG40854,0000115 ­19­23SEP05­5/8

000084.31 — Vehicle Speed Mismatch
The wheel speed from the BCU (PWM signal) and
the BIF (CAN) do not match at the ECU.

000084.31 Vehicle Speed Mismatch Diagnostic Procedure

NOTE: If DTC 001069.31 occurs with DTC 000084.31, diagnose DTC 001069.31 first.

•1 Connection Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLESPEED MISMATCH supporting information. No faulty connections:
GO TO•2

Perform a preliminary inspection of ECU connectors, BIF, and BCU connectors looking
for dirty, damaged, or poorly positioned terminals.

Faulty connections:
Repair faulty connection(s).

•2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLESPEED MISMATCH supporting information.
1. Connect to the DST or SERVICE ADVISOR.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of all DTCs, then clear all DTCs
5. Ignition ON, engine running 000084.31 reoccurs:

GO TO•36. Read DTCs using the DST orSERVICE ADVISOR™. 000084.31 doesn’t
reoccur:
Problem is intermittent. If
no other codes are present,
see INTERMITTENT
FAULT DIAGNOSTICS,
earlier in this Group.

SERVICE ADVISOR is a trademark of Deere & Company

•3 CAN Vehicle SpeedCheck NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLESPEED MISMATCH supporting information.
1. Drive vehicle under normal operating conditions Greater than 0 km/hr (0

mph):

GO TO•52. Read the CAN vehicle speed parameter 0 km/hr (0 mph):
GO TO•4

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Page 256

Trouble Code Diagnostics and Tests

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RG40854,0000115 ­19­23SEP05­7/8

RG40854,0000115 ­19­23SEP05­8/8

•4 BCU to BIF PWMWire Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLESPEED MISMATCH supporting information.
1. Ignition OFF
2. Disconnect BCU connector and BIF connector. 5 ohms or less:

Possible CAN error ­ follow
vehicle CAN diagnostic
procedure

3. Using multimeter, measure resistance between terminal 64 on the BCU connector
and terminal 21L on the BIF connector.

Greater than 5 ohms:
Open in wheel speed
sensor wire between BCU
and BIF wire.

•5 Calculated VehicleSpeed Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLESPEED MISMATCH supporting information.
1. Drive vehicle under normal operating conditions Greater than 0 rpm:

Tire size misprogrammed in
BIF

2. Read the calculated vehicle speed parameter 0 rpm:

GO TO•6
•6 BCU to ECU PWMWire Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLESPEED MISMATCH supporting information.

1. Ignition OFF
2. Disconnect ECU connector and BCU connector. 5 ohms or less:

Faulty ECU connector
OR
Faulty ECU

3. Using multimeter, measure resistance between terminal D2 of ECU connector and
terminal 64 of BCU connector.

Greater than 5 ohms:
Open in wheel speed
sensor wire between ECU
and BCU.

CTM331 (15FEB11) 04­160­100 4.5L and 6.8L Level 12 Electronic Fuel System
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Page 509

Index

Page

Operation ....................................................... 03­140­18
Trouble codes
Diagnostic procedure..................................... 04­160­30
Listing of......................................................... 04­160­26

Trouble Codes
on Diagnostic Gauge (Earlier Model)
Clearing Stored Codes............................... 04­160­15
Viewing Active Codes................................. 04­160­14
Viewing Stored Codes................................ 04­160­14

on Diagnostic Gauge (Later Model)
Clearing Stored Codes............................... 04­160­20
Viewing Active Codes................................. 04­160­18
Viewing Stored Codes................................ 04­160­19

U

Unified inch bolt and screw torque
values ................................................................ 06­200­1

Page

W

Water in Fuel Sensor
Operation ....................................................... 03­140­13

Wiring diagram
Instrument panel (OEM)................................. 06­210­23
OEM engines
Base ECU................................................... 06­210­18
Extended ECU ­ Early ................................ 06­210­21
Extended ECU ­ Later ................................ 06­210­19

CTM331 (15FEB11) Index­7 4.5L and 6.8L Level 12 Electronic
Fuel System

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Page 510

Index

CTM331 (15FEB11) Index­8 4.5L and 6.8L Level 12 Electronic
Fuel System

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