CTM331 (1 4045T Engine Service)

COMPONENT TECHNICAL MANUALPowerTech® 4.5 & 6.8 L Diesel Engines—Level 12 Electronic Fuel System with DE10 Pump CTM331 09APR02 (English) POWERTECH® 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel System With Stanadyne DE10 Pump TECHNICAL MANUAL POWERTECH® 4.5 L & 6.8 L Diesel Engines—Level 12 Electronic Fuel System with DE10 Pump CTM331 09APR02 (ENGLISH) For complete service information also see: POWERTECH 4.5 L and 6.8 L Diesel Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104 Alternators and Starter Motors . . . . . . . . . . . CTM77 OEM Engine Accessories . . . . . . CTM67 (English Only) ® John Deere Power Systems LITHO IN U.S.A. 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. This is the safety-alert 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 product-model/component type-model 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. OUO1080,00001FE –19–16NOV01–1/1 CTM331 (09APR02) 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=2 Introduction POWERTECH® 4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10 Pump –UN–06NOV01 RG11931 Left Side of Engine Right Side of Engine POWERTECH is a registered trademark of Deere & Company DPSG,OUO1004,129 –19–15MAY98–1/1 CTM331 (09APR02) 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=3 RG11932 –UN–06NOV01 Introduction CTM331 (09APR02) 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=4 Contents 01 SECTION 01—General Information Group 000—Safety Group 001—Engine Identification Group 002—Fuels SECTION 02—Repair and Adjustments Group 090—Electronic Fuel System Repair and Adjustments Group 110—Electrical Engine Control Repair and Adjustment SECTION 03—Theory of Operation Group 130—Electronic Fuel System Operation Group 140—Electronic Control System Operation SECTION 04—Diagnostics Group 150—Observable Diagnostics and Tests Group 160—Trouble Code Diagnostics and Tests SECTION 05—Tools and Other Materials Group 170—Electronic Fuel/Control System Repair Tools and Other Materials Group 180—Diagnostic Service Tools SECTION 06—Specifications Group 200—Repair Specifications Group 210—Diagnostic Specifications 04 02 03 05 06 INDX All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2002 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION® Manual CTM331 (09APR02) i 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=1 Contents 01 02 03 04 05 06 INDX CTM331 (09APR02) ii 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=2 01 Section 01 General Information Contents Page Group 000—Safety . . . . . . . . . . . . . . . . . . . .01-000-1 Group 001—Engine Identification Engine Model Designation. . . . . . . . . . . . . . . .01-001-1 Engine Serial Number Plate Information . . . . .01-001-2 OEM Engine Option Code Label . . . . . . . . . . .01-001-3 Information Relative to Emissions Regulations . . . . . . . . . . . . . . . . . . . . . . . . .01-001-3 Engine Application Charts . . . . . . . . . . . . . . . .01-001-4 Group 002—Fuels Lubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Dieselscan Fuel Analysis. . . . . . . . . . . . . . . . .01-002-2 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-3 CTM331 (09APR02) 01-1 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=1 Contents 01 CTM331 (09APR02) 01-2 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=2 5 L & 6. Make sure machine is clean of trash. ambulance service. and store in a cool.FIRE2 –19–03MAR93–1/1 CTM331 (09APR02) 01-000-1 4. Do not incinerate or puncture a starting fluid container. hospital. DX.FIRE3 –19–16APR92–1/1 Prepare for Emergencies Be prepared if a fire starts. and debris. Do not incinerate or puncture pressurized containers. Keep a first aid kit and fire extinguisher handy.8 L Level 12 Electronic Fuel System 040902 PN=9 TS291 TS1356 TS227 –UN–23AUG88 . To prevent accidental discharge when storing the pressurized can. –UN–18MAR92 DX.Group 000 Safety Handle Fluids Safely—Avoid Fires When you work around fuel. Do not store oily rags. keep the cap on the container. 01 000 1 DX. Keep starting fluid away from batteries and cables. –UN–23AUG88 Keep emergency numbers for doctors. they can ignite and burn spontaneously. do not smoke or work near heaters or other fire hazards. protected location. Keep all sparks and flame away when using it. grease. and fire department near your telephone. Store flammable fluids away from fire hazards.FLAME –19–29SEP98–1/1 Handle Starting Fluid Safely Starting fluid is highly flammable. 8 L Level 12 Electronic Fuel System 040902 PN=10 TS206 –UN–23AUG88 X9811 . Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Illinois. Such information is available from Deere & Company Medical Department in Moline.S.5 L & 6. –UN–23AUG88 Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. DX. Operating equipment safely requires the full attention of the operator. Tighten all connections before applying pressure. If an accident occurs. U. Prolonged exposure to loud noise can cause impairment or loss of hearing. Protect hands and body from high pressure fluids.Safety 01 000 2 Avoid High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Do not wear radio or music headphones while operating machine. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. DX. Search for leaks with a piece of cardboard.A.WEAR –19–10SEP90–1/1 CTM331 (09APR02) 01-000-2 4.FLUID –19–03MAR93–1/1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. see a doctor immediately. open the doors and get outside air into the area –UN–23AUG88 DX.LOOSE –19–04JUN90–1/1 Work In Ventilated Area Engine exhaust fumes can cause sickness or death. If these items were to get caught. scarf. remove the exhaust fumes from the area with an exhaust pipe extension. Do not wear a necktie. DX. do not attempt shortcuts. Have the right parts on hand. –UN–23AUG88 01 000 3 DX. loose clothing.CLEAN –19–04JUN90–1/1 CTM331 (09APR02) 01-000-3 4.5 L & 6.AIR –19–17FEB99–1/1 Work in Clean Area Before starting a job: • • • • Clean work area and machine. If it is necessary to run an engine in an enclosed area.8 L Level 12 Electronic Fuel System 040902 PN=11 T6642EJ –UN–18OCT88 TS220 TS228 . If you do not have an exhaust pipe extension. or necklace when you work near machine tools or moving parts. Read all instructions thoroughly.Safety Service Machines Safely Tie long hair behind your head. Make sure you have all necessary tools to do your job. severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. 8 L Level 12 Electronic Fuel System 040902 PN=12 TS953 –UN–15MAY90 TS220 . Do not use a chlorinated solvent in areas where welding will take place. Hazardous fumes can be generated when paint is heated by welding. Do not heat by welding. Remove paint before heating: • Remove paint a minimum of 76 mm (3 in. Do all work in an area that is well ventilated to carry toxic fumes and dust away.) from area to be affected by heating.TORCH –19–03MAR93–1/1 CTM331 (09APR02) 01-000-4 4.PAINT –19–19JUL01–1/1 Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines. or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Wear an approved respirator.Safety 01 000 4 Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. –UN–23AUG88 DX. • If you sand or grind paint. or using a torch. DX. remove stripper with soap and water before welding. Allow fumes to disperse at least 15 minutes before welding or heating. • If you use solvent or paint stripper. soldering. Remove solvent or paint stripper containers and other flammable material from area. avoid breathing the dust. resulting in severe burns to yourself and bystanders. soldering. Dispose of paint and solvent properly.5 L & 6. When constructing tools.TOOLS –19–10OCT97–1/1 CTM331 (09APR02) 01-000-5 4. quality materials. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.Safety Illuminate Work Area Safely Illuminate your work area adequately but safely. Make sure the bulb is enclosed by a wire cage. –UN–01JUL97 DX.SAFE.5 L & 6. use proper.LIGHT –19–04JUN90–1/1 Construct Dealer-Made Tools Safely Faulty or broken tools can result in serious injury. Use a portable safety light for working inside or under the machine. 01 000 5 DX.8 L Level 12 Electronic Fuel System 040902 PN=13 LX1016749 TS223 –UN–23AUG88 . Do not weld tools unless you have the proper equipment and experience to perform the job. and good workmanship. On self-propelled equipment. use the correct size tools.8 L Level 12 Electronic Fuel System 040902 PN=14 TS779 –UN–08NOV89 TS218 –UN–23AUG88 . On towed implements. Makeshift tools and procedures can create safety hazards. Remove the key. Keep all parts in good condition and properly installed. Use only service parts meeting John Deere specifications. Stop the engine. or debris. Allow machine to cool. oil. Never lubricate. Fix damage immediately.SERV –19–17FEB99–1/1 Use Proper Tools Use tools appropriate to the work.5 L & 6. Securely support any machine elements that must be raised for service work. disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine. measurement tools on metric fasteners. Lower equipment to the ground. Disengage all power and operate controls to relieve pressure. disconnect battery ground cable (—) before making adjustments on electrical systems or welding on machine. or adjust machine while it is moving. Replace worn or broken parts. For loosening and tightening hardware. service.S. Avoid bodily injury caused by slipping wrenches. DO NOT use U. Keep hands. Use power tools only to loosen threaded parts and fasteners.REPAIR –19–17FEB99–1/1 CTM331 (09APR02) 01-000-6 4.Safety 01 000 6 Practice Safe Maintenance Understand service procedure before doing work. DX. feet . Keep area clean and dry. DX. and clothing from power-driven parts. Remove any buildup of grease. down a drain. make sure machine is functioning properly. Potentially harmful waste used with John Deere equipment include such items as oil. and batteries.LIVE –19–25SEP92–1/1 CTM331 (09APR02) 01-000-7 4. Do not use food or beverage containers that may mislead someone into drinking from them. Install all guards and shields. or from your John Deere dealer. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Use leakproof containers when draining fluids.8 L Level 12 Electronic Fuel System 040902 PN=15 TS231 TS1133 .DRAIN –19–03MAR93–1/1 Live With Safety Before returning machine to customer. especially the safety systems. Do not pour waste onto the ground. fuel. filters. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center.Safety Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology.5 L & 6. brake fluid. –UN–26NOV90 01 000 7 DX. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. coolant. or into any water source. –19–07OCT88 DX. 8 L Level 12 Electronic Fuel System 040902 PN=16 .5 L & 6.Safety 01 000 8 CTM331 (09APR02) 01-000-8 4. .................................................................... user code.................................................. Number of cylinders Liter displacement Aspiration code User code POWERTECH® application code Naturally aspirated Turbocharged...................................... North Carolina) Goldoni S.................. E .................................. Mexico) Larson & Toubro Ltd............... FM ............................... LA ............................................................................................... aspiration........ later in this Group 01 001 1 POWERTECH is a registered trademark of Deere & Company OUO1080................................. Brazil) John Deere Davenport Works (Davenport............................................................................................................................ Tennessee) John Deere Werke Mannheim (Germany) John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump) John Deere Commercial Products (Augusta............................................... 275 ...................... India) John Deere Waterloo Tractor Works (Waterloo............. etc...... PY ..................... .... Iowa) Industrias John Deere Mexico S......... Italy) Marine Engines John Deere Harvester Works (East Moline... Aspiration Code D ........ CQ ....... A ...........................................5 L & 6....................... H ...................................................................... no aftercooling Turbocharged and Air-to-Coolant Aftercooled Turbocharged and Air-to-Air Aftercooled Agritalia srl (Vittoria.. Iowa) Cameco Industries (Thibodaux................ Georgia) John Deere Des Moines Works (Des Moines. (Modena.................................................... Limited (China) John Deere WERKE Zweibrucken (Germany) See ENGINE APPLICATION CHARTS............................................ YC ... (Saltillo/Monterrey..................... FF ..................Group 001 Engine Identification Engine Model Designation John Deere Engine Model—4045 and 6068 Engines John Deere engine model designation includes number of cylinders......................................... Italy) John Deere Brazil (Horizontina........................... F ...................... RW ........... KV .......................................................... F ......................P.......................................................... T ..............5 .............. N ................... TJ ................................................................................ Illinois) John Deere Commercial Worksite Products (Knoxville.................................. (Pune............................. Z ... User Factory Code AT .....A. Sicily................... Iowa) OEM (Outside Equipment Manufacturers) Deere-Hitachi (Kernersville.....8 L Level 12 Electronic Fuel System 040902 PN=17 ................................. For example: 4045TF275 Engine 4 ............ Iowa) John Deere Ottumwa Works (Ottumwa........................ de C......................................................... FG .......V...................... T8 ..... Application Code 001..................A.............................................................. H .................. L ..................................................................................................... T .................................... 4.......................................... P .... displacement in liters............................... LV ............................................................. Louisiana) Timberjack (Deere) (Sweden/Finland/Canada) John Deere Jialian Harvester Co.............. T ............. Iowa) John Deere Dubuque Works (Dubuque......... and application code..................00001FA –19–15NOV01–1/1 CTM331 (09APR02) 01-001-1 4..... DW ......... .......... Dubuque... and a 6-digit sequential number....... France PE ....... Factory producing engine 4045T ....... See ENGINE APPLICATION CHARTS later in this group.00001FB –19–15NOV01–1/1 CTM331 (09APR02) 01-001-2 4............. Coefficient of Absorption (D) — (Saran-Built Engines Only) The second line of information on the Saran serial number plate also contains the coefficient of absorption value for smoke emissions..... Sequential serial number Factory Code (Engine Manufacturer) T0 ...... Engine Serial Number (B) Each engine has a 13-digit John Deere engine serial number identifying the producing factory. See ENGINE MODEL DESIGNATION earlier in this group...... Rosario...5 L & 6............ Engine model designation 000000 .Engine Identification 01 001 2 Engine Serial Number Plate Information IMPORTANT: The engine serial number plate (A) can be easily destroyed........ remove the plate......... The following is an example: Engine Serial Number Plate CD4045T000000 CD .... Mexico J0 ........ 6-digit sequential serial number –UN–15NOV01 Engine Application Data (C) The second line of information on the serial number plate identifies the engine/machine or OEM relationship......................... Sequential Number 000000 .8 L Level 12 Electronic Fuel System 040902 PN=18 RG11948 –UN–06NOV01 RG11949 –UN–07NOV01 RG9060 –UN–16MAR98 RG11816 ........ Saran........... engine model designation................ Argentina Engine Model Designation 4045T ............... Before “hot tank” cleaning the block. Iowa CD .. Dubuque Engine Serial Number Plate Saran Engine Serial Number Plate A—Engine Serial Number Plate B—Engine Serial Number C—Engine Application Data D—Coefficient of Absorption (Saran Engines Only) Torreon Engine Serial Number Plate OUO1080.... Definition explained previously................................. Torreon.... Such engines are called “CERTIFIED” and receive an emission label stuck on the engine.Engine Identification OEM Engine Option Code Label An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition. A listing of option codes is given in parts catalogs and operator’s manuals. It is also illegal to install a part or component where the principle effect of that component is to bypass.5 L & 6. The regulations prohibit tampering with the emission-related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications.0000035 –19–29AUG01–1/1 CTM331 (09APR02) 01-001-3 4. To summarize. the Directive 97/68/EC relating the measures against the emissions of particles and gaseous pollutant from internal combustion engines. or render inoperative any engine component or device which would affect the engine’s conformance to the emission regulations. Always provide option code information and engine base code when ordering repair parts.000020E –19–26NOV01–1/1 Information Relative to Emissions Regulations Depending on the final destination. engines can meet the emissions regulations according to the US Environmental Protection Agency (EPA). List of emission-related components: • • • • • Fuel injection system Intake manifold Turbocharger Charge air cooling system Piston OUO1080. California Air Resources Board (CARB) and for Europe. –UN–03DEC01 01 001 3 NOTE: Before “hot tank” cleaning. it is illegal to do anything except return the engine to its original published specifications.8 L Level 12 Electronic Fuel System 040902 PN=19 RG12027 . ensure that option codes are recorded elsewhere. OUO1080. defeat. T04045DT058 PE4045TT085. Germany 3800 TeleHandler JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS) CD4045TF275 PE4045HF275 CD4045TF275 PE4045TF275 CD6068HF275 PE6068HF275 CD6068TF275 PE6068TF275 CD4045HZ050 Engine Model PE4045HP050 PE4045HP051 PE4045TT084. T04045TT089 Engine Model OUO1089. T04045TT087 PE4045TT086.Engine Identification 01 001 4 Engine Application Charts JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT Machine Model Dubuque 310G Backhoe Loader (XXXXXX—) 310G Backhoe Loader (Alt Comp) (XXXXXX—) 310SG Backhoe Loader (XXXXXX—) 315SG Backhoe Loader (XXXXXX—) 450H Crawler Dozer (Alt Comp) (XXXXXX—) 450H Crawler Dozer (Nat Asp) (XXXXXX—) 450H LGP Crawler Dozer (XXXXXX—) 550H Crawler Dozer (XXXXXX—) 550H LGP Crawler Dozer (XXXXXX—) Saltillo. T04045TT085 PE4045TT087.5 L & 6.0000205 –19–09NOV01–1/1 CTM331 (09APR02) 01-001-4 4. T04045TT084 PE4045DT058. T04045DT058 PE4045TT088. T04045TT088 PE4045TT089. T04045TT086 PE4045DT058.8 L Level 12 Electronic Fuel System 040902 PN=20 . Mexico 120C Excavator 160C LC Excavator Timberjack 810 Forwarder 1010 (1058) Forwarder 1410 (1458) Forwarder 770 (863) Harvester 1070 (1063) Harvester CD4045HTJ01 T04045HTJ76 CD6068HTJ02 CD4045HTJ03 CD6068HTJ03 JOHN DEERE AGRICULTURAL EQUIPMENT Machine Model Zweibrucken. maximum scar diameter of 0. diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or. (See recommendation for Diesel Engine Oil.OUO1004. Cetane number greater than 50 is preferred. In general.8 L Level 12 Electronic Fuel System 040902 PN=21 . Diesel fuels specified to EN 590 or ASTM D975 are recommended.05% (500 ppm) is used.) • DO NOT use diesel fuel with sulfur content greater than 1. crankcse oil service intervals may be affected.Group 002 Fuels Lubricants and Coolant NOTE: Refer to Section 01. Group 002 of CTM104 Base Engine Manual for information on lubricants and coolants.0%. OUOD002. especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft). Sulfur content: • Diesel fuel quality and fuel sulfur content must comply with all existing regulations for the area in which the engine operates. Required fuel properties In all cases.05% (500 ppm) is preferred. Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C (9°F) below the expected low temperature. the fuel must meet the following properties: Cetane number of 45 minimum. • If diesel fuel with sulfur content greater than 0. • Sulfur content less than 0.5 L & 6.45 mm as measured by ASTM D6079. IMPORTANT: DO NOT mix used engine oil or any other type of lubricating oil with diesel fuel.2761 –19–16MAY00–1/1 Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. 01 002 1 DPSG.0000171 –19–18DEC01–1/1 CTM331 (09APR02) 01-002-1 4. water content. DIESELSCAN is a trademark of Deere & Company DX. and will cause engine failure by leaving deposits on injectors and in the combustion chamber. Areas of concern include: • Quality of new fuel • Water content of the fuel • Problems due to aging of the fuel Potential problems resulting from deficiencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms: • • • • • • • • Power loss and deterioration of performance Fuel leakage Corrosion of fuel injection equipment Coked and/or blocked injector nozzles. These oils do not burn completely. Check with your John Deere dealer for availability of DIESELSCAN kits. IMPORTANT: Raw pressed vegetable oils are NOT acceptable for use for fuel in any concentration in John Deere engines. If the oil becomes diluted with fuel. This makes proper storage and handling of bio-diesel fuel especially important. A major environmental benefit of bio-diesel fuel is its ability to biodegrade. cleanliness.8 L Level 12 Electronic Fuel System 040902 PN=22 . Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM PS121. resulting in engine misfire Filter plugging Lacquering and/or seizure of internal components Sludge and sediments Reduced service life of engine components RG41183.Fuels 01 002 2 Bio-Diesel Fuel Consult your local fuel distributor for properties of the bio-diesel fuel available in your area. When using a blend of bio-diesel fuel. DIN 51606 or equivalent specification. shorten oil change intervals accordingly.5 L & 6.FUEL6 –19–06DEC00–1/1 CTM331 (09APR02) 01-002-2 4. the engine oil level must be checked daily when the air temperature is -10°C (14°F) or lower.0000046 –19–18DEC01–1/1 Dieselscan Fuel Analysis DIESELSCAN™ is a John Deere fuel sampling program to help you monitor the quality of your fuel source. suitability for cold weather operation. It verifies fuel type. and if fuel is within ASTM specifications. It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend in petroleum diesel fuel. hard starting. and engine smoke.8 L Level 12 Electronic Fuel System 040902 PN=23 . Diesel fuel in the European Union requires sulfur content less than 0. engine speed instability. Fuel lubricity should pass a minimum load level of 3100 gram as measured by the ASTM D6078 or maximum scar diameter of 0. Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. Use of low lubricity diesel fuels may also cause accelerated wear.0000179 –19–18DEC01–1/1 CTM331 (09APR02) 01-002-3 4. ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.45 mm as measured by ASTM D6079. add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks. If fuel of low or unknown lubricity is used. Diesel fuels for highway use in the United States and Canada require sulfur content less than 0. 01 002 3 OUOD002.05% (500 ppm). injection nozzle erosion or corrosion.Fuels Lubricity of Diesel Fuel Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components.5 L & 6.05% (500 ppm). low power. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=24 .Fuels 01 002 4 CTM331 (09APR02) 01-002-4 4. 02-090-16 Clean Fuel Injection Nozzle Bore . .02-090-23 Install Seals on Fuel Injection Nozzle . . . . . . . . . .02-110-3 Remove and Install Oil Pressure Sensor .02-090-19 Disassemble Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2 Replace Crankshaft Position Sensor .02-110-11 Repair (Pull Type) METRI-PACK™ Connectors . . . . . . . . . . . . . . .02-110-20 02-1 4. . . . . . . . . . . . . . . . . . . . . .02-110-6 Use Electrical Insulating Compound . .02-110-2 Remove and Install Loss of Coolant Temperature Sensor . .02-110-12 Repair (Push Type) METRI-PACK™ Connectors . . . . . . . . . . .02-090-11 Inspect Injection Pump Drive Gear ID and Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 PN=1 . . . . . . . . . .02-090-22 Adjust Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . .02-090-25 Bleed the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-6 Using High-Pressure Washer . . . . . . . . . . . . .02-110-17 Repair AMP Connector . . . . . . . . . . . . . . . .02-110-4 Remove and Install Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . .02-090-6 Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl. . . . . . . . . .02-090-7 Remove Fuel Supply Pump. . . . . . . . . . .02-090-26 Group 110—Electrical Engine Control Repair and Adjustment Engine Control Unit (ECU) . . . . . . . . . . . . . . . .02-090-18 Clean Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . .02-090-2 Fuel Pre-Filter/Water Bowl Assembly (Optional). . . . . . . . . .Section 02 Repair and Adjustments Contents Page Page 02 Group 090—Electronic Fuel System Repair and Adjustments Fuel System—General Information . . . . . . . . . . . . . .02-090-18 Fuel Injection Nozzle Test . .02-110-14 Repair DEUTSCH™ Connectors . . .02-090-24 Install Fuel Injection Nozzles . . . .02-110-8 CTM331 (09APR02) Remove Blade Terminals from Connector Body . . . . . . . . . . . . . . . . . . . . .02-110-3 Remove and Install Manifold Air Temperature Sensor . . . . . . . . . . . .5 L & 6. . . . .02-110-4 Remove and Install Fuel Heater . . . . . . . . . . . . . . . . . . . . .02-090-13 Install Injection Pump .02-090-13 Remove Fuel Injection Nozzles . . . . . . . . . . . . . . . .02-090-1 Relieve Fuel System Pressure . . . . . . . . . . . . .02-090-1 Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base . . . . . . . . . . . . .02-090-9 Install Fuel Supply Pump. . . . . . . . . .02-090-10 Remove Injection Pump .02-090-5 Final Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Connectors . . . . .02-110-1 Remove and Install Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10 Injection Pump Static Timing . . . . . . . . . . . .02-110-7 Repair WEATHERPACK™ Connector . . Contents 02 CTM331 (09APR02) 02-2 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=2 . Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline.00001F7 –19–06NOV01–1/1 Relieve Fuel System Pressure CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin. High Pressure Fluids RG. All engines use Stanadyne Rate Shaping Nozzles (RSN). it will be necessary to bleed air from the system. Field-installed options include fuel heater. or other knowledgeable medical source. Engines may be equipped with an optional fuel pre-filter/water bowl. Use a piece of cardboard or wood. Before disconnecting lines.35. Hand primer on top of filter element is optional. it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. All engines are equipped with a round final fuel filter with water bowl.JW7625 –19–20NOV97–1/1 CTM331 (09APR02) 02-090-1 4. If ANY fluid is injected into the skin. be sure ALL connections are tight and lines. Any time the fuel system has been opened up for service (lines disconnected or filters removed). causing serious injury. to search for suspected leaks. rather than hands. See BLEED THE FUEL SYSTEM in this group.8 L Level 12 Electronic Fuel System 040902 PN=27 X9811 –UN–23AUG88 . be sure to relieve pressure.5 L & 6. Keep hands and body away from pinholes and nozzles which eject fluid under pressure.Group 090 Electronic Fuel System Repair and Adjustments Fuel System—General Information Stanadyne DE10 pumps are static lock-pin timed during installation of the injection pump. pipes and hoses are not damaged. water bowl and hand fuel primer. Illinois. Before applying pressure to the system. 02 090 1 OUO1089. The fuel supply pump is a separate component mounted on upper right-hand side of engine block and is actuated by a pin in block that rides on engine camshaft lobe. Engines are equipped with a final fuel filter/water bowl (A) and may have an optional pre-filter/water bowl.00001F6 –19–06NOV01–1/3 CTM331 (09APR02) 02-090-2 4.Electronic Fuel System Repair and Adjustments Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base Refer to operator’s manual for proper servicing and (hourly) replacement intervals. A—Final Fuel Filter/Water Bowl –UN–15NOV01 02 090 2 Final Fuel Filter Continued on next page OUO1089. Final fuel filters/water bowls can be equipped with a transparent (see-through) water collection bowl and/or hand primer on machines equipped with only one filter.8 L Level 12 Electronic Fuel System 040902 PN=28 RG11989 .5 L & 6. .. ensure that they are reinstalled in the correct headers.... Final Fuel Filter Base NOTE: Pre-filter and final filter fuel lines may be connected to different filter inlet and outlet ports depending on engine application. 7..........00001F6 –19–06NOV01–2/3 CTM331 (09APR02) 02-090-3 4. in this group................. Replace parts as necessary. If equipped........... Fuel Pre-Filter Bracket-to-Cylinder Head and Alternator—Torque ... Disconnect fuel lines from all ports...... Specification Final Fuel Filter Bracket-to-Cylinder Head— Torque ....... remove pre-filter base..................5 L & 6............. Fuel Pre-Filter/Water Bowl Mounting Base-to-Bracket— Torque ... Connect a drain line to filter drain adapters and drain all fuel from system........................ 5....... See REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL....... as they are different between the pre...8 L Level 12 Electronic Fuel System 040902 PN=29 RG12021 ................. 3...... Final Fuel Filter Mounting Base-to-Bracket—Torque ... if desired..........................and final filter bases. Remove final fuel filter element and pre-filter/water bowl... A—Final Fuel Filter Base 73 N•m (54 lb-ft) 73 N•m (54 lb-ft) 73 N•m (54 lb-ft) 50 N•m (36 lb-ft) Continued on next page OUO1089... Remove final fuel filter base (A)................ Install mounting brackets and tighten to torque specifications provided below........Electronic Fuel System Repair and Adjustments 1......... 8.... Thoroughly clean fuel filter/pre-filter assemblies and surrounding area to keep from getting dirt and debris into fuel system....... 02 090 3 –UN–26NOV01 NOTE: The fuel filters are keyed to the filter header... 6... 2.............. Refer to markings on fuel filter base for fuel inlet/outlet ports..... 4.. If both pre-filter and final filter are removed.. Mark fuel line location to aid during assembly..... 5 L & 6. 11.00001F6 –19–06NOV01–3/3 CTM331 (09APR02) 02-090-4 4. Bleed the fuel system. See REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL. in this group. 02 090 4 10.Electronic Fuel System Repair and Adjustments 9. Connect fuel lines to all ports. OUO1089. Install pre-filter and final filter fuel filter/water bowl elements.8 L Level 12 Electronic Fuel System 040902 PN=30 . See BLEED THE FUEL SYSTEM in this group. 8 L Level 12 Electronic Fuel System 040902 PN=31 RGT7751HS –UN–19NOV97 RGT7751HR –UN–19NOV97 .35.Electronic Fuel System Repair and Adjustments Fuel Pre-Filter/Water Bowl Assembly (Optional) A—Drain Adapter B—Packing C—Cap Screw D—Water Bowl E—Retaining Ring F—Filter Element G—Filter Base with Seal Ring H—Vent Plug I—Packing J—Plug (2 used) K—Diaphragm L—Spring Seat M—Spring N—Spring Cover O—Pump Knob P—Retaining Ring 02 090 5 Primary Filter/Water Bowl Assembly RG.JW7623 –19–21JAN02–1/1 CTM331 (09APR02) 02-090-5 4.5 L & 6. 8 L Level 12 Electronic Fuel System 040902 PN=32 RG12015 –UN–16NOV01 .00001FC –19–15NOV01–1/1 CTM331 (09APR02) 02-090-6 4.5 L & 6.Electronic Fuel System Repair and Adjustments Final Fuel Filter Assembly 1—Retaining Ring 2—O-Ring 3—Stem 4—O-Ring 5—Retaining Ring 6—Filter 7—O-Ring 8—O-Ring 9—Drain Adapter 10—Screw 11—O-Ring 12—Water Bowl 13—Adapter 14—O-Ring 15—Fuel Heater (Optional) 16—O-Ring 17—Filter Base 18—Primer Assembly (Optional) 19—Cap 02 090 6 Final Fuel Filter OUO1080. 5 L & 6. onto new filter element. Final Fuel Filter Shown A—Retaining Ring B—Filter Element 02 090 7 –UN–15NOV01 NOTE: Lifting up on retaining ring (A) as it is rotated helps to get it past raised locators. 7. 1. 6. Thoroughly inspect filter base dust seal ring. Remove transparent (see-through) water bowl. 3.and final fuel filter elements are similar. Differences will be noted. Firmly grasp the retaining ring (A) and rotate it counterclockwise 1/4 turn. if equipped. if equipped. if not previously done.Electronic Fuel System Repair and Adjustments Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl NOTE: Refer to operator’s manual for proper servicing and (hourly) replacement intervals. Replacement of pre. 4. Clean as required. Remove ring with filter element (B). Inspect filter mounting base for cleanliness.00001F5 –19–06NOV01–1/2 CTM331 (09APR02) 02-090-7 4. Thoroughly clean fuel filter/water bowl assembly and surrounding area. Make sure O-ring is properly installed in the top groove of bowl. 2. Dry with compressed air.8 L Level 12 Electronic Fuel System 040902 PN=33 RG11990 . Connect a drain line to filter drain adapters and drain all fuel from filters. Continued on next page OUO1089. Replace as needed. 5. Make sure correct embossments on filter elements match the slots in the mounting header. Final fuel filters can be equipped with a transparent (see-through) water bowl and/or hand primer on machines equipped with only one filter. Drain and clean water bowl. Install transparent (see-through) water bowl. Be sure element is properly indexed on mounting base.5 L & 6.Electronic Fuel System Repair and Adjustments NOTE: The fuel filters must be indexed properly and the key on canister must be oriented in slot of mounting base for correct installation. 02 090 8 8. Install retaining ring onto mounting base and tighten about 1/3 turn until ring “snaps” into the detent. DO NOT overtighten the retaining ring. 9. See BLEED THE FUEL SYSTEM. in this group. 10. Install new filter element onto mounting base and position element using a slight rocking motion.8 L Level 12 Electronic Fuel System 040902 PN=34 . Bleed fuel system. OUO1089.00001F5 –19–06NOV01–2/2 CTM331 (09APR02) 02-090-8 4. If lever face is worn flat or concave. The cylinder head must be removed to remove this push rod. Fuel Supply Pump Lines A—Supply Pump Inlet from Fuel Tank B—Supply Pump Outlet to Final Fuel Filter C—Cap Screws D—Push Rod Remove Fuel Supply Pump RG9051 –UN–16MAR98 4. 2. 1. Inspect face of pump lever for wear. replace pump. 02 090 9 –UN–15NOV01 NOTE: The fuel supply pump is driven by a push rod (D) that rides on an eccentric camshaft lobe.Electronic Fuel System Repair and Adjustments Remove Fuel Supply Pump IMPORTANT: A backup wrench must always be used when disconnecting fittings or fuel lines from supply pump to avoid damage to fittings.5 L & 6. Cover opening on cylinder block to prevent dirt from entering the engine. Remove cap screws (C) and remove fuel supply pump assembly from cylinder block. 3. Fuel Supply Pump Push Rod OUO1089.8 L Level 12 Electronic Fuel System 040902 PN=35 RG12022 –UN–27NOV01 RG11991 . Disconnect fuel inlet line (A) and outlet line (B) and cap connections on fuel supply pump and fuel lines to keep debris out of fuel system.00001F8 –19–06NOV01–1/1 CTM331 (09APR02) 02-090-9 4. .......... using a new O-ring........ 3. OUO1089. 2. Tighten cap screws (C) to specifications. –UN–15NOV01 02 090 10 1.Electronic Fuel System Repair and Adjustments Install Fuel Supply Pump IMPORTANT: Apply LOCTITE 242 to threads of supply pump mounting cap screws (C) and fuel line fittings when reinstalling supply pump.... See INSTALL INJECTION PUMP later in this group........ Install the fuel supply pump to cylinder block with pumping lever resting on top of push rod. See BLEED THE FUEL SYSTEM in this group................ Fuel Supply Pump Lines A—Supply Pump Inlet from Fuel Tank B—Supply Pump Outlet to Final Fuel Filter C—Cap Screws OUO1089.... Connect supply pump inlet line (A) and outlet line (B) and tighten securely... Bleed fuel system....... 30 N•m (22 lb-ft) IMPORTANT: ALWAYS use a backup wrench when installing fittings and/or fuel lines onto supply pump to avoid damage to fittings........... DO NOT allow sealant to get into fuel system....8 L Level 12 Electronic Fuel System 040902 PN=36 RG11991 ... Specification Fuel Supply Pump Cap Screws— Torque .00001FA –19–06NOV01–1/1 Injection Pump Static Timing Static lock-pin timing is accomplished during installation of the injection pump.........00001FB –19–06NOV01–1/1 CTM331 (09APR02) 02-090-10 4.5 L & 6. Remove injection pump drive gear cover (shown removed). Attach JDG1560 Drive Gear Puller to injection pump drive gear (B) using two screws (C). Remove drive gear retaining nut and washer from end of pump shaft. install JDG1559 Injection Pump Timing Pin (A) into pump timing pin bore. 1. 6. 7. Be careful not to let washer fall inside timing gear cover.00001FE –19–07NOV01–1/2 CTM331 (09APR02) 02-090-11 4. lines and area around the pump with cleaning solvent or a steam cleaner. Tighten center forcing screw (D) until pump drive gear is free from tapered shaft. 5. Remove JDG1560 Puller from drive gear.Electronic Fuel System Repair and Adjustments Remove Injection Pump IMPORTANT: Never steam clean or pour cold water on a fuel injection pump while the pump is running or while it is warm.5 L & 6. 2. 4. A—JDG1559 Timing Pin B—Injection Pump Drive Gear C—Screws (2 used) D—Center Forcing Screw –UN–21JAN02 –UN–16NOV01 02 090 11 Stanadyne DE10 Fuel Injection Pump JDG1559 Injection Pump Timing Pin Injection Pump Drive Gear Removal Continued on next page OUO1089. Doing so may cause seizure of internal rotating pump parts. Evenly tighten the two screws (C) and snugly tighten center forcing screw (D) against end of pump shaft. Rotate engine to TDC of number 1 cylinder compression stroke and install JDG1571 Timing Pin in flywheel.8 L Level 12 Electronic Fuel System 040902 PN=37 RG12000 –UN–21JAN02 RG12036 RG12002 . Before removing injection pump from engine. Clean the fuel injection pump. 3. Disconnect fuel supply line (D) and return line (C). A—Temperature Sensor Connector B—Fuel Control Solenoid Connector C—Fuel Return Line D—Fuel Supply Line E—Clamp F—Fuel Delivery Lines G—Nut (3 used) Injector Pump Electrical Connector Removal Disconnect Fuel Delivery Lines OUO1089. 10.00001FE –19–07NOV01–2/2 CTM331 (09APR02) 02-090-12 4. –UN–16NOV01 02 090 12 9. Remove injection pump from mounting studs. 12. 11. See INSPECT INJECTION PUMP DRIVE GEAR ID AND SHAFT OD later in this group. IMPORTANT: ALWAYS use a backup wrench when loosening or tightening fuel delivery lines at fuel injection pump.8 L Level 12 Electronic Fuel System 040902 PN=38 RG12003 –UN–16NOV01 RG12001 .Electronic Fuel System Repair and Adjustments 8. Remove temperature sensor connector (A) and fuel control solenoid connector (B). This prevents possible internal pump damage. Place pump on a clean flat surface and inspect shaft OD and drive gear as outlined later in this group. Disconnect all fuel delivery lines (F) from injection pump and install protective caps.5 L & 6. Remove clamp (E) retaining fuel delivery (pressure) lines (F). Remove three injection pump mounting stud nuts (G). so that the pump discharge fittings are not altered. Electronic Fuel System Repair and Adjustments Inspect Injection Pump Drive Gear ID and Shaft OD IMPORTANT: Use a good light source to thoroughly inspect gear ID and shaft OD. 02 090 13 OUO1089. Use a suitable cleaner that does not leave a residue.8 L Level 12 Electronic Fuel System 040902 PN=39 RG12019 –UN–19NOV01 . the tapered surfaces of the pump drive shaft OD and drive gear ID MUST BE cleaned to remove protective coatings and oily residue. A—JDG1559 Timing Pin B—Hole in Drive Shaft A B Install Timing Pin Continued on next page OUO1089. Before installing injection pump on engine.5 L & 6. Mating surfaces MUST BE ASSEMBLED DRY and LUBRICANTS MUST NOT BE USED. 2. Inspect injection pump drive shaft OD full 360° for presence of metal transfer from gear slippage. 1.0000204 –19–08NOV01–1/3 CTM331 (09APR02) 02-090-13 4. Install a small punch or screwdriver into hole in pump drive shaft (B) and turn shaft until timing pin drops into recess in injection pump drive shaft. If there is clear evidence of metal transfer on pump shaft OD or in drive gear ID. Inspect injection pump drive gear ID full 360° for metal transfer as a result of slippage on shaft. install JDG1559 Injection Pump Timing Pin (A) into pump timing pin bore. injection pump and drive gear MUST BE replaced.00001FC –19–06NOV01–1/1 Install Injection Pump 1. IMPORTANT: When replacing injection pump drive gear or installing a new pump. ........................ 2...... 25 N•m (19 lb-ft) Injection Pump Mounting Stud Nuts 4.. Injection Pump Timing Pin Specification Injection Pump Gear Mounting Nut—Torque ............. Make sure that number 1 cylinder is locked at TDC of compression stroke and install JDG1571 Timing Pin in flywheel. 9........ 195 N•m (145 lb-ft) 6. Install injection pump gear access plate and remove timing pin (B) from pump.0000204 –19–08NOV01–2/3 CTM331 (09APR02) 02-090-14 4.........5 N•m (7... Install plug in injection pump timing pin hole and tighten to specification. turn engine only in direction of rotation to prevent gear backlash........... Backlash of gears is enough to throw the injection pump timing off by several degrees............. Specification Injection Pump Mounting Stud Nuts—Torque .. resulting in poor engine performance............. 02 090 14 3..... Position drive gear while installing pump......... Install injection pump gear (D) on drive shaft......... Install........ Remove JDG1571 Timing Pin from flywheel........... Install injection pump onto mounting studs and tighten three pump mounting stud nuts (A) to specification.. but do not tighten............. –UN–16NOV01 . 5..8 L Level 12 Electronic Fuel System 040902 RG12008 PN=40 RG12007 –UN–16NOV01 RG12004 NOTE: Retain JDG1559 Timing Pin (B) in pump during installation. Injection Pump Gear Installation A—Injection Pump Mounting Stud Nut (3 used) B—JDG1559 Injection Pump Lock Timing Pin C—Gear Mounting Nut D—Pump Gear Continued on next page OUO1089................... and tighten gear mounting nut to specification......5 lb-ft) –UN–16NOV01 7.........Electronic Fuel System Repair and Adjustments NOTE: When rotating engine to TDC of compression stroke on number 1 cylinder...5 L & 6..... Specification Injection Pump Timing Pin Plug— Torque ....... injection pump gear mounting nut (C)..... Rotate gear counterclockwise (viewed from front of engine) to remove any backlash....... NOTE: Hold the injection pump gear while applying torque to prevent the gear from rotating..... .... attach lines in same order as engine firing (1-5-3-6-2-4 on 6-cylinder engines and 1-3-4-2 on 4-cylinder engines). Start engine. run for several minutes and check entire fuel system for leaks.. so that the pump discharge fittings are not altered. Install clamp (E). Install temperature sensor connector (A) and fuel control solenoid connector (B)..... 12.... Specification Injection Pump Fuel Delivery (Pressure) Lines—Torque . Connect fuel supply line (D) and fuel return line (C). Beginning with outlet (I) and continuing around the pump head in counterclockwise direction.... 11... Tighten fuel delivery lines at pump to specification. This prevents possible internal pump damage.8 L Level 12 Electronic Fuel System 040902 PN=41 RG12035 –UN–11JAN02 RG12003 –UN–16NOV01 RG12001 –UN–16NOV01 .. Bleed air from fuel system as outlined in this group.... 13.. 9....0000204 –19–08NOV01–3/3 CTM331 (09APR02) 02-090-15 4... 27 N•m (20 lb-ft) 02 090 15 Injector Pump Electrical Connectors 10..... Connect injection pump fuel delivery (pressure) lines (F).Electronic Fuel System Repair and Adjustments 8...... See BLEED THE FUEL SYSTEM in this group.... A—Temperature Sensor Connector B—Fuel Control Solenoid Connector C—Fuel Return Line D—Fuel Supply Line E—Clamp F—Fuel Delivery Lines G—Nut (3 used) H—Engine Block Side I—Outlet Connection to No. IMPORTANT: ALWAYS use a backup wrench when loosening or tightening fuel delivery lines at fuel injection pump.5 L & 6..... 1 Cylinder Connect Fuel Delivery Lines OUO1089.... Plug the bore in the cylinder head after each nozzle has been removed.00001FF –19–07NOV01–2/4 CTM331 (09APR02) 02-090-16 4. Clean with compressed air to prevent dirt from entering the cylinders.8 L Level 12 Electronic Fuel System 040902 PN=42 RG11994 –UN–15NOV01 RG11993 Before removal.00001FF –19–07NOV01–1/4 1. A—Tube Nuts Fuel Leak-Off Lines Continued on next page OUO1089. Do not bend the fuel delivery lines. Fuel Injection Nozzle OUO1089. hold male union of nozzle line stationary with a backup wrench. thoroughly remove all dirt from the cylinder head around fuel injection nozzles. Loosen tube nuts (A) at each nozzle to remove leak-off lines and T-fittings as an assembly.Electronic Fuel System Repair and Adjustments Remove Fuel Injection Nozzles General Nozzle Service Precautions 02 090 16 Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage and getting debris in fuel system. –UN–15NOV01 . When loosening the fuel pressure lines. as this may affect their durability. Cap fuel line openings as soon as they are disconnected.5 L & 6. Disconnect fuel injection line from nozzle using a backup wrench on nozzle connection as shown.00001FF –19–07NOV01–4/4 CTM331 (09APR02) 02-090-17 4. 3.5 L & 6. or similar tools for this as they might damage the injection nozzle beyond repair. Pull injection nozzle out of cylinder head using JDG1515-1 Nozzle Puller (A). A—JDG1515-1 Nozzle Puller –UN–16NOV01 Injection Nozzle Puller Set OUO1089. pry bars.00001FF –19–07NOV01–3/4 4. Remove cap screw securing nozzle in cylinder head nozzle bore.8 L Level 12 Electronic Fuel System 040902 PN=43 RG12018 RG11999 . IMPORTANT: Do not use screwdrivers. –UN–19NOV01 02 090 17 Fuel Injection Line at Nozzle OUO1089.Electronic Fuel System Repair and Adjustments 2. –UN–15NOV01 RG7743 Clean Fuel Injection Nozzle A—Carbon Stop Seal B—Upper Sealing Washer TEFLON is a registered trademark of the DuPont Co. Never use a steel wire brush or scraper. and plug the bore to prevent entry of foreign material. After soaking. clean nozzle tip with brass wire brush. Place nozzle in solvent or clean diesel fuel.Electronic Fuel System Repair and Adjustments Clean Fuel Injection Nozzle Bore IMPORTANT: Always turn tool clockwise in bore to prevent dulling of cutting edges. 2. and soak for a while. A—Nozzle Bore Cleaning Tool –UN–07NOV97 02 090 18 Clean Injection Nozzle Bore RG.8 L Level 12 Electronic Fuel System 040902 PN=44 RG11995 . IMPORTANT: Do not scrape or disturb the TEFLON® coating on the nozzle body above the carbon stop seal groove. Blow debris from bore using compressed air.00001FD –19–15NOV01–1/1 CTM331 (09APR02) 02-090-18 4. but this is not harmful. so carbon stop seal groove is submerged. OUO1080. Discard seal and washer. Remove carbon stop seal (A) from groove in nozzle body using razor blade or sharp knife and remove upper sealing washer (B).35. even when removing tool from bore. Do not use a motor-driven brush to clean nozzle body.5 L & 6. 3. This coating will become discolored during normal operation. Clean injection nozzle bore using JDE39 Nozzle Bore Cleaning Tool (A).JW7596 –19–20NOV97–1/1 Clean Fuel Injection Nozzles 1. use a piece of cardboard or wood. Fluid escaping from a very small hole can be almost invisible. To search for suspected leaks.0000200 –19–07NOV01–1/3 CTM331 (09APR02) 02-090-19 4. High Pressure Fluid Use only carefully filtered diesel fuel for testing the injection nozzles. Enclosing the nozzle in a clear glass beaker is recommended. rather than hands. use a nozzle tester JT25510 (1) and pressure line KJD10109 (2). it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Close the gauge shut-off valve and flush (bleed) the nozzle by operating test pump rapidly. Fuel Injection Nozzle Test Connect the nozzle to the tester so that the axis of the nozzle forms an angle of approximately 30° to the vertical and the spray of fuel is directed downwards. If ANY fluid is injected into the skin. Fuel from the spray orifices can penetrate clothing and skin causing serious personal injury.5 L & 6. To obtain a true check of nozzle performance. Before applying pressure to the nozzle tester. be sure that all connections are tight. since dirty fuel will severely damage the precision parts of a nozzle.8 L Level 12 Electronic Fuel System 040902 PN=45 L30741 –UN–08AUG89 NOTE: Testing the performance of a nozzle while the engine is running is just a rough test.Electronic Fuel System Repair and Adjustments Fuel Injection Nozzle Test CAUTION: The nozzle tip should always be directed away from the operator. X9811 –UN–23AUG88 02 090 19 . 1—Nozzle Tester 2—Pressure Line Continued on next page OUO1089. and that the fittings are not damaged. Check all connections for leaks. Deviations from the regular spray pattern or angle may be due to the complete or partial clogging of a nozzle orifice..5 L & 6. evenly shaped spray cone..Electronic Fuel System Repair and Adjustments Spray Pattern Test Close gauge shut-off valve and operate the pump lever at 60 strokes per minute. After the last stroke of the pump. This spray cone is inclined from the centerline of the nozzle body. disassemble for servicing.. After the first drop has formed. Work the pump lever quickly several times in succession to make the nozzle spray in the normal way... the fuel should issue through all nozzle orifices in a fine.. If the nozzle is not quite leakproof. 1 to 14 drops (maximum) within 30 seconds 02 090 20 Checking Valve Seat Connect the nozzle to tester in horizontal position.. count the drops for 30 seconds and compare with specification. but should be distributed. Cover the tip and pump the tester to a pressure of 10 300 kPa (103 bar) (1500 psi). observe again. Dry the tip of the nozzle thoroughly. However some weeping or light moisture on the tip is considered acceptable. Now operate the pump lever slowly until the indicated pressure is approximately 2800 to 3500 kPa (28 to 35 bar) (400 to 500 psi) below opening pressure (see specification for opening pressure)... In this case the fuel issues in a jet rather than in a fine spray. Fuel Injection Nozzle—Specification Nozzle—Return Leakage at 10 300 kPa (103 bar) (1500 psi) . Operate the pump lever rapidly to bleed the nozzle and allow the valve to seat..0000200 –19–07NOV01–2/3 CTM331 (09APR02) 02-090-20 4.. Under these conditions the fluid should not drip out of the nozzle tip. Keep watching the nozzle. Keep the pressure constant and observe how much fuel leaks out of the nozzle return end. Checking Valve Stem and Guide Wear Connect fuel injection nozzle to the nozzle tester with the tip raised a little higher than its opposite end. Continued on next page OUO1089. For a better check. place a piece of paper or cardboard at a suitable distance below the nozzle and check the appearance of the damp circular spots made by the fuel.8 L Level 12 Electronic Fuel System 040902 PN=46 . If the fuel injection nozzle is working properly.. ......... Open gauge shut-off valve............... adjust opening pressure...0000200 –19–07NOV01–3/3 CTM331 (09APR02) 02-090-21 4........... 21 800 kPa (218 bar) (3170 psi) Min Rate Shaping Nozzle—Opening pressure difference between cylinders.......... 23 000—23 600 kPa (230—236 bar) (3340—3420 psi) Opening Pressure for Checking (Used) ...8 L Level 12 Electronic Fuel System 040902 PN=47 ......... Fuel Injection Nozzle—Specification Rate Shaping Nozzle—Opening Pressure for Setting (New or Reconditioned)................................................... 700 kPa (7 bar) (100 psi) Max 02 090 21 If spray pattern........................ and valve wear test are good but the opening pressure test is unsatisfactory......... 24 400—24 900 kPa (244—249 bar) (3540—3620 psi) Opening Pressure for Checking (New or Reconditioned)....................... Pump the pressure up to the point where the pressure gauge needle falls rapidly. 24 100 kPa (241 bar) (3500 psi) Min Opening Pressure for Setting (Used) ...............................5 L & 6... Close gauge shut-off valve and actuate the pump several times to allow the nozzle valve to seat properly............................. OUO1089...................Electronic Fuel System Repair and Adjustments Opening Pressure Test NOTE: Absolute opening pressure is less important than equal opening pressure of all nozzles... This point (take reading) is the nozzle valve opening pressure..... leakage test.... 0000201 –19–07NOV01–1/1 CTM331 (09APR02) 02-090-22 4.8 L Level 12 Electronic Fuel System 040902 PN=48 RG11996 .5 L & 6. If an injection nozzle is not operating properly and must be disassembled for cleaning and/or reconditioning. no further service is necessary and the nozzle can be reinstalled.Electronic Fuel System Repair and Adjustments Disassemble Fuel Injection Nozzles NOTE: If all tests prove that the nozzle performs properly. see your “Stanadyne” dealer. A—T-Fitting B—Cap C—O-Ring (2 used) D—Retainer E—Protection Cap F—Carbon Stop Seal G—Seal Washer H—Protection Cap –UN–15NOV01 02 090 22 RSN Nozzle Disassembly OUO1089. be sure all connections are tight. 4. Tighten pressure adjusting screw lock nut (E) to specification. Before applying pressure to nozzle tester. it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Unscrew lift adjusting screw with 7/8 turn.5 L & 6. –UN–15NOV01 High Pressure Fluids RSN Nozzle Adjust A—Pressure Adjusting Screw B—Lift Adjusting Screw C—Spring Chamber Cap D—Lift Adjusting Screw Lock Nut E—Pressure Adjusting Screw Lock Nut F—Spring Seat Continued on next page OUO1089. Loosen pressure adjusting screw lock nut (E) using JDG1515-2 Special Wrench. and fittings are not damaged. Use a piece of cardboard or wood. Fuel from spray orifices can penetrate clothing and skin causing serious personal injury. 1. rather than hands.Electronic Fuel System Repair and Adjustments Adjust Fuel Injection Nozzle CAUTION: Nozzle tip should always be directed away from operator. Enclosing nozzle in a glass beaker is recommended. then adjust opening pressure to specifications by turning the pressure adjusting screw (A). Tighten lift adjusting screw lock nut (D) to specification. 7. Connect nozzle to tester. 3.0000202 –19–07NOV01–1/2 CTM331 (09APR02) 02-090-23 4. 2. 5. Unscrew spring chamber cap (C) using JDG1521 Spring Chamber Cap Wrench. then recheck opening pressure. Fluid escaping from a very small hole can be almost invisible. 6. Use JDG1522 Pressure Adjusting Screw Tool. 8. If ANY fluid is injected into the skin. to search for suspected leaks. Carefully screw lift adjusting screw (B) until it bottoms on spring seat (F). Loosen and remove lift adjusting screw lock nut (D).8 L Level 12 Electronic Fuel System 040902 PN=49 RG11997 X9811 –UN–23AUG88 02 090 23 . JW7586 –19–20NOV97–1/1 CTM331 (09APR02) 02-090-24 4....... Position JD258 (JD-258) Nozzle Carbon Stop Seal Installer (A) over nozzle tip............ 2......... Plug all other openings in nozzle to prevent contamination...................8 L Level 12 Electronic Fuel System 040902 PN=50 RG9096 –UN–27MAR98 ....... Recheck opening pressure.....5 lb-ft) 02 090 24 OUO1089. 3.35......... 1... install a No.. Slide the carbon seal until it seats in its groove on nozzle body..... 5 N•m (3.........5 L & 6...... RG............0000202 –19–07NOV01–2/2 Install Seals on Fuel Injection Nozzle IMPORTANT: Each time an injection nozzle is removed from the cylinder head.......... 10 N•m (7 lb-ft) Lift Adjusting Screw Lock Nut— Torque ............ Fuel Injection Nozzle—Specification Pressure Adjusting Screw Lock Nut—Torque ........... replace carbon stop seal (B) with a new one... Fuel Injection Nozzle Seals A—Carbon Stop Seal Installer B—Carbon Stop Seal C—Seal Washer NOTE: If nozzle is not going to be installed at this time............ Install a new seal washer (C) onto nozzle body..Electronic Fuel System Repair and Adjustments 9... 16189 Nozzle Protector Cap over nozzle tip.. Position a new carbon stop seal (B) on seal installer........ . This could prevent proper sealing...........................Electronic Fuel System Repair and Adjustments Install Fuel Injection Nozzles IMPORTANT: Before installing injection nozzles....... Illustration shows relationship of parts required for proper installation. Install nozzle with spacer and clamps in cylinder head using a slight twisting motion as nozzle is seated in bore.......... Tighten nozzle hold-down clamp cap screws to specifications..... See REMOVE FUEL INJECTION NOZZLES earlier in this group..... making the valve stick...... Dirt and roughness could also cause nozzle to be distorted when the attaching screw is tightened.. NOTE: If nozzle bore in cylinder head must be cleaned.. make sure nozzles are clean and free from oil or grease.. 2.8 L Level 12 Electronic Fuel System 040902 PN=51 RG11998 ... Connect fuel pressure line to nozzle..... Specification Fuel Leak-Off Line Hex Nut— Torque . Leave connection slightly loose until air is bled from system.... 4.. 3.. 5 N•m (3....) Continued on next page OUO1080. 1.....0000200 –19–16NOV01–1/2 CTM331 (09APR02) 02-090-25 4....... 5............. Install leak-off line assembly.......... use JDE39 Nozzle Bore Cleaning Tool..... Remove plug (if installed previously) from nozzle bore in cylinder head and blow out bore with compressed air. Do not tighten cap screw at this stage.. Specification Fuel Injection Nozzle Hold-Down Clamp Cap Screws—Torque..7 lb-ft) (44 lb-in.... –UN–19NOV01 02 090 25 NOTE: Make sure that the sealing surface of the cylinder head (on which the seal washer will be resting) is smooth and free of damage or dirt..... 40 N•m (30 lb-ft) Injection Nozzle in Cylinder Head 6...5 L & 6. Align nozzle clamps and install cap screw.. .. Illinois. Tighten connection using two wrenches to the following specifications..... If an accident occurs. it will be necessary to bleed air from the system....Electronic Fuel System Repair and Adjustments 7. Nozzle Fuel Pressure Line OUO1080....... On some engine applications it may be necessary to consult your operator’s manual and choose the best location for your engine/machine application.. The fuel system may be bled at one of several locations..5 L & 6.0000203 –19–07NOV01–1/5 CTM331 (09APR02) 02-090-26 4.........8 L Level 12 Electronic Fuel System 040902 PN=52 X9811 –UN–23AUG88 RG11999 –UN–19NOV01 ..... Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result...0000200 –19–16NOV01–2/2 Bleed the Fuel System CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.. Protect hands and body from high pressure fluids...... Bleed air from loose injection line connection....... or other knowledgeable medical source. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines.. see a doctor immediately. 27 N•m (20 lb-ft) See BLEED THE FUEL SYSTEM in this group..... High Pressure Fluids Continued on next page OUO1089. Search for leaks with a piece of cardboard........... 02 090 26 Specification Fuel Injection Nozzle Delivery Line—Torque ... Any time the fuel system has been opened up for service (lines disconnected or filters removed)..... Tighten all connections before applying pressure... If engine will not start. Operate fuel supply pump prime lever (B) or primer button on fuel filter base (if equipped).Electronic Fuel System Repair and Adjustments 1. continue operating primer until pumping action is not felt. 3.8 L Level 12 Electronic Fuel System 040902 PN=53 RG11806 RG11805 . A—Bleed Vent Screw –UN–25OCT01 02 090 27 Final Fuel Filter Bleed Vent Screw OUO1089. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base. Tighten bleed plug securely. Start engine and check for leaks. it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.5 L & 6. 4.0000203 –19–07NOV01–3/5 CTM331 (09APR02) 02-090-27 4.0000203 –19–07NOV01–2/5 2. B—Primer Lever –UN–25OCT01 Fuel Supply Pump Primer Lever Continued on next page OUO1089. Specification Fuel Injection Nozzle Delivery Lines—Torque ....... Retighten connection to specifications......0000203 –19–07NOV01–5/5 CTM331 (09APR02) 02-090-28 4... 3. Place throttle lever in half-throttle position...........0000203 –19–07NOV01–4/5 At Fuel Injection Nozzles 1..... Crank engine over with starter motor for 15 seconds (but do not start engine) until fuel without any air bubbles flows out of loosened connection.......Electronic Fuel System Repair and Adjustments At Fuel Injection Pump 1... Loosen fuel return line (A) at fuel injection pump... loosen two fuel line connections at injection nozzles.......... If engine still will not start.... 27 N•m (20 lb-ft) Nozzle Fuel Pressure Line 4....5 L & 6. Using two open-end wrenches....... IMPORTANT: Always use a backup wrench when loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage.............. 27 N•m (20 lb-ft) Fuel Injection Pump Return Line A—Fuel Return Line OUO1089.... see your authorized servicing dealer or engine distributor......... OUO1089......8 L Level 12 Electronic Fuel System 040902 PN=54 RG11808 –UN–25OCT01 RG11807 3..... 02 090 28 Specification Fuel Injection Pump Return Line—Torque ...... Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system.......... 2.. ... As soon as fuel flow is free from air bubbles......... Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). tighten fuel return line to specifications............. –UN–25OCT01 2.. Primer lever is spring-loaded and will return to normal position.. NOTE: The sealed ECU assembly is the system component LEAST likely to fail.8 L Level 12 Electronic Fuel System 040902 PN=55 RG12006 . Provide the 13-digit engine serial number when ordering a new ECU. –UN–15NOV01 02 110 1 Engine Control Unit (ECU) NOTE: For diagnosis and testing of the electronic engine control and sensors. poor performance. Ensure that it is isolated and identified as the defective component before replacing. protect the ECU from high-current damage as follows: 1. Disconnect ECU-to-vehicle frame ground connection. IMPORTANT: If an ECU is not programmed identically with the original (failed) ECU.5 L & 6. The ECU is not repairable. Disconnect all other connectors from ECU. replace it as a unit. refer to Group 150. If it is found to be defective. Also disconnect module connector at injector pump. OUO1080. See operation and test manual for proper troubleshooting procedures. 2. Before welding on engines with ECU.0000201 –19–16NOV01–1/1 CTM331 (09APR02) 02-110-1 4.Group 110 Electrical Engine Control Repair and Adjustment Engine Control Unit (ECU) IMPORTANT: DO NOT pressure wash the Engine Control Unit (ECU). IMPORTANT: DO NOT OPEN ENGINE CONTROL UNIT. Connect welder ground close to welding point and make sure ECU and other electrical components are not in the ground path. misleading diagnostic messages. 3. or engine damage can occur. . Specification Engine Coolant Temperature Sensor—Torque ........... Disconnect loss of coolant temperature sensor wiring connector and remove sensor.............. 2....Electrical Engine Control Repair and Adjustment Remove and Install Engine Coolant Temperature Sensor 1.............5 L & 6..... 15 N•m (11 lb-ft) 02 110 2 3.................. Tighten to specifications...... Specification Loss of Coolant Temperature Sensor—Torque .......8 L Level 12 Electronic Fuel System 040902 RG10766 PN=56 RG12009 –UN–16NOV01 ......... 2... Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in thermostat housing... RG40854.............. Disconnect engine coolant temperature sensor wiring connector and remove sensor... Install sensor wiring connector...... 35 N•m (26 lb-ft) –UN–26MAY00 Loss of Coolant Temperature (Rear of Cylinder Head) A—Loss of Coolant Temperature Sensor 3. Install sensor wiring connector....000014A –19–11FEB02–1/1 CTM331 (09APR02) 02-110-2 4.. Engine Coolant Temperature Sensor A—Engine Coolant Temperature Sensor OUO1080. Tighten to specifications........ Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in the rear of the cylinder head.......0000202 –19–16NOV01–1/1 Remove and Install Loss of Coolant Temperature Sensor 1... .......... Install sensor wiring connector..Electrical Engine Control Repair and Adjustment Replace Crankshaft Position Sensor 1... OUO1080............... 2.......... Specification Oil Pressure Sensor—Torque ....... Tighten sensor to specifications...... Install sensor in oil cooler housing and tighten to specifications......... Specification Crankshaft Position Sensor— Torque ....5 L & 6....... 15 N•m (11 lb-ft) –UN–02DEC99 Oil Pressure Sensor 3.... 2...0000203 –19–16NOV01–1/1 Remove and Install Oil Pressure Sensor 1........ Install sensor wiring connector...... LOCTITE is a registered trademark of Loctite Corp.. Crankshaft Position Sensor A—Crankshaft Position Sensor OUO1080. Coat threads of sensor with LOCTITE® 592 Pipe Sealant with TEFLON®...... 14 N•m (10 lb-ft) 02 110 3 –UN–16NOV01 4.. Replace sensor and O-ring in timing gear cover.. Using a deep well socket.. Disconnect sensor wiring connector.0000204 –19–16NOV01–1/1 CTM331 (09APR02) 02-110-3 4.8 L Level 12 Electronic Fuel System 040902 PN=57 RG10550 RG12011 ..... Disconnect oil pressure sensor wiring connector (shown disconnected) and remove sensor from cylinder block.......... 3... remove crankshaft position sensor (A).... TEFLON is a registered trademark of Du Pont Co......... ...... 2... Install sensor wiring connector.. 13—18 N•m (10—13 lb-ft) 3......00001F5 –19–09NOV01–1/1 Remove and Install Fuel Temperature Sensor 1..... Specification Manifold Air Temperature Sensor—Torque ......5 L & 6......... Manifold Air Temperature Sensor A—Manifold Air Temperature Sensor OUO1080........... 10 N•m (7 lb-ft) –UN–16NOV01 02 110 4 3....... Replace O-ring and install sensor in air intake line..... –UN–16NOV01 Specification Fuel Temperature Sensor— Torque .. Disconnect air temperature sensor wiring connector and remove sensor (A) from air intake line.......8 L Level 12 Electronic Fuel System 040902 PN=58 RG12014 RG12013 .... Tighten sensor to specifications.........Electrical Engine Control Repair and Adjustment Remove and Install Manifold Air Temperature Sensor 1...................................... 2. Install sensor wiring connector..... Disconnect fuel temperature sensor wiring connector and remove sensor (A) from fuel injection pump.....00001F6 –19–12NOV01–1/1 CTM331 (09APR02) 02-110-4 4.. A— Fuel Temperature Sensor Fuel Temperature Sensor OUO1080........ Replace O-ring and install sensor into fuel injection pump and tighten to specifications... 00001F7 –19–12NOV01–1/1 CTM331 (09APR02) 02-110-5 4..... Specification Fuel Heater—Torque ............ Replace O-ring and install fuel heater in primary fuel filter inlet port to specifications..8 L Level 12 Electronic Fuel System 040902 PN=59 RG12016 .... 9 N•m (7 lb-ft) 02 110 5 3.............. Fuel Heater OUO1080..... Install heater wiring connector..... –UN–16NOV01 2..5 L & 6..........Electrical Engine Control Repair and Adjustment Remove and Install Fuel Heater 1... Disconnect fuel heater wiring connector and remove heater from filter base....... it is important to protect the connectors from debris.8 L Level 12 Electronic Fuel System 040902 PN=60 . especially in wet and humid conditions. A good crimp is important to mechanical and electrical soundness.Electrical Engine Control Repair and Adjustment Connectors Connectors are devices that provide for assembly and disassembly of systems. This provides a moisture barrier.1335 –19–23OCT97–1/1 CTM331 (09APR02) 02-110-6 4.RG34710. Repaired connectors should be physically tested by pulling to be sure the contact is firmly attached to the conductor.RG34710. RG. 02 110 6 RG. IMPORTANT: If for some reason the connectors are not connected. such as when the fuel injection pump is removed. Connectors should always be serviced using tools designed for that type of connector.1328 –19–23OCT97–1/1 Use Electrical Insulating Compound Apply AT66865 Compound directly to the terminals between the wire seal and connector body. Refer to the procedures which follow for repair of various types of connectors.5 L & 6. Electrical Engine Control Repair and Adjustment Using High-Pressure Washer IMPORTANT: Reduce pressure when directing pressurized water at electronic or electrical components and connectors as this may cause the components to malfunction. and spray at a 45 to 90 degree angle.5 L & 6. Using High-Pressure Washer RG.8 L Level 12 Electronic Fuel System 040902 PN=61 T6642EJ –UN–18OCT88 02 110 7 .1329 –19–23OCT97–1/1 CTM331 (09APR02) 02-110-7 4. Always reduce pressure.RG34710. Using JDG145 Universal Electrical Pliers2. –UN–23AUG88 02 110 8 WEATHERPACK is a trademark of Packard Electric 1 Included in JT07195B Electrical Repair Kit 2 Included in JDG155 Electrical Repair Tool Kit Continued on next page AG. go to step 5. 3. Insert JDG364 Extraction Tool1 over terminal contact in connector body.OUOD008. Identify wire color/number to the connector cavity.8 L Level 12 Electronic Fuel System 040902 PN=62 TS0128 .296 –19–06MAR02–1/4 CTM331 (09APR02) 02-110-8 4. strip 6 mm (1/4 in.) insulation from end of wire.Electrical Engine Control Repair and Adjustment Repair WEATHERPACK™ Connector 1. Disconnect WEATHERPACK™ connector. Open the secondary lock on the back of the connector. 4. Make sure each wire goes back to the correct cavity location. 5. gently pull the wire from the back of the connector.5 L & 6. If any part of the seal is still on the wire. 6. When tool is seated. If the wires and terminals are OK and only the connector is being replaced. If the wire(s) or terminal(s) are being repaired. go to step 9. dispose of it. Remove the tie bands and tape. Using JDG145 Universal Electrical Pliers2. 2. cut off wire directly behind the terminal seal crimp. Extraction tool needs to be fully seated to unlock terminal tangs from the connector body. 14—16 Gauge Wire • #19 . Select correct size terminal on wire and crimp in position with a W-type crimp using a JDG783 WEATHER PACK™ Crimping Tool.10—12 Gauge Wire AG. Slide the seal over the wire insulation with the smaller diameter side facing the end of the wire. 02 110 9 • Green .OUOD008.296 –19–06MAR02–3/4 CTM331 (09APR02) 02-110-9 4. Select correct size of seal.14—16 Gauge Wire • Blue .5 L & 6.OUOD008. Small diameter side of seal should line up with the outer edge of the insulation.296 –19–06MAR02–2/4 8.18—20 Gauge Wire • Gray .18—20 Gauge Wire –UN–02NOV94 WEATHER PACK is a trademark of Packard Electric Continued on next page AG. NOTE: Terminals have numbered identification for two sizes of wire: • #15 .8 L Level 12 Electronic Fuel System 040902 PN=63 TS1623 TS0136 NOTE: Cable seals are color coded for three sizes of wire: .Electrical Engine Control Repair and Adjustment 7. –UN–23AUG88 IMPORTANT: The seal must fit snug over the cable insulation without a gap between the cable seal and the insulation. 8 L Level 12 Electronic Fuel System 040902 PN=64 TS0139 –UN–02DEC88 TS0130 –UN–23AUG88 IMPORTANT: Terminal tangs must be carefully spread to ensure good seating on connector body. Terminal should click when it is fully seated. Repair or transfer remaining wires. Close the secondary lock on the back of the connector.Electrical Engine Control Repair and Adjustment 9. Retape wires and add the required tie bands to the harness. make sure tangs are spread. 02 110 10 NOTE: Connector bodies are “keyed” for correct terminals.296 –19–06MAR02–4/4 CTM331 (09APR02) 02-110-10 4. . Gently pull on wire to insure that the terminal is locked in position. 13. 12.OUOD008. 10. Make sure the wire is inserted into the correct connector cavity. Insert terminal into connector. If terminal is being reused in a new connector. Correct terminal installation for sleeve (A) and pin (B) is illustrated. 11. A—Sleeve B—Pin AG.5 L & 6. Be sure terminals are correctly aligned. 280. 1. Use JDG777 Extraction Tool with 150 Series METRI-PACK terminals. A—Locking Tang B—Original Position 1 Included in JT07195B Electrical Repair Kit AG.297 –19–06MAR02–1/1 CTM331 (09APR02) 02-110-11 4. 3.Electrical Engine Control Repair and Adjustment Remove Blade Terminals from Connector Body NOTE: Use JDG776 Extraction Tool with 56. Gently pull wire and remove terminal from connector. 2.OUOD008. Insert JDG776 or JDG777 Terminal Extraction Tool1 into connector body pushing the terminal locking tang inward. and 630 Series METRI-PACK terminals. Adjust the locking tang on the terminal to it’s original position before installing into a connector.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=65 RW4218 –UN–23AUG88 02 110 11 . Make sure each wire goes back to the correct cavity location. Using JDG776 Terminal Extraction Tool (C). 6.298 –19–06MAR02–1/2 CTM331 (09APR02) 02-110-12 4. 3. 5. 7.OUOD008. If terminal does not extract. angle the tip so it slides along the top edge of the connector. 4. A—Connector B—Connector Seal C—JDG777 Terminal Extraction Tool D—Terminal Locking Tang E—Terminal METRI-PACK is a trademark of Delphi Packard Electric Systems 1 Included JT07195B Electrical Repair Kit Continued on next page AG. Remove tie bands and tape from the wiring harness behind the connector. NOTE: Extraction tool must be used from the back of the connector.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=66 RW16935A –UN–05AUG98 . Using JDG776 Terminal Extraction Tool (C)1. Push wire until terminal has extracted from the front of the connector. Remove extraction tool from back of connector. –UN–13MAR02 RG12232A –UN–13MAR02 RG12231A 02 110 12 2. 8. With extraction tool inserted into the connector. carefully remove the connector seal (B) from the back of the connector.Electrical Engine Control Repair and Adjustment Repair (Pull Type) METRI-PACK™ Connectors 1. repeat steps 4-6. Identify wire color/number to the connector cavity. Make sure the extraction tool is centered in the connector cavity and push the tool in until resistance is felt. Disconnect the METRI-PACK connector (A) from the ECU. gently rotate tool clockwise and counter-clockwise (no more than 1/8 turn each direction) to depress the terminal locking tang (D). IMPORTANT: Make sure no damage to the seal occurs or water and contaminants will corrode terminals. Using either JDG783 (G) or JDG707 (H) Crimping Pliers. 12. 16. Slide the connector seal back into the connector. Using JDG145 Universal Electrical Pliers1. 11. cut off wire directly behind the terminal. 13. all of the strain will be placed on them.) insulation from end of wire. Damage to the harness may occur.Electrical Engine Control Repair and Adjustment 9.OUOD008. IMPORTANT: Save as much wire as possible. Using JDG145 Universal Electrical Pliers1. 15. If only a couple of wires are shorter than the rest.8 L Level 12 Electronic Fuel System 040902 PN=67 RW16935A –UN–05AUG98 . RG12233A RG12234A –UN–13MAR02 02 110 13 D—Terminal Locking Tang E—Correct Terminal Orientation F—Wire G—JDG783 Terminal Crimping Tool H—JDG707 Terminal Crimping Tool 1 Included in JDG155 Electrical Repair Tool Kit AG. check for correct terminal alignment (E). 10. make sure the wire is fed through the connector (F) and in the correct cavity. 14.298 –19–06MAR02–2/2 CTM331 (09APR02) 02-110-13 4. Push on the wire to make sure terminal is locked into the connector. If wire has been removed from the connector. Make sure seal is in it’s origional position. strip 6 mm (1/4 in. –UN–13MAR02 NOTE: Terminal will seat only one way. If terminal does not pull into the connector body socket. Make sure terminal locking tang (D) on new terminal is in outward position. Pull wire back into connector cavity until terminal locks. crimp a new terminal on the wire.5 L & 6. Retape the wires and add the required tie bands to the harness. Use JDG777 Extraction Tool with 150 Series METRI-PACK terminals.Electrical Engine Control Repair and Adjustment Repair (Push Type) METRI-PACK™ Connectors 1. Remove secondary lock (A). Slide the seal over the wire insulation with the smaller diameter side facing the end of the wire.OUOD008. Remove extraction tool and pull wire from the back of the connector. 8.299 –19–06MAR02–1/3 2 CTM331 (09APR02) 02-110-14 4. 280. –UN–08DEC98 02 110 14 6. –UN–23AUG88 NOTE: Use JDG776 Extraction Tool with 56. Make sure each wire goes back to the correct cavity location.8 L Level 12 Electronic Fuel System 040902 PN=68 TS0136 5. Disconnect the METRI-PACK connector. Insert JDG776 or JDG777 Terminal Extraction Tool1 (B) into connector cavity (C) pushing the terminal locking tab inward.) insulation from end of wire. 4. 2. A—Connector Secondary Lock B—Extraction Tool C—Connector Body Socket D—Terminal METRI-PACK is a trademark of Delphi Packard Electric Systems 1 Included in JT07195B Electrical Repair Kit Included in JDG155 Electrical Repair Tool Kit Continued on next page AG. Select correct size of seal. 3. Identify wire color/number to the connector cavity. Small diameter side of seal should line up with the outer edge of the insulation. cut off wire directly behind the terminal. Using JDG145 Universal Electrical Pliers2. and 630 Series METRI-PACK terminals. RW77137 . 7.5 L & 6. Remove the tie bands and tape. Using JDG145 Universal Electrical Pliers2 strip 6 mm (1/4 in. Electrical Engine Control Repair and Adjustment IMPORTANT: The seal must fit snug over the cable insulation.14—16 Gauge Wire • Blue .10—12 Gauge Wire 9. NOTE: Cable seals are color coded for three sizes of wire: • Green .OUOD008.299 –19–06MAR02–2/3 CTM331 (09APR02) 02-110-15 4. 02 110 15 Continued on next page AG. without a gap between the cable seal and the insulation.5 L & 6. Select correct size contact for wire.8 L Level 12 Electronic Fuel System 040902 PN=69 .18—20 Gauge Wire • Gray . 11. Push terminal into the correct connector cavity until terminal locks. Place the secondary lock back on the connector. Make sure locking tang (D) on the new terminal is in the outward position. Retape the wires and add the required tie bands to the harness. Crimp cable seal (C) on contact using JDG865 Crimping Tool (B). 14.5 L & 6. 13. Crimp contact (A) on wire with a “W” type crimp using JDG865 Crimping Tool (B). 12. Gently pull on wire to verify terminal is locked into the connector. A—Contact B—Tool C—Cable Seal D—Terminal Locking Tang –UN–07DEC98 02 110 16 AG.299 –19–06MAR02–3/3 CTM331 (09APR02) 02-110-16 4.OUOD008. 15. 16.Electrical Engine Control Repair and Adjustment 10.8 L Level 12 Electronic Fuel System 040902 PN=70 RW77140A –UN–15MAR02 RW77138A –UN–15MAR02 RW77139 . ) insulation from end of wire. Slide extraction tool rearward along wire until tool tip snaps onto wire. Disconnect the Deutsch connector. 5. Start inserting the wire into the handle end (A) of the correct size extraction tool.OUOD008. Remove the tie bands and tape.Electrical Engine Control Repair and Adjustment Repair DEUTSCH™ Connectors 1. 8. –UN–07DEC98 2. strip 6 mm (1/4 in. DEUTSCH is a trademark of Deutsch Company 1 Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCH Electrical Repair Kit 2 Included in JDG359 DEUTSCH Electrical Repair Kit Included in JT07195B Electrical Repair Tool Kit Included in JDG155 Electrical Repair Tool Kit 3 4 Continued on next page AG. 9. Using JDG145 Universal Electrical Pliers4. 6. Select correct size extractor tool for size of wire to be removed: • • • • JDG361 JDG362 JDG363 JDG785 Extractor Extractor Extractor Extractor Tool Tool Tool Tool 12—14 Gauge Wire1 16—18 Gauge Wire1 20 Gauge Wire2 6-8 Gauge Wire3 02 110 17 A—Handle 4. Pull wire from connector body using extraction tool. Using JDG145 Universal Electrical Pliers4 cut off wire directly behind the terminal. 3. Slide extraction tool along wire into connector body until tool is positioned over terminal contact. Make sure each wire goes back to the correct cavity location.8 L Level 12 Electronic Fuel System 040902 PN=71 RW77142 .5 L & 6. Identify wire color/number to the connector cavity.304 –19–03NOV99–1/4 CTM331 (09APR02) 02-110-17 4. IMPORTANT: DO NOT twist tool when inserting in connector. 7. A—Selector B—Lock Nut C—Adjusting Screw –UN–23AUG88 02 110 18 1 Included in JDG359 Electrical Repair Kit AG. 13. Insert terminal (A) and turn adjusting screw (D) until terminal is flush with cover (B).304 –19–03NOV99–3/4 CTM331 (09APR02) 02-110-18 4. Loosen lock nut (B) and turn adjusting screw (C) in until screw stops. 11.OUOD008. Tighten lock nut (C).304 –19–03NOV99–2/4 12. A—Terminal B—Cover C—Lock Nut D—Adjusting Screw –UN–23AUG88 Continued on next page AG.Electrical Engine Control Repair and Adjustment 10.8 L Level 12 Electronic Fuel System 040902 PN=72 TS0134 TS117 .5 L & 6. Adjust selector (A) on JDG360 Crimping Tool1 for correct wire size .OUOD008. IMPORTANT: Select correct size terminal to fit connector body. Transfer remaining wires to correct cavity in new connector. TS0135 TS118 . Insert wire in terminal and crimp until handle contacts stop. Release handle and remove terminal. 15. AG. Inspect terminals to ensure all wires are in crimped barrel.OUOD008. Retape the wires and add the required tie bands to the harness. IMPORTANT: Terminal must remain centered between indenters while crimping. Gently pull on wire to verify terminal is locked into the connector.5 L & 6. –UN–23AUG88 17.8 L Level 12 Electronic Fuel System 040902 PN=73 RW77141 –UN–07DEC98 20. cut off wire at terminal and repeat terminal installation procedures. IMPORTANT: If all wire strands are not crimped into terminal.Electrical Engine Control Repair and Adjustment 14. 19. 16. –UN–23AUG88 02 110 19 NOTE: Readjust crimping tool for each crimping procedure. 18.304 –19–03NOV99–4/4 CTM331 (09APR02) 02-110-19 4. IMPORTANT: Install terminal in correct connector cavity using correct size grommet. Push terminal straight into correct connector cavity until positive stop is felt. See instructions provided with tool.Electrical Engine Control Repair and Adjustment Repair AMP Connector 02 110 20 Using AMP Crimping Tool A—Locator Assembly B—Locator C—Wire D—Crimping Slot E—Crimping Slot F—Terminal G—Insulation Barrel H—Wire Barrel 1. Press JDG1369 Terminal Extraction Tool into face of connector and remove wire and terminal from back of connector.5 L & 6. Place the terminal up into the nest so that the movable locator (B) drops into the slot in the terminal as shown.8 L Level 12 Electronic Fuel System 040902 PN=74 RG10742 –UN–31MAY00 . Continued on next page DPSG. Squeeze tool handles together and allow them to open fully. 8. Butt the front end of the wire barrel (H) against the movable locator.OUO1004. through the front of the tool and into the appropriate crimp slot (D or E). Identify wire color/number to the connector cavity. IMPORTANT: Make sure that both sides of the insulation barrel (G) are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned terminal. Hold the terminal (F) in position and squeeze the tool handles together until ratchet engages sufficiently to hold the terminal in position. NOTE: Verify wire stripping length and crimp height before using AMP crimping tool. 5. Strip new wire to length indicated in tool instructions. insert the insulation barrel (G) first. 7. Disconnect AMP connector. Position the terminal so that the open “U” of the wire and insulation barrels (H and G) face the top of the tool. 3.2867 –19–06MAR02–1/2 CTM331 (09APR02) 02-110-20 4. NOTE: See instructions provided with tool to determine which crimping slot (D or E) to use. 9. Make sure the each wire goes back into the correct cavity location. Do not nick or cut wire strands. Insert stripped wire (C) into terminal insulation and wire barrels until it is butted against the wire stop. Hold JDG708 AMP Crimping Tool so that the back (wire side) is facing you. 6. DO NOT deform insulation barrel or wire barrel. 4. Remove the tie bands and tape. Holding the terminal (F) by the mating end. 2. Retape the wires and add the required tie bands to the harness. Squeeze tool handles together until ratchet releases. 11. Hold the wire and terminal (A) in place. A—Wire and Terminal B—Locator 02 110 21 DPSG.2867 –19–06MAR02–2/2 CTM331 (09APR02) 02-110-21 4.OUO1004. Allow tool handles to open and remove crimped terminal. 12.Electrical Engine Control Repair and Adjustment 10. It can be easily removed by pushing downward on the top of the locator (B).5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=75 T112335E –UN–15MAR02 . Install wire in correct connector cavity. NOTE: The crimped terminal may stick in the crimping area. Electrical Engine Control Repair and Adjustment 02 110 22 CTM331 (09APR02) 02-110-22 4.8 L Level 12 Electronic Fuel System 040902 PN=76 .5 L & 6. . . . . . . . . . . . . . . . .03-140-7 Measuring Throttle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 03 Theory of Operation Contents Page Group 130—Electronic Fuel System Operation About this Group . .03-140-5 Measuring Pressure . . . . . . . . . . . . . . . . . .03-130-1 Fuel System Operation . . . . . . . . . . . . . . . . .03-140-2 Electronic Control System Operation . . . .03-140-11 Cruise Control Operation. . . . . . . . . . . .03-140-14 Engine Control Unit (ECU) Self-Diagnosis. .03-130-6 Fuel Injection Nozzle Operation. . .03-140-13 Derate Programs. . . . . . . . . . . . . . . . . . .03-140-14 Governor Droop Mode Selection . . . . .03-140-4 Measuring Temperature . . . . . .03-140-1 Electronic Control System Terminology . . . . . . . . . . . . . . . . . . . . . .03-140-12 Intake Air Heater Operation.03-130-8 Group 140—Electronic Control System Operation About This Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4 Final Fuel Filter Operation. . . . . . . . .03-140-15 03 CTM331 (09APR02) 03-1 4. . . . . . . . . . .03-130-2 Fuel Supply Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-9 Pump Solenoid . .03-140-9 Engine Control Unit (ECU) . . . . . .03-140-8 Measuring Engine Speed . . . . . . . . . . . . . . .03-130-5 Fuel Injection Pump Operation . . . . . . . . . . . . . . .5 L & 6. . .03-140-12 Engine Protection . . .03-140-3 Electronic Control System Overview . . . . . . . . .03-140-3 Monitoring Engine Parameters . . . . . . . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 PN=1 . . . . . .03-140-13 Multiple Torque Curve Selection . . . . . . . . . . . . . . . . . .03-140-10 Controller Area Network (CAN) . . . . . Contents 03 CTM331 (09APR02) 03-2 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=2 . the fuel system information is described in the following categories: • • • • • Fuel System Operation Fuel Supply Pump Operation Final Fuel Filter Operation Fuel Injection Pump Operation Fuel Injection Nozzle Operation 03 130 1 RG40854.8 L Level 12 Electronic Fuel System 040902 PN=79 .000001C –19–03DEC01–1/1 CTM331 (09APR02) 03-130-1 4.Group 130 Electronic Fuel System Operation About this Group In this group.5 L & 6. it travels through the final fuel filter (D) to the fuel injection pump (E). Once the fuel is pressurized in the fuel supply pump. A water bowl can be included with either the prefilter or final fuel filters.000001D –19–03DEC01–1/2 CTM331 (09APR02) 03-130-2 4. the water bowl is located at the first filter in the system. On some applications.8 L Level 12 Electronic Fuel System 040902 PN=80 RG11957 –UN–21DEC01 .5 L & 6.Electronic Fuel System Operation Fuel System Operation 03 130 2 A—Fuel Tank B—Prefilter C—Fuel Supply Pump D—Final Fuel Filter E—Fuel Injection Pump F—Overflow Valve G—Fuel Injection Nozzle H—Fuel Leak-off Line I—Tank Pressure Fuel J—Supply Pump Pressure Fuel K—Injection Pump Pressure Fuel The fuel supply pump (C) draws fuel from the tank (A) by pressurizing the fuel. Typically. fuel is routed through a prefilter (B) prior to the fuel supply pump. Continued on next page RG40854. On some applications.000001D –19–03DEC01–2/2 CTM331 (09APR02) 03-130-3 4. Once the pressure of the fuel inside the injection nozzle (G) overcomes the nozzle valve.8 L Level 12 Electronic Fuel System 040902 PN=81 . This allows for fuel to atomize as it enters the combustion chamber. fuel is forced 03 130 3 otu a small orifice in the nozzle tip. This high pressure fuel is routed through the delivery (pressure) lines to the fuel injection nozzles (G). RG40854. If there is excess fuel in the injection pump. the fuel goes through a fuel cooler before returning to the fuel tank. it is released through an overflow valve (F) and returned to tank through the fuel leak-off line (H).Electronic Fuel System Operation The fuel injection pump raises the required fuel pressure for injection.5 L & 6. Excess fuel from the nozzles is routed through the fuel return leak-off line and returns to the fuel tank. delivering fuel through the outlet (A) to the injection pump.8 L Level 12 Electronic Fuel System 040902 PN=82 RG9119 .Electronic Fuel System Operation Fuel Supply Pump Operation The Sofabex fuel supply pump uses an eccentric lobe on the engine camshaft to operate the lever (G) on supply pump to pressurize fuel system. the rod (F) pulls diaphragm (I) down. The resulting fuel pressure closes the inlet check valve (C) and opens the outlet check valve (B). A hand primer lever (H) is provided for manually forcing fuel through the system to bleed air from the fuel filter. Fuel flows from the fuel tank at gravity pressure to the inlet side (D) of the diaphragm-type pump.0000110 –19–16JAN02–1/1 CTM331 (09APR02) 03-130-4 4. Suction pressure opens the inlet check valve (C) and fuel is drawn into the pump. the return spring (E) forces the diaphragm (I) upward. As the lever (G) rides on the high side of the camshaft lobe. etc.5 L & 6. As the camshaft lobe rotates to the low side. –UN–17APR98 03 130 4 A—Fuel Outlet B—Outlet Check Valve C—Inlet Check Valve D—Fuel Inlet E—Return Spring F—Rod G—Lever H—Hand Primer Lever I—Diaphragm RG40854. lines. a drain plug (E) is provided.0000111 –19–16JAN02–1/1 CTM331 (09APR02) 03-130-5 4. Air in the system can be expelled through the air vent when bleed screw (A) is loosened.Electronic Fuel System Operation Final Fuel Filter Operation Fuel enters the filter at inlet (C). A—Bleed Screw B—Fuel Outlet C—Fuel Inlet D—Filter Element E—Drain Plug F—Primer Pump 03 130 5 RG40854. flows through filter element (D) and exits through outlet (B) to the fuel injection pump. The 5 micron filter element is housed in a sediment bowl attached to the base with a threaded retaining ring. Optional priming pump (F) draws fuel from the fuel tank to fill the filter bowl when the filter element is changed.5 L & 6. On some options. a water bowl is attached to the bottom of the sediment bowl.8 L Level 12 Electronic Fuel System 040902 PN=83 RG9090 –UN–27MAR98 . Since water and contaminants settle at the bottom of the sediment bowl. The priming pump also supplies fuel from the filter to the injection pump. distributor rotor (H). and recirculated back to the fuel inlet passage. The fuel transfer pump (inside the injection pump) draws fuel from the final filter through the fuel inlet fitting (A). and fuel control solenoid (F). The fuel in the high pressure chamber is spilled out of the high pressure chamber into the transfer pump fuel. the plungers in the high pressure chamber create injection pressure because they are forced inward by the rotation of the cam ring.8 L Level 12 Electronic Fuel System 040902 PN=84 RG11958 –UN–20DEC01 . The main components of the Stanadyne DE10 fuel injection pump are the driveshaft (B).Electronic Fuel System Operation Fuel Injection Pump Operation 03 130 6 A—Fuel Inlet Fitting B—Heavy Duty Driveshaft C—Transfer Pump D—Cam Ring E—Discharge Fitting F—Fuel Control Solenoid G—Pump Control Valve H—Distributor Rotor I—Fuel Temperature Sensor J—Fuel Return Fitting/Housing Pressure Regulator NOTE: The above illustration has been reprinted with permission from Stanadyne Automotive Corporation. When the fuel control solenoid is deenergized. The rotation of the driveshaft moves the transfer pump. the pump control valve opens. Once the fuel has been pressurized by the transfer pump. When the pump control valve is open. it can travel to three locations: inside the plungers of the cam ring (D). the transfer pump (C).5 L & 6. With each revolution. cam shoes and rollers. and distributor shaft since all of these components are engaged. When the pump control valve is closed. High pressure fuel is forced through the discharge fittings to the injection nozzles. it allows the transfer pump pressurized fuel to enter the high pressure chamber. The crankshaft of the engine drives the driveshaft of the pump using gears between the two components. cam ring (D) and shoes.0000112 –19–16JAN02–1/2 CTM331 (09APR02) 03-130-6 4. pump control valve (G). The Engine Control Unit (ECU) energizes the fuel control solenoid which causes the pump control valve to close. Continued on next page RG40854. it pressurizes fuel between 0—1100 kPa (0—11 bar) (0—160 psi) depending on the rotational speed of the pump. into the injection pump housing cavaties. The purpose of housing pressure fuel is to keep the injection pump components cooled and lubricated. The pressure of the housing is controlled by the fuel return fitting/pressure regulator (J). 03 130 7 RG40854. If the pressure exceeds the regulator. It circulates the fuel back through the transfer pump.0000112 –19–16JAN02–2/2 CTM331 (09APR02) 03-130-7 4. For more information on the fuel temperature sensor. it will return fuel to the fuel tank.5 L & 6. see MEASURING TEMPERATURE in Group 140 of this Section.8 L Level 12 Electronic Fuel System 040902 PN=85 . The ECU monitors the fuel temperature of the housing through a fuel temperature sensor (I). This allows for fuel to return to injection pump inlet pressure. The amount of fuel that is released into the housing is determined by the size of the vent wire. The remaining transfer pump pressure fuel travels through a transfer pump regulating valve.Electronic Fuel System Operation Some of the transfer pump pressure fuel is released through a port that contains a vent wire into injection pump housing cavaties. The lift of nozzle valve (C) is adjusted by screw (K) located in pressure adjusting screw.Electronic Fuel System Operation Fuel Injection Nozzle Operation The nozzle spray tip (A) forms an integral unit with nozzle body (D) from which it cannot be separated. The fuel injection nozzle works basically in the same way as a normal spray type nozzle. The contact pressure is limited by a spacer ring. The nozzle is sealed in the cylinder head at its lower end with a carbon stop seal (B). –UN–12FEB02 03 130 8 The carbon stop seal (B) prevents carbon from collecting around nozzle in cylinder head.0000020 –19–03DEC01–1/1 CTM331 (09APR02) 03-130-8 4.5 L & 6. Its opening pressure is adjusted by the pressure adjusting screw (O). Clamp (P) ensures correct position of the complete fuel injection nozzle in the cylinder head. The top end is sealed with seal washer (D). A—Spray tip B—Carbon stop seal C—Nozzle valve D—Nozzle body E—Seal washer F—Connection for injection line G—Nozzle valve guide H—Union nut I—Spring seat J—Adjustable pressure spring K—Lift adjusting screw L—Lock nut for pressure adjusting screw M—T-fitting N—Lock nut for lift adjusting screw O—Pressure adjusting screw P—Location clamp Q—Nipple R—Filter screen S—Fuel pressure line T—Cap RG40854. The fuel injection nozzles have four orifices. The injection nozzle is secured in the cylinder head by three superimposed spring clamps which press on a location clamp and a cap screw. which is fitted on the nozzle body and secured a cap with O-ring seal (T). The leak-off line is connected by T-fitting (M).8 L Level 12 Electronic Fuel System 040902 PN=86 RG11959 . the electronic control system is described in the following categories: • • • • • Electronic Control System Terminology Electronic Control System Operation Monitoring Engine Parameters Electronic Control System Measuring Temperature – ECT (Engine Coolant Temperature) Sensor – MAT (Manifold Air Temperature) Sensor – Loss of Coolant Temperature Sensor – Fuel Temperature Sensor Measuring Pressure – Oil Pressure Sensor Measuring Throttle Position Measuring Engine Speed – Crank Position Sensor Engine Control Unit (ECU) Controller Area Network (CAN) Cruise Control Operation Intake Air Heater Operation Engine Protection Derate Programs Multiple Torque Curves Selection Governor Droop Mode Selection Engine Control Unit (ECU) Self Diagnosis 03 140 1 • • • • • • • • • • • • RG40854.Group 140 Electronic Control System Operation About This Group In this group.5 L & 6.0000021 –19–03DEC01–1/1 CTM331 (09APR02) 03-140-1 4.8 L Level 12 Electronic Fuel System 040902 PN=87 . Usually 0 to 5 volt or 0 to 12 volt signals. The first half of the code is the Suspect Parameter Number (SPN). See ENGINE CONTROL UNIT (ECU) later in this Group for details.8 L Level 12 Electronic Fuel System 040902 PN=88 . J1708 is the hardware standard. Measures the temperature of the air in the intake manifold. See MEASURING TEMPERATURE later in this Group for details. The first half of a two-part code that identifies control system fault codes according to the SAE J1939 Standard.Electronic Control System Operation Electronic Control System Terminology Actuator Analog Boost CAN A device controlled by the (ECU) to perform a certain function. The DST consists of an Windows (’95. The second part of a two-part code that identifies control system trouble codes according to the SAE J1939 standard. DTC 03 140 2 DST Digital ECT ECU FMI J1587/J1708 MAT PDM PROM PWM RAM SAE Sensor SPN Continued on next page RG40854. The SPN identifies the system or component that has the failure. Random Access Memory. A signal which consists of only two-volt levels — usually 0 volts and +5 volts. The electronic pathway network on vehicles that allows communication between controllers. Measures the temperature of the engine coolant.ECU Communication Hardware Kit. Programmable. The computer which controls the fuel. check DTCs. the on time of the signal is increased or decreased (modulated) to increase or decrease the output of the actuator. When an actuator is controlled by a PWM signal. Device used by the ECU to monitor various engine parameters. Diagnostic Trouble Code. This is a diagnostic software that is used to read engine parameters. Device used as part of the DST that allows communication with the ECU. and ignition systems on the engine. Diagnostic Scan Tool. Failure Mode Identifier. and run special tests. 2000) or NT compatible computer and a hardware kit available from John Deere Distribution Service Center (DSC): JDIS121 . Working with society to promote vehicle safety and maintenance and energy resource conservation. The computer chip which contains the calibration information for the engine control system. See ENGINE CONTROL UNIT (ECU) later in this Group for details. Suspect Parameter Number. See MEASURING TEMPERATURE later in this Group for details. Pulse Width Modulation. The software is available to download from your John Deere home page. Parallel Data Module. See ENGINE CONTROL UNIT (ECU) later in this Group for details. ’98. air. Manifold Air Temperature (sensor). The second half of the code is the Failure Mode Identifier (FMI). Engine Coolant Temperature (sensor). Air charge pressure in the intake manifold. A code which is stored in the ECU’s memory when the ECU detects a problem in the electronic control system. Controller Area Network. A digital signal (not analog) which consists of a pulse generated at a fixed frequency. The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty vehicles. J1587 is the software standard. Society of Automotive Engineers. The portion of computer memory within the ECU which changes as the engine is running and is stored while the engine is off.0000023 –19–03DEC01–1/2 CTM331 (09APR02) 03-140-2 4.5 L & 6. Signal which has a continuous range of possible voltages. The FMI identifies the type of failure that has occurred. Read-Only Memory. Engine Control Unit. the pump control valve closes and injection begins. Switched voltage RG40854. the Engine Coolant Temperature (ECT) sensor. The fuel is delivered to all of the cylinders. the engine will not start. When the ECU energizes the solenoid.Electronic Control System Operation VBAT VSW Battery voltage or unswitched voltage. causing the pump control valve to open.5 L & 6. This energizes the ECU and allows it to “boot-up” and ready itself for engine start. the amount of fuel injected is based on the temperature measured by RG40854.0000022 –19–03DEC01–1/1 Monitoring Engine Parameters In order for the electronic control system to deliver fuel according to a given set of operating conditions. and fuel injection to stop. which will allow injection pressure to be developed. then determines the optimum amount of fuel to inject and the optimum injection timing in order to allow the engine to develop high power while maintaining low exhaust emission output.8 L Level 12 Electronic Fuel System 040902 PN=89 . As soon as the ECU receives an input from the crankshaft position sensor that the engine is cranking. To provide cold temperature enrichment. the following parameters are monitored by the ECU: • • • • • • • Engine Coolant Temperature (ECT) Loss of Coolant Temperature Manifold Air Temperature (MAT) Oil Pressure Fuel Temperature Throttle Position Crankshaft Position Sensor RG40854. When the correct amount of fuel has been injected. At this point. the ECU de-energizes the solenoid.0000023 –19–03DEC01–2/2 Electronic Control System Operation Engine Starting Mode When the key is turned to the “ON” position. the engine will start and the ECU will go into the running mode. it will move the pump control valve to the “pressure” position. a switched power voltage is sent to the Electronic Control Unit (ECU). Engine Running Mode In the running mode.0000026 –19–03DEC01–1/1 CTM331 (09APR02) 03-140-3 4. The ECU controls fuel delivery by energizing and de-engergizing the pump control valve solenoid. 03 140 3 NOTE: If a wiring problem prevents the key ON signal from getting to the ECU. the ECU monitors information from the various sensors. the engine control system peforms the following funtions: • Constantly monitors engine operating conditions • Delivery an optimum amount of fuel for operating conditions • Provides multiple control modes • Performs self-diagnosis RG40854. In order to achieve this. and at a precise time in relation to piston position.0000024 –19–03DEC01–1/1 CTM331 (09APR02) 03-140-4 4. in precise amounts.5 L & 6.8 L Level 12 Electronic Fuel System 040902 RG11960 –UN–18DEC01 PN=90 . The electronic control system serves as an engine governor by controlling the pump control valve through a solenoid so that fuel is delivered according to a given set of engine conditions.Electronic Control System Operation Electronic Control System Overview 03 140 4 A—Oil Pressure Sensor B—Pump Control Solenoid C—Engine Control Unit (ECU) D—Crank Position Sensor E—Fuel Temperature Sensor F—ECT Sensor G—Manifold Air Temperature (MAT) Sensor H—Loss of Coolant Temperature Sensor NOTE: Some of the components shown are optional and not used on all applications. • Starting fuel quantity determination — The ECU will adjust the amount of fuel delivered during start-up based on initial ECT readings. RG11819 –UN–17AUG01 03 140 5 RG40854.Electronic Control System Operation Measuring Temperature The Engine Coolant Temperature (ECT) sensor. The sensors’ resistance goes down as the temperature that it is exposed to goes up (negative temperature coefficient). Higher temperatures result in lower voltages and lower temperatures result in higher voltages. –UN–29JAN02 A—ECT Sensor Continued on next page RG40854.0000025 –19–03DEC01–2/5 CTM331 (09APR02) 03-140-5 4. the ECU will increase idle speed after start-up if a low coolant temperature is measured. On other applications. Manifold Air Temperature (MAT) sensor. In addition to temperature sensors. some applications use temperature switches. • Idle speed determination — In order to speed engine warm-up. ENGINE PROTECTION or DERATE PROGRAMS later in this Group. The loss of coolant temperature switch is an example. monitors the voltage drop across the sensor. it may be located at the rear of the cylinder head. and compares the voltage drop to preprogrammed values in the ECU’s memory in order to determine temperature. The Engine Control Unit (ECU) sends 5 volts to the sensor.5 L & 6. the Engine Coolant Temperature (ECT) sensor is located in the thermostat housing (A). and Fuel Temperature sensor are thermistors (temperature sensitive variable resistors). Temperature switches close when a specific temperature is reached. The ECU monitors coolant temperature for: • Engine protection purposes. For more information on engine protection and derate programs see.8 L Level 12 Electronic Fuel System 040902 RG11963 PN=91 .0000025 –19–03DEC01–1/5 Engine Coolant Temperature (ECT) Sensor On most applications. Loss of Coolant Temperature sensor. This sensor is optional and is not included on all applications. see ENGINE PROTECTION or DERATE PROGRAMS later in this Group.5 L & 6. A—MAT Sensor RG10766 Continued on next page RG40854. ENGINE PROTECTION or DERATE PROGRAMS later in this Group. For more information on engine protection and derate programs see. A—Loss of Coolant Temperature Sensor –UN–26MAY00 03 140 6 RG40854. The ECU also monitors manifold air temperature for engine protection purposes.0000025 –19–03DEC01–3/5 Manifold Air Temperature (MAT) Sensor The Manifold Air Temperature (MAT) sensor is located in the cross over tube (A) or in the intake manifold. The ECU monitors loss of coolant temperature for engine protection purposes. The MAT sensor measures intake air temperature to help the ECU calculate the correct fueling and for cold starting.0000025 –19–03DEC01–4/5 CTM331 (09APR02) 03-140-6 4.Electronic Control System Operation Loss of Coolant Temperature Sensor The Loss of Coolant Temperature sensor is located in the rear of the cylinder head (A) on some applications using this engine.8 L Level 12 Electronic Fuel System 040902 PN=92 RG11964 –UN–29JAN02 . For more information on engine protection and derate programs. As the pressure changes. It measures the temperature of the fuel in the injection pump that is going through the overflow valve. some applications use pressure switches. sensor resistance changes.0000025 –19–03DEC01–5/5 Measuring Pressure The system’s pressure sensors are 3 wire variable resistors.8 L Level 12 Electronic Fuel System 040902 RG11820 –UN–17AUG01 RG11962 03 140 7 PN=93 . The ECU sends a 5 volt reference voltage to the sensor. Continued on next page RG40854. The temperature is used to help the ECU to calculate the correct amount of fueling rENGINE PROTECTION or DERATE PROGRAMS laster in this Group. A—Fuel Temperature Sensor –UN–29JAN02 RG40854.0000027 –19–03DEC01–1/2 CTM331 (09APR02) 03-140-7 4.Electronic Control System Operation Fuel Temperature Sensor The fuel temperature sensor (A) is located on top of the injection pump. monitors the voltage returning on the sensor signal wire.5 L & 6. and compares the voltage drop to preprogrammed values in the ECU’s memory to determine pressure. Pressure switches close when a specific pressure is reached. In addition to pressure sensors. The throttle information is sent to the ECU by the Pump and Valve controller.0000031 –19–05DEC01–1/1 CTM331 (09APR02) 03-140-8 4. Analog Throttle An analog throttle signal comes from a potentiometer-type sensor. RG40854. A—Oil Pressure Sensor 03 140 8 RG40854.0000027 –19–03DEC01–2/2 Measuring Throttle Position The 4. The ECU must convert the voltage into percent throttle. Excavator Throttle The Excavator uses an analog throttle signal that come from a potentiometer-type sensor.5 L & 6. For more information on engine protection and derate programs see. CAN Throttle CAN throttle is information sent to the ECU by another controller over CAN of the desired throttle position.8 L engines have the option of operating with a analog throttle position sensor output signal or CAN throttle.8 L Level 12 Electronic Fuel System 040902 RG11961 –UN–29JAN02 PN=94 . The ECU converts the voltage returning from the potentiometer into a percent of full throttle signal.Electronic Control System Operation Oil Pressure Sensor The oil pressure sensor is an optional sensor located in the main engine galley (A). multiple throttles are used.5 L and 6. Multi-State Throttle The multi-state throttle is used when a few fixed engine speeds are desired. ENGINE PROTECTION or DERATE PROGRAMS later in this Group. The ECU monitors oil pressure for engine protection purposes. On some applications. The crank position sensor (A) is located on the front of the crankshaft. This controls the quantity of fuel delivered to the engine. –UN–29JAN02 A—Crank Position Sensor RG40854. The sensor is located on the front of the crankshaft. Thus. When the ECU supplies current to the solenoid. the valve does not move.0000115 –19–24JAN02–1/1 CTM331 (09APR02) 03-140-9 4. This allows fuel to be delivered from the injection pump. the pump solenoid (A) controls the movement of the pump control valve. The ECU monitors this voltage signal to determine the position of the timing wheel. When a notch on the timing wheel is directly under the sensor. The quantity of fuel is determined by various sensors in the control system and messages sent to the ECU. When the Engine Control Unit (ECU) supplies no current to the solenoid.Electronic Control System Operation Measuring Engine Speed Crank Position Sensor The crank position sensor operates by detecting notches on their respective timing wheels. the pump control valve closes off the high injection chamber. a voltage signal is induced.5 L & 6. the injection pump delivers no fuel. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. behind the pressed-on crank gear. RG11965 03 140 9 A A—Pump Solenoid Connector RG40854.8 L Level 12 Electronic Fuel System 040902 RG11966 –UN–29JAN02 PN=95 . The ECU uses the crank position input to determine engine speed.0000028 –19–03DEC01–1/1 Pump Solenoid Located on the end of the injection pump. It also controls the self diagnostic system. The CPU controls the pump control solenoid for desired fuel quantity and timing.Electronic Control System Operation Engine Control Unit (ECU) A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 03 140 10 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 ECU Connector The Engine Control Unit (ECU) is the “brains” of the Electronic Control System.5 L & 6. The ECU is a self-contained unit containing electronic circuitry and computer software which together perform the following functions: • Converts the electrical signals from the various sensors into digital signals • Makes decisions of optimum fuel quantity and timing based on information from various sensors • Limits maximum fuel for operation on multiple power curves • Controls pump control valve solenoid for desired fuel delivery • Provides all-speed governing • Performs self diagnosis on the control system • Stores trouble codes in memory The ECU is composed of the following subsystems: Analog/Digital Converters This portion of the ECU converts the analog voltage signals from the various sensors into digital signals that the central processing unit can “understand”. Continued on next page RG40854. Central Processing Unit (CPU) The central processing unit performs the mathematical computations and logical functions that are necessary in controlling injection fuel quantity and injection timing.0000029 –19–03DEC01–1/2 CTM331 (09APR02) 03-140-10 4.8 L Level 12 Electronic Fuel System 040902 RG11967 –19–19DEC01 PN=96 . etc. application requested derates and or engine protection. All of the controllers that are required to communicate over CAN are connected together using wires forming a bus. and application data. serial numbers.0000029 –19–03DEC01–2/2 Controller Area Network (CAN) Controller Area Network (CAN) is used to allow communication between other controllers on the engine or vehicle and for connecting to diagnostic software. SERVICE ADVISOR is a trademark of Deere & Company RG40854. displaying diagnostic fault codes on vehicle displays. This information includes part numbers. Information in the EEPROM is retained when battery voltage is removed.000002A –19–03DEC01–1/1 CTM331 (09APR02) 03-140-11 4. Data from the various sensors and the results of various calculations are temporarily stored in RAM.ROM — Electrical Erasable Programmable Read Only Memory . fan speed. J1939 is an SAE standard that utilizes CAN. Depending on the application.8 L Level 12 Electronic Fuel System 040902 PN=97 . Just about any type of information can be communicated over the CAN Bus. ROM information is retained when battery voltage is removed. engine speed. The engine also uses CAN to talk to other vehicle controllers.EEPROM The EEPROM contains information programmed in at the factory including engine specific data.RAM The RAM is like the working desk top of the ECU. The ROM contains programmed information. CAN also allows diagnostic software like the Diagnostic Scan Tool (DST) and SERVICE ADVISOR™ to communicate with our engine controller. information like throttle position. Information in ROM can only be read. not changed.5 L & 6.Electronic Control System Operation Memory The ECU contains 3 different types of memory: — Random Access Memory . Information in RAM is lost when battery voltage to the ECU is removed. All of the information viewed through the software is transferred via the CAN Bus. — Read Only Memory . etc. 03 140 11 RG40854. 000002B –19–03DEC01–1/1 Intake Air Heater Operation An optional function not included in all ECUs. RG40854. the operator brings the engine speed above 1300 rpm and activates the Cancel/Resume function again to resume cruise speed. Both locations have the normal cruise control functions. When the ECU has determined that the preheat time is adequate.5 L & 6. the intake air heater is used to increase intake manifold air temperature to improve cold starting. the engine will crank and start. the engine speed can be set from two different locations. When the operator turns the key from “OFF” to “ON”. turns on the “Air Heater Indicator” light on the dash. If the operator turns the ignition from “ON” to “START” at this time.000002C –19–03DEC01–1/1 CTM331 (09APR02) 03-140-12 4. This function is especially intended for field applications where an operator faces the need to turn the vehicle around at the end of each row. The primary location would normally be in the cab of the vehicle and is used to set a constant engine speed while the vehicle is being driven. This cruise control allows the driver to use the throttle and/or brake to turn the vehicle around. The secondary cruise control is normally used in a location that provides PTO speed control and is used with the engine in “neutral” or out of gear. When ready to resume field operations. The cruise control has the normal functions of: • • • • Cruise control power “ON” or “OFF” “Set” or “Bump Up” engine speed “Resume” or “Bump Down” engine speed Vehicle brake or clutch pedal to disengage cruise control 03 140 12 On 12 volt ECUs. it will turn off the “Air Heater Indicator” light and de-energize the air heater relay. and energizes the air heater relay. a key-off/key-on cycle will be required before preheating is allowed again.Electronic Control System Operation Cruise Control Operation The ECU is available with and without the cruise control function. the ECU uses the fuel temperature sensor to determine engine temperature and ambient air temperature. the ECU will de-energize the air heater relay and a key-off/key-on cycle is required before preheating is allowed again. It is an off-road cruise control that maintains constant engine speed under varying load conditions. If the operator turns the key from “START” to “ON” without waiting for the “Air Heater Indicator” light to turn off. Anytime the engine cranks but does not start. The ECU will keep the air heater relay energized for an amount of time that is determined by the measured temperatures. The air heater relay will in turn energize the air heater coils located in the intake manifold. RG40854.8 L Level 12 Electronic Fuel System 040902 PN=98 . An internal timer gives the operator one minute to complete the turnaround maneuver. Each time the switch is pushed. It is the responsibility of the operator to react to warning light(s) on their application.000002F –19–04DEC01–1/1 CTM331 (09APR02) 03-140-13 4.8 L Level 12 Electronic Fuel System 040902 PN=99 . The engine protection shutdowns can be overridden for 30 seconds at a time. A Diagnostic Trouble Code (DTC) always accompanies a fuel derate. and the engine will run in a derated power mode. There are three different engine protection programs available in Engine Control Units (ECUs): • No Protection — The ECU does not have the software to derate or shut the engine down. RG40854. See APPLICATION SPECIFICATIONS in Section 06. Refer to the operator’s manual to retrieve this information for a given application. It is the responsibility of the operator to react to warning light(s) on their application to identify if it is necessary to shut the engine down. Group 210 of this manual for engine protection features on different sensors on your application. See APPLICATION SPECIFICATIONS in Section 06.Electronic Control System Operation Engine Protection Engine protection is necessary to prevent damage to an engine. Refer to the operator’s manual to identify this information for a given application. the power will increase at a particular rate until full power is reached. This can be used to move a vehicle to a safe location. • Engine Protection WITHOUT Shutdown — The ECU has the capability to derate an engine. If the problem is corrected within the 30 second delay period. the shutdown timer is reset to 30 seconds. Shutdown Override Feature NOTE: Holding the shutdown override switch continuously “ON” will not reset the 30 second timer.5 L & 6. • Engine Protection with Shutdown— The ECU will derate the engine for given DTCs.000002D –19–04DEC01–1/1 Derate Programs The Electronic Control Unit (ECU) will derate the amount of fuel that is delivered to the engine when sensor inputs exceed normal operating ranges. 03 140 13 RG40854. If a DTC that requires shutdown is set. Derating or shutting the engine down may be necessary depending on the Diagnostic Trouble Code (DTC) that is set. the ECU will severely derate the engine and shut the engine down in 30 seconds. Group 210 of this manual for sensor derate specifications on your application. See APPLICATION SPECIFICATIONS in Section 06.000002E –19–04DEC01–1/1 Governor Droop Mode Selection The electronic control system provides all-speed governing. the ECU will command one of the other curves depending on the resistance in the line. Droop selection can be determined by engine speed. For example: a machine can choose multiple torque curves using simple switching arrangement. When in isochronous. load. In most applications. The normal droop gives a drop in engine speed with an increase in load or an increase in engine speed with a decrease in load. When the switch is closed. one torque curve is used for “normal” operation.8 L Level 12 Electronic Fuel System 040902 RG8552 –19–18SEP98 PN=100 .5 L & 6. or by messages from other controllers on the machine’s Controller Area Network (CAN). 03 140 14 RG40854. etc. When the switch is open. and any of the other torque curves. The selection of multiple torque curves is determined by either switch inputs into the ECU’s torque curve select terminal.Electronic Control System Operation Multiple Torque Curve Selection The ECU has the ability to limit the maximum fuel quantity such that multiple torque curves can be individually selected while the engine is running. the droop is set at 0%. hitches. The ECU also has the ability to provide normal and isochronous (0%) droop. See APPLICATION SPECIFICATIONS in Section 06. and transmissions. The factory low idle speed is always set for isochronous governing. A simple on/off toggle switch and resistor can be used to switch between torque curve 1 (maximum power).0000030 –19–04DEC01–1/1 CTM331 (09APR02) 03-140-14 4. and there is a no change in engine speed with changing loads until engine’s torque limit is reached. and cruise control depending on the application. The Engine Control Unit (ECU) controls the engine speed based on the analog throttle input. RG40854. under certain operating conditions. the ECU will command torque curve 1. Group 210 of this manual and refer to the corresponding governor droop mode for your application. Several other derated torque curves will be used to protect vehicle axles. Group 210 of this manual and refer to the corresponding torque curve selection for your application. Suspect Parameter Number (SPN). The second part of the code is called the Failure Mode Identifier (FMI) code. If the ECU detects a problem with the electronic control system.5 L & 6. There are two types of DTCs: • Active • Stored Active DTCs indicate that the failure is occurring. both the SPN and FMI are required. a Diagnostic Trouble Code (DTC) specific to the failed system will be stored in the ECU’s memory. In this manual. the diagnostic procedures are titled by SPN/FMI codes. There are several different methods for displaying both stored and active DTCs from the ECU. Combining SPN 110 with FMI 3 yields engine coolant temperature input voltage high. To find out the equ On all applications with the Level 12 Engine Control Unit (ECU). for example FMI 3 indicates value above normal. it will be necessary to convert these codes to the SPN/FMI code in order to follow the correct diagnostic procedure. and the Diagnostic Gauge to display active and stored DTCs.8 L Level 12 Electronic Fuel System 040902 PN=101 .Electronic Control System Operation Engine Control Unit (ECU) Self-Diagnosis The Engine Control Unit (ECU) has the ability to detect problems internally and in the electronic control system.1540 –19–30SEP97–1/2 CTM331 (09APR02) 03-140-15 4. the calculated value for that sensor will be the “limp home” value and the voltage will be the actual sensor voltage. it contains between 2 and 4 digits. or when the code is blinked for various reasons. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU in Group 160 of this manual. for example SPN 110 indicates a failure in the engine coolant temperature circuit. These could be problems such as a bad connection or a wire intermittently shorting to ground. Stored DTCs indicate that a failure has occurred in the past. In most of these cases. If used on an application with multiple controllers. An example of a 2-digit code is 18 for engine coolant temperature input voltage high. The FMI identifies the type of failure that has occurred. In order to determine the exact failure. This type of DTC can be caused by an “intermittent” failure. the code is displayed as a 2-digit code. SERVICE ADVISOR™.RG34710. This allows for service tools such as the DST. The first part is called the SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG. 2-DIGIT CODES Some applications do not display engine codes as an SPN/FMI. This includes determining if any sensor input voltages are too high or too low. but is not currently occurring. the ECU transmits SPN/FMI codes over the Controller Area Network (CAN). ECU may be displayed in front of the numbers. The SPN identifies the system or the component that has the failure. the on-board display. The FMI contains 2 digits. SPN/FMI CODES SPN/FMI codes are written from the SAE J1939 standard as a two part code. A 2-digit code may be seen on SERVICE ADVISOR™. Typically. These type of failures are sometimes called “hard” failures. Use the voltage during diagnostics unless otherwise directed by a diagnostic chart. OTHER CODES 03 140 15 NOTE: If the Diagnostic Scan Tool (DST) or SERVICE ADVISOR™ is used to read a sensor voltage and calculated value. In CTM 331. and there is an active DTC for that sensor. such as ECU 018. There are several different methods of displaying both stored and active DTCs from the ECU. Electronic Control System Operation If codes are not displayed as SPN/FMI or as 2-digit codes. there is a warning lamp that is used when a code becomes active. Refer to Operator’s Manual for a given application for more detailed information.1540 –19–30SEP97–2/2 CTM331 (09APR02) 03-140-16 4. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU WARNING LAMP On some applications. it is necessary to convert this format of code into an SPN/FMI code to ensure that the correct diagnostic procedure is followed. the code F455 is displayed for engine coolant temperature input voltage high.RG34710.5 L & 6. there may be another format that the application is using. This may be seen on some applications within SERVICE ADVISOR™. 03 140 16 SERVICE ADVISOR is a trademark of Deere & Company RG. In this manual. Refer to the vehicle machine manual or see CLEARING STORED DTCS ON DIAGNOSTIC GAUGE in Group 160 later in this manual to determine how to clear the code reader. and a blinking light indicates that the ECU has detected a fault and engine performance may be affected. For example on some applications. a solid light indicates that the ECU is taking extreme measures to protect the engine. CLEARING STORED DTCS Stored DTCs can be cleared through the Diagnostic Scan Tool (DST) or SERVICE ADVISOR™. Typically.8 L Level 12 Electronic Fuel System 040902 PN=102 . 04-150-33 Level 12 ECU . .ECU Does Not Communicate With DST or SERVICE ADVISOR™ . . . . .04-150-16 Level 12 ECU . . . . .E2 . .04-150-11 Level 12 ECU . . . . . . . . . . . . . . . . .E3 .Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-7 Level 12 ECU . . .04-150-48 Test for Air in Fuel . . . . . . . . . . . .A1 . . . .D1 . . . . . . . . .A1 . . . .04-150-19 Level 12 ECU . .04-160-14 Blinking DTCs . . . . . . . . . . . . . .04-160-1 Using a Digital Multimeter .Engine Idles Poorly . . . . . . .Intake Air Heater Check Diagnostic Procedure. . . . . .Engine Emits Excessive Black Or Gray Smoke . . . . .Engine Does Not Develop Full Power Diagnostic Procedure . . . . . . . . . . . . .04-160-12 Clearing Stored DTCs on Diagnostic Gauge .8 L Level 12 Electronic Fuel System 040902 PN=1 . . .04-150-50 Bench Test Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Misfires/Runs Irregularly. . . . . . . . . . . . .04-160-2 Troubleshooting Circuit Malfunctions . . . . . . . . . . . .Abnormal Engine Noise . .F2 . . .04-150-42 Level 12 ECU . .04-150-37 Level 12 ECU . . . .04-150-47 Test for Fuel Drain Back . . . . . . .04-150-7 Level 12 ECU . . . . . . . . . . . . . . . . . . .04-150-32 Level 12 ECU . . . . .04-150-51 Bleed the Fuel System . . . . . . . . . . . . .04-160-19 Continued on next page 04 04-1 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-26 Level 12 ECU . . .04-150-33 CTM331 (09APR02) Level 12 ECU . . . . . . .04-150-43 Level 12 ECU . . . . . . . . .Fuel Injection Nozzle Check . . .04-150-22 Level 12 ECU . . . . . . . . . . . . . . .Section 04 Diagnostics Contents Page Page Group 150—Observable Diagnostics and Tests About This Group of the Manual . . . . . . .Intake Air Heater Check . . . . . . . . . . . . . . . . . .04-150-26 Level 12 ECU . .Engine Cranks/Won’t Start. . . .04-150-49 Check Fuel Supply Pressure .04-150-2 Level 12 ECU . .E9 .E6 . . .Continued . . . . . . . . .F5 . .E1 . . . . . . . . . .04-160-5 Engine Configuration Data Parameters on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intake Air Heater Check . . . . . . . .04-150-44 Check Fuel Supply Quality . .04-150-22 Level 12 ECU . . . . .D1 . . . . . .ECU Does Not Communicate with DST or SERVICE ADVISOR™ Diagnostic Procedure .Diagnostic Gauge Does Not Communicate With ECU . .E1 .F3 . . . . . . . . .Fuel Supply System Check Diagnostic Procedure .04-150-23 Level 12 ECU . . .E2 . . . . . . . . . . . . . . . . . . . .D2 . . . . . . . . . . . . . . . .Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Will Not Crank. . . . . . . . .ECU Does Not Communicate With DST or SERVICE ADVISOR™ . . . . . . . . . . . . . . . . . . .04-150-2 Level 12 ECU . . . . .04-150-56 Group 160—Trouble Code Diagnostics and Tests About this Group of the Manual. . . . . . . . .04-150-16 Level 12 ECU . .04-150-25 . .F1 . . . . . . . . .04-150-30 Level 12 ECU . . . . . . . . . . .E5 . .04-160-15 Data Parameter Description . . .Engine Emits Excessive White Exhaust Smoke. . . . .04-150-19 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E3 .E7 . . . . . . . . . . . . . . . . . .04-160-10 Viewing Active DTCs on Diagnostic Gauge . . . . . . . . . . . . . . .A1 . .Analog Throttle (B) Does Not Respond . . . . . . . . . . . .04-150-29 Level 12 ECU . . . . . . . . . . . . . . . . . . .Continued . . . . . . . . . . . . .5 L & 6. . . . . . . . . . . . . . . . .Fuel in Oil. . . . . . . . .04-150-11 Level 12 ECU . . . . . . . . . . .04-150-53 Test for Cylinder Misfire (Engine Running) . . . . . . . . . . . . . . . . . . . . .D2 . . . . . . . .04-150-29 Level 12 ECU . . . . . . . . . . . . .04-150-37 Level 12 ECU .04-160-2 Electrical Circuit Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Excavator Torque Curve Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E8 . . . . . . .04-150-36 . . .D1 . . . . . . . . . . .Engine Cranks/Won’t Start Diagnostic Procedure . . . . . . . . . . . . . .Engine Misfires/Runs Irregularly Diagnostic Procedure . . . . . . .E4 . . . . .Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure . . . . .04-150-1 Level 12 ECU . . .04-160-12 Viewing Stored DTCs on Diagnostic Gauge . . .04-160-13 Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR™ . . . . . .04-160-1 Electrical Concepts . . . . . . . . .Engine Does Not Develop Full Power . .Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure . . . . . . . . . . . .04-160-16 Engine Test Instructions . . . . . .E5 .E4 . . . . . . . . . . . . . . . . . . . . . . . . .04-160-82 Level 12 ECU . . . . . . . . . . . . .Excavator Throttle Reference Voltage High.Throttle Not Calibrated Properly . . . . . . . . . . . . . . .04-160-59 Level 12 ECU .04-160-90 Level 12 ECU . . . . . . . . . . . . . . . . . . . .04-160-46 .T12 . . 10. .Excavator Throttle Ground Voltage Low .Excavator Throttle Input Voltage High . . . .T12 . .Excavator Throttle Reference Voltage Low . . . . . . . . . .DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High Diagnostic Procedure . . . . . .T15 . .T19 . . . . . . . . . .Throttle Input Voltage Below Lower Calibration Limit .Throttle Calibration Aborted . . . . . . . . . . . . .04-160-38 . . . 29.Multi-state Throttle Input Low. . .04-160-66 . .Excavator Throttle Ground Voltage High Diagnostic Procedure . . . . . . . . . . . . . .04-160-63 CTM331 (09APR02) Level 12 ECU . . . .04-160-71 Level 12 ECU . . . . . . .04-160-35 Level 12 ECU . . . . . . .T11 . . . . . . . . . . . . . . . . . . . .T13 . . . . . . . . . . . . . . . . .04-160-85 Level 12 ECU . . . . .04-160-51 Level 12 ECU . . . . . . . . . . .04-160-67 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . .04-160-90 Level 12 ECU .Analog Throttle (B) Input Low Diagnostic Procedure . . . . . . . . . . . . . .Excavator Throttle Input Voltage Low Diagnostic Procedure . . . . .T20 . . . . . . . .T4 . . .04-160-30 .DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low. . . . . . . . . . . . .T11 . .8 L Level 12 Electronic Fuel System 040902 PN=2 .Excavator Throttle Ground Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 FMI 3. . . . .CAN Throttle Invalid Diagnostic Procedure. .04-160-84 Level 12 ECU . . . . . .DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High. . .DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low . . . . . . . . . . . . . . . . . . . . . .Excavator Throttle Ground Voltage High .04-160-20 Listing of Diagnostic Trouble Codes (DTCs) on ECU . . . . . . . . . . . . . . . . . . .T2 .Multi-State Throttle Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . .CAN Throttle Invalid . . . . . . . . . . .5 L & 6. . . . . . . . . . . . . . . . .Analog Throttle (A) Input Voltage Out of Range . .Multi-state Throttle Input High . . . . . . .T22 . . . . . . . . . . . . . . . .T5 . . . . . . . . . . . . . .T4 . . . . . . . . .Analog Throttle (B) Input High Diagnostic Procedure . . . . . . . . . . . . . . . .T16 .T16 . . . . . . . . . . . . . . . .04-160-81 Level 12 ECU . .T3 . . . . . .Contents Page Page 04 Diagnostic Trouble Codes (DTCs) . . . . . . . . . . . . . . . . . . . . . .04-160-47 Level 12 ECU . 9. . . . . . . . . . . . . . . . . . . . . . . 4. . . . .T15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low Diagnostic Procedure . . . . . . . .04-160-79 Level 12 ECU .04-160-58 . . .04-160-96 Continued on next page 04-2 4. . .04-160-75 Level 12 ECU . .Analog Throttle (A) Input Low Diagnostic Procedure . . . . . . . . .Continued . . . .04-160-55 Level 12 ECU . . . . . . . . .04-160-88 . .Excavator Throttle Input Voltage High Diagnostic Procedure . . . . . . . . . . .T6 .04-160-35 Level 12 ECU . . . . . . .04-160-47 Level 12 ECU . . . . . . . . . . .04-160-75 Level 12 ECU . .Multi-state Throttle Input Voltage Out of Range . . . . . . . . . . . . . . .T23 . . . .Multi-State Throttle Input High Diagnostic Procedure . . .04-160-31 Level 12 ECU . . . .04-160-62 . . . . . . . . . . . . . . . .04-160-67 Level 12 ECU . . . . . .DTC SPN 28. . . . . . . . . . .04-160-86 Level 12 ECU .04-160-51 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-34 .T1 . . . . . . . . . . . . . . . . . .T7 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-43 Level 12 ECU . .04-160-59 Level 12 ECU . . . . . . . . . . . . .T3 . . . . . . . . . . . . . . . . . . . . . . . . .T14 . . . . . . . . . .04-160-39 Level 12 ECU . . . . . . . .04-160-27 Intermittent Fault Diagnostics . . . . . . . . . .04-160-70 . . . . . . . . . . . .04-160-42 . . . . . . . . . . . . . . . . . . . . .Excavator Throttle Reference Voltage Low Diagnostic Procedure . . . 13. . . .T5 . .04-160-79 Level 12 ECU . . . .Excavator Throttle Input Voltage Low .04-160-28 Listing of Throttle Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-78 . . . . . . . . . . .Analog Throttle (A) Input High . . . . . . . . . . . . . . .Analog Throttle (B) Input High . . . . . . . . . .Excavator Throttle Reference Voltage High Diagnostic Procedure . . . . . . .04-160-39 Level 12 ECU . . .04-160-50 . . .04-160-63 Level 12 ECU .04-160-92 . . . . . . . . . 7. . .04-160-31 Level 12 ECU .T14 . . . . . . . .04-160-93 Level 12 ECU . . . . . . . . . . . . . .04-160-93 Level 12 ECU . . . . . . . . .04-160-55 Level 12 ECU . . . . . . . . . . . . . .04-160-54 . . . . . .04-160-43 Level 12 ECU . . . . . . . .T13 .T7 . . . . . . . . .T2 . . . . . . . . .04-160-71 Level 12 ECU . . . . . . . . . . .Excavator Throttle Input Voltage High . .Analog Throttle (A) Input Low. . . . . . . . . 14 . . . . . . . . . . . . . . . . . . . . .Analog Throttle (A) Input High Diagnostic Procedure . . . . . . . . . . . . . . . . .T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T21 .04-160-74 Level 12 ECU . . . .T6 . . . . . . . . . . .04-160-29 Level 12 ECU . . .04-160-83 Level 12 ECU . . . . . . .T15 . .Analog Throttle (B) Input Low.04-160-22 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe Diagnostic Procedure. . . . . . . . . .DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low . . . . . . . . . . .04-160-113 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-109 Level 12 ECU . . . .04-160-131 Level 12 ECU . . . .DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure . . .8 L Level 12 Electronic Fuel System 040902 PN=3 . . . . .04-160-108 . . . . . . . . . . . . . .DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High. . . . . . . . . . . . . . . .04-160-127 Level 12 ECU . . . . . . . . . . . . . . . . . . .04-160-130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-143 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low .DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low . . . .DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe . . . . .04-160-143 Level 12 ECU . . . . . . . . . . .DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low . . . . . . . . . . . . . . . . . . . .DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-105 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-105 Level 12 ECU . . . . . . .04-160-112 . . . . . . . .5 L & 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-147 Continued on next page 04 04-3 4. . . . . . . . . . . . . . . .04-160-129 Level 12 ECU . . . . .DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe . . . . . . . . . . . . .04-160-114 . .DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High Diagnostic Procedure .04-160-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-131 Level 12 ECU . .04-160-121 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-128 . . . . . . . . . . . .04-160-127 Level 12 ECU . . . . . . . . .Contents Page Page . . . . . .04-160-139 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe . . .04-160-125 Level 12 ECU . . . .DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High. . . . . . . . . . .DTC SPN 158 FMI 17 ECU Power Down Error. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-135 Level 12 ECU .04-160-117 Level 12 ECU . . . . . . . . . . . . . . . . . .DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High.DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low Diagnostic Procedure .04-160-103 Level 12 ECU . . . . .04-160-146 . . . . . . . . . . . . . . . . . . . . . .04-160-138 . . . . . .04-160-117 Level 12 ECU . . .DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High . .04-160-109 Level 12 ECU . . . . . . . . . . . .04-160-98 Level 12 ECU . . . . . . . . . . . . .04-160-113 Level 12 ECU . . . . . . . . . . . . . .DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High. . . . . . . . .DTC SPN 158 FMI 17 ECU Power Down Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . .04-160-120 . . . .04-160-115 Level 12 ECU . . . . . . . . . . . . . . . . . . . . .04-160-129 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High Diagnostic Procedure. . . . . .DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-139 Level 12 ECU . . . . .DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . .04-160-98 Level 12 ECU . . .04-160-103 Level 12 ECU . . . .04-160-125 Level 12 ECU . . . . .DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . .04-160-116 . . . . . . . . . . . . . .04-160-121 CTM331 (09APR02) Level 12 ECU . . . . . . . . .04-160-135 Level 12 ECU . . . . . . . . . . . . . .DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe Diagnostic Procedure . . .04-160-115 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102 . . . . .04-160-134 . . . . . . . . . . .DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe Diagnostic Procedure . . .DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High Diagnostic Procedure . . . . .04-160-124 . . .DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low . . . . . . . . . . . . . . . . .04-160-142 . . . . . . . . . . . .04-160-193 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 174 FMI 16 Fuel Temperature Moderately High . .04-160-178 .04-160-150 . .DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted Diagnostic Procedure . . . . . . . . . . . . .04-160-179 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-185 Level 12 ECU .04-160-192 . . . . . . . . . . .04-160-181 Level 12 ECU . . . . . .DTC SPN 627 FMI 4 ECU Unswitched Power Missing . . . . . . . . . . . . . . . . . . . .DTC SPN 629 FMI 13 ECU Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . .DTC SPN 637 FMI 2 Crank Position Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-161 Level 12 ECU .5 L & 6. . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 971 FMI 31 External Engine Derate Switch Active . .04-160-201 Level 12 ECU . . . . . . . . . . . .04-160-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 174 FMI 16 Fuel Temperature Moderately High Diagnostic Procedure . . . .04-160-155 Level 12 ECU . . . .DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted . . . . .8 L Level 12 Electronic Fuel System 040902 PN=4 . .04-160-188 . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted . . . . . . . .04-160-157 Level 12 ECU . . . . .DTC SPN 637 FMI 2 Crank Position Input Noise Diagnostic Procedure . . . . . . . . . . . . . . .04-160-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 637 FMI 10 Crank Position Input Pattern Error . . . . . . . . .DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . .04-160-151 Level 12 ECU . . . .DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long . . . . . . . . . . .04-160-171 Level 12 ECU .04-160-151 Level 12 ECU . . . . . . . . . . . . .DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-200 . . . . . . . . . .04-160-147 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 620 FMI 3 Sensor Supply Voltage High .04-160-205 Level 12 ECU . . . . . . . . . . . . . . . . . .DTC SPN 639 FMI 13 CAN Error . . . .DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected . . . . . . . . . . . . . . . . . . . . . .DTC SPN 629 FMI 13 ECU Error . . . .04-160-175 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 1076 FMI 3 Pump Solenoid Current High Diagnostic Procedure . . . . . . .DTC SPN 620 FMI 3 Sensor Supply Voltage High Diagnostic Procedure . . . . . . . . . . .04-160-168 Level 12 ECU .04-160-201 Level 12 ECU . . . .04-160-182 Level 12 ECU . . . . . . . .04-160-179 CTM331 (09APR02) Level 12 ECU . . . . . . . . . . . . . . . .04-160-197 Level 12 ECU . . . . . . . . . . . .DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short . . . . . .DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-164 . . . . . . . . . . . . . . . . . . .04-160-193 Level 12 ECU . . .DTC SPN 627 FMI 4 ECU Unswitched Power Missing Diagnostic Procedure . . . . . . .DTC SPN 639 FMI 13 CAN Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-165 Level 12 ECU . . . . .DTC SPN 1076 FMI 3 Pump Solenoid Current High . . .DTC SPN 970 FMI 31 Auxiliary Engine Shutdown Switch Active . . . .04-160-183 Level 12 ECU .DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long Diagnostic Procedure . . . . . . . . . . . . . . . .04-160-170 . . . .DTC SPN 898 FMI 9 Vehicle Speed or Torque Message Invalid . . . .Contents Page Page 04 Level 12 ECU . . . . . . . .DTC SPN 637 FMI 10 Crank Position Input Pattern Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-189 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 190 FMI 0 Engine Overspeed Extreme . . . . . . . . . . . . . . . . . . . . . .DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short Diagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-154 Level 12 ECU . . . . . . . . .04-160-205 Level 12 ECU . . . .04-160-165 Level 12 ECU . . . . . . . . . . . . . . . . . .04-160-204 . . . . . . . . . .DTC SPN 620 FMI 4 Sensor Supply Voltage Low Diagnostic Procedure . . . . .04-160-168 Level 12 ECU . . . .04-160-197 Level 12 ECU . . .DTC SPN 190 FMI 16 Engine Overspeed Moderate . . . . . . .04-160-156 . . . . . . . . . . . . . .04-160-208 Continued on next page 04-4 4. . . . . .DTC SPN 620 FMI 4 Sensor Supply Voltage Low. . . . . . . .04-160-175 Level 12 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-157 Level 12 ECU . . . . . .DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open Diagnostic Procedure . . . . . . . . . . . .04-160-161 Level 12 ECU .04-160-184 . . . . . . . . . . . . . . . . . . . . . . . .04-160-189 Level 12 ECU . . . . . . . . . .04-160-185 Level 12 ECU .04-160-160 . . . . . . . . . . .04-160-171 Level 12 ECU . . . . . . . . . . . . . . . . . .04-160-217 Level 12 ECU . . . . . . . . . .5 L & 6. . .Contents Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DTC SPN 2000 FMI 6 Internal ECU Failure . . . . . . . . . . . . . . . . . .DTC SPN 1079 FMI 3 Sensor Supply Voltage High . . . . . . . . . . . .04-160-209 Level 12 ECU . . . . . . .04-160-217 Level 12 ECU . . . .04-160-224 04 CTM331 (09APR02) 04-5 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-216 . .DTC SPN 1110 FMI 31 Engine Protection Shutdown . . .DTC SPN 1079 FMI 3 Sensor Supply Voltage High Diagnostic Procedure . . . . . . . . . . . . .DTC SPN 1079 FMI 4 Sensor Supply Voltage Low Diagnostic Procedure . . . . . . . . . . . . .DTC SPN 1569 FMI 31 Fuel Derate . . . . . . . . . . . . . . . . . . . . . . .04-160-213 Level 12 ECU . . . . . . . .04-160-212 . .DTC SPN 2000 FMI 13 Security Violation . .04-160-220 Level 12 ECU . . . . . . . . . . . . . . . . .DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure. . . . . . .04-160-222 Level 12 ECU . . . . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 PN=5 . . .DTC SPN 1079 FMI 4 Sensor Supply Voltage Low. . .DTC SPN 1109 FMI 31 Engine Protection Shutdown Warning . . . . . .04-160-213 Level 12 ECU . . . .04-160-221 Level 12 ECU . . . .04-160-209 Level 12 ECU . .04-160-223 Level 12 ECU . 5 L & 6.Contents 04 CTM331 (09APR02) 04-6 4.8 L Level 12 Electronic Fuel System 040902 PN=6 . The diagnosing malfunctions area is further divided into the following headings. The second part of this section manual contains the following testing procedures: • Fuel System Testing Procedures: – Check Fuel Supply Quality – Test for Fuel Drain Back – Test for Air in Fuel – Check Fuel Supply Pressure – Bleed the Fuel System – Test For Cylinder Misfire (Engine Running) NOTE: Follow the diagnostic procedure of an active or stored DTC before pursuing any observable diagnostic procedure.Abnormal engine noise – E9 .5 L & 6.Engine misfires/runs irregularly – E3 . see 4.5 L & 6.problem .Engine emits excessive black or gray smoke – E6 .Engine emits excessive white exhaust smoke – E5 . NOTE: To diagnose observable symptoms on engines with a mechanical fuel system.Fuel supply system check – F2 .Excessive fuel consumption – F3 . containing the following observable symptoms: – F1 .Intake Air Heater Check Procedures for diagnosing some of the above symptoms are formatted such that a test or repair is recommended.8 L Diesel Engines Mechanical Fuel Systems Manual (CTM 207). Symptoms arranged in both formats refer to testing procedures in the second part of this section.0000113 –19–16JAN02–1/1 CTM331 (09APR02) 04-150-1 4.Group 150 Observable Diagnostics and Tests About This Group of the Manual This section of the manual contains necessary information for observable diagnostics and fuel-related test procedures.Engine does not develop full power – E4 .Engine idles poorly – E8 .5 L & 6.Engine cranks/won’t start – E2 . • (E) Diagnosing General Engine Malfunctions: – E1 .Fuel injector nozzle check • (D) Diagnosing Diagnostic Software Malfunctions: – D1 .Analog Throttle (B) Does Not Respond • (F) Diagnosing Fuel System Malfunctions: 04 150 1 SERVICE ADVISOR is a trademark of Deere & Company RG40854.ECU does not communicate with DST or SERVICE ADVISOR™ – D2 . Other symptoms are formatted in a symptom .Engine will not crank – E7 .8 L Level 12 Electronic Fuel System 040902 PN=105 .8 L Diesel Engines Base Engine Manual (CTM 104). Use this information in conjunction with the 4. the problems are arranged in the most likely or easiest to check first.Fuel in oil – F5 .Diagnostic Gauge Does Not Communicate With ECU • (A) Diagnosing Intake Air Heater Malfunctions: – A1 . Group 150 is divided into two areas: diagnosing malfunctions and test procedures. In these symptoms. then based on the results another test or repair is recommended.solution format. 3. See CHECK FUEL SUPPLY QUALITY later in this Group.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR DIAGNOSTIC PROCEDURE later in this Group. engine OFF 3. Connect the DST or SERVICE ADVISOR™.8 L Diesel Engines Base Engine Manual (CTM 104). See TEST ENGINE CRANKING SPEED in Group 150 of 4. If any of the DTCs have a SPN 637. Ensure that oil viscosity is correct. but engine will not start or only starts after prolonged cranking. Ignition ON.00000D3 –19–02JAN02–1/1 Level 12 ECU . Can not communicate with ECU: See D1 . If engine will not crank.5 L & 6. Verify air heater operation in cold temperatures No problems found: GO TO 2 Problem found: Repair and retest – – –1/1 2 Active DTC Test 1. For instructions on connecting to the DST or SERVICE ADVISOR™. Ensure that fuel quality and quantity are OK.Preliminary Check Before using this diagnostic procedure: 1.Observable Diagnostics and Tests Level 12 ECU . 2. Crank engine for 15 seconds 5.E1 .Engine Cranks/Won’t Start Diagnostic Procedure 04 150 2 – – –1/1 1 E1 . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. 2. Ensure that engine cranking speed is OK. Read DTCs using DST or SERVICE ADVISOR™.Engine Cranks/Won’t Start NOTE: This procedure applies to engines with John Deere Engine Control Units (ECUs).8 L Level 12 Electronic Fuel System 040902 PN=106 . diagnose them first. RG40854. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-150-2 4. No active DTCs present: GO TO 3 Active DTC(s) present: Diagnose DTCs. 4. This procedure should be used if engine cranking speed is OK.5 L & 6. Start the ECU Communication Software 4.E1 .ENGINE WILL NOT CRANK later in this Group. see E6 . . Illinois.... Damaged engine speed sensor 3.. – – –1/1 4 Vehicle Wiring Inspection Check Inspect the vehicle for possible failures that can cause either of the following conditions: 1........... 27 N•m (20 lb-ft) – – –1/1 CTM331 (09APR02) 04-150-3 4. Bad electrical connections 2.............. If ANY fluid is injected into the skin. Using the DST or SERVICE ADVISOR..8 L Level 12 Electronic Fuel System 040902 PN=107 .. Crank Position Noise above 0: GO TO 4 Crank Position Noise is 0: GO TO 5 NOTE: For an explanation of this parameter..... it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result......... Using two open-end wrenches.. Crank engine while monitoring loosened connection for consistent squirts of fuel. Doctors unfamiliar with this type of injury may call the Deere and Company Medical Department in Moline....... 04 150 3 – – –1/1 5 Fuel Present at Injection Nozzles Check Perform following procedure to check for fuel at injection nozzle: Consistent squirts of fuel observed: GO TO 7 Don’t observe consistent squirts of fuel: GO TO 6 CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury....... Retighten connection at nozzle to specification.5 L & 6. read the Crank Position Noise parameter while cranking. or other electronic devices 4.. repair and retest. Specification Fuel Injection Nozzle Delivery Lines— Torque ...... 1....... or other knowledgeable medical source... see DATA PARAMETER DESCRIPTION in Group 160. Start cranking engine 2.... loosen fuel line connection at one of the injection nozzles......Observable Diagnostics and Tests 3 Crank Position Sensor Indicator Test 1... Once problem is found.. EMI from improperly installed radio equipment..... 3.... 2.... Keep hands and body away from pinholes and nozzles which could inject fluids under high pressure.......... Observable Diagnostics and Tests 6 Fuel Supply System Check Check the fuel supply system.FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group. Group 150 of 4. All components operating correctly: GO TO 8 Restrictions are found: Repair faulty component and retest.5L & 6. Fuel supply system is OK: GO TO 7 Fuel supply system problem found: Repair fuel supply system problem and retest. – – –1/1 04 150 4 7 Intake and Exhaust Restrictions Test Check for intake and exhaust restrictions. Faulty injection nozzle(s) found: Repair or replace injection nozzle(s) – – –1/1 CTM331 (09APR02) 04-150-4 4.8 L Level 12 Electronic Fuel System 040902 PN=108 . Injection nozzles OK: Faulty injection pump. See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS in Section 04. Repair problem and retest. Compression pressure is within specification: GO TO 9 Compression pressure is not within specification: GO TO 10 – – –1/1 9 Fuel Injection Nozzles Check Test fuel injection nozzles.FUEL INJECTION NOZZLE CHECK later in this Group. See F1 . Group 150 of 4. See TEST ENGINE COMPRESSION PRESSURE in Section 04.5 L & 6. See F5 .8L Diesel Engines Base Engine Manual (CTM104). – – –1/1 8 Compression Test Check compression pressure.8 L Diesel Engines Base Engine Manual (CTM 104).5 L & 6. 04 150 5 – – –1/1 12 Valve Lift Check Check valve lift.5 L & 6.5 L & 6. Group 020 of 4. See MEASURE VALVE LIFT in Section 02. Valve lash is within specification: GO TO 12 Valve lash on one or more valves out of specification: Adjust valve lash and retest.8 L Diesel Engines Base Engine Manual (CTM104).5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=109 .8 L Diesel Engines Base Engine Manual (CTM104). Lift on all valves within specification: GO TO 13 Valve lift on one or more valves is out of specification: Reset clearance to specification after measuring lift. 2.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). See REMOVE FUEL INJECTION NOZZLES in Section 02. Retest the compression pressure. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. 1. Compression pressure is within specification: GO TO 13 Compression pressure is not within specification: GO TO 11 – – –1/1 11 Valve Lash Check Check valve lash. Group 020 of 4. Group 090 of this manual. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. Apply oil to ring area of piston through injection nozzle bore. Group 020 of 4. – – –1/1 CTM331 (09APR02) 04-150-5 4. DO NOT get oil on the valves.Observable Diagnostics and Tests 10 Piston Ring Check NOTE: DO NOT use too much oil. Rings.Observable Diagnostics and Tests 13 Pistons. and/or liners or valve guides: Repair problem as necessary. Check the most likely items as needed. – – –1/1 04 150 6 CTM331 (09APR02) 04-150-6 4.8 L Level 12 Electronic Fuel System 040902 PN=110 . rings. • • • • • • • • • Oil control rings worn or broken Scored cylinder liners or pistons Piston ring grooves excessively worn Piston rings sticking in ring grooves Insufficient piston ring tension Piston ring gaps not staggered Cylinder liners glazed (insufficient load during engine break-in) Worn valve guides or stems Cylinder head may need reconditioning Problem found with pistons. rings. and/or cylinder liners or in the valve guides.5 L & 6. the most likely cause of the low engine compression pressure is one of the following failures in the pistons. Cylinder Liners Check At this point. Read DTCs using DST or SERVICE ADVISOR™. No problems found: GO TO 2 Problem found: Repair and retest 04 150 7 – – –1/1 2 Active DTC Test 1.Engine Misfires/Runs Irregularly Diagnostic Procedure – – –1/1 1 E2 . Check for mechanical problems 3. For instructions on connecting to the DST or SERVICE ADVISOR™.Engine Misfires/Runs Irregularly RG40854. Ignition ON. Check engine accessories.5 L & 6. 2. cycling on and off 5.E2 . Not running rough: GO TO 4 Running rough: GO TO 6 – – –1/1 CTM331 (09APR02) 04-150-7 4. No active DTCs: GO TO 3 Active DTCs present: Diagnose DTCs. If any of the DTCs have a SPN 637. Check for transmission problems 4. such as A/C.Preliminary Check Before using this diagnostic procedure. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual.8 L Level 12 Electronic Fuel System 040902 PN=111 . Check for electromegnetic interference (EMI) from improperly installed radios. 2. Connect the DST or SERVICE ADVISOR™. Observe engine performance. Check for intake manifold air leaks 2. engine idling 5. Start the ECU Communication Software 4.Observable Diagnostics and Tests Level 12 ECU . engine OFF 3.E2 . engine idling. make the following checks that could cause or be mistaken as miss/rough running: 1. Ignition ON.00000D4 –19–02JAN02–1/1 Level 12 ECU . etc. diagnose them first SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 3 Engine Performance Test 1. Ignition ON. 8 L Diesel Engines Base Engine Manual (CTM104). Read DTCs No active DTCs: GO TO 6 Active DTCs present: Diagnose DTCs. diagnose them first. If any of the DTCs have a SPN 637.FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group.Observable Diagnostics and Tests 4 Recreate Conditions Operate engine under conditions where the miss/rough running complaint occurs. See CHECK FOR HEAD GASKET FAILURES in Section 04. Ignition ON. – – –1/1 7 Cylinder Misfire Check Check cylinders for misfire. See TEST FOR CYLINDER MISFIRE (ENGINE RUNNING) later in this Group. Running rough: GO TO 5 Not running rough: No problem found.8 L Level 12 Electronic Fuel System 040902 PN=112 . Single cylinder misfire: GO TO 8 Random or all cylinder misfire: See F1 . – – –1/1 5 Active DTC Test 04 150 8 1. verify complaint and try to reproduce conditions of miss/rough running complaint. Group 150 of 4. No sign of head gasket failure: GO TO 7 Signs of head gasket failure found: Replace head gasket and retest.5 L & 6. engine idling 2. – – –1/1 6 Head Gasket Failure Check Check for head gasket joint failures.5 L & 6. – – –1/1 CTM331 (09APR02) 04-150-8 4. 2.Observable Diagnostics and Tests 8 Compression Pressure Check Check compression pressure. Lines are not restricted: GO TO 10 Lines are restricted: Repair or replace lines and retest. 2. – – –1/1 11 Piston Ring Check NOTE: DO NOT use too much oil. Retest the compression pressure. Compression pressure is within specification: GO TO 14 Compression pressure is not within specification: GO TO 12 – – –1/1 CTM331 (09APR02) 04-150-9 4. If the delivery line is not restricted. See REMOVE FUEL INJECTION NOZZLES in Section 02. See TEST ENGINE COMPRESSION PRESSURE Section 04.8 L Level 12 Electronic Fuel System 040902 PN=113 . 1.5 L & 6. DO NOT get oil on the valves. Group 150 of 4.8 L Diesel Engines Base Engine Manual (CTM104). See F5 . Compression pressure is within specification: GO TO 9 Compression pressure is not within specification: GO TO 11 – – –1/1 9 Fuel Delivery Line Check Perform the following steps to determine if fuel delivery lines are restricted: 1. the compressed air should flow freely out the other side. Injection nozzles test OK: Faulty injection pump Faulty injection nozzle(s) found: Repair or replace injection nozzles. If air does not flow freely. 04 150 9 – – –1/1 10 Fuel Injection Nozzle Check Test fuel injection nozzles. Apply oil to ring area of piston through injection nozzle bore. Force air through one end of the delivery line. Disconnect the suspected fuel delivery line on the injection nozzle end and injection pump end. Group 090 of this manual.FUEL INJECTION NOZZLE CHECK later in this Group. there are restrictions in the fuel line. 4. 3.5 L & 6. the most likely cause of the low engine compression pressure is one of the following failures in the pistons. See CHECK AND ADJUST VALVE CLEARANCE in Section 02.8 L Level 12 Electronic Fuel System 040902 PN=114 .5 L & 6.5 L & 6. – – –1/1 CTM331 (09APR02) 04-150-10 4. Valve lash is within specification: GO TO 13 Valve lash on one or more valves out of specification: Adjust valve lash and retest. rings. Group 020 of 4.5L & 6. • • • • • • • • • Oil control rings worn or broken Scored cylinder liners or pistons Piston ring grooves excessively worn Piston rings sticking in ring grooves Insufficient piston ring tension Piston ring gaps not staggered Cylinder liners glazed (insufficient load during engine break-in) Worn valve guides or stems Cylinder head may need reconditioning Problem found with pistons.8 L Diesel Engines Base Engine Manual (CTM104). Lift on all valves within specification: GO TO 14 Valve lift on one or more valves is out of specification: Reset clearance to specification after measuring lift.Observable Diagnostics and Tests 12 Valve Lash Check Check valve lash. rings. and/or liners or valve guides: Repair problem as necessary.8L Diesel Engines Base Engine Manual (CTM104). Group 020 of 4. Rings.8 L Diesel Engines Base Engine Manual (CTM104). Cylinder Liners Check At this point. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. – – –1/1 14 Pistons. Check the most likely items as needed.5 L & 6. – – –1/1 13 Valve Lift Check 04 150 10 Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4. and/or cylinder liners or in the valve guides. No DTCs present: GO TO 3 DTCs present: Go to appropriate diagnostic procedure.Observable Diagnostics and Tests Level 12 ECU . engine OFF 5.5 L & 6.E3 . For instructions on connecting to the DST or SERVICE ADVISOR™.Preliminary Check Before using this diagnostic procedure.Engine Does Not Develop Full Power RG40854. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-150-11 4. Connect the DST or SERVICE ADVISOR™. 2. Start the ECU Communication Software 4.8 L Level 12 Electronic Fuel System 040902 PN=115 . the ECU derates fuel in order to protect the engine. engine OFF 3. Ignition ON.00000D5 –19–02JAN02–1/1 Level 12 ECU . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. Ignition ON. ensure that: • • • • • • There are no problems with transmission There are no engine mechanical problems There is not an excessive load on the engine There is no unbalanced ballast The air and fuel filters are not restricted or plugged Fuel quality is OK No problems found: GO TO 2 Problem found: Repair and retest 04 150 11 – – –1/1 2 Active DTC Test 1.E3 . Read DTCs using DST or SERVICE ADVISOR™.Engine Does Not Develop Full Power Diagnostic Procedure – – –1/1 1 E3 . NOTE: On some DTCs. 8 L Level 12 Electronic Fuel System 040902 PN=116 . see DATA PARAMETER DESCRIPTION in Group 160.5L & 6. Operate engine and attempt to recreate the low power condition. 3. CTM331 (09APR02) 04-150-12 4.Observable Diagnostics and Tests 3 Exhaust Emission Test 1. Under these conditions. Operate engine at full load rated speed. Group 210 of this manual and refer to the corresponding maximum speed and desired speed governor curves for your application. Correct torque curve number displayed for corresponding operating conditions: GO TO 5 Incorrect torque curve number displayed for corresponding operating conditions: Refer to machine manual to determine components that if faulty could prevent the correct torque curve from being selected OR Faulty torque curve select wiring NOTE: For an explanation of this parameter.ENGINE EMITS EXCESSIVE BLACK or GRAY EXHAUST SMOKE DIAGNOSTIC PROCEDURE later in this Group. Recreate the conditions of the low power complaint. Heavy black or gray exhaust smoke: See E5 . Compare the Torque Curve Parameter to the appropriate torque curve chart. 2. Read the Desired Speed Governor parameter and the Maximum Speed Governor parameter using the DST or SERVICE ADVISOR. 2. See APPLICATION SPECIFICATIONS in Section 06. Compare governor selection to the appropriate governor mode chart. To check that the engine is operating on the correct torque curve under the operating conditions where there is a low power complaint: 1. Read the Torque Curve parameter on the DST or SERVICE ADVISOR. 04 150 12 – – –1/1 4 Torque Curve Selection Check The ECU on 4. See APPLICATION SPECIFICATIONS in Section 06. 3. determine type of exhaust emitted.5 L & 6.ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE DIAGNOSTIC PROCEDURE later in this Group. Small amount or no exhaust smoke: GO TO 4 Heavy white exhaust smoke: See E4 . 2. Group 210 of this manual and refer to the corresponding torque curve for your application. see DATA PARAMETER DESCRIPTION in Group 160.8L diesel engines has the ability to operate on multiple torque curves. Correct governor selection: GO TO 6 Incorrect governor selection: Refer to machine manual to determine components that if faulty could prevent the correct governor from being selected OR Faulty governor select wiring – – –1/1 NOTE: For an explanation of this parameter. – – –1/1 5 Governor Droop Mode Selection Check 1. Observable Diagnostics and Tests 6 Throttle Test 1.8 L Diesel Engines Base Engine Manual (CTM 104). 97% or above: GO TO 7 Below 97%: Refer to machine manual and perform the throttle calibration procedure. Intake manifold pressure within range or above.5 L & 6. Compression pressure is within specification: GO TO 10 Compression pressure is not within specification: GO TO 13 – – –1/1 CTM331 (09APR02) 04-150-13 4. – – –1/1 9 Compression Pressure Check Check compression pressure. 2. Fuel supply system is OK: Engine appears to be delivering full power. see DATA PARAMETER DESCRIPTION in Group 160.8 L Level 12 Electronic Fuel System 040902 PN=117 . – – –1/1 7 Turbocharger Boost Pressure Check Check the Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE (TURBOCHARGER BOOST/POWER CHECK) in Section 04. Fuel supply system problem found: Repair fuel supply system problem and retest. Read the Percent Throttle parameter using the DST or SERVICE ADVISOR. Check for vehicle problems that could cause an excessive load on the engine. See F1 . then retest. Group 150 of 4.FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group. Group 150 of 4.5 L & 6.5 L & 6. Operate engine at full load rated speed. compared to boost specification: GO TO 8 Intake manifold pressure below range compared to boost specification: GO TO 9 04 150 13 – – –1/1 8 Fuel Supply System Check with Normal Boost Pressure Check the fuel supply system.8 L Diesel Engines Base Engine Manual (CTM104). NOTE: For an explanation of this parameter. See TEST ENGINE COMPRESSION PRESSURE Section 04. DO NOT get oil on the valves.FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group. See F5 . 2.8 L Level 12 Electronic Fuel System 040902 PN=118 . Restricted air cleaner 2. – – –1/1 11 Fuel Supply System Check with Low 04 Boost Pressure 150 14 Check the fuel supply system. Retest the compression pressure. Group 090 of this manual. Intake air leak 3. None of the above problems found: GO TO 11 Problem found: Repair problem and retest. – – –1/1 13 Piston Ring Check NOTE: DO NOT use too much oil. Injection nozzles test OK: Faulty injection pump OR Faulty ECU Faulty injection nozzle(s) found: Repair or replace faulty injection nozzles. Exhaust air leak 4. Faulty turbocharger.8 L Diesel Engines Base Engine Manual (CTM 104).5 L & 6. 1. See TURBOCHARGER INSPECTION in Section 02. Group 080 of 4. Apply oil to ring area of piston through injection nozzle bore.5 L & 6. F1 . Fuel supply system is OK: GO TO 12 Fuel supply system problem found: Repair fuel supply system problem and retest.FUEL INJECTION NOZZLE CHECK later in this Group. See REMOVE FUEL INJECTION NOZZLES in Section 02. Compression pressure is within specification: GO TO 16 Compression pressure is not within specification: GO TO 14 – – –1/1 CTM331 (09APR02) 04-150-14 4. – – –1/1 12 Fuel Injection Nozzles Test Test fuel injection nozzles.Observable Diagnostics and Tests 10 Checking Potential Causes of Low Boost Pressure Check for the following that can cause reduced boost pressure: 1. Restriction in exhaust 5. Ensure there are no engine mechanical problems and that there isn’t something drawing excessive engine power 2. Cylinder Liners Check At this point.5 L & 6.5 L & 6. Group 020 of 4.8 L Level 12 Electronic Fuel System 040902 PN=119 . and/or cylinder liners or in the valve guides.8 L Diesel Engines Base Engine Manual (CTM104).5 L & 6. Group 020 of 4. Rings. rings. Valve clearance within specification: GO TO 15 Valve clearance out of specification: Adjust valves to specification and retest. Lift on all valves within specification: GO TO 16 Valve lift on one or more valves is out of specification: Reset clearance to specification after measuring lift.Observable Diagnostics and Tests 14 Valve Lash Check 1. – – –1/1 CTM331 (09APR02) 04-150-15 4. Check the most likely items as needed. the most likely cause of the low engine compression pressure is one of the following failures in the pistons. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. • • • • • • • • • Oil control rings worn or broken Scored cylinder liners or pistons Piston ring grooves excessively worn Piston rings sticking in ring grooves Insufficient piston ring tension Piston ring gaps not staggered Cylinder liners glazed (insufficient load during engine break-in) Worn valve guides or stems Cylinder head may need reconditioning Problem found with pistons. and/or liners or valve guides: Repair problem as necessary. Ensure that valve lash is correctly adjusted.8 L Diesel Engines Base Engine Manual (CTM 104). See MEASURE VALVE LIFT in Group 020 in Section 02 of 4. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. – – –1/1 15 Valve Lift Check Check valve lift. rings. 04 150 15 – – –1/1 16 Pistons.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). Preliminary Check Before using this diagnostic procedure: • Ensure fuel quantity and quality are OK. No problems found: GO TO 2 Problem found: Repair and retest – – –1/1 2 Head Gasket Failure Test Check for a failed head gasket. Compression pressure is within specification: GO TO 4 Compression pressure is not within specification: GO TO 6 – – –1/1 CTM331 (09APR02) 04-150-16 4. Group 150 of 4.8 L Diesel Engines Base Engine Manual (CTM 104).5L/6.5 L & 6.8L .Engine Emits Excessive White Exhaust Smoke RG40854. This type of smoke causes a burning sensation to the eyes. See CHECK FOR HEAD GASKET FAILURES in Group 150 of 4.8 L Diesel Engines Base Engine Manual (CTM104). – – –1/1 3 Compression Pressure Check Check compression pressure. Group 150 of 4.E4 .8 L Level 12 Electronic Fuel System 040902 PN=120 .L1 EXCESSIVE OIL CONSUMPTION in Section 04.5 L & 6.00000D6 –19–02JAN02–1/1 Level 12 ECU . bluish exhaust smoke see 4.5 L & 6.5 L & 6.Observable Diagnostics and Tests Level 12 ECU .8 L Diesel Engines Base Engine Manual (CTM 104). No signs of head gasket failure: GO TO 3 Signs of head gasket failure are found: See CHECK FOR HEAD GASKET FAILURES in Group 020 of 4. 04 150 16 – – –1/1 1 E4 . See CHECK FUEL SUPPLY QUALITY later in this Group. See TEST ENGINE COMPRESSION PRESSURE Section 04.E4 . If engine emits a less heavy.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure NOTE: This procedure should be used if the engine emits excessive white exhaust smoke. • Ensure engine coolant temperature is not extremely low. See F1 . Group 020 of 4. Fuel pressure within specification: GO TO 5 Fuel pressure below specification: Check fuel supply system. – – –1/1 CTM331 (09APR02) 04-150-17 4. DO NOT get oil on the valves. Valve clearance within specification: GO TO 8 Valve clearance out of specification: Adjust valves to specification and retest. 1. See REMOVE FUEL INJECTION NOZZLES in Section 02.Observable Diagnostics and Tests 4 Fuel Supply Pressure Check Check fuel pressure. Ensure there are no engine mechanical problems and that there isn’t something drawing excessive engine power 2.8 L Diesel Engines Base Engine Manual (CTM 104). 2.5 L & 6. Retest the compression pressure. Apply oil to ring area of piston through injection nozzle bore. See CHECK FUEL SUPPLY PRESSURE later in this Group.5 L & 6.FUEL INJECTION NOZZLE CHECK later in this Group. Compression pressure is within specification: GO TO 9 Compression pressure is not within specification: GO TO 7 – – –1/1 7 Valve Lash Check 1. See CHECK AND ADJUST VALVE CLEARANCE in Section 02.FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group.8 L Level 12 Electronic Fuel System 040902 PN=121 . See F5 . Injection nozzles test good: Faulty injection pump Faulty injection nozzle(s) found: Repair or replace injection nozzles 04 150 17 – – –1/1 6 Piston Ring Check NOTE: DO NOT use too much oil. – – –1/1 5 Fuel Injection Nozzle Check Test fuel injection nozzles. Group 090 of this manual. Ensure that valve lash is correctly adjusted. Rings.Observable Diagnostics and Tests 8 Valve Lift Check Check valve lift.5 L & 6. Group 020 of 4. Cylinder Liners Check At this point. • • • • • • • • • Oil control rings worn or broken Scored cylinder liners or pistons Piston ring grooves excessively worn Piston rings sticking in ring grooves Insufficient piston ring tension Piston ring gaps not staggered Cylinder liners glazed (insufficient load during engine break-in) Worn valve guides or stems Cylinder head may need reconditioning Problem found with pistons. rings. Check the most likely items as needed.8 L Diesel Engines Base Engine Manual (CTM104). rings.5 L & 6. and/or cylinder liners or in the valve guides. 04 150 18 – – –1/1 9 Pistons.8 L Level 12 Electronic Fuel System 040902 PN=122 . – – –1/1 CTM331 (09APR02) 04-150-18 4. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. the most likely cause of the low engine compression pressure is one of the following failures in the pistons. and/or liners or valve guides: Repair problem as necessary. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). Lift on all valves within specification: GO TO 9 Valve lift on one or more valves is out of specification: Reset clearance to specification after measuring lift. If engine emits a less heavy. 3. read the Torque Curve parameter using the DST or SERVICE ADVISOR. Group 210 of this manual.L1 . SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-150-19 4. GO TO 3 . check the following: • Ensure fuel quantity and quality are OK.E5 . Compare the Torque Curve Parameter to the appropriate torque curve chart. See EXCAVATORS .5L/6.8 L Level 12 Electronic Fuel System 040902 PN=123 .5 L & 6.00000D7 –19–02JAN02–1/1 Level 12 ECU . With the engine running.TORQUE CURVE SELECTION in Section 06. see DATA PARAMETER DESCRIPTION in Group 160. Correct torque curve number displayed: GO TO 3 Incorrect torque curve number displayed: Adjust torque curve using DST or SERVICE ADVISOR.Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure NOTE: This procedure should be used if the engine emits excessive black or gray smoke. 2. Group 150 of 4.5 L & 6. 1. For all other applications. See ENGINE TEST INSTRUCTIONS EXCAVATOR TORQUE CURVE CHANGE TEST in Section 4.EXCESSIVE OIL CONSUMPTION in Section 04.8L . bluish exhaust smoke see 4. Connect the DST or SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE ADVISOR™. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual.E5 . – – –1/1 2 Torque Curve Check NOTE: This check is only required for Excavators. 04 150 19 – – –1/1 1 E5 .8 L Diesel Engines Base Manual (CTM 104). • Ensure engine is not excessively loaded • Ensure air filter is not restricted or plugged No problem found: GO TO 2 Problem found: Repair and retest. NOTE: For an explanation of this parameter. Group 160 of this manual.Preliminary Check Before using this diagnostic procedure. See CHECK FUEL SUPPLY QUALITY later in this Group.Observable Diagnostics and Tests Level 12 ECU .Engine Emits Excessive Black Or Gray Smoke RG40854. 8 L Level 12 Electronic Fuel System 040902 PN=124 . TEST FOR INTAKE AIR LEAKS and CHECK FOR EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04.8 L Diesel Engines Base Engine Manual (CTM 104).5 L & 6.5 L & 6. Group 150 of 4.8 L Diesel Engines Base Engine Manual (CTM104). – – –1/1 5 Valve Lash Check Check valve lash. Valve lash on all valves within specification: GO TO 6 Valve lash on one or more valves out of specification: Adjust valve lash and retest – – –1/1 6 Fuel Return Line Check Check for restricted fuel return line and fitting.5 L & 6. – – –1/1 4 Turbocharger Check 04 150 20 Check for turbocharger failure.5 L & 6.5 L & 6.Observable Diagnostics and Tests 3 Air Intake and Exhaust Test Check for intake and exhaust restrictions and air leaks. – – –1/1 CTM331 (09APR02) 04-150-20 4. No restriction found: GO TO 7 Restriction found: Repair and restest. Group 080 of 4. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 of 4. See TURBOCHARGER INSPECTION in Section 02. No restrictions or leaks found: GO TO 4 Restrictions or leaks found: Repair or replace components as necessary. No turbocharger failure found: GO TO 5 Turbocharger failure found: Follow appropriate repair procedure in Group 080 of 4.8 L Diesel Engines Base Engine Manual (CTM104).8 L Diesel Engines Base Engine Manual (CTM 104). See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS . Observable Diagnostics and Tests 7 Fuel Injection Nozzle Check Test fuel injection nozzles. Injection nozzles test good: Faulty injection pump Faulty injection nozzle(s) found: Repair or replace injection nozzles – – –1/1 04 150 21 CTM331 (09APR02) 04-150-21 4.8 L Level 12 Electronic Fuel System 040902 PN=125 .5 L & 6.FUEL INJECTION NOZZLE CHECK later in this Group. See F5 . Engine Will Not Crank Symptom Problem Solution Level 12 ECU . See E2 .E7 . and relays.E6 . Replace starter. fuses.5 L & 6. Corroded or loose battery connections Defective main switch or start safety switch Starter solenoid defective 04 150 22 Clean battery terminals and connections. See AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS in Section 06.Engine Idles Poorly Symptom Problem Solution Level 12 ECU .E7 . Replace solenoid.00000DA –19–02JAN02–1/1 CTM331 (09APR02) 04-150-22 4.Observable Diagnostics and Tests Level 12 ECU .5 L & 6.E6 .8 L Level 12 Electronic Fuel System 040902 PN=126 .Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality fuel of the proper grade. Group 200 of 4. Check hose and pipe connections for tightness.Engine Will Not Crank Weak battery Replace battery.00000D8 –19–02JAN02–1/1 Level 12 ECU . Repair switch as required. Starter defective Start circuit defective Engine is seized up RG40854.ENGINE MISFIRES/RUNS IRREGULARLY DIAGNOSTIC PROCEDURE earlier in this Group. Check by rotating engine by hand. Air leak on suction side of air intake system Electronic control system problem or basic engine problem RG40854. Check wiring. repair as required.8 L Diesel Engines Base Engine Manual (CTM 104). Group 050 of 4. Group 030 of 4. PISTON. Group 040 of 4.E8 .8 L Diesel Engines Base Engine Manual (CTM 104). Group 200 of 4.Abnormal Engine Noise Worn main or connecting rod bearings Determine bearing clearance.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See MEASURE TIMING GEAR BACKLASH in Section 02.5 L & 6.Observable Diagnostics and Tests Level 12 ECU .8 L Level 12 Electronic Fuel System 040902 PN=127 . See CRANKSHAFT . See INSPECT PISTON PINS AND BUSHINGS in Section 02. Check crankshaft end play.8 L Diesel Engines Base Engine Manual (CTM 104). AND RODS SPECIFICATIONS in Section 06. AND FLYWHEEL SPECIFICATIONS in Section 06. PISTONS. Check timing gear back lash. MAIN BEARINGS. 04 150 23 Excessive crankshaft end play Loose main bearing caps Worn connecting rod bushings and piston pins Scored pistons Worn timing gears or excess back lash Continued on next page RG40854. See CYLINDER BLOCK.8 L Diesel Engines Base Engine Manual (CTM 104).8 L Diesel Engines Base Engine Manual (CTM 104). MAIN BEARINGS.5 L & 6.5 L & 6.5 L & 6. See PRELIMINARY LINER. LINERS.5 L & 6. Check bearing clearance.E8 . Inspect pistons.00000DB –19–02JAN02–1/2 CTM331 (09APR02) 04-150-23 4. Group 200 of 4. See CHECK CRANKSHAFT END PLAY in Section 02.Abnormal Engine Noise Symptom Problem Solution Level 12 ECU . AND ROD CHECKS in Section 02. AND FLYWHEEL SPECIFICATIONS in Section 06. Group 200 or CRANKSHAFT . Group 030 of 4. replace bearings and bearing cap screws as required.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Inspect piston pins and bushings. Group 020 of 4.5 L & 6.8L .ENGINE OIL PRESSURE LOW in Section 04.5 & 6.8 L Level 12 Electronic Fuel System 040902 PN=128 .5 L & 6. Group 150 of 4.Observable Diagnostics and Tests Symptom Problem Solution Excessive valve clearance Check and adjust valve clearance. See 4. Group 020 of 4. Inspect camshaft.8 L Diesel Engines Base Engine Manual (CTM 104). See DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY in Section 02. See CHECK AND ADJUST VALVE CLEARANCE in Section 02. Inspect rocker arm shafts.8 L Diesel Engines Base Engine Manual (CTM 104).8 L Diesel Engines Base Engine Manual (CTM 104).5L/6. Group 050 of 4. See TURBOCHARGER INSPECTION in Section 02.5 L & 6.5 L & 6.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104).8 L Diesel Engines Base Engine Manual (CTM 104).00000DB –19–02JAN02–2/2 CTM331 (09APR02) 04-150-24 4.L2 . Worn camshaft Worn rocker arm shaft(s) 04 150 24 Insufficient engine lubrication Turbocharger noise RG40854. Group 080 of 4. See VISUALLY INSPECT CAMSHAFT in Section 02. 5 L & 6.Observable Diagnostics and Tests Level 12 ECU .Analog Throttle (B) Does Not Respond NOTE: This procedure is necessary for OEM applications only.8 L Level 12 Electronic Fuel System 040902 PN=129 .0000145 –19–11FEB02–1/1 CTM331 (09APR02) 04-150-25 4. See T6 . Go to the diagnostic procedure for the corresponding DTC. 04 150 25 Analog Throttle (B) Check SERVICE ADVISOR is a trademark of Deere & Company RG40854. For other applications.ANALOG THROTTLE (B) INPUT LOW DIAGNOSTIC PROCEDURE in Group 160 of this manual. Symptom Problem Solution Level 12 ECU . check for Diagnostic Trouble Codes (DTCs) and follow the corresponding procedure.Analog Throttle (B) Does Not Respond Active DTC Check Read DTCs on DST or SERVICE ADVISOR™.E9 .E9 . Check fuel supply pressure. See TEST FOR AIR IN FUEL later in this Group. See BLEED THE FUEL SYSTEM later in this Group. Pressure within specification: GO TO 7 Pressure is below specification: GO TO 4 – – –1/1 CTM331 (09APR02) 04-150-26 4.8 L Level 12 Electronic Fuel System 040902 PN=130 . – – –1/1 2 Air In Fuel Check NOTE: For fuel system operation information. No air found in fuel system: GO TO 3 Air found in fuel system: Bleed fuel system. see FUEL SYSTEM OPERATION in Section 03. Check for air in the fuel.Observable Diagnostics and Tests Level 12 ECU .Fuel Supply System Check RG40854. • If fuel system has recently been opened.Fuel Supply System Check Diagnostic Procedure – – –1/1 04 150 26 1 F1 . No problem found: GO TO 2 Problem found: Repair and retest. see FUEL SYSTEM OPERATION in Section 03. See BLEED THE FUEL SYSTEM later in this Group.00000DD –19–02JAN02–1/1 Level 12 ECU . See CHECK FUEL SUPPLY QUALITY after this Group. bleed fuel system. – – –1/1 3 Fuel Supply Pressure Check NOTE: For fuel system operation information. • Inspect all fuel lines and fittings for ruptures or leaks.F1 . See CHECK FUEL SUPPLY PRESSURE later in this Group. see FUEL SYSTEM OPERATION in Section 03. Group 130 earlier in this manual.F1 . Group 130 earlier in this manual. Group 130 earlier in this manual.5 L & 6.Preliminary Check NOTE: For fuel system operation information. Before using this diagnostic procedure: • Ensure fuel quantity and quality are OK. retighten all fittings. – – –1/1 04 150 27 6 Fuel Supply Pump Check NOTE: For fuel system operation information. Operate hand primer on fuel supply pump until fuel flows out the overflow valve fitting location. see FUEL SYSTEM OPERATION in Section 03. see FUEL SYSTEM OPERATION in Section 03. Group 130 earlier in this manual. Check fuel supply pressure. Turn ignition switch to “ON” position. Group 130 earlier in this manual.5 L & 6. the most likely cause for low fuel pressure is a failure in the fuel supply pump.Observable Diagnostics and Tests 4 Fuel Filter Test NOTE: For fuel system operation information. If fuel flow out the hole cannot be obtained. Good fuel flow out of loose overflow valve: No fuel supply problem found. see FUEL SYSTEM OPERATION in Section 03. Disconnect fuel line from injection pump overflow valve. Replace final fuel filter and retest. Remove fuel supply lines and determine if there are any internal restrictions. Loosen overflow valve from injection pump. Replace prefilter (if equipped) and retest. See BENCH TEST FUEL SUPPLY PUMP later in this Group. 2. No restrictions found: GO TO 6 Restrictions found: Repair or replace components as needed. NOT good fuel flow or no flow out of loose overflow valve: GO TO 8 – – –1/1 CTM331 (09APR02) 04-150-27 4. 3.8 L Level 12 Electronic Fuel System 040902 PN=131 . Group 130 earlier in this manual. see FUEL SYSTEM OPERATION in Section 03. See CHECK FUEL SUPPLY PRESSURE later in this Group. At this point. Group 130 earlier in this manual. 1. Pressure within specification: Problem resolved Pressure below specification: GO TO 5 – – –1/1 5 Fuel Supply Lines Check NOTE: For fuel system operation information. – – –1/1 7 Return Fuel Check NOTE: For fuel system operation information. 1. 3. 2. 4. Group 130 earlier in this manual. This check will help determine if the pre-injection fuel line is restricted.ENGINE DOES NOT DEVELOP FULL POWER DIAGNOSTIC PROCEDURE Restrictions found: Repair or replace components as needed. see FUEL SYSTEM OPERATION in Section 03. Return to diagnostic procedure earlier in this Group for: E1 .5 L & 6. • Force air through the fuel line.8 L Level 12 Electronic Fuel System 040902 PN=132 . No restrictions found: No fuel supply problems found.ENGINE CRANKS/WON’T START DIAGNOSTIC PROCEDURE OR E3 . • Disconnect fuel line from the final filter to the injection pump.Observable Diagnostics and Tests 8 Restricted Pre-Injection Fuel Line Check NOTE: For fuel system operation information. 04 150 28 – – –1/1 CTM331 (09APR02) 04-150-28 4. 8 L Level 12 Electronic Fuel System 040902 PN=133 .5 L & 6.Observable Diagnostics and Tests Level 12 ECU . RG40854.F3 . Reduce engine load Replace air cleaner element as required.00000DE –19–02JAN02–1/1 Level 12 ECU .Excessive Fuel Consumption Symptom Problem Solution Level 12 ECU . 04 150 29 Engine overloaded Air cleaner restricted or dirty Compression too low Leaks in fuel supply system RG40854.F2 . Determine cause of low compression and repair as required.F3 .F2 .00000DF –19–02JAN02–1/1 CTM331 (09APR02) 04-150-29 4. Locate source of leak and repair as required.Fuel in Oil Faulty injection pump front seal Replace front seal.Fuel in Oil Symptom Problem Solution Level 12 ECU .Excessive Fuel Consumption Poor fuel quality Drain fuel and replace with quality fuel of the proper grade. Group 130 of this manual.Fuel Injection Nozzle Check The Level 12 ECU . Incorrect Opening Pressure Improper adjustment Adjust opening pressure.Fuel Injection Nozzle Check provides a list of possible failures and there solutions. Group 090 of this manual.See DISASSEMBLE FUEL INJECTION NOZZLES in Section 02. Group 090 of this manual. Group 090 of this manual. Clean greave and install new seal. Group 090 of this manual. Group 090 of this manual. Solution Failed Carbon Stop Seal Washer Nozzle replaced without using new seal or washer Carbon stop seal groove not cleaned when new seal was installed.See CLEAN FUEL INJECTION NOZZLES and CLEAN FUEL INJECTION NOZZLE BORE in Section 02. Group 090 of this manual. • Operation . • Adjusting . Replace injection nozzle Replace injection nozzle. • Cleaning . Broken spring Nozzle Will Not Open Plugged orifices Chipped orifices Bottomed lift screw Poor Spray Pattern Plugged orifices Chipped orifices Cracked nozzle tip Poor Atomization Plugged orifice Chipped orifice Cracked nozzle tip Continued on next page RG40854.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=134 .See FUEL INJECTION NOZZLE TEST in Section 02.See ADJUST FUEL INJECTION NOZZLE in Section 02. • Removal . See FUEL INJECTION NOZZLE TEST in Section 02.See FUEL INJECTION NOZZLE OPERATION in Section 03. Group 090 of this manual.F5 .See REMOVE FUEL INJECTION NOZZLES in Section 02. Clean groove and install new seal and washer. • Installation . • Installing Seals . Clean orifices. This list below provides references to assist in the diagnosis and repair of the nozzle. Replace injection nozzle Replace injection nozzle. Replace injection nozzle Adjust lift screw. Clean orifice. • Disassembly . Group 090 of this manual.F5 .See INSTALL SEALS ON FUEL INJECTION NOZZLE in Section 02. 04 150 30 Symptom Problem • Performance Tests .Observable Diagnostics and Tests Level 12 ECU .0000001 –19–06MAR02–1/2 CTM331 (09APR02) 04-150-30 4. Replace spring Clean orifices.See INSTALL FUEL INJECTION NOZZLES in Section 02. 5 L & 6. Lap valve to seat. See FUEL INJECTION NOZZLE TEST in Section 02. Replace injection nozzle as necessary. Replace nozzle as necessary. Replace nozzle as necessary. Clean Guide Area Clean nozzle. Replace nozzle as necessary. Replace injection nozzle Replace injection nozzle Lap valve to guide. 04 150 31 Tip seat pitted Valve not free Distorted body Cracked tip High Leak-Off Wear or scratched at guide Low Leak-Off Varnish on valve Insufficient clearance RG40854. Group 090 of this manual. Lap valve to guide.Observable Diagnostics and Tests Symptom Problem Solution Seat Leakage Deposits in seat area Valve seat eroded or pitted Clean seat. Lap tip to seat.0000001 –19–06MAR02–2/2 CTM331 (09APR02) 04-150-31 4.8 L Level 12 Electronic Fuel System 040902 PN=135 . 5 L & 6.00000E0 –19–02JAN02–1/1 CTM331 (09APR02) 04-150-32 4.ECU Does Not Communicate With DST or SERVICE ADVISOR™ CAN Low CAN High CAN Shield F1 G1 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S E F G 04 150 32 D C A J H B D C E B A F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 C O N N E C T O R Switched Voltage Static Ground K1 K2 K3 Diagnostic Connector B A A C C CAN Terminator This diagnostic procedure should be used if communication between the Diagnostic Scan Tool (DST) or SERVICE ADVISOR and the Engine Control Unit (ECU) cannot be established.D1 . SERVICE ADVISOR is a trademark of Deere & Company RG40854.8 L Level 12 Electronic Fuel System 040902 PN=136 RG11972 –19–14DEC01 B B A C . For more information on CAN. see CONTROLLER AREA NETWORK (CAN) in Group 130 earlier in this manual.Observable Diagnostics and Tests Level 12 ECU . Ignition ON 4. For instructions on connecting to the DST or SERVICE ADVISOR. Disconnect ECT sensor 3.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1.5 L & 6.D1 . If no other codes are present. Ignition OFF 2. Connect the DST or SERVICE ADVISOR. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.00000E9 –19–04JAN02–1/1 Level 12 ECU . engine OFF 4. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. see D1 . and all connections in between.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information Perform a preliminary inspection of the ECU connector. the diagnostic connector. damaged. – – –1/1 3 Sensor Voltage Test NOTE: For wiring and theory of operation information.ECU Does Not Communicate With DST or SERVICE ADVISOR™ Continued SERVICE ADVISOR is a trademark of Deere & Company RG40854. Ignition ON. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. This will ensure that terminal damage does not occur. or poorly positioned terminals.ECU Does Not Communicate with DST or SERVICE ADVISOR™ Diagnostic Procedure SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Make sure all communication cables are properly connected 3.0 V: GO TO 4 – – –1/1 CTM331 (09APR02) 04-150-33 4. Look for dirty. see D1 . Start the ECU Communication Software DST or Service ADVISOR does not communicate with ECU: GO TO 3 DST or Service ADVISOR communicates with ECU: Problem is intermittent.D1 .0 V or above: GO TO 5 Below 3. 04 150 33 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=137 .Observable Diagnostics and Tests Level 12 ECU . 2. see D1 . Using a multimeter. measure the voltage between both terminals of the selected sensor harness connector 3. see D1 . Ignition ON 2. Ignition ON 4. measure voltage between switched voltage terminal and ground terminal of the harness end of the diagnostic connector Substantially less than battery voltage: GO TO 7 At or near battery voltage: Faulty diagnostic connector OR Faulty diagnostic cable OR Faulty Parallel Port Data Module (PDM) – – –1/1 7 Harness Power/Ground Wire Checks NOTE: For wiring and theory of operation information.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1.8 L Level 12 Electronic Fuel System 040902 PN=138 .ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1. measure the voltage between a good ground and terminal A2 in the harness end of the ECU connector 3. Ignition OFF 2. Ignition OFF 2.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1.Observable Diagnostics and Tests 4 Power Supply Test NOTE: For wiring and theory of operation information. Probe the ground terminal in the harness side of the diagnostic connector with a test light connected to battery voltage. see D1 . Using a multimeter. Observe the power light on the Parallel Data Module (PDM) Green power light ON: GO TO 8 Red power light or power light OFF: GO TO 6 – – –1/1 6 Open in Diagnostic Ground Connector Wire Test NOTE: For wiring and theory of operation information. see D1 . Disconnect ECU connector 3. see D1 . Disconnect the diagnostic cable from the diagnostic connector 3. Light ON: Faulty diagnostic connector OR Open or short in power wire Light OFF: Faulty diagnostic connector OR Open ground wire – – –1/1 CTM331 (09APR02) 04-150-34 4.5 L & 6.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1. Ignition ON 4. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector 3. Using a multimeter.0 V or above: Faulty ECU power fuse OR Faulty ECU power wiring OR Faulty ECU Below 3.0 V: Key-on signal wire open or shorted to ground OR Faulty ignition switch OR Faulty key-on power fuse – – –1/1 04 150 34 5 PDM Power Light Test NOTE: For wiring and theory of operation information. measure voltage between a good chassis ground and : • Terminal C in the diagnostic connector • Terminal D in the diagnostic connector Both measurements between 1. see D1 .5 or greater than 3. see D1 . measure resistance between terminals C and D in the harness end of the diagnostic connector. Disconnect ECU connector and diagnostic cable from the diagnostic connector 3. Using a multimeter.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1.Observable Diagnostics and Tests 8 Open in Harness Circuit Test NOTE: For wiring and theory of operation information.5 . see D1 .3.5 volts: CAN wiring shorted to ground or voltage OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-150-35 4. Reconnect ECU connector 3. Ignition OFF 2.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1. Using a multimeter. Ignition OFF 2. measure resistance on the harness end of both connectors between: • CAN low terminal D in the diagnostic connector and terminal F1 in the ECU connector • CAN high terminal C in the diagnostic connector and terminal G1 in the ECU connector Both measurements 5 ohms or less: GO TO 9 One or more measurements greater than 5 ohms: Open in harness circuit – – –1/1 9 CAN Resistance Test NOTE: For wiring and theory of operation information. Using a multimeter.8 L Level 12 Electronic Fuel System 040902 PN=139 . ECU and diagnostic connector still disconnected. Ignition ON.5 volts: Faulty ECU/Cab Harness connection OR Faulty diagnostic cable OR Faulty diagnostic connector OR Faulty Parallel Port Data Module (PDM) OR Faulty diagnostic software/computer configuration OR Faulty ECU Either measurement less than 1. engine OFF 4.5 L & 6. 3.75 ohms: GO TO 10 Less than 45 or greater than 75 ohms: Faulty or missing CAN terminator connector OR Open or short in CAN wiring harness 04 150 35 – – –1/1 10 CAN High and Low Voltage Test NOTE: For wiring and theory of operation information. Between 45 . Ignition OFF 2.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information 1. Diagnostic Gauge Does Not Communicate With ECU diagnostic procedure should be followed if the diagnostic gauge shows the following error codes or it can not communicate with the ECU: – EE-error – ACP-Err/No Addr – ACP-Err/Bus EP – ACP-Err/Bus Error RG40854.Diagnostic Gauge Does Not Communicate With ECU CAN Low CAN High CAN Shield F1 G1 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H G F A B C D 04 150 36 E B G F E D H1 H2 H3 J1 J2 J3 K1 K2 K3 C O N N E C T O R Switched Voltage Static Ground Diagnostic Gauge Connector B A A B B A C C C CAN Terminator NOTE: For more information on CAN.D2 .00000E2 –19–02JAN02–1/1 CTM331 (09APR02) 04-150-36 4.8 L Level 12 Electronic Fuel System 040902 PN=140 RG11973 –19–14DEC01 . see CONTROLLER AREA NETWORK (CAN) in Group 130 earlier in this manual.Observable Diagnostics and Tests Level 12 ECU .5 L & 6. Internal Diagnostic Gauge Errors • The D2 . and all connections in between. see D2 .0000147 –19–11FEB02–1/1 Level 12 ECU .5 L & 6. Ignition OFF 2. 1. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.Diagnostic Gauge Does Not Communicate With ECU . This will ensure that terminal damage does not occur. or poorly positioned terminals. If no other codes are present. see D2 . – – –1/1 CTM331 (09APR02) 04-150-37 4. Perform a preliminary inspection of the ECU connector.Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. Ignition ON Error or no power found in diagnostic gauge: GO TO 3 No error found and power present in diagnostic gauge: Problem is intermittent.D2 . damaged.8 L Level 12 Electronic Fuel System 040902 PN=141 . the diagnostic gauge connector.Observable Diagnostics and Tests Level 12 ECU .DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information.D2 . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. Look for dirty. 04 150 37 – – –1/1 2 Intermittent Fault Test NOTE: For wiring information.Continued RG40854. measure the voltage between a good ground and terminal A2 in the harness end of the ECU connector. 3.0 V: Key-on signal wire open or short to ground OR Faulty ignition switch OR Faulty key-on power fuse – – –1/1 5 Diagnostic Gauge Power Test NOTE: For wiring information. measure voltage between switched voltage terminal and ground terminal of the harness end of the diagnostic connector Substantially less than battery voltage: GO TO 7 At or near battery voltage: Faulty diagnostic connector OR Faulty diagnostic cable OR Faulty Parallel Port Data Module (PDM) – – –1/1 CTM331 (09APR02) 04-150-38 4.Observable Diagnostics and Tests 3 Sensor Voltage Test NOTE: For wiring information. Ignition ON 4. Ignition OFF 2.5 L & 6. Using a multimeter. see D2 . 1. Ignition ON 4. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector 3. Using a multimeter. see D2 .DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. Disconnect ECU connector 3. 1. measure the voltage between both terminals of the selected sensor harness connector.0 V or above: Faulty ECU power fuse OR Faulty ECU power wiring OR Faulty ECU Below 3. 1. Ignition ON 2. see D2 .8 L Level 12 Electronic Fuel System 040902 PN=142 . see D2 .0 V: GO TO 4 04 150 38 – – –1/1 4 Power Supply Test NOTE: For wiring information.0 V or above: GO TO 5 Below 3. Ignition ON 4. Ignition OFF 2.DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU DIAGNOSTIC PROCEDURE supporting information.DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. Using a multimeter. Disconnect any of the following: • Fuel temperature sensor • MAT sensor • ECT sensor 3. View diagnostic gauge Gauge has power: GO TO 8 Gauge does not have power: GO TO 6 – – –1/1 6 Open in Diagnostic Ground Connector Wire Test NOTE: For wiring information.DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. 3. 1. Disconnect the diagnostic cable from the diagnostic connector 3. 1.Observable Diagnostics and Tests 7 Harness Power/Ground Wire Checks NOTE: For wiring information. 3. Ignition OFF 2.DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. Using a multimeter. Probe the ground terminal in the harness side of the diagnostic connector with a test light connected to battery voltage. Using a multimeter. 1. • Terminal G in the diagnostic gauge connector and terminal G1 in the ECU connector. ECU and diagnostic connectors still disconnected. Disconnect the ECU connector and the diagnostic cable from the diagnostic connector. 1. see D2 .DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. All measurements 5 ohms or less: GO TO 9 One or more measurements greater than 5 ohms: Open in harness circuit OR Connector terminals in wrong position 04 150 39 – – –1/1 9 CAN Resistance Test NOTE: For wiring information. Between 45-75 ohms: GO TO 10 Less than 45 or greater than 75 ohms: Faulty or missing CAN terminator connector(s) OR Open or short in CAN wiring harness – – –1/1 CTM331 (09APR02) 04-150-39 4. measure resistance on the harness end of both connectors between: • Terminal B in the diagnostic gauge connector and terminal F1 in the ECU connector. see D2 . see D2 .8 L Level 12 Electronic Fuel System 040902 PN=143 . Light ON: Faulty diagnostic connector OR Open or short in power wire Light OFF: Faulty diagnostic connector OR Open ground wire – – –1/1 8 Open in Harness Circuit Test NOTE: For wiring information.DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. measure resistance between terminals B and G in the harness end of the diagnostic connector. Ignition OFF 2.5 L & 6. 3. Ignition OFF 2. Ignition ON 4. see D2 .8 L Level 12 Electronic Fuel System 040902 PN=144 .DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information. Reconnect ECU connector 3. Ignition OFF 2.5 V or greater than 3.5 V: CAN wiring shorted to ground or power OR Faulty ECU 04 150 40 – – –1/1 CTM331 (09APR02) 04-150-40 4.5 .5 L & 6.Observable Diagnostics and Tests 10 CAN High and Low Voltage Test NOTE: For wiring information. Using a multimeter. measure voltage between a good chassis ground and: • Terminal B in the diagnostic gauge connector • Terminal G in the diagnostic gauge connector Both measurements between 1. 1.3.5 V: Faulty ECU connection OR Faulty diagnostic gauge connection OR Faulty diagnostic software/computer configuration OR Faulty ECU Either measurement less than 1. 8 L Level 12 Electronic Fuel System 040902 PN=145 .Observable Diagnostics and Tests 04 150 41 CTM331 (09APR02) 04-150-41 4.5 L & 6. At this time. RG40854. At this time. Its function is to heat the intake air during cold starting conditions. The table on the corresponding page explains this relationship. and the air heater turns ON.5 L & 6. the solenoid deactivates. the ECU will illuminate the air heater indicator light. and the air heater turns OFF.00000E6 –19–03JAN02–1/1 CTM331 (09APR02) 04-150-42 4. the solenoid in the relay activates.Intake Air Heater Check Air Heater Indicator Light Switched Voltage G2 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 Air Heater Relay Enable K3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 150 42 NOTE: Wiring schematic shows OEM engine applications only. Its operation time is dependent on the fuel temperature that the ECU detects at key-on. a key-off/key-on cycle will be required before preheating is allowed again. Intake Air Heater The intake air heater is located between the intake pipe and intake manifold.A1 . To ensure full utilization of the intake air heater. the ECU will turn the air heater indicator light OFF. When the ECU stops sending battery voltage. Anytime the engine cranks but does not start. For non-OEM engine wiring information. see APPLICATION SPECIFICATIONS in Section 06.Observable Diagnostics and Tests Level 12 ECU . the operator should wait until the light goes out before starting the engine.8 L Level 12 Electronic Fuel System 040902 RG12049 E CC UO N HN AE RC NT EO SR S –19–23JAN02 PN=146 . When the ECU sends battery voltage to the air heater relay. Group 210 of this manual. A1 .8 L Level 12 Electronic Fuel System 040902 PN=147 . Group 210 of this manual.00000E7 –19–04JAN02–1/1 CTM331 (09APR02) 04-150-43 4.Intake Air Heater Check .5 L & 6.Continued NOTE: The table below is for OEM applications ONLY. see APPLICATION SPECIFICATIONS in Section 06. For specifications on other applications.Observable Diagnostics and Tests Level 12 ECU . Intake Air Heater Operating Conditions Intake Air Heater Operation Fuel Temperature -5°C (23°F) -10°C (14°F) -15°C (5°F) -20°C (-4°F) -25°C (-13°F) and below Operation Time 5 seconds 15 seconds 20 seconds 30 seconds 30 seconds 04 150 43 RG40854. see A1 . air heater relay connector. NOTE: For wiring and theory of operation information. Key ON.Continued RG40854.Intake Air Heater Check .Observable Diagnostics and Tests Level 12 ECU . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. – – –1/1 1 Connection Check 04 150 44 IMPORTANT: Do not force probes into connector terminals or damage will result. engine OFF 2. – – –1/1 2 Air Heater Indicator Light Check NOTE: Do not run engine during this diagnostic procedure. and all connections in between.INTAKE AIR HEATER CHECK supporting information Perform a preliminary inspection of the ECU connector.00000EB –19–04JAN02–1/1 Level 12 ECU . check for trouble codes or a short to ground in the air heater indicator light wire.INTAKE AIR HEATER CHECK supporting information 1. air heater connector. or poorly positioned terminals.A1 . This will ensure that terminal damage does not occur. damaged.5 L & 6. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Verify that the air heater indicator light is working Light works: GO TO 3 Light does not work: Faulty air heater indicator light wiring OR Faulty air heater indicator light – – –1/1 CTM331 (09APR02) 04-150-44 4.Intake Air Heater Check Diagnostic Procedure NOTE: The air heater indicator light is the same light that trouble codes are displayed on. see A1 . Look for dirty.8 L Level 12 Electronic Fuel System 040902 PN=148 . If the light stays on past 25 seconds.A1 . Observable Diagnostics and Tests 3 Active DTC Test NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER CHECK supporting information 1. Connect the DST or SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU Communication Software 4. Key ON, engine OFF 5. Read DTCs using DST or SERVICE ADVISOR. No active DTC(s) present: GO TO 4 Active DTC(s) present: Go to appropriate diagnostic procedure 04 150 45 SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 4 Fuel Temperature Check NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKE AIR HEATER CHECK supporting information 1. Key ON, engine OFF 2. Read the Fuel Temperature parameter using the DST or SERVICE ADVISOR. Below -5°C (23°F): GO TO 5 At or above -5°C (23°F): No air heater-related problem found – – –1/1 5 Voltage at Air Heater Check NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKE AIR HEATER CHECK supporting information 1. Key OFF 2. Using a multimeter, measure the voltage between the air heater power stud and a good chassis ground while turning key ON (engine OFF) At or near battery voltage: GO TO 6 No voltage detected: GO TO 7 NOTE: Voltage must be read as key is turned ON – – –1/1 6 Air Heater Check NOTE: For wiring and theory of operation information, see LEVEL 12 ECU - A1 INTAKE AIR HEATER CHECK supporting information 1. Key OFF 2. Using a multimeter, measure the temperature of air heater housing 3. Key ON, engine OFF 4. Continue to monitor temperature of air heater housing Temperature increases: No air heater related problem found Temperature does not increase Faulty air heater – – –1/1 CTM331 (09APR02) 04-150-45 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=149 Observable Diagnostics and Tests 7 Air Heater Relay Check NOTE: For wiring and theory of operation information, see LEVEL 12 ECU - A1 INTAKE AIR HEATER CHECK supporting information 1. Key OFF 2. Listen for air heater relay to click while turning key ON (engine OFF) Relay clicks: Faulty power wire to relay OR Faulty wire between relay and heater OR Faulty air heater relay Relay does not click: Faulty air heater enable wire OR Faulty relay ground OR Faulty relay 04 150 46 – – –1/1 CTM331 (09APR02) 04-150-46 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=150 Observable Diagnostics and Tests Check Fuel Supply Quality 04 150 47 The quality of diesel fuel affects engine performance. Check your operators manual for correct fuel specifications. Poor quality or contaminated fuel will make the engine hard to start, misfire, run rough or produce low power. If poor quality or contaminated fuel is suspected, perform the following: 1. Check prefilter (if equipped) and final fuel filter for serviceability. If filter is equipped with a water bowl, empty and clean water bowl. 2. Start engine and operate under load, observing engine performance. 3. Ignition OFF, engine off 4. Disconnect fuel line from inlet side of prefilter (if equipped) or inlet side of final filter on engines without prefilter. 5. Connect a hose to inlet port. 6. Submerge hose in a container of clean, good quality fuel meeting engine specifications. 7. Operate engine under load and observe performance. If performance improves, fuel is contaminated or not of the proper grade. Check fuel source. RG40854,00000EC –19–04JAN02–1/1 CTM331 (09APR02) 04-150-47 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=151 RG11969 –UN–23JAN02 Observable Diagnostics and Tests Test for Fuel Drain Back Fuel draining back through the fuel system may cause hard starting. This procedure will determine if air is entering the system at connections and allowing fuel to siphon back to the fuel tank. 1. Disconnect fuel supply and return lines at fuel tank. IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including the fuel supply pump, fuel injection pump, fuel filters, and water bowl (if equipped). 3. Securely plug off the end of the fuel return pipe. CAUTION: Maximum air pressure should be 100 kPa (1 bar) (14.5 psi) when performing this test. 4. Using a low pressure air source, pressurize the fuel system at the fuel supply line. 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. 04 150 48 NOTE: Connections may allow air to enter the system without allowing fuel to leak out. 6. If any leaks are found, take necessary steps to repair. 7. Reconnect supply and return lines and prime system. 8. Start engine and run for approximately 10 minutes. 9. Allow engine to sit overnight and try starting the following morning. RG40854,00000EE –19–04JAN02–1/1 CTM331 (09APR02) 04-150-48 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=152 Observable Diagnostics and Tests Test for Air in Fuel 04 150 49 NOTE: If engine cranks but won’t start, see BLEED THE FUEL SYSTEM later in this Group. Air in the fuel system will make the engine hard to start, run rough, misfire or produce low power. Additionally, it can cause excessive smoke and knocking. Whenever the fuel system is opened for repair, it must be bled to remove any air that has entered the system. 1. Disconnect hose from end of fuel leak-off line assembly. Connect a clear plastic hose to end of leak-off line assembly and place opposite end of hose in a suitable container filled with fuel as shown. 2. Operate engine and check for air bubbles in container. If bubbles are present, bleed the fuel system and repeat test. See BLEED THE FUEL SYSTEM later in this Group. 3. If bubbles are still present, check the following: • Check for loose fuel fittings from the suction side of the fuel supply pump to the fuel tank to include all lines and filters. • Check fuel tank suction tube (if equipped) and welded joints for cracks or holes. Perform any necessary repairs, bleed fuel system and repeat test. RG40854,00000EF –19–04JAN02–1/1 CTM331 (09APR02) 04-150-49 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=153 RG11970 –UN–23JAN02 Observable Diagnostics and Tests Check Fuel Supply Pressure IMPORTANT: Before disconnecting any fuel line, completely clean any debris from around the fitting. DO NOT allow debris to enter fuel line. 1. Remove plug on final fuel filter base. 2. Install test equipment as shown. 3. Start engine. Fuel pump should maintain minimum positive pressure listed below. If pressure is low, replace filter element and recheck pressure. 04 150 50 Specification Fuel Supply Pump—Static Pressure ....................................................... 25—30 kPa (0.25—0.30 bar) (3.5—4.5 psi) Fuel Supply Pump—Minimum Static Pressure at 850 rpm Engine Speed .................................................. 15 kPa (0.15 bar) (2.0 psi) Fuel Supply Pump—Minimum Positive Pressure at 2400 rpm Engine Speed ............................................... 21—34 kPa (0.21—0.34 bar) (3—5 psi) Fuel Supply Pump—Minimum Flow at 2400 rpm Engine Speed ............................. 1.5 L/min (0.42 gpm) –UN–15JAN98 RG40854,00000F9 –19–15JAN02–1/1 CTM331 (09APR02) 04-150-50 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 RG7946 PN=154 Observable Diagnostics and Tests Bench Test Fuel Supply Pump The following bench tests can be performed on a supply pump installed on the engine when the pump is suspected to be defective. See CHECK FUEL SUPPLY PRESSURE in Section 04, Group 150. Perform the Vacuum/Pressure Test and Leakage Test, listed below. Replace the supply pump if either test shows the pump to be defective. There is no repair procedure. Vacuum/Pressure Test Fuel Supply Pump with Metal Cover NOTE: This test will give a good indication of condition of both the inlet and outlet valves, as well as the diaphragm. The numerical values obtained on both the vacuum and pressure sides are not important; rather it is the needle movement that is important (very slow for a good pump; very fast or not at all for a defective pump). 1. Remove inlet and outlet fittings. 2. Install vacuum/pressure gauge to inlet side of pump (C). 3. Move primer lever (D) all the way downward. Release lever and at the same time observe gauge: • The gauge needle should read the same value each time, and then very slowly return to “0”. This indicates that the inlet valve and diaphragm are in good condition. Proceed to next step. • If the gauge needle does not move at all, or if the needle rapidly returns to “0”, the pump is defective and must be replaced. 4. Remove vacuum/pressure gauge and install onto outlet side of pump (B). 5. Move primer lever all the way to upward position. Release lever and at same time observe gauge reading: A—Lever B—Outlet Side of Pump C—Inlet Side of Pump D—Primer Lever RG9052 –UN–16MAR98 04 150 51 Continued on next page RG40854,0000146 –19–11FEB02–1/3 CTM331 (09APR02) 04-150-51 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=155 Observable Diagnostics and Tests • The gauge needle should initially read 28—41 kPa (0.28—0.41 bar) (4—6 psi), then return to “0” very slowly. This indicates that the outlet valve and diaphragm are in good condition. Supply pump is operating properly and should be reinstalled on engine. Specification Fuel Supply Pump—Pressure ...................... 28—41 kPa (0.28—0.41 bar) (4—6 psi) • If the gauge needle initially reads same value as above and then returns immediately back to “0”, the pump is defective and must be replaced. 04 150 52 RG40854,0000146 –19–11FEB02–2/3 Leakage Test The leakage test should be performed if a supply pump is suspected of leaking fuel externally, or internally into the engine crankcase. 1. Install an air line on inlet side of pump (C) and apply 140 kPa (1.4 bar) (20 psi) pressure. 2. Hold finger over outlet side of pump (B) or install a plug. Submerge pump into a container of clean diesel fuel. Fuel Supply Pump with Metal Cover –UN–16MAR98 • If air bubbles occur around banded connection holding the two halves of pump together (indicating leakage), replace pump. • If the diaphragm is bad, there will be leakage through vent holes (if equipped) and around the rocker arm. Replace pump as necessary. A—Lever B—Outlet Side of Pump C—Inlet Side of Pump D—Primer Lever RG40854,0000146 –19–11FEB02–3/3 CTM331 (09APR02) 04-150-52 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=156 RG9052 Observable Diagnostics and Tests Bleed the Fuel System CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. The fuel system may be bled at one of several locations. On some engine applications it may be necessary to consult your operator’s manual and choose the best location for your engine/machine application. X9811 –UN–23AUG88 04 150 53 RG40854,00000F0 –19–04JAN02–1/5 1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base. A—Bleed Vent Screw –UN–25OCT01 Continued on next page RG40854,00000F0 –19–04JAN02–2/5 CTM331 (09APR02) 04-150-53 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=157 RG11805 Tighten bleed plug securely.00000F0 –19–04JAN02–4/5 CTM331 (09APR02) 04-150-54 4....... If engine will not start. As soon as fuel flow is free from air bubbles..Observable Diagnostics and Tests 2. Start engine and check for leaks..... it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next... Operate fuel supply pump prime lever (B) or primer button on fuel filter base (if equipped).......5 L & 6...... 27 N•m (20 lb-ft) A—Fuel Return Line Continued on next page RG40854......... 3... Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 4....... 2.00000F0 –19–04JAN02–3/5 At Fuel Injection Pump 1...... Specification Fuel Injection Pump Return Line—Torque ..8 L Level 12 Electronic Fuel System 040902 PN=158 RG11807 –UN–25OCT01 RG11806 . 3.... tighten fuel return line to specifications... continue operating primer until pumping action is not felt............... B—Primer Lever –UN–25OCT01 04 150 54 RG40854.. Primer lever is spring-loaded and will return to normal position. Loosen fuel return line (A) at fuel injection pump. ...... loosen two fuel line connections at injection nozzles... RG40854. see your authorized servicing dealer or engine distributor..........Observable Diagnostics and Tests At Fuel Injection Nozzles 1......... 2. Specification Fuel Injection Nozzle Delivery Lines—Torque ..... Using two open-end wrenches... 27 N•m (20 lb-ft) Nozzle Fuel Pressure Line RG11808 –UN–25OCT01 04 150 55 4....00000F0 –19–04JAN02–5/5 CTM331 (09APR02) 04-150-55 4.. Place throttle lever in half-throttle position............5 L & 6.. If engine still will not start..... 3.... Retighten connection to specifications.. IMPORTANT: Always use a backup wrench when loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage.... Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system....8 L Level 12 Electronic Fuel System 040902 PN=159 .... Crank engine over with starter motor for 15 seconds (but do not start engine) until fuel free from bubbles flows out of loosened connection. 6.. 4. it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result..5 L & 6....... Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline. a cylinder is faulty... Tighten fuel lines to specifications.... Remove faulty injection nozzles and repair as required...... • If engine speed changes.. the cylinder is probably working satisfactory.....FUEL INJECTION NOZZLE CHECK earlier in this Group.... Keep hands and body away from pinholes and nozzles which could inject fluids under high pressure. 27 N•m (20 lb-ft) 5. or other knowledgeable medical source.......00000F1 –19–04JAN02–1/1 CTM331 (09APR02) 04-150-56 4. Slowly loosen the fuel pressure line at one of the nozzles until fuel escapes at the connection (fuel not opening nozzle valve). If ANY fluid is injected into the skin. • If engine speed does not change. Illinois..... 04 150 56 1.. 3. Place a shop towel around nozzle-to-line connection to absorb escaping fuel.. RG40854...... 2.....Observable Diagnostics and Tests Test for Cylinder Misfire (Engine Running) CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury..8 L Level 12 Electronic Fuel System 040902 PN=160 ....... Repeat test for each remaining cylinder... Specification Fuel Injection Nozzle Delivery Lines—Torque ...... Operate engine at intermediate speed with no load.. See F5 ... 8 L Diesel Engines Base Engine Manual (CTM 104) for: • • • • • Removal of base engine components Base engine repair procedures Base engine disassembly Base engine inspection Base engine assembly SPECIFICATIONS contains useful information. Section 06.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). IMPORTANT: Under NO circumstances.Group 160 Trouble Code Diagnostics and Tests About this Group of the Manual This section of the manual contains necessary information to diagnose the electronic control system.00000FA –19–15JAN02–1/1 Electrical Concepts Tests will include making measurements of voltage and resistance and making checks for open circuits and short circuits. and wiring harnesses are serviceable and available. such as ECU terminal identification and a system wiring schematic.5 L & 6.00000FB –19–15JAN02–1/1 CTM331 (09APR02) 04-160-1 4. Measurements should never be made in the ECU end of the connection. connectors. Parts such as sensors. Group 210 DIAGNOSTIC NOTE: Instruction is given throughout the diagnostic charts to make resistance and voltage measurements in the ECU connector. Use this information in conjunction with the 4. Note that these measurements are always made in the harness end of the connector. To help diagnose electronic control system problems. actuators. should the Engine Control Unit (ECU) be opened. An understanding of the following concepts is required to use the diagnostic procedures: • • • • • Voltage (volts) Current (amps) Resistance (ohms) Open Circuit Short Circuit RG40854. 04 160 1 RG40854.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=161 . See the 4. all voltage measurements are direct current (D.5 L & 6. A knowledge of the operation of the particular meter used is assumed. Disconnect appropriate connectors or turn off key switch. Grounded circuit 4.C. as directed by diagnostic procedures later in this group. In making a resistance measurement. High-resistance circuit 2. the positive test lead from the volt-ohm input of the meter should be connected to Point A and the negative test lead from the common input of the meter should be connected to Point B. Digital Multimeter 04 160 2 RG40854. Open circuit 3.00000FD –19–15JAN02–1/6 CTM331 (09APR02) 04-160-2 4. They are: 1. Shorted circuit Continued on next page RG40854.Trouble Code Diagnostics and Tests Using a Digital Multimeter It is recommended that a digital multimeter (JT07306 or equivalent with an analog display) be used to make the required measurements in the diagnostic procedures. Instructions for measuring voltages take the following form: • Measure voltage from Point A (+) to Point (B) (-) In this example. be careful to use the correct resistance range on the meter. Unless otherwise stated.).8 L Level 12 Electronic Fuel System 040902 PN=162 RG11126 –UN–19JUN00 .00000FC –19–15JAN02–1/1 Electrical Circuit Malfunctions Circuit Malfunctions There are four major circuit malfunctions. Open Circuit: A circuit having a break or a separation (A) that prevents current from flowing in the circuit.00000FD –19–15JAN02–4/6 CTM331 (09APR02) 04-160-3 4.00000FD –19–15JAN02–3/6 RG9893 –UN–06JAN99 Grounded Circuit A—Voltage Wire in Contact with Machine Frame 3.Trouble Code Diagnostics and Tests RG9891 –UN–06JAN99 High Resistance Circuit A—Unwanted Resistance Definition of Circuit Malfunctions 1. High Resistance Circuit: A circuit having unwanted resistance (A) that causes a voltage drop and reduces current flow. RG40854. providing continuity with the battery ground terminal.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=163 .00000FD –19–15JAN02–2/6 RG9892 –UN–06JAN99 04 160 3 Open Circuit A—Break or Separation in Circuit 2. RG40854. Grounded Circuit: A voltage wire in contact with the machine frame (A). Continued on next page RG40854. Shorted Circuit: A wire-to-wire contact of two adjacent wires that provides unwanted continuity between the two wires.5 L & 6. After the load (B). • Ground wire shorted to another ground wire (wires of zero voltage).00000FD –19–15JAN02–6/6 CTM331 (09APR02) 04-160-4 4. removed some oxidation and re-established good continuity through the connector. RG40854. Before the controlling switch (A). Electrical components can become faulty with the same four circuit malfunctions. but it operates after reconnecting the connector. Between the controlling switch (A) and the load (B). They are: 1.00000FD –19–15JAN02–5/6 RG9895 –UN–06JAN99 Locations of Circuit Malfunctions A—Controlling Switch B—Load Locations of Circuit Malfunctions: In a “Simple Electrical Circuit” the circuit malfunctions occur at only three locations. care must be exercised when isolating the cause of the problem. Disconnecting and reconnecting the connector. shorted to a ground wire connecting a component to the battery negative terminal). Example: A component may not operate before disconnecting an electrical connection. • Voltage wire shorted to a sensor signal wire (wires of unequal voltage). Therefore. Sometimes component malfunctions can easily be confused with circuit malfunctions.Trouble Code Diagnostics and Tests Shorted Circuit 04 160 4 4. The following are types of short circuits: • Voltage wire shorted to another voltage wire (wires of equal or unequal voltage). RG40854. • Voltage wire shorted to a ground wire (wires of battery voltage or regulated voltage. Reason: Oxidation of the terminals created “High Resistance” and a voltage drop that prevents the proper amount of current flow to the component.8 L Level 12 Electronic Fuel System 040902 RG9894 –UN–06JAN99 PN=164 . Therefore. 3. NOTE: This type of short does not create an observable malfunction. no further explanation for trouble shooting is necessary. 2. Open Circuit: An “Open” circuit results in no component operation because the circuit is incomplete (for example: broken wire.Trouble Code Diagnostics and Tests Troubleshooting Circuit Malfunctions RG9896 –UN–06JAN99 Troubleshooting Circuit Malfunctions A—Battery B—Switch C—Component Terminal D—Unwanted Resistance E—Circuit Connector F—Open Circuit G—Circuit Connector H—Component Terminal I—Load (Lamp) J—Ground 1. 04 160 5 NOTE: The example shows high resistance (D) between (C) and (E) and the open circuit (F) between (E) and (G). With the controlling switch (B) closed (on) and the load (I) connected into the circuit. open protective device or open switch). Repair the circuit as required. Do the following to isolate the location of a “High Resistance” or “Open” circuit: a. dirty or oily terminals. Continued on next page RG40854. terminals disconnected.8 L Level 12 Electronic Fuel System 040902 PN=165 . • If voltage is low. gauge of wire too small or broken strands of wire). b. High Resistance Circuit: A “High Resistance” circuit can result in slow. move toward the voltage source (A) to locate the point of voltage drop. check for proper voltage at a location easily accessible between (C) and (H). Perform an operational check-out on the component after completing the repair. corroded. move toward the load (I) and ground terminal (J) to locate the voltage drop. dim or no component operation (for example: loose. c.00000FE –19–15JAN02–1/4 CTM331 (09APR02) 04-160-5 4. 2.5 L & 6. • If voltage is correct. • If there is continuity. • Perform an operational check-out on the component after completing the repair. Check for continuity to ground between (B) and (C). check for continuity to ground between (D) and (E). Continued on next page RG40854.8 L Level 12 Electronic Fuel System 040902 PN=166 . • If there is continuity. Disconnect the load (H) at component terminal (G). Do the following to isolate the location of a “Grounded” circuit: a. 04 160 6 b. go to step b. With the controlling switch (C) open (off).00000FE –19–15JAN02–2/4 CTM331 (09APR02) 04-160-6 4.5 L & 6.Trouble Code Diagnostics and Tests RG9897 –UN–06JAN99 Ground Circuit A—Fuse “A” Terminal B—Fuse “B” Terminal C—Switch D—Component Terminal E—Wire Terminal F—Grounded Circuit G—Component Terminal H—Load (Lamp) 3. • No continuity. NOTE: The example is grounded between (D) and (E) at (F). Repair the circuit. Switch (C) must be open (off). c. Repair the circuit. there is a grounded circuit between (B) and (C). chassis or component housing). Ground Circuit: A “Grounded” circuit (F) results in no component operation and the fuse or circuit breaker opens (for example: a power wire contacting the machine frame. there is a grounded circuit between (D) and (E). RG9898 –UN–06JAN99 04 160 7 1 The sensor signal voltage goes out of range and a fault code may be restored. Shorted Circuit: Machines equipped with several electronic control devices contain wiring harnesses that can become shorted by one of the following ways shown above.1 9. Sensor voltage wire is shorted at (I) to the sensor ground wire. 2) is shorted at (D) to a regulated voltage wire. Battery wire from fuse (F1) is shorted at (C) to a ground wire. • Result: The sensor signal voltage is distorted.1 6. Battery wire from switch (Sw. • Result: Both lamps (E1 & E2) operate on either switch (Sw. obtain mating connector terminals from repair parts. • Result: Fuse (F2) opens after closing switch (Sw. 2) and the sensor signal is distorted. Review the machine electrical schematic to identify the circuits for the component that does not operate. Battery wire from switch (Sw.5 L & 6. 8. Battery wire from switch (Sw. Continued on next page RG40854.1 & 2). DO NOT force meter probes into connector terminals. 3. c. • Result: The sensor signal is distorted. • Result: Fuse (F1) opens after closing switch (Sw. • Result: The sensor signal is distorted. • Result: Lamp (E1) is on all of the time. 1 or 2). To prevent damage to connector terminals.2).1 7.00000FE –19–15JAN02–3/4 CTM331 (09APR02) 04-160-7 4. 2. The controller may shut down or provide limited operation for its function. • Result: The sensor signal is distorted. Battery wire from fuse (F1) is shorted at (B) to another battery wire after switches (Sw. 2) is shorted at (F) to the sensor ground wire. Disconnect the components at each end of the circuits.Trouble Code Diagnostics and Tests Shorted Circuit 4.8 L Level 12 Electronic Fuel System 040902 PN=167 . 1. Battery wire from fuse (F1) is shorted at (A) to another battery wire after switch (Sw. to single out the affected wires. Controller regulated voltage wire is shorted at (H) to the sensor ground wire. b. Controller regulated voltage wire is shorted at (G) to the sensor signal voltage wire.1 5.1 Do the following to isolate a “Shorted Circuit:” a. 1) 4. • Result: The sensor signal is distorted. 2) is shorted at (E) to the sensor signal voltage wire. Perform an operational check-out on the component after completing the repair. g. The meter should show no continuity between the two circuits. replace the harness. touch the other meter probe to the remaining 36 wires.8 L Level 12 Electronic Fuel System 040902 PN=168 . h. If there is continuity between any two wires. Repeat the check across another combination of two circuits until all affected circuits have been checked. Repair the circuit. 04 160 8 RG40854.5 L & 6. With one meter probe attached to each of the three wires. turn the key switch on. If hot sports are not noticeable. Example: A 37 pin connector contains three wires to a sensor. Connect one meter lead to a good frame ground. Repair the “Shorted Circuit” as follows: • Wires not in a loom: Wrap individual wires with electrical tape or replace the damaged wire and band as required. e. If there is a voltage reading. The meter should show no continuity between any two circuits. Connect the meter leads across two of the affected circuits. one at a time. Use tie bands to secure the wire to outside of the harness. the circuit is shorted.Trouble Code Diagnostics and Tests d. connect a meter lead to each affected circuit one at a time and touch the other meter leads to all terminals in the connector. With the components disconnected at each end of the suspected circuits. touch each of the suspected circuits one at a time. With the other meter probe. Then. • Wires in a loom: If hot spots exist in shorted area of the harness.00000FE –19–15JAN02–4/4 CTM331 (09APR02) 04-160-8 4. Repair the circuit. f. Alternate Method to Check for Shorted Circuit. install a new wire of proper gauge between the last two connections. the circuit is shorted to another voltage wire. Trouble Code Diagnostics and Tests 04 160 9 CTM331 (09APR02) 04-160-9 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=169 . Trouble Code Diagnostics and Tests Engine Configuration Data Parameters on Diagnostic Gauge Accessing Engine Configuration Data Parameters: –19–19JAN01 1.8 L Level 12 Electronic Fuel System 040902 PN=170 RG10031 –UN–28OCT99 RG11647 . 3. Scroll through the “E-Config”sub-menu to view Engine Configuration Parameters by pressing either the right or the left touch switch until desired parameter is found.5 L & 6. 4. In order to exit “E-Config” sub-menu. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. The numbers next to the parameters correspond to the number on the graph. simultaneously press the right and left touch switch A—Diagnostic Gauge B—Touch Switches C—Lights 04 160 10 Continued on next page RG40854.00000FF –19–15JAN02–1/2 CTM331 (09APR02) 04-160-10 4. Select “E-Config” sub-menu by simultaneously pressing the right and the left touch switch. Torque 2 equals the desired torque of the ECU divided by the reference torque. and 5 are optional and can be located anywhere between points 1 and 2. The maximum engine torque that the engine will allow when operating in a torque control/limit mode. 4. and 5 are optional and can be located anywhere between points 1 and 2. Torque 1 equals the desired torque of the ECU divided by the reference torque. Points 3. Torque 3 equals the desired torque of the ECU divided by the reference torque. It is only defined once and doesn’t change if a difference engine torque map becomes valid. This is defined as the kick-in point for which torque is reduced to zero. Equals the change of torque between points 2 and 6 divided by the change of engine speed between points 2 and 6.8 L Level 12 Electronic Fuel System 040902 PN=171 . The maximum time limit allowed to override the engine’s high idle speed.5 L & 6. The minimum engine speed that the engine will allow when operating in a speed control/limit mode The maximum engine speed that the engine will allow when operating in a speed control/limit mode. Points 3. Engine speed of high idle. Engine speed at point 4 of the engine configuration map. The minimum engine torque that the engine will allow when operating in a torque control/limit mode. Engine speed at point 5 of the configuration map. Torque 6 equals the desired torque of the ECU divided by the reference torque. Torque 5 equals the desired torque of the ECU divided by the reference torque. 4. Engine speed at point 2 of the engine configuration map.00000FF –19–15JAN02–2/2 CTM331 (09APR02) 04-160-11 4.Trouble Code Diagnostics and Tests Engine Configuration Parameter Description Parameter Displayed on Diagnostic Gauge Speed 1 Units RPM Description Stationary low idle speed of engine which includes influences due to engine temperature and other stationary changes. The maximum engine speed above point 6 allowed by the engine control during a momentary high idle override. 4. 04 160 11 Torque 1 Speed 2 Torque 2 Speed 3 Torque 3 Speed 4 Torque 4 Speed 5 Torque 5 Speed 6 Torque 6 Gov Gain Ref Torque % RPM % RPM % RPM % RPM % RPM % % Nm (ft-lbs) Speed 7 RPM Time Limit Lo Limit Hi Limit Low Limit Hi Limit sec RPM RPM % % RG40854. and 5 are optional and can be located anywhere between points 1 and 2. This is point 1 on the engine configuration map. Points 3. This duration is limited by the maximum momentary override time limit. Torque 4 equals the desired torque of the ECU divided by the reference torque. Engine speed at point 3 of the engine configuration map. This parameter is the 100% reference value for all defined indicated engine torque parameters. Select “StorCode” sub-menu by simultaneously pressing the right and the left touch switch. In order to exit “StorCode”sub menu.2842 –19–21OCT99–1/1 CTM331 (09APR02) 04-160-12 4. In order to exit “SrvcCode” sub menu. there are no stored codes. 3.OUOD007. simultaneously press the right and left touch switch A—Diagnostic Gauge B—Touch Switches C—Lights 04 160 12 RG40854.5 L & 6. 4. Select “SrvcCode” sub-menu by simultaneously pressing the right and the left touch switch. NOTE: If “No Data” is on the gauge.8 L Level 12 Electronic Fuel System 040902 PN=172 RG10031 –UN–28OCT99 RG10031 –UN–28OCT99 . 4.Trouble Code Diagnostics and Tests Viewing Active DTCs on Diagnostic Gauge Accessing Active Diagnostic Trouble Codes (DTCs): 1. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. simultaneously press the right and left touch switch A—Diagnostic Gauge B—Touch Switches C—Lights DPSG. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. Scroll through the “StorCode”sub-menu to view stored DTCs by pressing either the right or the left touch switch until all codes are found. 3. Scroll through the “SrvcCode ”sub-menu to view active DTCs by pressing either the right or the left touch switch until all codes are found.0000100 –19–15JAN02–1/1 Viewing Stored DTCs on Diagnostic Gauge Accessing Stored Diagnostic Trouble Codes (DTCs): 1. 6. In order to exit “StorCode” sub menu. there are no stored codes. Scroll through the “StorCode”sub-menu to view stored DTCs by pressing either the right or the left touch switch until all codes are found. simultaneously press the right and left switch for at least 8 seconds A—Diagnostic Gauge B—Touch Switches C—Lights 04 160 13 NOTE: If the switches are held for less than 8 seconds. If the display reads “*Send* **DM3 *”.5 L & 6. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2.Trouble Code Diagnostics and Tests Clearing Stored DTCs on Diagnostic Gauge Clearing Stored Diagnostic Trouble Codes (DTCs): 1. NOTE: If “No Data” is on the gauge. If display reads “***********”. the sub menu will be exited. the sub menu will be exited. 3. the codes are now cleared.8 L Level 12 Electronic Fuel System 040902 PN=173 RG10031 –UN–28OCT99 . 4. NOTE: If the switch is held for less than 8 seconds. Select “StorCode” sub-menu by simultaneously pressing the right and the left touch switch. press the right switch for at least 8 seconds.000006A –19–23JAN01–1/1 CTM331 (09APR02) 04-160-13 4. 5. simultaneously press the right and left touch switch RG40854. In order to clear codes. ECU communication Hardware Kit is required to connect the DST or SERVICE ADVISOR™ to the ECU. engine off or running. 2. verify that power light on MagiKey is illuminated green. circular connector with a square mounting flange and a dust cap. SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG40854. The diagnostic connector is a black.5 L & 6. 6. 3. On OEM the connector is located near the ECU on the engine wiring harness. 4.8 L Level 12 Electronic Fuel System 040902 RG11737A –UN–18MAY01 PN=174 . Connect John Deere Controller Cable (B) to the diagnostic connector on the engine harness using the diagnostic connector mate (A). 1. Please refer to your John Deere Dealer website for obtaining the latest version of software.Trouble Code Diagnostics and Tests Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR™ 04 160 14 Connecting to the DST or SERVICE ADVISOR™ A—Diagnostic Connector Mate B—John Deere Controller Cable C—MagiKey D—26 Pin MagiKey Connector E—25 Pin MagiKey Connector F—PC Cable G—PC Connector JDIS121 . 5. Connect the PC cable (F) to the MagiKey (C) module at the 25 pin MagiKey connector (E). Depending on application. Connect the other end of the John Deere Controller Cable (B) to the MagiKey (C) module at the 26 pin MagiKey connector (D). Connect the PC cable (F) to the computer with the Diagnostic Scan Tool (DST) or SERVICE ADVISOR™ installed through the PC connector (G). the location of the diagnostic connector may vary. There are nine available pins. Locate diagnostic connector on engine and remove dust cap. Key ON.0000101 –19–15JAN02–1/2 CTM331 (09APR02) 04-160-14 4. .0000101 –19–15JAN02–2/2 Blinking DTCs On OEM applications that have a Fault Lamp.. 6. Hold Override Shutdown Switch for a few seconds 3.8 L Level 12 Electronic Fuel System 040902 PN=175 .. The CAN light on the MagiKey should illuminate red when the connection to the ECU is made. If there is more than one active DTC. the ECU has the ability to display DTCs using blinking sequence of the fault lamp. To retrieve DTCs from the ECU using the “blink code” method: 5. Replace the dust cap on the diagnostic connector. Following the active codes. if an engine had an active DTC 18 and stored DTC 53. flash three times.short pause three times..short pause two times. the ECU will flash each code in numerical order. the Fault Lamp will flash a code 88. 4... the above sequence will be repeated.ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR DIAGNOSTIC PROCEDURE in Group 150 of this manual. When complete.. the Fault Lamp will flash a code 88.short pause eight times. If there is more than one stored DTC.short pause.long pause three times. For example. the Fault Lamp will flash it’s 2–digit number. 8. turn ignition “OFF” As an example.long pause five times.long pause. this indicates the start of blinking active codes. see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU later in this Group. this indicates the start of blinking stored codes. If there are no stored DTCs. 2.. Start the diagnostic software and select the appropriate application.. SERVICE ADVISOR is a trademark of Deere & Company RG40854. 7.. the Fault Lamp will flash a code 33. In order to convert the codes to SPN/FMI codes... Turn the ignition switch “ON”.Trouble Code Diagnostics and Tests 7.... the ECU will flash it’s 2–digit number. 9. 1. Connect to the application. This example is code 32. the ECU will flash each code in numerical order.0000102 –19–15JAN02–1/1 CTM331 (09APR02) 04-160-15 4. The ECU begins the flashing sequence by flashing a code 32... If DST or SERVICE ADVISOR™ does not connect see D1 . the flashing sequence would be: • • • • • • • • flash flash flash flash flash flash flash flash three times.5 L & 6. If there are no active DTCs. If there are any active DTCs. RG40854. If there are any stored DTCs..flash two times. The Fault Lamp will begin to flash a code number.. 10. Once complete.short pause three times 04 160 15 NOTE: The ECU blinks the codes in 2-digit codes only..long pause one time. Voltage from analog throttle (B) position sensor (potentiometer) on OEM applications ONLY.8 L Level 12 Electronic Fuel System 040902 PN=176 . a trouble code is thrown. When 100 is reached. EOL = End of Line Crank Position Sensor Speed Desired Speed Governor Curve rpm N/A a ECU Boot Block Part Number ECU Configuration File Part Number ECU EOL Data Part Number a N/Aa N/A a N/Aa N/A = Not Applicable Service ADVISOR is a trademark of Deere & Company Continued on next page RG40854. Part number for the data programmed into the ECU at the end of the assembly line. and the ECU Communication Software Kit. Switched battery voltage may vary depending on application "0" reading means that there is NO noise. The mode selected is dependent on the application. Voltage from analog throttle (C) position sensor (potentiometer).5 L & 6. Parameter Air Heater Time Remaining Analog Throttle (A) Input Voltage (OEM) 04 160 16 Analog Throttle (A) Input Voltage Analog Throttle (B) Input Voltage (OEM) Analog Throttle (B) Input Voltage Analog Throttle (C) Input Voltage Battery Voltage Crank Position Input Noise Indicator Units sec volts volts volts volts volts volts % Description Amount of time the air heater will continue to heat the air prior to starting.0000103 –19–15JAN02–1/3 CTM331 (09APR02) 04-160-16 4. Voltage from analog throttle (B) position sensor (potentiometer) on non-OEM applications. Between 0—100.Trouble Code Diagnostics and Tests Data Parameter Description Following is a list of the data parameters that can be read on the Diagnostic Scan Tool (DST) or Service ADVISOR™. the noise on the crank sensor signal becomes progressively worse. Part number for the Engine Control Unit (ECU) boot block. Part number for the configuration file in the ECU. Voltage from analog throttle (A) position sensor (potentiometer) on non-OEM applications. See APPLICATION SPECIFICATIONS in Section 06. The speed of the crank timing wheel. Voltage from analog throttle (A) position sensor (potentiometer) on OEM applications ONLY. The DST consists of a Windows (’95 or ’98) or NT compatible computer. Included in the list below is a brief description of each parameter. available from John Deere. JDIS121 ECU Communication Hardware Kit. Group 210 of this manual and refer to the corresponding desired speed governor curve for your application. and each parameter’s unit of measurement. the range of possible readings. 5 L & 6. The part number for the fuel system used on the engine. Engine Load at Current Speed Engine Model Number Engine Oil Pressure Engine Serial Number Engine Speed Fuel Mode Fuel System Part Number Fuel System Serial Number Fuel Temperature Percentage of load on the engine at a given speed. The speed that the crank sensor detects the crank timing wheel to be moving at. 04 160 17 N/Aa °C (°F) volts L (gal) °C (°F) Fuel Temperature Input Voltage Fuel Usage Rate Manifold Air Temperature NOTE: If there is an active fault for the MAT circuit. MAT will be displayed as NA a N/A = Not Applicable Continued on next page RG40854. The serial number for the fuel system used on the engine. the fuel temperature will be displayed as NA Fuel temperature sensor input voltage to the ECU. NOTE: If there is an active fault for the fuel temperature circuit. the ECT will be displayed as NA Engine Coolant Temperature Input Voltage Engine Hourmeter volts hr -minsec % N/Aa kPa (psi) N/Aa rpm N/Aa N/A a Engine Coolant Temperature sensor input voltage to the ECU Total hours the ECU has run on an engine. Manifold Air Temperature value. Total amount of fuel the ECU has commanded the pump control unit to deliver during the total hours shown by the Engine Hour Meter parameter. Engine Oil pressure value Serial number for the engine. N/Aa N/A a N/Aa °C (°F) NOTE: If there is an active fault for the ECT circuit. The model number for the engine.0000103 –19–15JAN02–2/3 CTM331 (09APR02) 04-160-17 4. Fuel temperature value. Engine Coolant Temperature value. Serial number for the Engine Control Unit (ECU).8 L Level 12 Electronic Fuel System 040902 PN=177 . This code explains the operation mode of the engine. Part number for the Engine Control Unit (ECU) operating software.Trouble Code Diagnostics and Tests Parameter ECU Part Number ECU Serial Number ECU Software Assembly Part Number ECU Software Part Number Engine Coolant Temperature Units N/A a Description Part number for the Engine Control Unit (ECU) hardware. Part number for the Engine Control Unit (ECU) software assembly. a N/A = Not Applicable RG40854. This displays the torque curve the ECU is currently using to limit maximum fuel. Oil pressure value.0000103 –19–15JAN02–3/3 CTM331 (09APR02) 04-160-18 4. the ECU limits the max fuel on multiple torque curves. Group 210 of this manual and refer to the corresponding maximum speed governor curve for your application. the oil pressure will be displayed as NA Oil Pressure Input Voltage Sensor Supply Voltage Throttle Type Throttle Position Torque Curve Number 04 160 18 volts volts N/Aa % N/Aa Oil Pressure sensor input voltage to the ECU Voltage that ECU supplies sensors on voltage supply #1 Type of throttle(s) active Percentage of throttle On some applications. Oil Pressure kPa (psi) NOTE: If there is an active fault for the oil pressure circuit. Group 210 of this manual and refer to the corresponding torque curve for your application. See APPLICATION SPECIFICATIONS in Section 06. See APPLICATION SPECIFICATIONS in Section 06. The mode selected is dependent on the application.Trouble Code Diagnostics and Tests Parameter Manifold Air Temperature Input Voltage Maximum Speed Governor Curve Units volts N/Aa Description Manifold Air Temperature sensor input voltage to the ECU.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=178 . Select the option that corresponds to the desired operation. For instructions on connecting to the DST or SERVICE ADVISOR™.5 L & 6. Select Excavator Torque Curve Change Test on the DST or SERVICE ADVISOR™. 1. Torque curve adjustment can only be accomplished with the DST or SERVICE ADVISOR™. undesired observable symptoms such as excessive black smoke can be significantly reduced or eliminated. Normal operation 2. Ignition ON. 2. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. 3. By selecting the altitude derate option.Trouble Code Diagnostics and Tests Engine Test Instructions . Altitude derate 04 160 19 SERVICE ADVISOR is a trademark of Deere & Company RG40854.8 L Level 12 Electronic Fuel System 040902 PN=179 .0000171 –19–27FEB02–1/1 CTM331 (09APR02) 04-160-19 4. Performing the Torque Curve High-altitude Adjustment 1. engine off.Excavator Torque Curve Change Test Torque curve adjustment may be necessary for excavators operating in high altitude areas. The FMI identifies the type of failure that has occurred. To find out the equ On all applications with the Level 12 Engine Control Unit (ECU). the on-board display. In this manual. The first part is called the Suspect Parameter Number (SPN). a solid light indicates that the ECU is taking extreme measures to protect the engine. In CTM 331. The second part of the code is called the Failure Mode Identifier (FMI) code. CLEARING STORED DTCS Stored DTCs can be cleared through the OEM instrument panel. it contains between 2 and 4 digits. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU in Group 160 of this manual. through the Diagnostic Scan Tool (DST) or SERVICE ADVISOR™.0000104 –19–15JAN02–1/1 CTM331 (09APR02) 04-160-20 4. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU WARNING LAMP On some applications. it is necessary to convert this format of code into an SPN/FMI code to ensure that the correct diagnostic procedure is followed. A 2-digit code may be seen on SERVICE ADVISOR™. or when the code is blinked for various reasons. such as ECU 018. When a code is active. 04 160 20 SERVICE ADVISOR is a trademark of Deere & Company RG40854. In this manual. 2-DIGIT CODES Some applications do not display engine codes as an SPN/FMI. it will be necessary to convert these codes to the SPN/FMI code in order to follow the correct diagnostic procedure. For more information on clearing DTCs using the diagnostic code reader on the instrument panel. Typically. there is a warning lamp that is used when a code becomes active. The FMI contains 2 digits. Refer to Operator’s Manual for a given application for more detailed information. Combining SPN 110 with FMI 3 yields engine coolant temperature input voltage high.8 L Level 12 Electronic Fuel System 040902 PN=180 . An example of a 2-digit code is 18 for engine coolant temperature input voltage high. for example SPN 110 indicates a failure in the engine coolant temperature circuit. there may be another format that the application is using. and the Diagnostic Gauge to display active and stored DTCs. In most of these cases. and a blinking light indicates that the ECU has detected a fault and engine performance may be affected. ECU may be displayed in front of the numbers. This may be seen on some applications within SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Diagnostic Trouble Codes (DTCs) There are several different methods of displaying both stored and active DTCs from the ECU. This allows for service tools such as the DST. for example FMI 3 indicates value above normal. If used on an application with multiple controllers. Typically. The SPN identifies the system or the component that has the failure. SPN/FMI CODES SPN/FMI codes are written from the SAE J1939 standard as a two part code. the diagnostic procedures are titled by SPN/FMI codes. OTHER CODES If codes are not displayed as SPN/FMI or as 2-digit codes. In order to determine the exact failure. SERVICE ADVISOR™. both the SPN and FMI are required. this lamp will either blink or stay on solid. see CLEARING STORED DTCS ON DIAGNOSTIC GAUGE earlier in this Group. For example on some applications.5 L & 6. the code is displayed as a 2-digit code. the code F455 is displayed for engine coolant temperature input voltage high. the ECU transmits SPN/FMI codes over the Controller Area Network (CAN). 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=181 .Trouble Code Diagnostics and Tests 04 160 21 CTM331 (09APR02) 04-160-21 4. 14 See LISTING OF THROTTLE CODES later in this Group. 29 3 See LISTING OF THROTTLE CODES later in this Group. 10 See LISTING OF THROTTLE CODES later in this Group.8 L Level 12 Electronic Fuel System 040902 PN=182 . 4 See LISTING OF THROTTLE CODES later in this Group.0000106 –19–15JAN02–1/5 CTM331 (09APR02) 04-160-22 4.Trouble Code Diagnostics and Tests Listing of Diagnostic Trouble Codes (DTCs) on ECU Ascending SPN/FMI Codes DTC’s Listing in Ascending SPN/FMI Codes SPN FMI Definition 28 3 See LISTING OF THROTTLE CODES later in this Group.5 L & 6. 13 See LISTING OF THROTTLE CODES later in this Group. 100 1 Engine Oil Pressure Extremely Low 3 Engine Oil Pressure Input Voltage High 4 Engine Oil Pressure Input Voltage Low 18 Engine Oil Pressure Moderately Low 105 3 Manifold Air Temperature Input Voltage High 4 Manifold Air Temperature Input Voltage Low 16 Manifold Air Temperature Moderately High 110 0 Engine Coolant Temperature High Most Severe 3 Engine Coolant Temperature Input Voltage High 4 Engine Coolant Temperature Input Voltage Low 15 Engine Coolant Temperature High Least Severe 16 Engine Coolant Temperature High Moderately Severe 111 0 Loss of Coolant Temperature Extremely High 3 Loss of Coolant Temperature Input Voltage High 4 Loss of Coolant Temperature Input Voltage Low 158 17 ECU Power Down Error 174 3 Fuel Temperature Input Voltage High 4 Fuel Temperature Input Voltage Low 16 Fuel Temperature Moderately High 190 0 Engine Overspeed Extreme 190 16 Engine Overspeed Moderate 620 3 Sensor Supply Voltage High 4 Sensor Supply Voltage Low 627 4 ECU Unswitched Power Missing 629 13 ECU Error 637 2 Crank Position Input Noise 10 Crank Position Input Pattern Error 639 13 CAN Error 898 9 Vehicle Speed Invalid/Missing 970 31 Auxiliary Engine Shutdown Switch Active 971 31 External Engine Derate Switch Active 1076 0 Pump Control Valve Closure Too Long 1 Pump Control Valve Closure Too Short 3 Pump Solenoid Current High 5 Pump Solenoid Circuit Open 6 Pump Solenoid Circuit Severely Shorted 04 160 22 Continued on next page RG40854. 4 See LISTING OF THROTTLE CODES later in this Group. 91 3 See LISTING OF THROTTLE CODES later in this Group. 14 See LISTING OF THROTTLE CODES later in this Group. 7 See LISTING OF THROTTLE CODES later in this Group. 4 See LISTING OF THROTTLE CODES later in this Group. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=183 .Trouble Code Diagnostics and Tests 7 10 3 4 31 31 31 6 13 Pump Control Valve Closure Not Detected Pump Solenoid Circuit Moderately Shorted Sensor Supply Voltage High Sensor Supply Voltage Low Engine Shutdown Warning Engine Shutdown Fuel Derate Internal ECU Failure Security Violation 1079 1109 1110 1569 2000 2000 Continued on next page RG40854.0000106 –19–15JAN02–2/5 04 160 23 CTM331 (09APR02) 04-160-23 4. signifies start of active fault codes. See LISTING OF THROTTLE CODES later in this Group.8 L Level 12 Electronic Fuel System 040902 PN=184 . See LISTING OF THROTTLE CODES later in this Group. signifies start of previously active fault codes. LISTING OF THROTTLE CODES later in this Group. When reading blink codes. Fuel Temperature Input Voltage High Fuel Temperature Input Voltage Low Crank Position Input Noise Crank Position Input Pattern Error Engine Overspeed Extreme Engine Overspeed Moderate ECU Power Down Error CAN Error Engine Coolant Temperature High Least Severe Engine Coolant Temperature High Moderately Severe Engine Oil Pressure Moderately Low Engine Oil Pressure Extremely Low Manifold Air Temperature Moderately High Fuel Derate Engine Coolant Temperature High Most Severe Pump Control Valve Closure Too Long Pump Control Valve Closure Too Short Pump Solenoid Circuit Open Pump Solenoid Circuit Severely Shorted Pump Control Valve Closure Not Detected Pump Solenoid Circuit Moderately Shorted Pump Solenoid Current High Security Violation Internal ECU Error Fuel Temperature Moderately High Engine Protection Shutdown Auxilary Engine Shutdown Switch Active ECU Power Down Error External Engine Derate Switch Active 04 160 24 Continued on next page RG40854. Engine Coolant Temperature Input Voltage High Engine Coolant Temperature Input Voltage Low Sensor Supply Voltage High Sensor Supply Voltage High Sensor Supply Voltage Low Sensor Supply Voltage Low Engine Oil Pressure Input Voltage High Engine Oil Pressure Input Voltage Low Manifold Air Temperature Input Voltage High Manifold Air Temperature Input Voltage Low ECU Error When reading blink codes. See LISTING OF THROTTLE CODES later in this Group.5 L & 6. See LISTING OF THROTTLE CODES later in this Group.0000106 –19–15JAN02–3/5 CTM331 (09APR02) 04-160-24 4.Trouble Code Diagnostics and Tests Ascending 2-Digit/Other Codes DTC’s Listing in Ascending 2-Digit Codes 2-Digit/Other SPN FMI Code 11 12 13 14 15 16 18 110 3 19 110 4 21 620 3 1079 3 22 620 4 1079 4 23 100 3 24 100 4 25 105 3 26 105 4 28 629 13 32 N/Aa N/Aa 33 N/Aa N/Aa 37 174 3 38 174 4 39 637 2 10 42 190 0 16 54 158 17 55 639 13 62 110 15 63 110 16 64 100 18 65 100 1 66 105 16 68 1569 31 69 110 0 71 1076 0 72 1076 1 73 1076 5 74 1076 6 75 1076 7 76 1076 10 77 1076 3 78 200 13 79 2000 6 81 174 16 82 1110 31 83 970 31 84 158 17 971 31 a N/A = Not Applicable Definition See LISTING OF THROTTLE CODES later in this Group. Skidders ONLY .0000106 –19–15JAN02–4/5 CTM331 (09APR02) 04-160-25 4. signifies that no fault codes are in buffer.Pump Solenoid Circuit Moderately Shorted Fuel Temperature Input Voltage Low Fuel Temperature Moderately High Fuel Temperature Input Voltage High Skidders ONLY .Fuel Temperature Input Voltage Low Fuel Temperature Moderately High See LISTING OF THROTTLE CODES later in this Group. Sensor Supply Voltage High See LISTING OF THROTTLE CODES later in this Group.Engine Oil Pressure Input Voltage High Engine Oil Pressure Input Voltage Low Manifold Air Temperature Input Voltage High Manifold Air Temperature Input Voltage Low Manifold Air Temperatrue Moderately High Engine Coolant Temperature High Most Severe See LISTING OF THROTTLE CODES later in this Group.Fuel Derate 620 100 620 100 100 105 105 105 110 110 4 1 3 3 4 3 4 16 0 3 04 160 25 620 629 637 637 100 639 F445 100 F446 100 F450 110 F455 110 F457 110 F459 1076 F460 105 1076 F461 1076 F462 1076 F463 1076 F464 1076 F465 105 1076 F470 174 F474 174 F475 174 1569 a N/A = Not Applicable Continued on next page RG40854.CAN Error Engine Oil Pressure Input Voltage High Engine Oil Pressure Extremely Low Engine Coolant Temperature Input Voltage Low Engine Coolant Temperature Input Voltage High Engine Coolant Temperature High Most Severe Pump Control Valve Closure Too Long Manifold Air Temperature Input Voltage Low Skidders ONLY . See LISTING OF THROTTLE CODES later in this Group. Skidders ONLY . See LISTING OF THROTTLE CODES later in this Group. Sensor Supply Voltage Low ECU Error Crank Position Input Noise Crank Position Improper Pattern Engine Oil Pressure Input Voltage Low Skidders ONLY . See LISTING OF THROTTLE CODES later in this Group.Engine Coolant Temperature Input Voltage Low Engine Coolant Temperature High Moderately Severe See LISTING OF THROTTLE CODES later in this Group. Skidders ONLY . LISTING OF THROTTLE CODES later in this Group.Pump Control Valve Closure Too Short Pump Solenoid Current High Pump Solenoid Circuit Open Pump Solenoid Circuit Severely Shorted Pump Control Valve Closure Not Detected Manifold Air Temperature Input Voltage High Skidders ONLY . Sensor Supply Voltage Low Engine Oil Pressure Extremely Low Sensor Supply Voltage High Skidders ONLY . See LISTING OF THROTTLE CODES later in this Group.Engine Coolant Temperature Input Voltage High See LISTING OF THROTTLE CODES later in this Group. See LISTING OF THROTTLE CODES later in this Group.ECU Power Down Error Fuel Temperature Input Voltage High See LISTING OF THROTTLE CODES later in this Group.5 L & 6.Trouble Code Diagnostics and Tests 88 F400 F401 F402 F403 F404 F405 F411 F413 F414 F415 F416 F417 F418 F419 F420 F421 F422 F423 F424 F425 F426 F428 F429 F42A F430 F432 F436 F439 F440 110 110 158 174 174 174 620 4 16 17 3 4 16 3 4 13 2 10 4 13 3 1 4 3 0 0 4 1 3 5 6 7 3 10 4 16 3 31 N/Aa N/Aa When reading blink codes. Skidders ONLY .8 L Level 12 Electronic Fuel System 040902 PN=185 . 8 L Level 12 Electronic Fuel System 040902 PN=186 .5 L & 6.Trouble Code Diagnostics and Tests F476 F477 F48A F48B F490 F491 F492 F493 F494 F495 F49A F4A0 F4A5 F4A7 F4E0 F4E3 F4EA F4ED 04 160 26 RG40854.0000106 –19–15JAN02–5/5 2000 2000 637 637 1076 1076 1076 1076 1076 1076 1076 111 111 111 2000 629 158 2000 6 13 10 2 6 1 3 7 0 5 10 4 3 0 6 13 17 13 Internal ECU Failure Security Violation Crank Position Input Pattern Error Crank Position Input Noise Pump Solenoid Circuit Severely Shorted Pump Control Valve Closure Too Short Pump Solenoid Current High Pump Control Valve Closure Not Detected Pump Control Valve Closure Too Long Pump Solenoid Circuit Open Pump Solenoid Circuit Moderately Shorted Loss of Coolant Temperature Input Voltage Low Loss of Coolant Temperature Input Voltage High Loss of Coolant Temperature Extremely High Internal ECU Failure ECU Error ECU Power Down Error Security Violation CTM331 (09APR02) 04-160-26 4. Trouble Code Diagnostics and Tests Diagnostic Procedure Diagnosis of the electronic control system should be performed according to the following procedure: 1. go to the chart corresponding to the lowest number DTC and diagnose that problem to correction unless directed to do otherwise. NOTE: After using the DST or SERVICE ADVISOR™.8 L Level 12 Electronic Fuel System 040902 PN=187 . These adapters will ensure that terminal damage does not occur. If an SPN/FMI code is not used. 2. Probes should not be poked into or around the terminals or damage will result. Go to the diagnostic procedure that corresponds to the DTC(s) present.0000105 –19–15JAN02–1/1 CTM331 (09APR02) 04-160-27 4. 5. 3. and actuators. always replace the dust cap on the diagnostic connector. 04 160 27 SERVICE ADVISOR is a trademark of Deere & Company RG40854.5 L & 6. NOTE: If more than one DTC is present. Make sure all engine mechanical and other systems not related to the electronic control system are operating properly. Read and record DTC(s). If no DTC(s) are present. sensors. and actuators. convert the code to SPN/FMI. After any repairs are made. recheck to make sure all DTCs have been eliminated. sensors. IMPORTANT: Care should be used during diagnostic procedures to avoid damaging the terminals of connectors. Probes should only be touched against the terminals to make measurements. 4. proceed to the appropriate symptom diagnostic chart in Group 150 of this Section. It is recommended that JT07328 Connector Adapter Test Kit be used to make measurements in connectors. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU earlier in this Group. • To check the connection between the harness and a sensor or the harness and the ECU. and wire-to-wire shorts. Check for loose. as it SERVICE ADVISOR is a trademark of Deere & Company RG40854. This function permits the recording of data parameter values during a diagnostic session. When diagnosing intermittent faults. If a DTC sets during a certain diagnostic session. • If a faulty connection or wire is suspected to be the cause of the intermittent problem: clear DTCs. rubbing against sharp sheet metal edges). includes a function called Recording. A problem such as a loose terminal that intermittently doesn’t make contact is a likely cause of an intermittent fault. Possible Causes of Intermittent Faults: • Faulty connection between sensor or actuator and harness. Inspect the wiring routing looking for possible shorts caused by contact with external parts (for example. • Faulty contact between terminals in connector. or disconnected connectors. etc.5 L & 6. etc.Trouble Code Diagnostics and Tests Intermittent Fault Diagnostics Intermittent faults are problems that periodically “go away”. poorly positioned terminals.0000107 –19–15JAN02–1/1 CTM331 (09APR02) 04-160-28 4. and corroded or damaged terminals. 04 160 28 NOTE: The ECU is the component LEAST likely to fail. damaged connectors. Other intermittent faults may be set only under certain operating conditions such as heavy load. • Faulty terminal/wire connection. dirty. Inspect the connector vicinity looking for wires that have pulled out of connector terminals. Insert the male end of the appropriate test adapter into the female end of the ECU or sensor connector terminal. replace the female terminal. There should be moderate resistance when the test adapter is inserted into the terminal. can cause faulty signals to be sent to the ECU. Look for broken wires. the parameters can be played back and observed to see what each parameters’ value was when the DTC occurred. Use good judgement if component replacement is thought to be required. try to reproduce the operating conditions that were present when the DTC set. use JT07328 Connector Adapter Test Kit. then check the connection or wire by wiggling it while watching the DST or SERVICE ADVISOR™ to see if the fault resets. • Electromagnetic interference (EMI) from an improperly installed 2-way radio. take special note of the condition of wiring and connectors since a high percentage of intermittent problems originate here. The Diagnostic Scan Tool (DST) or SERVICE ADVISOR™ can be used to help locate intermittent problems. If the connection is loose. Suggestions for diagnosing intermittent faults: • If diagnostic chart indicates that the problem is intermittent. extended idle. damaged splices.8 L Level 12 Electronic Fuel System 040902 PN=188 . Throttle 1 7 .Analog Throttle (A) Input Voltage Out of Range T3 .Analog Throttle (A) Input Voltage Out of Range T1 .Throttle 1 4 .Throttle 1 4 .Throttle Input Voltage Below Lower Calibration Limit T21 .Throttle 1 91 .Throttle 2 14 .Analog Throttle (A) Input Low T22 .Multi-state Throttle Input High T2 .Throttle 1 10 . identify the application and the DTC.Throttle 1 RG40854.Multi-state Throttle Input Low T23 .Throttle 2 4 . and proceed to the page that the table below lists.Analog Throttle (A) Input High T4 .Throttle 1 3 . a SPN-FMI might refer to a different diagnostic procedure than another application.Analog Throttle (A) Input Low Tele-handlers 91 .Throttle Not Calibrated Properly T20 .8 L Level 12 Electronic Fuel System 040902 PN=189 .Throttle 1 91 .Throttle 1 91 91 91 91 91 91 28 28 29 29 91 91 29 29 91 91 28 29 29 91 91 91 91 91 29 29 29 3 . Application Backhoes 2-Digit/Other Code F425 F420 F42A F425 F420 F428 F421 F423 F42A 13 14 15 16 11 12 15 16 11 12 13 15 16 11 12 F403 F404 F405 F400 F401 F402 11 12 SPN-FMI Code 91 .Analog Throttle (A) Input Low T22 .Analog Throttle (A) Input Low T19 .Throttle 1 13 .4 . To get to the correct procedure.Analog Throttle (A) Input High T4 .3 .Throttle 1 14 .14 .0000108 –19–15JAN02–1/1 CTM331 (09APR02) 04-160-29 4.5 L & 6.4 .Trouble Code Diagnostics and Tests Listing of Throttle Codes NOTE: For each different application.Throttle 2 T3 .Throttle Calibration Aborted T22 .3 .Throttle 1 3 4 3 4 3 4 3 4 3 4 3 3 4 3 4 Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle 1 1 1 1 1 1 2 2 1 1 3 2 2 1 1 Go to page that reads: T3 .Analog Throttle (A) Input High T4 .Throttle 1 91 .Analog Throttle (A) Input Voltage Out of Range T11 T12 T13 T14 T15 T16 T5 T6 T3 T4 T5 T3 T4 T1 T2 Excavator Excavator Excavator Excavator Excavator Excavator Throttle Throttle Throttle Throttle Throttle Throttle (B) (B) (A) (A) Reference Voltage High Reference Voltage Low Ground Voltage High Ground Voltage Low Signal Voltage High Signal Voltage Low Input Input Input Input High Low High Low Crawlers 04 160 29 Excavators Forwarders Analog Analog Analog Analog Throttle Throttle Throttle Throttle OEM Analog Throttle (B) Input High Analog Throttle (A) Input High Analog Throttle (A) Input Low Multi-state Throttle Input High Multi-state Throttle Input Low Skidders 3 .Analog Throttle (A) Input High T4 .Throttle 1 14 .Multi-state Throttle Input Voltage Out of Range T3 . the following will occur: • If more than one throttle is available. the multi-state throttle will be in total control. • On certain applications. When the desired engine speed of the multi-state throttle is greater than the additional throttle. If this code sets. On some applications. If the desired engine speed of the additional throttle is greater than the multi-state throttle. the multi-state throttle will be overridden. This allows for high and low idle to be controlled. • If the multi-state throttle is the only throttle or all additional throttles are also faulted.00000A2 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-30 4.Multi-state Throttle Input High Instrument Panel Connector A1 A2 A3 X J B G W K L C A F V U T S H B1 B2 B3 C1 C2 C3 S Sensor Ground D3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S M D E N P R R High/Low Idle Input C1 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 S R 04 160 30 C O N N E C T O R High Idle Low Idle A B A B Idle Switch Connector Low Idle High Idle Idle Switch JOHN DEERE Instrument Panel Multi-state Throttle Switch • Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle.T1 . the ECU will use a default “limp-home” throttle value that will only allow idle engine speed. and will use the input values from another throttle. This code will set if: • The multi-state throttle input voltage exceeds the maximum threshold.5 L & 6. –19–14DEC01 RG40854. The voltage is higher than what is physically possible for the throttle lever to achieve.Trouble Code Diagnostics and Tests Level 12 ECU . there is a bump up and a bump down feature. an additional throttle is used in addition to the multi-state throttle. the ECU will ignore the input from the multi-state throttle.8 L Level 12 Electronic Fuel System 040902 PN=190 RG11976 . or poorly positioned terminals. Move the multi-state switch through all the positions. If no other codes are present. 6.T1 . Look for dirty. Read DTCs using the DST or SERVICE ADVISOR™ 5.00000A1 –19–07DEC01–1/1 Level 12 ECU .Multi-state Throttle Input High .Multi-State Throttle Input High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.8 L Level 12 Electronic Fuel System 040902 PN=191 . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. This will ensure that terminal damage does not occur.Trouble Code Diagnostics and Tests Level 12 ECU . engine OFF 7. Read DTCs using the DST or SERVICE ADVISOR™.Continued RG40854. Perform a preliminary inspection of the ECU connector and the multi-state throttle connector. Make note of any DTCs. then clear all DTCs. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. engine OFF 3.5 L & 6. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Start the ECU communication software 4.MULTI-STATE THROTTLE INPUT HIGH supporting information. For instructions on connecting to the DST or SERVICE ADVISOR™.MULTI-STATE THROTTLE INPUT HIGH supporting information.T1 . SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-31 4. 1. 04 160 31 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. see T1 . 8. Ignition ON. NOTE: Skidder applications use a different SPN for multi-state throttle than other applications. Connect the DST or SERVICE ADVISOR™. 2. Ignition ON. SPN 91 FMI 3 (Skidders: SPN 29 FMI 3) reoccurs: GO TO 3 SPN 91 FMI 3 (Skidders: SPN 29 FMI 3) does not reoccur: Problem is intermittent. see T1 . damaged. Ignition ON. engine OFF 7.MULTI-STATE THROTTLE INPUT HIGH supporting information. Ignition OFF 2. SPN 91 FMI 3 (Skidders: SPN 29 FMI 3) reoccurs: GO TO 4 SPN 91 FMI 4 (Skidders: SPN 29 FMI 3) occurs: Faulty multi-state throttle switch connector OR Faulty multi-state throttle switch NOTE: Skidder applications use a different SPN for multi-state throttle than other applications. measure voltage between multi-state switch 5 V input terminal and a good chassis ground. Ignition ON.0 V: Open in multi-state switch ground circuit OR Faulty ECU connection OR Faulty ECU Below 4. 3.MULTI-STATE THROTTLE INPUT HIGH supporting information.0 V: Open in multi-state switch 5 V input circuit OR Faulty ECU connection OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-32 4. Ignition OFF 2.8 L Level 12 Electronic Fuel System 040902 PN=192 . engine OFF 4. Between 4.0 V and 6. 04 160 32 – – –1/1 4 Throttle Position Ground Circuit Open Test NOTE: For wiring and theory of operation. 1. Install a jumper wire between both terminals of the switch harness connector. Read DTCs using the DST or SERVICE ADVISOR. see T1 . then clear all DTCs 6. 4. 1. Disconnect multi-state throttle switch at two wire connector behind instrument panel. Read DTCs using the DST or SERVICE ADVISOR 5. Make note of any DTCs. 3.5 L & 6. see T1 . Using a multimeter. Remove jumper wire.Trouble Code Diagnostics and Tests 3 Throttle Position Input Shorted Test NOTE: For wiring and theory of operation. Trouble Code Diagnostics and Tests 04 160 33 CTM331 (09APR02) 04-160-33 4.8 L Level 12 Electronic Fuel System 040902 PN=193 .5 L & 6. the following will occur: • If more than one throttle is available. If the desired engine speed of the additional throttle is greater than the multi-state throttle. the ECU will ignore the input from the multi-state throttle. the ECU will use a default “limp-home” throttle value that will only allow idle engine speed. –19–14DEC01 RG40854. This code will set if: • The multi-state throttle input voltage drops below the minimum threshold. and will use the input values from another throttle.8 L Level 12 Electronic Fuel System 040902 PN=194 RG11976 . If this code sets. the multi-state throttle will be overridden. The voltage is lower than what is physically possible for the throttle lever to achieve.Multi-state Throttle Input Low Instrument Panel Connector A1 A2 A3 X J B G W K L C A F V U T S H B1 B2 B3 C1 C2 C3 S Sensor Ground D3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S M D E N P R R High/Low Idle Input C1 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 S R 04 160 34 C O N N E C T O R High Idle Low Idle A B A B Idle Switch Connector Low Idle High Idle Idle Switch JOHN DEERE Instrument Panel Multi-state Throttle Switch • Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. an additional throttle is used in addition to the multi-state throttle. • If the multi-state throttle is the only throttle or all additional throttles are also faulted.Trouble Code Diagnostics and Tests Level 12 ECU . When the desired engine speed of the multi-state throttle is greater than the additional throttle. the multi-state throttle will be in total control.5 L & 6. On some applications. there is a bump up and a bump down feature.T2 . • On certain applications. This allows for high and low idle to be controlled.00000A0 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-34 4. Connect the DST or SERVICE ADVISOR™. Perform a preliminary inspection of the ECU connector and the multi-state throttle connector. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-35 4. Read DTCs using the DST or SERVICE ADVISOR™ 5. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. NOTE: Skidder applications use a different SPN for multi-state throttle than other applications. see T2 .T2 . Start the ECU communication software 4. 04 160 35 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. engine OFF 7. For instructions on connecting to the DST or SERVICE ADVISOR™. engine OFF 3. Read DTCs using DST or SERVICE ADVISOR™.5 L & 6. 2. If no other codes are present. see T2 . damaged. Move the multi-state switch through all the positions.MULTI-STATE THROTTLE INPUT LOW supporting information. 1. or poorly positioned terminals. Make note of any DTCs. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.MULTI-STATE THROTTLE INPUT LOW supporting information.T2 . 8. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. SPN 91 FMI 4 (Skidders: SPN 29 FMI 4) reoccurs: GO TO 3 SPN 91 FMI 4 (Skidders: SPN 29 FMI 4) does not reoccur: Problem is intermittent.Multi-State Throttle Input Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Ignition ON.Continued RG40854.8 L Level 12 Electronic Fuel System 040902 PN=195 .Trouble Code Diagnostics and Tests Level 12 ECU . then clear all DTCs. This will ensure that terminal damage does not occur.Multi-state Throttle Input Low .00000A3 –19–11DEC01–1/1 Level 12 ECU . Look for dirty. 6. Ignition ON. Trouble Code Diagnostics and Tests 3 Throttle Position Wiring Test NOTE: For wiring and theory of operation. Read DTCs using the DST or SERVICE ADVISOR. SPN 91 FMI 4 (Skidders: SPN 29 FMI 4) reoccurs: Short to ground in multi-state input circuit OR Open in multi-state input circuit OR Faulty ECU SPN 91 FMI 3 (Skidders: SPN 29 FMI 3) occurs: Faulty multi-state throttle switch connector OR Faulty multi-state throttle switch. 1. Disconnect multi-state throttle switch at two wire connector behind instrument panel. engine OFF 6.MULTI-STATE THROTTLE INPUT LOW supporting information. then clear all DTCs 5. 04 160 36 – – –1/1 CTM331 (09APR02) 04-160-36 4. Ignition OFF 2.5 L & 6. NOTE: Skidder applications use a different SPN for multi-state throttle than other applications.8 L Level 12 Electronic Fuel System 040902 PN=196 . Ignition ON. see T2 . 3. Make note of any DTCs. Read DTCs using the DST or SERVICE ADVISOR. 4. 5 L & 6.Trouble Code Diagnostics and Tests 04 160 37 CTM331 (09APR02) 04-160-37 4.8 L Level 12 Electronic Fuel System 040902 PN=197 . and will use the input values from another throttle.5 L & 6.0 volt and 4.Analog Throttle (A) Input High Instrument Panel Connector A1 A2 A3 J K L M N C H X B G W A F V E S U T R B1 B2 B3 C1 C2 C3 C L Sensor Return Sensor Input D3 E1 E2 D1 D2 D3 E1 E2 E3 E C U H A R N E S S D P M Sensor 5V F1 F2 F3 G1 G2 G3 H1 H2 H3 CLM 04 160 38 J1 J2 J3 K1 K2 K3 C O N N E C T O R Analog Throttle (A) Sensor Connector –19–14DEC01 Analog Throttle (A) Sensor A B C A B C JOHN DEERE Instrument Panel NOTE: Wiring schematic shows OEM engine applications only. the following will occur: • If more than one throttle is available.8 L Level 12 Electronic Fuel System 040902 PN=198 RG11974 . • If the analog throttle is the only throttle or all additional throttles are also faulted. – For OEM applications. The voltage is higher than what is physically possible for the throttle lever to achieve. This code will set if: • The analog throttle (A) input voltage exceeds the sensor’s high voltage specification. the ECU will ignore the input from the analog throttle. If this code sets.0 and 4.0 volts depending on throttle position.000009E –19–07DEC01–1/1 CTM331 (09APR02) 04-160-38 4. RG40854. Group 210 of this manual for the high analog throttle (A) input voltage specification. Analog throttle voltage at low idle will be approximately 1.Trouble Code Diagnostics and Tests Level 12 ECU . For non-OEM engine wiring information. see APPLICATION SPECIFICATIONS in Section 06. – For non-OEM applications.0 volts at high idle. Group 210 of this manual. Analog Throttle Position Sensor • The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle.7 volts. the ECU will use a default “limp-home” throttle value that will only allow idle engine speed. the high analog throttle (A) input voltage specification is 4. The ECU has the ability to learn different voltages for low and high idle. see APPLICATION SPECIFICATIONS in Section 06.T3 . The throttle input voltage normally varies between 1. so the voltage range may change per application. Connect the DST or SERVICE ADVISOR™. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-39 4. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. For the high voltage specification on non-OEM applications. 04 160 39 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. the high analog throttle (A) input voltage specification is 4. This will ensure that terminal damage does not occur.ANALOG THROTTLE (A) INPUT HIGH supporting information. No faulty connection(s): GO TO 2 Faulty connection: Repair faulty connection(s) NOTE: For wiring and theory of operation.Continued RG40854. Using the DST or SERVICE ADVISOR™: • For OEM applications. Ignition ON.00000A4 –19–11DEC01–1/1 Level 12 ECU . 2. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Analog Throttle (A) in the idle position.8 L Level 12 Electronic Fuel System 040902 PN=199 . and any connectors in between them. damaged.7V.5 L & 6. Start the ECU communication software 4.T3 . see T3 . Perform a preliminary inspection of the ECU connector.7 V or greater: GO TO 4 Below 4. engine OFF 3. read Analog Throttle (A) Input Voltage 4. or poorly positioned terminals. Group 210 of this manual. 5. see T3 .Analog Throttle (A) Input High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. read Analog Throttle (A) Input Voltage (OEM) • For non-OEM applications.Analog Throttle (A) Input High . 1.ANALOG THROTTLE (A) INPUT HIGH supporting information. see APPLICATION SPECIFICATIONS in Section 06. For instructions on connecting to the DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU .7 V: GO TO 3 NOTE: For OEM applications. Look for dirty.T3 . the analog (A) throttle connector. use the DST or SERVICE ADVISOR for the following: • For OEM applications. Group 210 of this manual.3V. the high analog throttle (A) input voltage specification is 4.ANALOG THROTTLE (A) INPUT HIGH supporting information. 3. read Analog Throttle (A) Input Voltage (OEM) • For non-OEM applications. read Analog Throttle (A) Input Voltage (OEM) • For non-OEM applications. Using a test light connected to battery (+). 1. Using the DST or SERVICE ADVISOR™: • For OEM applications.7 V: Faulty analog throttle (A) sensor connector OR Open in analog throttle (A) sensor ground circuit OR Faulty analog throttle (A) sensor Never goes above 4. 1. read Analog Throttle (A) Input Voltage Goes above 4. the low analog throttle (A) input voltage specification is 0. probe the ground terminal in throttle (A) sensor harness connector. Ignition ON. Ignition OFF 2.3 V: Short to voltage in analog throttle (A) input circuit OR Faulty ECU NOTE: For OEM applications. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group NOTE: For OEM applications.7V. Group 210 of this manual. Ignition OFF 2. Engine OFF 4. read Analog Throttle (A) Input Voltage 0.ANALOG THROTTLE (A) INPUT HIGH supporting information. If no other codes are present. see T3 .8 L Level 12 Electronic Fuel System 040902 PN=200 . For the high voltage specification on non-OEM applications.3 V or less: GO TO 5 Above 0. see T3 . Analog throttle (A) sensor connector still disconnected. 04 160 40 – – –1/1 4 Throttle Position Input Shorted Test NOTE: For wiring and theory of operation. Disconnect analog throttle (A) sensor connector behind instrument panel. see T3 . see APPLICATION SPECIFICATIONS in Section 06. see APPLICATION SPECIFICATIONS in Section 06.ANALOG THROTTLE (A) INPUT HIGH supporting information.5 L & 6. 3. While slowly operating analog throttle (A) through its full travel.7 V: Problem is intermittent. Light ON: Faulty analog throttle (A) sensor connector OR Faulty analog throttle (A) sensor Light OFF: Open in analog throttle (A) ground circuit – – –1/1 CTM331 (09APR02) 04-160-40 4. For the low voltage specification on non-OEM applications. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 5 Throttle Position Ground Circuit Open Test NOTE: For wiring and theory of operation.Trouble Code Diagnostics and Tests 3 Throttle Travel Voltage Test NOTE: For wiring and theory of operation. 8 L Level 12 Electronic Fuel System 040902 PN=201 .Trouble Code Diagnostics and Tests 04 160 41 CTM331 (09APR02) 04-160-41 4.5 L & 6. the following will occur: • If more than one throttle is available.Analog Throttle (A) Input Low Instrument Panel Connector A1 A2 A3 J K L M N C H X B G W A F V E S U T R B1 B2 B3 C1 C2 C3 C L Sensor Return Sensor Input D3 E1 E2 D1 D2 D3 E1 E2 E3 E C U H A R N E S S D P M Sensor 5V F1 F2 F3 G1 G2 G3 H1 H2 H3 CLM 04 160 42 J1 J2 J3 K1 K2 K3 C O N N E C T O R Analog Throttle (A) Sensor Connector –19–14DEC01 Analog Throttle (A) Sensor A B C A B C JOHN DEERE Instrument Panel NOTE: Wiring schematic shows OEM engine applications only. so the voltage range may change per application. see APPLICATION SPECIFICATIONS in Section 06. This code will set if: • The analog throttle (A) input voltage goes below the sensor’s low voltage specification. Analog throttle voltage at low idle will be approximately 1.0 and 4. the low analog throttle (A) input voltage specification is 0. Group 210 of this manual.000009C –19–07DEC01–1/1 CTM331 (09APR02) 04-160-42 4. For non-OEM engine wiring information. and will use the input values from another throttle.8 L Level 12 Electronic Fuel System 040902 PN=202 RG11974 . see APPLICATION SPECIFICATIONS in Section 06.T4 .5 L & 6.Trouble Code Diagnostics and Tests Level 12 ECU . If this code sets. The throttle input voltage normally varies between 1. Analog Throttle Position Sensor • The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle. – For OEM applications. RG40854.0 volts depending on throttle position.0 volt and 4. • If the analog throttle is the only throttle or all additional throttles are also faulted. the ECU will ignore the input from the analog throttle. The voltage is lower than what is physically possible for the throttle lever to achieve. – For non-OEM applications.0 volts at high idle. Group 210 of this manual for the low analog throttle (A) input voltage specification. The ECU has the ability to learn different voltages for low and high idle. the ECU will use a default “limp-home” throttle value that will only allow idle engine speed.3 volts. Throttle (A) in the idle position. read Analog Throttle (A) Input Voltage 0. Using the DST or SERVICE ADVISOR™: • For OEM applications. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-43 4. and any connectors in between them.3 V: GO TO 3 NOTE: For OEM applications. For the low voltage specification on non-OEM applications. 2. 04 160 43 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. see T4 . or poorly positioned terminals. No faulty connection(s): GO TO 2 Faulty connection: Repair faulty connection.Trouble Code Diagnostics and Tests Level 12 ECU . damaged.00000A5 –19–13DEC01–1/1 Level 12 ECU .3V. read Analog Throttle (A) Input Voltage (OEM) • For non-OEM applications. 5. Perform a preliminary inspection of the ECU connector.T4 . NOTE: For wiring and theory of operation.8 L Level 12 Electronic Fuel System 040902 PN=203 .Analog Throttle (A) Input Low . 1. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.Continued RG40854. the low analog throttle (A) input voltage specification is 0. engine OFF 3. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.T4 . Connect the DST or SERVICE ADVISOR™. Ignition ON.3 V or less: GO TO 4 Above 0. Group 210 of this manual. see T4 . the analog (A) throttle connector.5 L & 6. This will ensure that terminal damage does not occur. Look for dirty. see APPLICATION SPECIFICATIONS in Section 06.Analog Throttle (A) Input Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.ANALOG THROTTLE (A) INPUT LOW supporting information.ANALOG THROTTLE (A) INPUT LOW supporting information. Start the ECU communication software 4. For instructions on connecting to the DST or SERVICE ADVISOR™. 1.ANALOG THROTTLE (A) INPUT LOW supporting information. Disconnect analog throttle (A) sensor connector. the high analog throttle (A) input voltage specification is 4. Ignition OFF 2.3V. For the low voltage specification on non-OEM applications. While slowly operating analog throttle (A) through its full travel.3 V: Problem is intermittent.3 V: Faulty analog throttle (A) sensor connector OR Open in analog throttle (A) sensor ground circuit OR Faulty analog throttle (A) sensor Never goes above 0. read Analog Throttle (A) Input Voltage (OEM) • For non-OEM applications. 4. read Analog Throttle (A) Input Voltage Below 4. For the high voltage specification on non-OEM applications.Trouble Code Diagnostics and Tests 3 Throttle Travel Voltage Test NOTE: For wiring and theory of operation. Group 210 of this manual. Group 210 of this manual. see T4 . – – –1/1 CTM331 (09APR02) 04-160-44 4. If no other codes are present. Using the DST or SERVICE ADVISOR: • For OEM applications.7 V or greater: Faulty analog throttle (A) sensor connector OR Faulty analog throttle (A) sensor NOTE: For OEM applications. the low analog throttle (A) input voltage specification is 0. 3.5 L & 6. see APPLICATION SPECIFICATIONS in Section 06. 04 160 44 – – –1/1 4 Throttle Position Wiring Test NOTE: For wiring and theory of operation. read Analog Throttle (A) Input Voltage Goes below 0. Install a jumper wire between the 5 V Supply terminal and the input terminal in the harness side of the sensor connector.7V. see APPLICATION SPECIFICATIONS in Section 06. engine OFF 5.8 L Level 12 Electronic Fuel System 040902 PN=204 . see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group NOTE: For OEM applications. read Analog Throttle (A) Input Voltage (OEM) • For non-OEM applications. Ignition ON. see T4 .ANALOG THROTTLE (A) INPUT LOW supporting information.7 V: GO TO 5 4. use the DST or SERVICE ADVISOR for the following: • For OEM applications. 1.0 V: Open in analog throttle (A) input circuit OR Short to ground in analog throttle (A) input circuit OR Faulty ECU connector OR Faulty ECU Below 4.5 L & 6.ANALOG THROTTLE (A) INPUT LOW supporting information. Between 4. engine OFF 4. Ignition OFF 2.Trouble Code Diagnostics and Tests 5 Throttle Position 5V Supply Test NOTE: For wiring and theory of operation. Remove jumper wire. see T4 . Ignition ON.8 L Level 12 Electronic Fuel System 040902 PN=205 . Using a multimeter.0 V and 6. 3.0 V: Open in analog throttle (A) 5 V Supply circuit OR Short to ground in analog throttle (A) 5 V Supply circuit 04 OR 160 Faulty ECU connector 45 OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-45 4. measure the voltage between the analog throttle (A) ground terminal and the 5 V Supply terminal in the sensor harness connector. Group 210 of this manual for the high analog throttle (B) input voltage specification. so the voltage range may change per application.0 and 4. Analog throttle voltage at low idle will be approximately 1. see APPLICATION SPECIFICATIONS in Section 06.5 L & 6. the ECU will use a default “limp-home” throttle value that will only allow idle engine speed. If this code sets.0 volts depending on throttle position.T5 . The ECU has the ability to learn different voltages for low and high idle. Group 210 of this manual. This code will set if: • The analog throttle (B) input voltage exceeds the sensor’s high voltage specification.7 volts.0 volts at high idle. see APPLICATION SPECIFICATIONS in Section 06. The throttle input voltage normally varies between 1. Analog Throttle Position Sensor • The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle.8 L Level 12 Electronic Fuel System 040902 PN=206 RG11975 –19–14DEC01 C O N N E C T O R .Analog Throttle (B) Input High Analog Throttle (B) Sensor Connector Sensor Return Analog Throttle (B) Sensor A B C A B C D3 A1 A2 A3 B1 B2 B3 Analog Throttle (B) Input F2 Sensor 5V E2 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S Throttle Emulator A B 04 160 46 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 C NOTE: Wiring schematic shows OEM engine applications only.0 volt and 4. The voltage is higher than what is physically possible for the throttle lever to achieve. – For non-OEM applications.000009A –19–07DEC01–1/1 CTM331 (09APR02) 04-160-46 4. the high analog throttle (B) input voltage specification is 4. For non-OEM engine wiring information.Trouble Code Diagnostics and Tests Level 12 ECU . RG40854. and will use the input values from another throttle. the following will occur: • If more than one throttle is available. • If the analog throttle is the only throttle or all additional throttles are also faulted. the ECU will ignore the input from the analog throttle. – For OEM applications. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=207 . 1.T5 .ANALOG THROTTLE (B) INPUT HIGH supporting information. 04 160 47 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation.T5 .7 V: GO TO 3 NOTE: For OEM applications. Connect the DST or SERVICE ADVISOR™. Using the DST or SERVICE ADVISOR™: • For OEM applications.Analog Throttle (B) Input High .7 V or greater: GO TO 4 Below 4. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. engine OFF 3. For the high voltage specification on non-OEM applications. Group 210 of this manual. and any connectors in between them.Analog Throttle (B) Input High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Ignition ON.ANALOG THROTTLE (B) INPUT HIGH supporting information.Trouble Code Diagnostics and Tests Level 12 ECU .00000A6 –19–13DEC01–1/1 Level 12 ECU . or poorly positioned terminals. see T5 . read Analog Throttle (B) Input Voltage 4. the analog (B) throttle connector. 2. the high analog throttle (B) input voltage specification is 4. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.7V. read Analog Throttle (B) Input Voltage (OEM) • For non-OEM applications. see T5 .Continued RG40854. Perform a preliminary inspection of the ECU connector. 5. damaged. Start the ECU communication software 4. Analog Throttle (B) in the idle position. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-47 4. Look for dirty. For instructions on connecting to the DST or SERVICE ADVISOR™. see APPLICATION SPECIFICATIONS in Section 06. This will ensure that terminal damage does not occur. ANALOG THROTTLE (B) INPUT HIGH supporting information.3 V: Short to voltage in analog throttle (B) input circuit OR Faulty ECU NOTE: For OEM applications. the low analog throttle (B) input voltage specification is 0.8 L Level 12 Electronic Fuel System 040902 PN=208 . Ignition OFF 2. see T5 . 04 160 48 – – –1/1 4 Throttle Position Input Shorted Test NOTE: For wiring and theory of operation. probe the ground terminal in throttle (B) sensor harness connector. see T5 .7 V: Faulty analog throttle (B) sensor connector OR Open in analog throttle (B) sensor ground circuit OR Faulty analog throttle (B) sensor Never goes above 4. If no other codes are present. read Analog Throttle (B) Input Voltage Goes above 4.7V. see T5 . use the DST or SERVICE ADVISOR for the following: • For OEM applications. Group 210 of this manual.3 V or less: GO TO 5 Above 0. Using a test light connected to battery (+). Analog throttle (B) sensor connector disconnected.3V. For the low voltage specification on non-OEM applications. Disconnect analog throttle (B) sensor connector behind instrument panel. read Analog Throttle (B) Input Voltage (OEM) • For non-OEM applications. 3. Engine OFF 4.ANALOG THROTTLE (B) INPUT HIGH supporting information. see APPLICATION SPECIFICATIONS in Section 06. read Analog Throttle (B) Input Voltage (OEM) • For non-OEM applications. While slowly operating analog throttle (B) through its full travel. 3. For the high voltage specification on non-OEM applications. Ignition ON. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group NOTE: For OEM applications. the high analog throttle (B) input voltage specification is 4.ANALOG THROTTLE (B) INPUT HIGH supporting information.Trouble Code Diagnostics and Tests 3 Throttle Travel Voltage Test NOTE: For wiring and theory of operation. 1.7 V: Problem is intermittent. see APPLICATION SPECIFICATIONS in Section 06. Using the DST or SERVICE ADVISOR: • For OEM applications. Ignition OFF 2. – – –1/1 5 Throttle Position Ground Circuit Open Test NOTE: For wiring and theory of operation. Group 210 of this manual. 1. read Analog Throttle (B) Input Voltage 0. Light ON: Faulty analog throttle (B) sensor connector OR Faulty analog throttle (B) sensor Light OFF: Open in analog throttle (B) ground circuit – – –1/1 CTM331 (09APR02) 04-160-48 4.5 L & 6. 8 L Level 12 Electronic Fuel System 040902 PN=209 .5 L & 6.Trouble Code Diagnostics and Tests 04 160 49 CTM331 (09APR02) 04-160-49 4. For non-OEM engine wiring information.5 L & 6.Analog Throttle (B) Input Low Analog Throttle (B) Sensor Connector Sensor Return Analog Throttle (B) Sensor A B C A B C D3 A1 A2 A3 B1 B2 B3 Analog Throttle (B) Input F2 Sensor 5V E2 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S Throttle Emulator A B 04 160 50 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 C NOTE: Wiring schematic shows OEM engine applications only. the ECU will use a default “limp-home” throttle value that will only allow idle engine speed. see APPLICATION SPECIFICATIONS in Section 06. This code will set if: • The analog throttle (B) input voltage goes below the sensor’s low voltage specification. see APPLICATION SPECIFICATIONS in Section 06. – For OEM applications. – For non-OEM applications.T6 . Group 210 of this manual for the low analog throttle (B) input voltage specification. The throttle input voltage normally varies between 1.0 volts at high idle. and will use the input values from another throttle.0 volts depending on throttle position. The ECU has the ability to learn different voltages for low and high idle. Analog throttle voltage at low idle will be approximately 1. the low analog throttle (B) input voltage specification is 0. Analog Throttle Position Sensor • The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle. so the voltage range may change per application.0 volt and 4.Trouble Code Diagnostics and Tests Level 12 ECU . the ECU will ignore the input from the analog throttle.3 volts. • If the analog throttle is the only throttle or all additional throttles are also faulted. RG40854. the following will occur: • If more than one throttle is available. If this code sets.8 L Level 12 Electronic Fuel System 040902 PN=210 RG11975 –19–14DEC01 C O N N E C T O R .0 and 4.0000098 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-50 4. Group 210 of this manual. The voltage is lower than what is physically possible for the throttle lever to achieve. Look for dirty.3 V or less: GO TO 4 Above 0. For instructions on connecting to the DST or SERVICE ADVISOR™. 5. see T6 .Analog Throttle (B) Input Low . read Analog Throttle (B) Input Voltage 0.T6 .Analog Throttle (B) Input Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. see T6 .00000A7 –19–13DEC01–1/1 Level 12 ECU . damaged. Group 210 of this manual. and any connectors in between them. 2. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-51 4. Ignition ON. Using the DST or SERVICE ADVISOR™: • For OEM applications.ANALOG THROTTLE (B) INPUT LOW supporting information.T6 . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation.3 V: GO TO 3 NOTE: For OEM applications. the analog (B) throttle connector.5 L & 6.ANALOG THROTTLE (B) INPUT LOW supporting information. engine OFF 3. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. For the low voltage specification on non-OEM applications.3V. Start the ECU communication software 4.8 L Level 12 Electronic Fuel System 040902 PN=211 . Perform a preliminary inspection of the ECU connector. Connect the DST or SERVICE ADVISOR™. 04 160 51 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation.Continued RG40854. Analog Throttle (B) in the idle position. This will ensure that terminal damage does not occur. see APPLICATION SPECIFICATIONS in Section 06. read Analog Throttle (B) Input Voltage (OEM) • For non-OEM applications. the low analog throttle (B) input voltage specification is 0. or poorly positioned terminals.Trouble Code Diagnostics and Tests Level 12 ECU . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. 1. Ignition ON. engine OFF 5. 3.3 V: Problem is intermittent. Install a jumper wire between the 5 V Supply terminal and the input terminal in the harness side of the sensor connector. read Analog Throttle (B) Input Voltage (OEM) • For non-OEM applications. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group 04 160 52 – – –1/1 4 Throttle Position Wiring Test NOTE: For wiring and theory of operation. see T6 . 4.3 V: Faulty analog throttle (B) sensor connector OR Open in analog throttle (B) sensor ground circuit OR Faulty analog throttle (B) sensor Never goes above 0.ANALOG THROTTLE (B) INPUT LOW supporting information.5 L & 6. read Analog Throttle (B) Input Voltage Goes below 0. Using the DST or SERVICE ADVISOR: • For OEM applications.7V. read Analog Throttle (B) Input Voltage (OEM) • For non-OEM applications. see T6 .7 V or greater: Faulty analog throttle (B) sensor connector OR Faulty analog throttle (B) sensor NOTE: For OEM applications. For the high voltage specification on non-OEM applications. – – –1/1 CTM331 (09APR02) 04-160-52 4.8 L Level 12 Electronic Fuel System 040902 PN=212 . Ignition OFF 2.Trouble Code Diagnostics and Tests 3 Throttle Travel Voltage Test NOTE: For wiring and theory of operation. see APPLICATION SPECIFICATIONS in Section 06. use the DST or SERVICE ADVISOR for the following: • For OEM applications.ANALOG THROTTLE (B) INPUT LOW supporting information. Group 210 of this manual. While slowly operating analog throttle (B) through its full travel. Disconnect analog throttle (B) sensor connector. If no other codes are present. read Analog Throttle (B) Input Voltage Below 4. 1. the high analog throttle (B) input voltage specification is 4.7 V: GO TO 5 4. ANALOG THROTTLE (B) INPUT LOW supporting information. Remove jumper wire. 3. see T6 .0 V and 6. measure the voltage between the analog throttle (B) ground terminal and the 5 V Supply terminal in the sensor harness connector.Trouble Code Diagnostics and Tests 5 Throttle Position 5 V Supply Test NOTE: For wiring and theory of operation. Using a multimeter.0 V: Open in analog throttle (B) input circuit OR Short to ground in analog throttle (B) input circuit OR Faulty ECU connector OR Faulty ECU Below 4. Ignition ON.0 V: Open in analog throttle (B) 5 V Supply circuit OR Short to ground in analog throttle (B) 5 V Supply circuit 04 OR 160 Faulty ECU connector 53 OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-53 4.8 L Level 12 Electronic Fuel System 040902 PN=213 . 1. Between 4.5 L & 6. Ignition OFF 2. engine OFF 4. Trouble Code Diagnostics and Tests Level 12 ECU . If this code sets. • If the CAN throttle is the only throttle or all additional throttles are also faulted. the ECU will ignore the input from the CAN throttle. and will use the input values from another throttle.8 L Level 12 Electronic Fuel System 040902 PN=214 RG11972 –19–14DEC01 B B A C .T7 .0000096 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-54 4. or the information received is not valid. the ECU will use a default “limp-home” throttle value that will only allow idle engine speed. This code will set if: • The ECU either does not receive throttle information over CAN.CAN Throttle Invalid CAN Low CAN High CAN Shield F1 G1 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S E F G 04 160 54 D C A J H B D C E B A F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 C O N N E C T O R Switched Voltage Static Ground K1 K2 K3 Diagnostic Connector B A A C C CAN Terminator CAN (Controller Area Network) Throttle • CAN (Controller Area Network) throttle is information sent to the ECU by another controller over CAN of the desired throttle position. the following will occur: • If more than one throttle is available.5 L & 6. RG40854. engine OFF 3. 2. SPN 91 FMI 9 reoccurs: GO TO 3 SPN 91 FMI 9 does not reoccur: Problem is intermittent. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. For instructions on connecting to the DST or SERVICE ADVISOR™. 5. or poorly positioned terminals. Ignition ON. 6.8 L Level 12 Electronic Fuel System 040902 PN=215 .CAN THROTTLE INVALID supporting information. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.Trouble Code Diagnostics and Tests Level 12 ECU . Start the ECU communication software 4. damaged. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-55 4. This will ensure that terminal damage does not occur. 04 160 55 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation.CAN THROTTLE INVALID supporting information.Continued RG40854.T7 . 1.CAN Throttle Invalid Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Make note of any DTCs. Read DTCs using DST or SERVICE ADVISOR™. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. Connect the DST or SERVICE ADVISOR™. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.T7 . engine running 7.CAN Throttle Invalid . Look for dirty. Ignition ON. see T7 . Perform a preliminary inspection of the ECU connector and any connectors associated with the CAN throttle. then clear all DTCs. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™.5 L & 6.00000A8 –19–13DEC01–1/1 Level 12 ECU . If no other codes are present. see T7 . 1. No CAN related DTCs found on other controllers: GO TO 4 Found CAN related DTCs found on other controllers: Refer to diagnostic procedure for that controller. – – –1/1 5 CAN Wiring Shorted to Ground or Voltage Test NOTE: For wiring and theory of operation. If application has other machine controllers communicating on the CAN bus.5 V or greater than 3. – – –1/1 04 160 56 4 Resistance Between CAN High and Low Test NOTE: For wiring and theory of operation.5 V: Faulty ECU connector OR Other connector in the CAN system OR Faulty ECU. Between 45-75 ohms: GO TO 5 Less than 45 or greater than 75 ohms: Faulty or missing CAN terminator connector(s) OR Open or short in CAN wiring harness.Trouble Code Diagnostics and Tests 3 Application Related DTCs Test NOTE: For wiring and theory of operation. 1.5 L & 6. see T7 . measure resistance between terminals C and D in the harness end of the diagnostic connector.CAN THROTTLE INVALID supporting information. • Terminal D in the diagnostic connector.5 V: CAN wiring shorted to ground or voltage OR Another controller in the CAN system is faulty OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-56 4.CAN THROTTLE INVALID supporting information. Using a multimeter. see T7 . Ignition OFF 2. Both measurements between 1. Ignition OFF 2.8 L Level 12 Electronic Fuel System 040902 PN=216 . Using a multimeter. measure voltage between a good chassis ground and: • Terminal C in the diagnostic connector.5 V and 3. check those controllers for CAN related DTCs.CAN THROTTLE INVALID supporting information. see T7 . Either measurement less than 1. 5 L & 6.Trouble Code Diagnostics and Tests 04 160 57 CTM331 (09APR02) 04-160-57 4.8 L Level 12 Electronic Fuel System 040902 PN=217 . Since the ECU and Pump and Valve controller do not share a common ground. RG40854.Excavator Throttle Reference Voltage High A1 A2 A3 Throttle Reference To Pump and Valve Controller Throttle Input F3 B3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 Throttle Ground C1 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 58 Excavator Throttle • The Excavator uses an analog throttle to measure throttle position. which sends throttle input information to the ECU through a dedicated wire. If this code sets. the following will occur: • The ECU will default excavator reference throttle voltage to 3.0000094 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-58 4. This throttle is connected to the Pump and Valve controller. The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire.T11 .Trouble Code Diagnostics and Tests Level 12 ECU .75 volts.8 L Level 12 Electronic Fuel System 040902 RG11977 –19–14DEC01 C O N N E C T O R PN=218 .2 volts. This code will set if: • The excavator throttle reference voltage to the ECU exceeds 4.5 L & 6. 2. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. engine OFF 3. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. 1. If no other codes are present. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Connect the DST or SERVICE ADVISOR™. follow those DTCs first.EXCAVATOR THROTTLE REFERENCE VOLTAGE HIGH supporting information. NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active. Read DTCs using DST or SERVICE ADVISOR™. SPN 28 FMI 3 reoccurs when engine is off and running: GO TO 3 SPN 28 FMI 3 reoccurs only when engine is running: GO TO 4 SPN 28 FMI 3 does not reoccur: Problem is intermittent. engine running SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-59 4.8 L Level 12 Electronic Fuel System 040902 PN=219 . 04 160 59 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. see T11 .Continued RG40854. Look for dirty. engine OFF • Ignition ON.00000A9 –19–13DEC01–1/1 Level 12 ECU .Excavator Throttle Reference Voltage High . or poorly positioned terminals. • Ignition ON. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™. see T11 .T11 . damaged. throttle sensor connector.EXCAVATOR THROTTLE REFERENCE VOLTAGE HIGH supporting information.Excavator Throttle Reference Voltage High Diagnostic Procedure NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle. – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.Trouble Code Diagnostics and Tests Level 12 ECU .T11 . This will ensure that terminal damage does not occur. 6. 5. Make note of any DTCs.5 L & 6. and any connectors in between them. then clear all DTCs using DST or SERVICE ADVISOR™. Ignition ON. Start the ECU communication software 4. Perform a preliminary inspection of the ECU connector. For instructions on connecting to the DST or SERVICE ADVISOR™. 3. see T11 . Using a multimeter. 1.95 V: Short to power in throttle reference wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller – – –1/1 4 Ground Test 04 160 60 NOTE: For wiring and theory of operation.Trouble Code Diagnostics and Tests 3 Throttle Reference Wire Test NOTE: For wiring and theory of operation. There is a difference between grounds of the ECU and Pump and Valve controller. measure voltage between terminal F3 in the harness end of the ECU connector and the ground stud of the Pump and Valve controller. Check for loose ground connections at each controller.5 L & 6. see T11 .EXCAVATOR THROTTLE REFERENCE VOLTAGE HIGH supporting information.95 V or less: GO TO 4 Greater than 3. 3. – – –1/1 CTM331 (09APR02) 04-160-60 4.8 L Level 12 Electronic Fuel System 040902 PN=220 .EXCAVATOR THROTTLE REFERENCE VOLTAGE HIGH supporting information. Disconnect ECU connector. Ignition OFF 2. 8 L Level 12 Electronic Fuel System 040902 PN=221 .Trouble Code Diagnostics and Tests 04 160 61 CTM331 (09APR02) 04-160-61 4.5 L & 6. This code will set if: • The excavator throttle reference voltage to the ECU goes below 2.Trouble Code Diagnostics and Tests Level 12 ECU .75 volts. the following will occur: • The ECU will default excavator reference throttle voltage to 3. a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire. If this code sets.T12 .7 volts.Excavator Throttle Reference Voltage Low A1 A2 A3 Throttle Reference To Pump and Valve Controller Throttle Input F3 B3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 Throttle Ground C1 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 62 Excavator Throttle • The Excavator uses an analog throttle to measure throttle position. This throttle is connected to the Pump and Valve controller. Since the ECU and Pump and Valve controller do not share a common ground. The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller.5 L & 6. which sends throttle input information to the ECU through a dedicated wire. RG40854.0000092 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-62 4.8 L Level 12 Electronic Fuel System 040902 RG11977 –19–14DEC01 C O N N E C T O R PN=222 . then clear all DTCs. Connect the DST or SERVICE ADVISOR™. throttle sensor connector.EXCAVATOR THROTTLE REFERENCE VOLTAGE LOW supporting information. NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.Trouble Code Diagnostics and Tests Level 12 ECU . and any connectors in between them. SPN 28 FMI 4 reoccurs when engine is off and running: GO TO 3 SPN 28 FMI 4 reoccurs only when engine is running: GO TO 4 SPN 28 FMI 4 does not reoccur: Problem is intermittent. Make note of any DTCs.T12 .EXCAVATOR THROTTLE REFERENCE VOLTAGE LOW supporting information. 04 160 63 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. follow those DTCs first. For instructions on connecting to the DST or SERVICE ADVISOR™. or poorly positioned terminals.8 L Level 12 Electronic Fuel System 040902 PN=223 . – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. • Ignition ON. This will ensure that terminal damage does not occur. see T12 .Excavator Throttle Reference Voltage Low Diagnostic Procedure NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.Continued RG40854. 1. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™. Ignition ON. engine OFF • Ignition ON. see T12 .T12 . engine OFF 3. Read DTCs using DST or SERVICE ADVISOR™.Excavator Throttle Reference Voltage Low . damaged. 2. Look for dirty. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. engine running SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-63 4. 6. Start the ECU communication software 4. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. If no other codes are present. Perform a preliminary inspection of the ECU connector.5 L & 6. 5.0000091 –19–07DEC01–1/1 Level 12 ECU . EXCAVATOR THROTTLE REFERENCE VOLTAGE LOW supporting information. Disconnect ECU connector 3. Ignition OFF 2. Check for loose ground connections at each controller. Using a multimeter. measure voltage between terminal F3 in the harness end of the ECU connector and the ground stud of the Pump and Valve controller.Trouble Code Diagnostics and Tests 3 Throttle Reference Wire Test NOTE: For wiring and theory of operation.EXCAVATOR THROTTLE REFERENCE VOLTAGE LOW supporting information. 1.5 L & 6. There is a difference between the grounds of the ECU and Pump and Valve controller. – – –1/1 CTM331 (09APR02) 04-160-64 4.55 V or greater: GO TO 4 Less than 3. see T12 . 3.8 L Level 12 Electronic Fuel System 040902 PN=224 . see T12 .55 V: Open in throttle reference wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller – – –1/1 4 Ground Test 04 160 64 NOTE: For wiring and theory of operation. 8 L Level 12 Electronic Fuel System 040902 PN=225 .5 L & 6.Trouble Code Diagnostics and Tests 04 160 65 CTM331 (09APR02) 04-160-65 4. a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire.Excavator Throttle Ground Voltage High A1 A2 A3 Throttle Reference To Pump and Valve Controller Throttle Input F3 B3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 Throttle Ground C1 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 66 Excavator Throttle • The Excavator uses an analog throttle to measure throttle position.5 L & 6. which sends throttle input information to the ECU through a dedicated wire. Since the ECU and Pump and Valve controller do not share a common ground.Trouble Code Diagnostics and Tests Level 12 ECU . This code will set if: • The excavator throttle ground voltage to the ECU exceeds 3.0000090 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-66 4. the following will occur: • The ECU will default excavator throttle ground voltage to 0 volts. This throttle is connected to the Pump and Valve controller.0 volts. RG40854. If this code sets.8 L Level 12 Electronic Fuel System 040902 RG11977 –19–14DEC01 C O N N E C T O R PN=226 . The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller.T13 . T13 .T13 . This will ensure that terminal damage does not occur. engine OFF • Ignition ON. 2. throttle sensor connector. For instructions on connecting to the DST or SERVICE ADVISOR™. see T13 . 04 160 67 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Look for dirty. 6.EXCAVATOR THROTTLE GROUND VOLTAGE HIGH supporting information. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-67 4. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. Read DTCs using DST or SERVICE ADVISOR™.Excavator Throttle Ground Voltage High Diagnostic Procedure NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.EXCAVATOR THROTTLE GROUND VOLTAGE HIGH supporting information. Start the ECU communication software 4. then clear all DTCs. Make note of any DTCs. engine running SPN 29 FMI 3 reoccurs when engine is off and running: GO TO 3 SPN 29 FMI 3 reoccurs only when engine is running: GO TO 4 SPN 29 FMI 3 does not reoccur: Problem is intermittent.Continued RG40854. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™.00000AA –19–13DEC01–1/1 Level 12 ECU . Ignition ON.Trouble Code Diagnostics and Tests Level 12 ECU .Excavator Throttle Ground Voltage High .5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=227 . If no other codes are present. see T13 . see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. or poorly positioned terminals. Connect the DST or SERVICE ADVISOR™. 5. • Ignition ON. – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. damaged. and any connectors in between them. engine OFF 3. Perform a preliminary inspection of the ECU connector. 1. 4. see T13 . – – –1/1 CTM331 (09APR02) 04-160-68 4. There is a difference between grounds of the ECU and Pump and Valve controller. Disconnect Pump and Valve controller connector. Disconnect ECU connector 3. Using a multimeter.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=228 . measure resistance between terminal C1 in the harness end of the ECU connector and the corresponding ground terminal of the Pump and Valve controller connector. 1. 770 ohms or less: GO TO 5 Greater than 770 ohms: Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller – – –1/1 5 Ground Test NOTE: For wiring and theory of operation. measure resistance between terminal C1 in the harness end of the ECU connector and the ground stud of the Pump and Valve controller.EXCAVATOR THROTTLE GROUND VOLTAGE HIGH supporting information. 3. see T13 . Ignition OFF 2. Check for loose ground connection at each controller. 1. ECU connector still disconnected.EXCAVATOR THROTTLE GROUND VOLTAGE HIGH supporting information. Ignition OFF 2. 770 ohms or less: GO TO 4 Greater than 770 ohms: Short to power in throttle ground wire between ECU and 750 ohm resistor OR Open in throttle ground wire OR Faulty 750 ohm resistor OR Faulty ECU connector OR Faulty ECU 04 160 68 – – –1/1 4 Pump and Valve Controller Test NOTE: For wiring and theory of operation.Trouble Code Diagnostics and Tests 3 Throttle Ground Wire Test NOTE: For wiring and theory of operation. see T13 .EXCAVATOR THROTTLE GROUND VOLTAGE HIGH supporting information. Using a multimeter. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=229 .Trouble Code Diagnostics and Tests 04 160 69 CTM331 (09APR02) 04-160-69 4. Trouble Code Diagnostics and Tests Level 12 ECU . The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller.8 L Level 12 Electronic Fuel System 040902 RG11977 –19–14DEC01 C O N N E C T O R PN=230 . the following will occur: • The ECU will default excavator throttle ground voltage to 0 volts. If this code sets.5 L & 6. which sends throttle input information to the ECU through a dedicated wire.T14 . This throttle is connected to the Pump and Valve controller. a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire.000008E –19–07DEC01–1/1 CTM331 (09APR02) 04-160-70 4. This code will set if: • The excavator throttle ground voltage to the ECU goes below 2. RG40854.0 volts.Excavator Throttle Ground Voltage Low A1 A2 A3 Throttle Reference To Pump and Valve Controller Throttle Input F3 B3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 Throttle Ground C1 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 70 Excavator Throttle • The Excavator uses an analog throttle to measure throttle position. Since the ECU and Pump and Valve controller do not share a common ground. 6. engine OFF • Ignition ON.Trouble Code Diagnostics and Tests Level 12 ECU . – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Read DTCs using DST or SERVICE ADVISOR™. Perform a preliminary inspection of the ECU connector. Start the ECU communication software 4. damaged. If no other codes are present. 1. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. and any connectors in between them.T14 .00000AB –19–13DEC01–1/1 Level 12 ECU . engine running SPN 29 FMI 4 reoccurs when engine is off and running: GO TO 3 SPN 29 FMI 4 reoccurs only when engine is running: GO TO 4 SPN 29 FMI 4 does not reoccur: Problem is intermittent.Excavator Throttle Ground Voltage Low . For instructions on connecting to the DST or SERVICE ADVISOR™. Ignition ON.EXCAVATOR THROTTLE GROUND VOLTAGE LOW supporting information.Continued RG40854. 5. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.T14 . SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-71 4. Look for dirty. then clear all DTCs. Connect the DST or SERVICE ADVISOR™. throttle sensor connector. 2. • Ignition ON. see T14 . Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™. see T14 . This will ensure that terminal damage does not occur. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Make note of any DTCs. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. or poorly positioned terminals.Excavator Throttle Ground Voltage Low Diagnostic Procedure NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle. 04 160 71 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. engine OFF 3.8 L Level 12 Electronic Fuel System 040902 PN=231 .EXCAVATOR THROTTLE GROUND VOLTAGE LOW supporting information.5 L & 6. 5 L & 6.Trouble Code Diagnostics and Tests 3 Throttle Ground Test NOTE: For wiring and theory of operation. There is a difference between grounds of the ECU and Pump and Valve controller. 1. Ignition OFF 2. see T14 . Disconnect ECU connector 3. Check for loose ground connection at each controller. measure resistance between terminal C1 in the harness end of the ECU connector and the corresponding ground terminal of the Pump and Valve controller connector. see T14 .8 L Level 12 Electronic Fuel System 040902 PN=232 .EXCAVATOR THROTTLE GROUND VOLTAGE LOW supporting information. – – –1/1 CTM331 (09APR02) 04-160-72 4. 730 ohms or greater: GO TO 4 Less than 730 ohms: Short to ground in throttle ground wire between ECU and resistor OR Faulty ECU connector OR Faulty ECU – – –1/1 4 Ground Test 04 160 72 NOTE: For wiring and theory of operation.EXCAVATOR THROTTLE GROUND VOLTAGE LOW supporting information. Using a multimeter. 5 L & 6.Trouble Code Diagnostics and Tests 04 160 73 CTM331 (09APR02) 04-160-73 4.8 L Level 12 Electronic Fuel System 040902 PN=233 . The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire.5 L & 6. RG40854. This throttle is connected to the Pump and Valve controller.0000089 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-74 4. This code will set if: • The excavator throttle input voltage to the ECU exceeds 4.8 L Level 12 Electronic Fuel System 040902 RG11977 –19–14DEC01 C O N N E C T O R PN=234 .Excavator Throttle Input Voltage High A1 A2 A3 Throttle Reference To Pump and Valve Controller Throttle Input F3 B3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 Throttle Ground C1 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 74 Excavator Throttle • The Excavator uses an analog throttle to measure throttle position. If this code sets.T15 . the following will occur: • The ECU will use a default “limp-home” throttle value that will only allow idle engine speed.9 volts. which sends throttle input information to the ECU through a dedicated wire.Trouble Code Diagnostics and Tests Level 12 ECU . Since the ECU and Pump and Valve controller do not share a common ground. If no other codes are present.T15 . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.5 L & 6. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. or poorly positioned terminals. engine OFF • Ignition ON. Perform a preliminary inspection of the ECU connector. Read DTCs using DST or SERVICE ADVISOR™. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™.EXCAVATOR THROTTLE INPUT VOLTAGE HIGH supporting information. engine running SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-75 4. Start the ECU communication software 4.Excavator Throttle Input Voltage High . see T15 .EXCAVATOR THROTTLE INPUT VOLTAGE HIGH supporting information.Trouble Code Diagnostics and Tests Level 12 ECU . follow those DTCs first. Look for dirty. 1. throttle sensor connector. NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active. then clear all DTCs. Make note of any DTCs. and any connectors in between them. For instructions on connecting to the DST or SERVICE ADVISOR™. Connect the DST or SERVICE ADVISOR™.Excavator Throttle Input Voltage High Diagnostic Procedure NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.8 L Level 12 Electronic Fuel System 040902 PN=235 . 04 160 75 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. Ignition ON. 6.T15 .00000AC –19–13DEC01–1/1 Level 12 ECU . engine OFF 3. see T15 .Continued RG40854. This will ensure that terminal damage does not occur. damaged. SPN 91 FMI 3 reoccurs when engine is off and running: GO TO 3 SPN 91 FMI 3 reoccurs only when engine is running: GO TO 4 SPN 91 FMI 3 does not reoccur: Problem is intermittent. 5. 2. • Ignition ON. 1.0 V or less: GO TO 4 Greater than 4. see T15 . Using a multimeter. Ignition OFF 2.EXCAVATOR THROTTLE INPUT VOLTAGE HIGH supporting information. – – –1/1 CTM331 (09APR02) 04-160-76 4.Trouble Code Diagnostics and Tests 3 Throttle Signal Wire Test NOTE: For wiring and theory of operation. Disconnect ECU connector 3.0 V: Short to power in throttle signal wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller – – –1/1 4 Ground Test 04 160 76 NOTE: For wiring and theory of operation. 4. Check for loose ground connection at each controller.5 L & 6. measure voltage between terminal B3 in the harness end of the ECU connector and the ground pin of the Pump and Valve controller.8 L Level 12 Electronic Fuel System 040902 PN=236 .EXCAVATOR THROTTLE INPUT VOLTAGE HIGH supporting information. see T15 . There is a difference between grounds of the ECU and Pump and Valve controller. Trouble Code Diagnostics and Tests 04 160 77 CTM331 (09APR02) 04-160-77 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=237 . 8 L Level 12 Electronic Fuel System 040902 RG11977 –19–14DEC01 C O N N E C T O R PN=238 .Excavator Throttle Input Voltage Low A1 A2 A3 Throttle Reference To Pump and Valve Controller Throttle Input F3 B3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 Throttle Ground C1 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 78 Excavator Throttle • The Excavator uses an analog throttle to measure throttle position. which sends throttle input information to the ECU through a dedicated wire. This throttle is connected to the Pump and Valve controller.T16 .Trouble Code Diagnostics and Tests Level 12 ECU .000008B –19–07DEC01–1/1 CTM331 (09APR02) 04-160-78 4. Since the ECU and Pump and Valve controller do not share a common ground. a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire. This code will set if: • The excavator throttle input voltage to the ECU goes below 0. RG40854. If this code sets. The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller.5 L & 6. the following will occur: • The ECU will use a default “limp-home” throttle value that will only allow idle engine speed.1 volts. If no other codes are present. This will ensure that terminal damage does not occur. For instructions on connecting to the DST or SERVICE ADVISOR™. Start the ECU communication software 4.Trouble Code Diagnostics and Tests Level 12 ECU .EXCAVATOR THROTTLE INPUT VOLTAGE LOW supporting information. engine OFF 3.Continued RG40854. throttle sensor connector. • Ignition ON. then clear all DTCs SPN 91 FMI 4 reoccurs when engine is off and running: GO TO 3 SPN 91 FMI 4 reoccurs only when engine is running: GO TO 4 SPN 91 FMI 4 does not reoccur: Problem is intermittent. 04 160 79 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation. 1. 5. damaged. Perform a preliminary inspection of the ECU connector. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. engine OFF • Ignition ON.T16 . 2. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. Make note of any DTCs. see T16 . Read DTCs using DST or SERVICE ADVISOR™. see T16 . Connect the DST or SERVICE ADVISOR™. Ignition ON. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Read DTCs using DST or SERVICE ADVISOR™.8 L Level 12 Electronic Fuel System 040902 PN=239 .00000AD –19–13DEC01–1/1 Level 12 ECU .5 L & 6. Look for dirty. engine running SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-79 4. and any connectors in between them. or poorly positioned terminals.EXCAVATOR THROTTLE INPUT VOLTAGE LOW supporting information. 6.T16 .Excavator Throttle Input Voltage Low Diagnostic Procedure NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle. NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active. – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.Excavator Throttle Input Voltage Low . follow those DTCs first. see T16 .EXCAVATOR THROTTLE INPUT VOLTAGE LOW supporting information. Using a multimeter. There is a difference between grounds of the ECU and Pump and Valve controller. 1. Ignition OFF 2. see T16 . Disconnect ECU connector 3.Trouble Code Diagnostics and Tests 3 Throttle Signal Wire Test NOTE: For wiring and theory of operation. measure voltage between terminal B3 in the harness end of the ECU connector and the ground pin of the Pump and Valve controller.5 L & 6.0 V: Open in throttle signal wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller – – –1/1 4 Ground Test 04 160 80 NOTE: For wiring and theory of operation. Check for loose ground connection at each controller. 1.0 V or greater: GO TO 4 Less than 1.8 L Level 12 Electronic Fuel System 040902 PN=240 . – – –1/1 CTM331 (09APR02) 04-160-80 4.EXCAVATOR THROTTLE INPUT VOLTAGE LOW supporting information. 5 L & 6.Trouble Code Diagnostics and Tests Level 12 ECU . the following will occur: • Throttle position will not match percent throttle.0000118 –19–28JAN02–1/1 CTM331 (09APR02) 04-160-81 4.N. – For 310SG/315SG Backhoe Loaders. • If no other DTCs are found. If this code sets. see THROTTLE POSITION SENSOR TEST (S. see THROTTLE POSITION SENSOR TEST (S. Group 120 of TM1883.T19 . XXXXXX— ) in Section 9015. perform throttle sensor diagnostics.N. If this code sets: • Diagnose other DTCs first. This code will set if: • The ECU detects an improper throttle calibration range. It is done when a new ECU or a new throttle has been installed. Group 120 of TM1885.8 L Level 12 Electronic Fuel System 040902 PN=241 . 04 160 81 RG40854. – For 310G Backhoe Loaders.Throttle Not Calibrated Properly Throttle Calibration Throttle calibration is necessary to allow the ECU to learn the range of the throttle. XXXXXX— ) in Section 9015. XXXXXX— ) in Section 9015. RG40854. XXXXXX— ) in Section 9015.T20 . see THROTTLE POSITION SENSOR TEST (S.N. – For 310SG/315SG Backhoe Loaders. This code will set if: • The ECU detects a throttle input voltage lower than the defined low calibration limit. perform throttle sensor diagnostics.N. – For 310G Backhoe Loaders. If this code sets. Group 120 of TM1883. • Throttle position will not match percent throttle.Trouble Code Diagnostics and Tests Level 12 ECU . the following will occur: 04 160 82 If this code sets: • Diagnose other DTCs first.000011F –19–28JAN02–1/1 CTM331 (09APR02) 04-160-82 4. see THROTTLE POSITION SENSOR TEST (S. It is performed when a new ECU or a new throttle has been installed.8 L Level 12 Electronic Fuel System 040902 PN=242 . Group 120 of TM1885. • If no other DTCs are found.Throttle Input Voltage Below Lower Calibration Limit Throttle Calibration Throttle calibration is necessary to allow the ECU to learn the range of the throttle.5 L & 6. If this code sets: • Diagnose other DTCs first. XXXXXX— ) in Section 9015.Throttle Calibration Aborted Throttle Calibration Throttle calibration is necessary to allow the ECU to learn the range of the throttle.N. see THROTTLE POSITION SENSOR TEST (S.Trouble Code Diagnostics and Tests Level 12 ECU . perform throttle sensor diagnostics. – For 310SG/315SG Backhoe Loaders. see THROTTLE POSITION SENSOR TEST (S. • If no other DTCs are found. If this code sets. the following will occur: • Throttle position will not match percent throttle. Group 120 of TM1883. Group 120 of TM1885. This code will set if: • Throttle calibration mode was enabled but was aborted before it was completed.000011E –19–28JAN02–1/1 CTM331 (09APR02) 04-160-83 4.N. – For 310G Backhoe Loaders. 04 160 83 RG40854.5 L & 6. XXXXXX— ) in Section 9015. It is done when a new ECU or a new throttle has been installed.T21 .8 L Level 12 Electronic Fuel System 040902 PN=243 . If this code sets: • Diagnose other DTCs first. see THROTTLE POSITION SENSOR TEST (S. – For 310G Backhoe Loaders.Trouble Code Diagnostics and Tests Level 12 ECU . XXXXXX— ) in Section 9015.8 L Level 12 Electronic Fuel System 040902 PN=244 .000011D –19–28JAN02–1/1 CTM331 (09APR02) 04-160-84 4. perform throttle sensor diagnostics. see THROTTLE POSITION SENSOR TEST (S. Analog throttle voltage at low idle will be approximately 1.N. so the voltage range may change per application. RG40854. Group 120 of TM1885. Diagnose those first. The ECU has the ability to learn different voltages for low and high idle.0 and 4. The throttle input voltage normally varies between 1. This code will set if: 04 160 84 • For engine with multiple throttles.0 volt and 4. • The ECU detects a high or low out of range analog throttle (A) input voltage.0 volts depending on throttle position. XXXXXX— ) in Section 9015.0 volts at high idle. – For 310SG/315SG Backhoe Loaders. Group 120 of TM1883. the ECU will not read the input of the faulty throttle. the ECU will not read the input of the throttle and run the engine at low idle. • Return throttle to 0% throttle position • Some applications require key OFF/restart cycle to clear the code.N. • If no other DTCs are found.5 L & 6.Analog Throttle (A) Input Voltage Out of Range Analog Throttle Sensor The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle. If this code sets. • Check for other throttle DTCs. so the ECU run entirely off of the other throttle. the following will occur: • For engines with only one throttle.T22 . the following will occur: • The engine will not run if this code is active. On some applications. there is a bump up and a bump down feature.8 L Level 12 Electronic Fuel System 040902 PN=245 . • Return throttle to 0% throttle position 04 160 85 RG40854. an additional throttle is used in addition to the multi-state throttle.000011C –19–28JAN02–1/1 CTM331 (09APR02) 04-160-85 4.Trouble Code Diagnostics and Tests Level 12 ECU . the multi-state throttle will be in total control. If the desired engine speed of the additional throttle is greater than the multi-state throttle.5 L & 6.Multi-state Throttle Input Voltage Out of Range Multi-state Throttle Switch • Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. If this code sets: • Check to see if DTC SPN 91 FMI 3 or 4 is active. Diagnose those first. This allows for high and low idle to be controlled. This code will set if: • The ECU detects a high or low out of range multi-state throttle input voltage. If this code sets. When the desired engine speed of the multi-state throttle is greater than the additional throttle.T23 . the multi-state throttle will be overridden. • On certain applications. 29.DTC SPN 28. 13.0000002 –19–12MAR02–1/1 04 160 86 CTM331 (09APR02) 04-160-86 4. 7. 91 FMI 3.Trouble Code Diagnostics and Tests Level 12 ECU . a table is necessary to give direction to the appropriate procedure for your application. Because of this.8 L Level 12 Electronic Fuel System 040902 PN=246 . 10. See LISTING OF THROTTLE CODES earlier in this Group. RG40854. 14 Diagnostic Trouble Codes (DTCs) assigned to throttles changes per application. 9.5 L & 6. 4. Trouble Code Diagnostics and Tests 04 160 87 CTM331 (09APR02) 04-160-87 4.8 L Level 12 Electronic Fuel System 040902 PN=247 .5 L & 6. As engine oil pressure increases. The switch is open when the engine is not running and engine is running with sufficient oil pressure. If DTC SPN 100 FMI 1 sets. see MEASURING PRESSURE in Section 03. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition. Group 210 of this manual. Group 140 earlier in this manual.8 L Level 12 Electronic Fuel System PN=248 RG12045 C O N N E C T O R –19–20DEC01 . the ECU sensses the oil pressure switch is open after the engine is above cranking RPM for several seconds. • The oil pressure switch is used to detect a loss of oil pressure.Trouble Code Diagnostics and Tests Level 12 ECU . For wiring on other applications. Oil pressure causes the contacts in the switch close when oil pressure drops below the minimum oil pressure threshold.5 L & 6.0000088 –19–07DEC01–1/2 CTM331 (09APR02) 04-160-88 4. • For engines with an oil pressure switch. see APPLICATION SPECIFICATIONS in Section 06. the following will occur: Continued on next page RG40854. the ECU senses an extremely low oil pressure. the oil pressure sensor input voltage increases. Oil Pressure Sensor or Switch • The oil pressure sensor is a pressure transducer connected to the main oil galley. DTC SPN 100 FMI 1 will set if: • For engines with an oil pressure sensor.DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low Oil Pressure Sensor B C A A C B B A C Oil Pressure Sensor Connector B 5V Supply C Oil Pressure Input A Sensor Ground D3 F3 E2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11978 040902 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 04 160 88 A1 B1 C1 D1 E1 ECU HARNESS CONNECTOR A1 A2 A3 Oil Pressure Switch P Oil Pressure Input C1 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 NOTE: Wiring schematics show OEM engine applications for the oil pressure sensor and Telehandler applications for the oil pressure switch. For further oil pressure sensor information. Group 140 of this manual. See ENGINE PROTECTION in Section 03. the engine derates 60% per minute until the engine is running at 40% of full power.0000088 –19–07DEC01–2/2 04 160 89 CTM331 (09APR02) 04-160-89 4.Trouble Code Diagnostics and Tests • Engine protection is enabled. Group 210 of this manual. and the engine will shut down after 30 seconds. – With Derate Feature: On OEM applications. see APPLICATION SPECIFICATIONS in Section 06. For non-OEM applications. – With Shutdown Feature: The derate feature will go into effect when the code is set.8 L Level 12 Electronic Fuel System 040902 PN=249 .5 L & 6. RG40854. L2 ENGINE OIL PRESSURE LOW in Section 04. Group 150 of 4. If oil pressure sensor or switch circuits are OK.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.Continued RG40854.DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low Diagnostic Procedure – – –1/1 1 Connection Check 04 160 90 IMPORTANT: Do not force probes into connector terminals or damage will result. See 4.5 L & 6. Oil pressure below specification: Low oil pressure problem. measure engine oil pressure.DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low . Use JT07328 Connector Adapter Test Kit to make measurements in connectors. damaged. See CHECK ENGINE OIL PRESSURE in Section 04. – – –1/1 2 Oil Pressure Check NOTE: For wiring and theory of operation information. see DTC SPN 100 FMI 1 ENGINE OIL PRESSURE EXTREMELY LOW supporting information Under the conditions where DTC SPN 100 FMI 1 occurs. see DTC SPN 100 FMI 1 ENGINE OIL PRESSURE EXTREMELY LOW supporting information Perform a preliminary inspection of the ECU connector.8 L Level 12 Electronic Fuel System 040902 PN=250 .5 L and 6. and any connectors in between them. – – –1/1 CTM331 (09APR02) 04-160-90 4. Oil pressure within specification: Verify that oil pressure sensor or switch circuits is OK. replace oil pressure sensor or switch and retest. Group 150 of 4. This will ensure that terminal damage does not occur. or poorly positioned terminals.8 L Diesel Engines Base Engine Manual (CTM 104).5L/6.00000B2 –19–13DEC01–1/1 Level 12 ECU .Trouble Code Diagnostics and Tests Level 12 ECU . Look for dirty.8L . the oil pressure sensor. Trouble Code Diagnostics and Tests 04 160 91 CTM331 (09APR02) 04-160-91 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=251 . Group 210 of this manual for the high oil pressure input voltage specification.Trouble Code Diagnostics and Tests Level 12 ECU . As engine oil pressure increases.DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High Oil Pressure Sensor B C A A C B B A C Oil Pressure Sensor Connector B 5V Supply C Oil Pressure Input A Sensor Ground D3 F3 E2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11978 040902 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 04 160 92 A1 B1 C1 D1 E1 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. RG40854. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition. If DTC SPN 100 FMI 3 sets. Group 140 earlier in this manual. • ECU’s low oil pressure engine protection feature disabled. For further oil pressure sensor information. The voltage is higher than what is physically possible for oil pressure. – For OEM applications. DTC SPN 100 FMI 3 will set if: • The oil pressure input voltage exceeds the sensor’s high voltage specification.8 L Level 12 Electronic Fuel System PN=252 .5 volts. see APPLICATION SPECIFICATIONS in Section 06. Oil Pressure Sensor • The oil pressure sensor is a pressure transducer connected to the main oil galley. see MEASURING PRESSURE in Section 03. the oil pressure sensor input voltage increases.0000086 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-92 4. For wiring on other applications. see APPLICATION SPECIFICATIONS in Section 06.5 bar). – For other applications. Group 210 of this manual. the high oil pressure input voltage specification is 4.5 L & 6. the following will occur: • ECU uses a default oil pressure of 260 kPa (2.6 bar) (37. Look for dirty. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-93 4. NOTE: For OEM applications. Start the ECU communication software 4.5 V or greater: GO TO 3 Below 4. and any connectors in between them.8 L Level 12 Electronic Fuel System 040902 PN=253 . see APPLICATION SPECIFICATIONS in Section 06. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. the high oil pressure input voltage specification is 4.DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. For the high voltage specification on other applications.00000B3 –19–14DEC01–1/1 Level 12 ECU . see INTERMITTENT FAULT DIAGNOSTICS.DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High .5 V: Problem is intermittent. Ignition ON. 5. engine running 7. Read Oil Pressure Input Voltage using the DST or SERVICE ADVISOR™. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. damaged. the oil pressure sensor connector. earlier in this Group. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.5 L & 6. engine OFF 3. Group 210 of this manual. 04 160 93 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.5V. Make note of any DTCs. For instructions on connecting to the DST or SERVICE ADVISOR™. Ignition ON. then clear all DTCs 6. This will ensure that terminal damage does not occur. 4. Read DTCs using DST or SERVICE ADVISOR™. or poorly positioned terminals. Connect the DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU . If no other codes are present.Continued RG40854. 2. see DTC SPN 100 FMI 3 ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information Perform a preliminary inspection of the ECU connector. see DTC SPN 100 FMI 3 ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information 1. Group 210 of this manual.3V.3 V or below: GO TO 4 Above 0. Disconnect oil pressure sensor connector 3. engine OFF 4. – – –1/1 04 160 94 4 Oil Pressure Ground Circuit Open Test NOTE: For wiring and theory of operation information.Trouble Code Diagnostics and Tests 3 Oil Pressure Input Shorted Test NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=254 . see DTC SPN 100 FMI 3 ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information Probe oil pressure sensor ground (Terminal A) in sensor harness connector with a test light connected to battery voltage. Ignition OFF 2. Read Oil Pressure Input Voltage using the DST or SERVICE ADVISOR.3 V: Short to voltage in oil pressure sensor input circuit OR Faulty ECU NOTE: For OEM applications.5 L & 6. Light ON: Faulty oil pressure sensor OR Faulty ECU connection OR Faulty ECU Light OFF: Open in oil pressure sensor ground circuit OR Faulty ECU connection OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-94 4. For the low voltage specification on other applications. Ignition ON. see APPLICATION SPECIFICATIONS in Section 06. the low oil pressure input voltage specification is 0. 0. see DTC SPN 100 FMI 3 ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information 1. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=255 .Trouble Code Diagnostics and Tests 04 160 95 CTM331 (09APR02) 04-160-95 4. DTC SPN 100 FMI 4 will set if: • For oil pressure sensors. see APPLICATION SPECIFICATIONS in Section 06. Continued on next page RG40854.Trouble Code Diagnostics and Tests Level 12 ECU .DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low Oil Pressure Sensor B C A A C B B A C Oil Pressure Sensor Connector B 5V Supply C Oil Pressure Input A Sensor Ground D3 F3 E2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11978 040902 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 04 160 96 A1 B1 C1 D1 E1 ECU HARNESS CONNECTOR A1 A2 A3 Oil Pressure Switch P Oil Pressure Input C1 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 NOTE: Wiring schematics show OEM engine applications for the oil pressure sensor and Telehandler applications for the oil pressure switch. The voltage is lower than what is physically possible for oil pressure. – For OEM applications.8 L Level 12 Electronic Fuel System PN=256 RG12045 C O N N E C T O R –19–20DEC01 . Oil Pressure Sensor or Switch • The oil pressure sensor is a pressure transducer connected to the main oil galley. Group 210 of this manual.0000084 –19–07DEC01–1/2 CTM331 (09APR02) 04-160-96 4. For further oil pressure sensor information. the oil pressure sensor input voltage increases. the oil pressure input voltage drops below the sensor’s low voltage specification. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition. As engine oil pressure increases.3 volts. see MEASURING PRESSURE in Section 03.5 L & 6. • The oil pressure switch is used to detect a loss of oil pressure. The switch is open when the engine is not running and engine is running with sufficient oil pressure. the low oil pressure input voltage specification is 0. A lack of oil pressure causes the contacts in the switch close when oil pressure drops below the minimum oil pressure threshold. For wiring on other applications. Group 140 earlier in this manual. • For oil pressure switches.Trouble Code Diagnostics and Tests – For other applications.5 bar). • ECU’s low oil pressure engine protection feature disabled.8 L Level 12 Electronic Fuel System 040902 PN=257 .5 L & 6. If DTC SPN 100 FMI 4 sets. the oil pressure switch is closed when key is on and there is no engine speed. the following will occur: • ECU uses a default oil pressure of 260 kPa (2. RG40854. see APPLICATION SPECIFICATIONS in Section 06.0000084 –19–07DEC01–2/2 04 160 97 CTM331 (09APR02) 04-160-97 4.6 bar) (37. Group 210 of this manual for the high oil pressure input voltage specification. or poorly positioned terminals.Continued RG40854.DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check 04 160 98 IMPORTANT: Do not force probes into connector terminals or damage will result. If no other codes are present. see DTC SPN 100 FMI 4 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information 1.Trouble Code Diagnostics and Tests Level 12 ECU . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. see INTERMITTENT FAULT DIAGNOSTICS. 5. Ignition ON. SPN 100 FMI 4 reoccurs: GO TO 3 SPN 100 FMI 4 doesn’t reoccur: Problem is intermittent. Connect the DST or SERVICE ADVISOR™. 2. see DTC SPN 100 FMI 4 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information Perform a preliminary inspection of the ECU connector. engine OFF 3.DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low . For instructions on connecting to the DST or SERVICE ADVISOR™. Read DTCs using DST or SERVICE ADVISOR™. Read DTCs using the DST or SERVICE ADVISOR™. Make note of any DTCs.8 L Level 12 Electronic Fuel System 040902 PN=258 . the oil pressure sensor connector. engine running 7. and any connectors in between them. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. This will ensure that terminal damage does not occur. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. damaged. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-98 4.00000B4 –19–14DEC01–1/1 Level 12 ECU .5 L & 6. Start the ECU communication software 4. earlier in this Group. then clear all DTCs 6. Ignition ON. Look for dirty. see DTC SPN 100 FMI 4 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information.0 V: Open in oil pressure 5 V supply circuit OR Short to ground in oil pressure 5 V supply circuit OR Faulty ECU connector OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-99 4. Remove jumper wire 3.8 L Level 12 Electronic Fuel System 040902 PN=259 .Trouble Code Diagnostics and Tests 3 Oil Pressure Sensor Check NOTE: For wiring and theory of operation information. Group 210 of this manual. For the high voltage specification on other applications.0 V and 6. Oil pressure sensor being used: GO TO 4 Oil pressure switch being used: GO TO 6 – – –1/1 4 Oil Pressure Sensor Wiring Test NOTE: For wiring and theory of operation information. see DTC SPN 100 FMI 4 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information. Using a multimeter.0 V: Open in oil pressure input circuit OR Short to ground in oil pressure input circuit OR Faulty ECU connector OR Faulty ECU Below 4. Below 4. measure voltage between oil pressure 5 V supply terminal and a good chassis ground Between 4.5 V or greater: 99 Faulty oil pressure sensor connector OR Faulty oil pressure sensor NOTE: For OEM applications.5 L & 6. – – –1/1 5 Oil Pressure Sensor 5 V Supply Test NOTE: For wiring and theory of operation information. Ignition OFF 2. Ignition OFF 2. see APPLICATION SPECIFICATIONS in Section 06.5 V: GO TO 5 04 160 4. Determine whether an oil pressure sensor or an oil pressure switch is being used. Install a jumper wire between oil pressure 5 V supply and oil pressure input in harness sensor connector 4. Ignition ON. see DTC SPN 100 FMI 4 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information. 1. engine OFF 4. Disconnect oil pressure sensor connector 3.5V. the high oil pressure input voltage specification is 4. Read the Oil Pressure Input Voltage parameter using the DST or SERVICE ADVISOR. 1. 100 CTM331 (09APR02) 04-160-100 4. measure the resistance between terminal C1 in the ECU and: • All other terminals in the ECU connector • A good ground All measurements greater than 2000 ohms: Faulty oil pressure switch OR Faulty ECU Any measurement less than 2000 ohms: Short in oil pressure input circuit – – –1/1 04 160 . Ignition OFF 2. Using a multimeter. Disconnect oil pressure switch connector and ECU connector 3.Trouble Code Diagnostics and Tests 6 Oil Pressure Switch Short in Wire Check NOTE: For wiring and theory of operation information. 1.8 L Level 12 Electronic Fuel System 040902 PN=260 .5 L & 6. see DTC SPN 100 FMI 4 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=261 .Trouble Code Diagnostics and Tests 04 160 .101 CTM331 (09APR02) 04-160-101 4. 8 L Level 12 Electronic Fuel System PN=262 .102 A1 B1 C1 D1 E1 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. DTC SPN 100 FMI 18 will set if: • For engines with an oil pressure sensor. the following will occur: • Engine protection is enabled.DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low Oil Pressure Sensor B C A A C B B A C Oil Pressure Sensor Connector B 5V Supply C Oil Pressure Input A Sensor Ground D3 F3 E2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11978 040902 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 04 160 . If DTC SPN 100 FMI 18 sets. the ECU senses a moderately low oil pressure. see MEASURING PRESSURE in Section 03. As engine oil pressure increases. For non-OEM applications. see APPLICATION SPECIFICATIONS in Section 06. Group 140 of this manual. See ENGINE PROTECTION in Section 03. Oil Pressure Sensor • The oil pressure sensor is a pressure transducer connected to the main oil galley.5 L & 6. – With Shutdown Feature: No shutdown available for this code. Group 140 earlier in this manual. see APPLICATION SPECIFICATIONS in Section 06. For wiring on other applications. – With Derate Feature: On OEM applications. the engine derates 40% per minute until the engine is running at 60% of full power. Group 210 of this manual. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition.Trouble Code Diagnostics and Tests Level 12 ECU . RG40854. Group 210 of this manual. the oil pressure sensor input voltage increases. For further oil pressure sensor information.0000082 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-102 4. 00000B5 –19–14DEC01–1/1 Level 12 ECU .5 L & 6. see DTC SPN 100 FMI 18 ENGINE OIL PRESSURE MODERATELY LOW supporting information Perform a preliminary inspection of the ECU connector. CHECK ENGINE OIL PRESSURE in Section 04. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. replace oil pressure sensor and retest.Trouble Code Diagnostics and Tests Level 12 ECU . If oil pressure sensor circuits are OK.8 L Level 12 Electronic Fuel System 040902 PN=263 . Look for dirty.8 L Diesel Engines Base Engine Manual (CTM 104).5 L & 6. – – –1/1 CTM331 (09APR02) 04-160-103 4.5 L and 6. See 4. Group 150 of 4.Continued RG40854.5L/6. damaged.8L . input.8 L Diesel Engines Base Engine Manual (CTM 104). see DTC SPN 100 FMI 18 ENGINE OIL PRESSURE MODERATELY LOW supporting information Under the conditions where DTC SPN 100 FMI 18 occurs.DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low . Group 150 of 4. Oil pressure within specification: Low oil pressure problem. or poorly positioned terminals. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. the oil pressure sensor connector.103 – – –1/1 2 Oil Pressure Check NOTE: For wiring and theory of operation information. measure engine oil pressure. and any connectors in between them. This will ensure that terminal damage does not occur. and ground circuits are OK. 04 160 .L2 ENGINE OIL PRESSURE LOW in Section 04. Oil pressure below specification: Verify that oil pressure sensor 5 V supply. lower temperatures result in higher voltages. the high manifold air temperature input voltage specification is 4. DTC SPN 105 FMI 3 will set if: • The manifold air temperture input voltage exceeds the sensor’s high voltage specification. – For OEM applications.104 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. Group 140. The MAT sensor’s variable resistance causes the input voltage to the ECU to vary. see APPLICATION SPECIFICATIONS in Section 06.9 volts.DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High MAT Sensor MAT Sensor Connector B A B A Sensor Ground MAT Input t D1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11979 04 160 .Trouble Code Diagnostics and Tests Level 12 ECU . see MEASURING TEMPERATURE in Section 03. If DTC SPN 105 FMI 3 sets. For further MAT sensor information. MAT (Manifold Air Temperature) Sensor • The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. Group 210 of this manual for the high manifold air temperature specification.8 L Level 12 Electronic Fuel System 040902 PN=264 . The MAT sensor is used to measure the temperature of the intake air. Higher intake air temperatures result in lower MAT input voltages to the ECU.5 L & 6. For wiring on other applications. Group 210 of this manual. – For other applications. • ECU’s high manifold air temperature engine protection feature disabled. RG40854.0000080 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-104 4. see APPLICATION SPECIFICATIONS in Section 06. The voltage is higher than what is physically possible for manifold air. the following will occur: • ECU uses a default MAT value of 60°C (140°F). DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.Trouble Code Diagnostics and Tests Level 12 ECU .5 L & 6. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR™. This will ensure that terminal damage does not occur.105 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. see APPLICATION SPECIFICATIONS in Section 06. Start the ECU communication software 4.00000B6 –19–18DEC01–1/1 Level 12 ECU . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=265 . 2. and any connectors in between them. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-105 4. 4. the manifold air temperature sensor connector. For instructions on connecting to the DST or SERVICE ADVISOR™. For the high voltage specification on other applications. see DTC SPN 105 FMI 3 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.9 V: Problem is intermittent. Ignition ON. If no other codes are present. engine OFF 5. NOTE: For OEM applications. engine OFF 3. Ignition ON. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. 04 160 . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Group 210 of this manual. or poorly positioned terminals. damaged.DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High Continued RG40854.9 V or greater: GO TO 3 Below 4. the high manifold air temperature input voltage specification is 4. Look for dirty.9V. 1. Connect the DST or SERVICE ADVISOR™. Perform a preliminary inspection of the ECU connector. see DTC SPN 105 FMI 3 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. For the low voltage specification on other applications. Ignition ON.Trouble Code Diagnostics and Tests 3 MAT Sensor and Connector Test NOTE: For wiring and theory of operation information. 3.5 L & 6.1 V or below: Open in MAT sensor ground circuit OR Faulty ECU connection OR Faulty ECU NOTE: For OEM applications. Group 210 of this manual.1 V: GO TO 4 0. Group 210 of this manual. For the low voltage specification on other applications. Ignition ON. see DTC SPN 105 FMI 3 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. – – –1/1 CTM331 (09APR02) 04-160-106 4. 4. Ignition OFF 2. Install jumper wire between MAT sensor harness connector input terminal and a good chassis ground. Install a jumper wire between both terminals in the MAT sensor harness connector 4. Ignition OFF 2. 04 160 . see APPLICATION SPECIFICATIONS in Section 06. the low manifold air temperature input voltage specification is 0.1 V or below: Faulty MAT sensor connector OR Faulty MAT sensor NOTE: For OEM applications. 1. the low manifold air temperature input voltage specification is 0.8 L Level 12 Electronic Fuel System 040902 PN=266 .1V. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. engine OFF 5. Remove jumper wire between both terminals. see APPLICATION SPECIFICATIONS in Section 06.1V. see DTC SPN 105 FMI 3 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. 1. Above 0.106 – – –1/1 4 MAT Sensor Open Ground Circuit Test NOTE: For wiring and theory of operation information. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. engine OFF 5. Above 0. Disconnect MAT sensor connector 3.1 V: Open in MAT sensor input circuit OR Faulty ECU connection OR Faulty ECU 0. 107 CTM331 (09APR02) 04-160-107 4.Trouble Code Diagnostics and Tests 04 160 .5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=267 . 000007D –19–07DEC01–1/1 CTM331 (09APR02) 04-160-108 4. If DTC SPN 105 FMI 4 sets. Group 140. The MAT sensor’s variable resistance causes the input voltage to the ECU to vary. For wiring on other applications. The voltage is lower than what is physically possible manifold air temperature to achieve.DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low MAT Sensor MAT Sensor Connector B A B A Sensor Ground MAT Input t D1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11979 04 160 . – For other applications. • ECU’s high manifold air temperature engine protection feature disabled. see APPLICATION SPECIFICATIONS in Section 06. the low manifold air temperature input voltage specification is 0. MAT (Manifold Air Temperature) Sensor • The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. see APPLICATION SPECIFICATIONS in Section 06. the following will occur: • ECU uses a default MAT value of 60°C (140°F) to run engine.5 L & 6. For further MAT sensor information. Group 210 of this manual for the low manifold temperature input voltage specification.Trouble Code Diagnostics and Tests Level 12 ECU . The MAT sensor is used to measure the temperature of the intake air.8 L Level 12 Electronic Fuel System 040902 PN=268 .108 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. lower temperatures result in higher voltages. – For OEM engine applications. see MEASURING TEMPERATURE in Section 03. DTC SPN 105 FMI 4 will set if: • The manifold air temperature input voltage goes below the sensor’s low voltage specification.1 volts. RG40854. Higher intake air temperatures result in lower MAT input voltages to the ECU. Group 210 of this manual. engine OFF 3. see DTC SPN 105 FMI 4 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. the manifold air temperature sensor connector. Connect the DST or SERVICE ADVISOR™. Look for dirty. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR™.5 L & 6.1 V or below: GO TO 3 Above 0.00000B7 –19–18DEC01–1/1 Level 12 ECU . Ignition ON. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-109 4. the low manifold air temperature input voltage specification is 0. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Group 210 of this manual. or poorly positioned terminals.DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low Continued RG40854.1 V: Problem is intermittent. Start the ECU communication software 4. Ignition ON. see DTC SPN 105 FMI 4 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. engine OFF 5. see APPLICATION SPECIFICATIONS in Section 06. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. 1. and any connectors in between them.109 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.Trouble Code Diagnostics and Tests Level 12 ECU . 2. If no other codes are present. 0. NOTE: For OEM engine applications. Perform a preliminary inspection of the ECU connector. 04 160 . damaged.1V.8 L Level 12 Electronic Fuel System 040902 PN=269 . For the low voltage specification on other applications. For instructions on connecting to the DST or SERVICE ADVISOR™. Disconnect MAT sensor connector. see DTC SPN 105 FMI 4 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. Ignition ON.5 L & 6. For the high voltage specification on other applications.9 V: Short to ground in MAT sensor input circuit OR Faulty ECU connector OR Faulty ECU 4. engine OFF 4.Trouble Code Diagnostics and Tests 3 MAT Sensor Test NOTE: For wiring and theory of operation information. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. 04 160 . 3. see APPLICATION SPECIFICATIONS in Section 06. 1.9 V or greater: Faulty MAT sensor connector OR Faulty MAT sensor NOTE: For OEM engine applications. the high manifold air temperature input voltage specification is 4. Ignition OFF 2.8 L Level 12 Electronic Fuel System 040902 PN=270 .110 – – –1/1 CTM331 (09APR02) 04-160-110 4.9V. Below 4. Group 210 of this manual. 8 L Level 12 Electronic Fuel System 040902 PN=271 .5 L & 6.111 CTM331 (09APR02) 04-160-111 4.Trouble Code Diagnostics and Tests 04 160 . 5 L & 6. lower temperatures result in higher voltages. see MEASURING TEMPERATURE in Section 03.DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High MAT Sensor MAT Sensor Connector B A B A Sensor Ground MAT Input t D1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11979 04 160 . For MAT specifications on other applications. the engine derates 2% per minute until the engine is running at 80% of full power. Group 140 of this manual. RG40854.8 L Level 12 Electronic Fuel System 040902 PN=272 . The MAT sensor is used to measure the temperature of the intake air. DTC SPN 105 FMI 16 will set if: • The ECU senses MAT on OEM applications above 100°C (212°F) for “H engines” and 120°C (248°F) for “T engines”. the following will occur: • Engine protection is enabled. – With Shutdown Feature: The ECU does not use shutdown feature with this code. For wiring on other applications. See ENGINE PROTECTION in Section 03. Group 210 of this manual.112 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. Group 210 of this manual. MAT (Manifold Air Temperature) Sensor • The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. For further MAT sensor information. For non-OEM applications. If DTC SPN 105 FMI 16 sets. see APPLICATION SPECIFICATIONS in Section 06. – With Derate Feature: On OEM applications. Group 140.000007B –19–07DEC01–1/1 CTM331 (09APR02) 04-160-112 4. Group 210 of this manual.Trouble Code Diagnostics and Tests Level 12 ECU . The MAT sensor’s variable resistance causes the input voltage to the ECU to vary. see APPLICATION SPECIFICATIONS in Section 06. see APPLICATION SPECIFICATIONS in Section 06. Higher intake air temperatures result in lower MAT input voltages to the ECU. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Damaged cooling fan shroud.00000B8 –19–18DEC01–1/1 Level 12 ECU . Restricted. see DTC SPN 105 FMI 16 MANIFOLD AIR TEMPERATURE MODERATELY HIGH supporting information. No cause of high MAT located: Verify that MAT sensor input and ground circuits are OK. Perform a preliminary inspection of the ECU connector.5 L & 6. If MAT sensor circuits are OK.Trouble Code Diagnostics and Tests Level 12 ECU .8 L Level 12 Electronic Fuel System 040902 PN=273 . Check the following items that can cause high intake air temperatures: • • • • • • Excessively high ambient air temperature. Restricted or damaged intake air piping. Look for dirty. and any connectors in between them. damaged. 04 160 . Cause of high MAT located: Repair problem and retest. replace MAT sensor and retest.DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High Continued RG40854. – – –1/1 CTM331 (09APR02) 04-160-113 4. This will ensure that terminal damage does not occur. or damaged charge air cooler.DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Loose cooling fan belt. the manifold air temperature sensor connector. see DTC SPN 105 FMI 16 MANIFOLD AIR TEMPERATURE MODERATELY HIGH supporting information. or poorly positioned terminals. dirty. Malfunctioning cooling fan.113 – – –1/1 2 Failures Causing High MAT Check NOTE: For wiring and theory of operation information. See ENGINE PROTECTION in Section 03.Trouble Code Diagnostics and Tests Level 12 ECU . For the most severe ECT specification on other applications. Group 210 of this manual. The ECT’s variable resistance causes the input voltage to the ECU to vary. RG40854. Group 210 of this manual. and the engine will shut down after 30 seconds. the engine derates 60% per minute until the engine is running at 40% of full power. It is used to measure the coolant temperature. For further ECT sensor information.8 L Level 12 Electronic Fuel System 040902 PN=274 .114 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. Group 140 earlier in this manual. If DTC SPN 110 FMI 0 sets. see APPLICATION SPECIFICATIONS in Section 06.0000071 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-114 4.5 L & 6. Group 140 of this manual. Higher coolant temperatures result in lower ECT input voltages to the Engine Control Unit (ECU). – With Shutdown Feature: The derate feature will go into effect when the code is set. see APPLICATION SPECIFICATIONS in Section 06. Group 210 of this manual. the following will occur: • Engine protection is enabled. see APPLICATION SPECIFICATIONS in Section 06.DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe ECT Sensor t ECT Sensor Connector ECT Ground B A B A ECT Input B1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11980 04 160 . Engine Coolant Temperature (ECT) Sensor • The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or in the rear of the cylinder head. For non-OEM applications. see MEASURING TEMPERATURE in Section 03. – With Derate Feature: On OEM applications. lower temperatures result in higher voltages. For wiring on other applications. DTC SPN 110 FMI 0 will set if: • The ECU senses ECT on OEM applications above 118°C (244°F). 115 – – –1/1 2 ECT Sensor and Circuit Test NOTE: For wiring and theory of operation information.ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04.8 L Level 12 Electronic Fuel System 040902 PN=275 .00000B9 –19–18DEC01–1/1 Level 12 ECU . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. See 4. This will ensure that terminal damage does not occur. ECT significantly less than 118°C (244°F): Verify that ECT input and ground circuits are OK If both circuits are OK.DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. For the most severe ECT specification on other applications. see APPLICATION SPECIFICATIONS in Section 06. damaged.5L/6. Look for dirty. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.5 L & 6. NOTE: On OEM applications. ECT 118°C (244°F) or above: Engine overheating problem.Trouble Code Diagnostics and Tests Level 12 ECU . Group 210 of this manual.8L C1 . the Engine Coolant Temperature (ECT) connector. see DTC SPN 110 FMI 0 ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE supporting information Perform a preliminary inspection of the ECU connector. 04 160 . or poorly positioned terminals.DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe Continued RG40854. replace ECT sensor and retest – – –1/1 CTM331 (09APR02) 04-160-115 4. the most severe ECT specification is 118°C•(244°F).5 L & 6. Group 150 of 4. use a temperature gauge and verify that engine coolant temperature is above the most severe ECT specification.8 L Diesel Engines Base Engine Manual (CTM 104). and any connectors in between them. see DTC SPN 110 FMI 0 ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE supporting information Under the conditions where DTC SPN 110 FMI 0 occurs. 5 L & 6. For further ECT sensor information. For wiring on other applications. Group 210 of this manual for the high ECT input voltage specification. see MEASURING TEMPERATURE in Section 03. Group 210 of this manual. The ECT’s variable resistance causes the input voltage to the ECU to vary. It is used to measure the coolant temperature. If DTC SPN 110 FMI 3 sets.Trouble Code Diagnostics and Tests Level 12 ECU . Higher coolant temperatures result in lower ECT input voltages to the Engine Control Unit (ECU). Group 140 earlier in this manual. see APPLICATION SPECIFICATIONS in Section 06. Engine Coolant Temperature (ECT) Sensor • The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or in the rear of the cylinder head. – For other applications. • When in running mode.DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High ECT Sensor t ECT Sensor Connector ECT Ground B A B A ECT Input B1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11980 04 160 .0000072 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-116 4.116 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. DTC SPN 110 FMI 3 will set if: • The ECT input voltage goes above the sensor’s high voltage specification. see APPLICATION SPECIFICATIONS in Section 06. the ECU will default the ECT to -30°C (-22°F).8 L Level 12 Electronic Fuel System 040902 PN=276 . the following will occur: • When in start mode. the ECU will default the ECT to 90°C (194°F).9 volts. This voltage corresponds to a temperature that is lower than what is physically possible for engine coolant. – For OEM engine applications. the high ECT input voltage specification is 4. • ECU’s high ECT engine protection feature disabled. lower temperatures result in higher voltages. RG40854. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.Trouble Code Diagnostics and Tests Level 12 ECU . and any connectors in between them. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-117 4. 04 160 . This will ensure that terminal damage does not occur. see APPLICATION SPECIFICATIONS in Section 06. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. see INTERMITTENT FAULT DIAGNOSTICS.9V. For instructions on connecting to the DST or SERVICE ADVISOR™.117 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. At or above 4.DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High Continued RG40854.8 L Level 12 Electronic Fuel System 040902 PN=277 . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. NOTE: On OEM applications. Ignition ON. Group 210 of this manual. 2. damaged. Ignition ON. Start the ECU communication software 4. or poorly positioned terminals. the Engine Coolant Temperature (ECT) connector. see DTC SPN 110 FMI 3 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information Perform a preliminary inspection of the ECU connector. Look for dirty. Connect the DST or SERVICE ADVISOR™. Read the Engine Coolant Temperature Input Voltage parameter using DST or SERVICE ADVISOR™. For high input voltage specifications on other applications.9 V: GO TO 3 Below 4. engine OFF 3. earlier in this Group. engine running 5. If no other codes are present. see DTC SPN 110 FMI 3 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information 1.DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.9 V: Problem is intermittent.5 L & 6.00000BA –19–19DEC01–1/1 Level 12 ECU . the high ECT input voltage specification is 4. 1 volts and below. For ECT input voltage specifications on other applications.1 V or below: Open in ECT sensor ground circuit OR Faulty ECU connection OR Faulty ECU NOTE: On OEM applications. Ignition ON. Install jumper wire between ECT sensor harness connector input terminal and a good chassis ground 4.5 L & 6. Ignition OFF 2.8 L Level 12 Electronic Fuel System 040902 PN=278 . the low ECT input voltage specification is 0. Read the Engine Coolant Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. Remove jumper wire between both terminals 3.Trouble Code Diagnostics and Tests 3 Engine Coolant Temperature (ECT) Sensor and Connector Test NOTE: For wiring and theory of operation information. Group 210 of this manual. For ECT input voltage specifications on other applications. – – –1/1 CTM331 (09APR02) 04-160-118 4. Group 210 of this manual. Ignition ON.1 V: GO TO 4 At or below 0. engine OFF 5. see APPLICATION SPECIFICATIONS in Section 06.1 V: Faulty ECT sensor connector OR Faulty ECT sensor NOTE: On OEM applications.118 – – –1/1 4 Engine Coolant Temperature (ECT) Open Ground Test NOTE: For wiring and theory of operation information. see DTC SPN 110 FMI 3 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information 1.1 volts and below. Above 0. 04 160 .1 V: Open in ECT input sensor circuit OR Faulty ECU connection OR Faulty ECU 0. Install a jumper wire between both terminals in the ECT sensor harness connector 4. Read the Engine Coolant Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. see DTC SPN 110 FMI 3 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information 1. Ignition OFF 2. see APPLICATION SPECIFICATIONS in Section 06. Disconnect ECT sensor connector 3. engine OFF 5. Above 0. the low ECT input voltage specification is 0. 8 L Level 12 Electronic Fuel System 040902 PN=279 .119 CTM331 (09APR02) 04-160-119 4.5 L & 6.Trouble Code Diagnostics and Tests 04 160 . – For OEM engine applications. lower temperatures result in higher voltages. The ECT’s variable resistance causes the input voltage to the ECU to vary. For wiring on other applications. Group 210 of this manual.DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low ECT Sensor t ECT Sensor Connector ECT Ground B A B A ECT Input B1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11980 04 160 . – For other applications. see MEASURING TEMPERATURE in Section 03.0000074 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-120 4.Trouble Code Diagnostics and Tests Level 12 ECU . the ECU will default the ECT to -30°C (-22°F). the low ECT input voltage specification is 0. the following will occur: • When in start mode. the ECU will default the ECT to 90°C (194°F). see APPLICATION SPECIFICATIONS in Section 06. This voltage corresponds to a temperature that is higher than what is physically possible for engine coolant.1 volts. Engine Coolant Temperature (ECT) Sensor • The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing. RG40854. • ECU’s high ECT engine protection feature disabled.120 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. Group 210 of this manual for the high ECT input voltage specification. • When in running mode. It is used to measure the coolant temperature.8 L Level 12 Electronic Fuel System 040902 PN=280 .5 L & 6. Higher coolant temperatures result in lower ECT input voltages to the ECU. Group 140 earlier in this manual. For further ECT sensor information. If DTC SPN 110 FMI 4 sets. see APPLICATION SPECIFICATIONS in Section 06. DTC SPN 110 FMI 4 will set if: • The ECT input voltage goes below the sensor’s low voltage specification. 8 L Level 12 Electronic Fuel System 040902 PN=281 . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.121 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.5 L & 6. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Read the Engine Coolant Temperature Input Voltage parameter using DST or SERVICE ADVISOR™.1 V or below: GO TO 3 Above 0.00000BB –19–19DEC01–1/1 Level 12 ECU . see APPLICATION SPECIFICATIONS in Section 06. Look for dirty.DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low Continued RG40854. Ignition ON. damaged.1 V: Problem is intermittent. engine OFF 5. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. NOTE: For OEM engine applications. Start the ECU communication software 4. engine OFF 3. see DTC SPN 110 FMI 4 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information Perform a preliminary inspection of the ECU connector. If no other codes are present. 04 160 . see DTC SPN 110 FMI 4 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information 1. Ignition ON. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-121 4. see INTERMITTENT FAULT DIAGNOSTICS. or poorly positioned terminals. 0. Connect the DST or SERVICE ADVISOR™. This will ensure that terminal damage does not occur.1V. For instructions on connecting to the DST or SERVICE ADVISOR™. For the low voltage specification on other applications. the Engine Coolant Temperature (ECT) sensor connector. the low ECT input voltage specification is 0. earlier in this Group. 2. Group 210 of this manual. and any connectors in between them.Trouble Code Diagnostics and Tests Level 12 ECU . Trouble Code Diagnostics and Tests 3 Engine Coolant Temperature (ECT) Sensor Test NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 4 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information 1. Ignition OFF 2. Disconnect ECT sensor connector 3. Ignition ON 4. Read the Engine Coolant Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. Below 4.9 V: Short to ground in ECT sensor input circuit OR Faulty ECU 4.9 V or greater: Faulty ECT sensor NOTE: For OEM engine applications, the high ECT input voltage specification is 4.9V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. 04 160 ,122 – – –1/1 CTM331 (09APR02) 04-160-122 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=282 Trouble Code Diagnostics and Tests 04 160 ,123 CTM331 (09APR02) 04-160-123 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=283 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe ECT Sensor t ECT Sensor Connector ECT Ground B A B A ECT Input B1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11980 04 160 ,124 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. Engine Coolant Temperature (ECT) Sensor • The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or at the rear of the cylinder head. It is used to measure the coolant temperature. The ECT’s variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC SPN 110 FMI 15 will set if: • The ECU senses ECT on OEM applications above 108°C (226°F). For the least severe ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC SPN 110 FMI 15 sets, the following will occur: • Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. – With Shutdown Feature: No shutdown available for this code. – With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 95% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. RG40854,0000076 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-124 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=284 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe Continued RG40854,00000BC –19–19DEC01–1/1 Level 12 ECU - DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 15 ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information Perform a preliminary inspection of the ECU connector, the Engine Coolant Temperature (ECT) sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals. 04 160 ,125 – – –1/1 2 Engine Coolant Temperature (ECT) Sensor and Circuit Test NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 15 ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information Under the conditions where DTC SPN 110 FMI 15 occurs, using a temperature gauge, verify that engine coolant temperature is above the least severe ECT specification. ECT above 108°C (226°F): Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). ECT significantly less than 108°C (226°F): Verify that ECT sensor input and ground circuits are OK. If ECT sensor circuits are OK, replace ECT sensor and retest NOTE: On OEM applications, the least servere ECT specification is 108°C (226°F). For the least severe ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. – – –1/1 CTM331 (09APR02) 04-160-125 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=285 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe ECT Sensor t ECT Sensor Connector ECT Ground B A B A ECT Input B1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11980 04 160 ,126 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. Engine Coolant Temperature (ECT) Sensor • The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or at the rear of the cylinder head. It is used to measure the coolant temperature. The ECT’s variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC SPN 110 FMI 16 will set if: • The ECU senses ECT on OEM applications above 113°C (235°F). For the moderately ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC SPN 110 FMI 16 sets, the following will occur: • Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. – With Shutdown Feature: No shutdown available for this code. – With Derate Feature: On OEM applications, the engine derates 40% per minute until the engine is running at 60% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. RG40854,0000079 –19–07DEC01–1/1 CTM331 (09APR02) 04-160-126 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=286 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe - Continued RG40854,00000BD –19–19DEC01–1/1 Level 12 ECU - DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 16 ENGINE COOLANT TEMPERATURE HIGH MODERATELY SEVERE supporting information Perform a preliminary inspection of the ECU connector, the Engine Coolant Temperature (ECT) sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals. 04 160 ,127 – – –1/1 2 Engine Coolant Temperature (ECT) Sensor and Circuit Test NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 16 ENGINE COOLANT TEMPERATURE HIGH MODERATELY SEVERE supporting information Under the conditions where DTC SPN 110 FMI 16 occurs, using a temperature gauge, verify that engine coolant temperature is above 113°C (235°F). ECT above 113°C (235°F): Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). ECT significantly less than 113°C (235°F): Verify that ECT sensor input and ground circuits are OK. If ECT sensor circuits are OK, replace ECT sensor and retest NOTE: On OEM applications, the moderately high ECT specification is 113°C•(235°F). For the moderately high ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. – – –1/1 CTM331 (09APR02) 04-160-127 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=287 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High Loss of Coolant Temperature Sensor t Loss of Coolant Temperature Sensor Connector Sensor Ground B A B A Input C1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–24JAN02 RG11981 04 160 ,128 ECU HARNESS CONNECTOR Loss of Coolant Temperature Sensor • The loss of coolant temperature sensor is a thermistor (temperature sensitive resistor) mounted in the rear of the cylinder head. It is used to measure the coolant temperature to detect whether there is a loss of coolant. The sensor’s variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower loss of coolant temperature input voltages to the ECU; lower temperatures result in higher voltages. For further loss of coolant temperature sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC SPN 111 FMI 0 will set if: • The ECU senses a coolant temperature above 124°C (255°F). If DTC SPN 111 FMI 0 sets, the following will occur: • The engine derates 20% per minute until the engine is running at 60% of full power. If the temperature goes below 124°C (255°F), the engine will regain power at 20% per minute. RG40854,000006F –19–06DEC01–1/1 CTM331 (09APR02) 04-160-128 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=288 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High Continued RG40854,00000BE –19–19DEC01–1/1 Level 12 ECU - DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 0 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH supporting information Perform a preliminary inspection of the ECU connector, the loss of coolant temperature sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals. 04 160 ,129 – – –1/1 2 Loss of Coolant Temperature Sensor and Circuit Test NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 0 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH supporting information Under the conditions where DTC SPN 111 FMI 0 occurs, using a temperature gauge, verify that loss of coolant temperature is above 124°C (255°F). Significantly less than 124°C (255°F): Verify that loss of coolant temperature sensor input and ground circuits are OK. If loss of coolant temperature sensor circuits are OK, replace loss of coolant temperature sensor and retest Temperature above 124°C (255°F): Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). – – –1/1 CTM331 (09APR02) 04-160-129 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=289 Trouble Code Diagnostics and Tests Level 12 ECU - DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High Loss of Coolant Temperature Sensor t Loss of Coolant Temperature Sensor Connector Sensor Ground B A B A Input C1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–24JAN02 RG11981 04 160 ,130 ECU HARNESS CONNECTOR Loss of Coolant Temperature Sensor • The loss of coolant temperature sensor is a thermistor (temperature sensitive resistor) mounted in the rear of the cylinder head. It is used to measure the coolant temperature to detect whether there is a loss of coolant. The sensor’s variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower loss of coolant temperature input voltages to the ECU; lower temperatures result in higher voltages. For further loss of coolant temperature sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC SPN 111 FMI 3 will set if: • The loss of coolant temperature input voltage exceeds 4.975 volts. This voltage corresponds to a temperature that is lower than what is physically possible for engine coolant. If DTC SPN 111 FMI 3 sets, the following will occur: • ECU’s high loss of coolant temperature engine protection feature disabled. RG40854,00000C0 –19–19DEC01–1/1 CTM331 (09APR02) 04-160-130 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=290 DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.8 L Level 12 Electronic Fuel System 040902 PN=291 . 2. Ignition ON. engine running 7. Read DTCs using DST or SERVICE ADVISOR™.00000C1 –19–19DEC01–1/1 Level 12 ECU . Connect the DST or SERVICE ADVISOR™. Look for dirty. then clear all DTCs 6. or poorly positioned terminals.Trouble Code Diagnostics and Tests Level 12 ECU . This will ensure that terminal damage does not occur.5 L & 6. earlier in this Group. 5. and any connectors in between them. SPN 111 FMI 3 reoccurs: GO TO 3 SPN 111 FMI 3 does not reoccur: Problem is intermittent. For instructions on connecting to the DST or SERVICE ADVISOR™. Make note of any DTCs. the loss of coolant temperature sensor connector. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. 04 160 . damaged. Ignition ON.DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High Continued RG40854. see INTERMITTENT FAULT DIAGNOSTICS. see DTC SPN 111 FMI 3 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information 1. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-131 4.131 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Read DTCs using the DST or SERVICE ADVISOR™. If no other codes are present. engine OFF 3. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. see DTC SPN 111 FMI 3 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information Perform a preliminary inspection of the ECU connector. Start the ECU communication software 4. 0 V: Open in loss of coolant temperature sensor ground circuit OR Faulty ECU connection OR Faulty ECU – – –1/1 CTM331 (09APR02) 04-160-132 4.Trouble Code Diagnostics and Tests 3 Loss of Coolant Temperature Sensor and Connector Test NOTE: For wiring and theory of operation information. Between 4.0 V and 6. Ignition OFF 2. measure voltage between loss of coolant temperature input (5V supply) terminal and a good chassis ground. Using a multimeter.8 L Level 12 Electronic Fuel System 040902 PN=292 . engine OFF 5. Remove jumper wire between both terminals 3. see DTC SPN 111 FMI 3 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information 1. Disconnect loss of coolant temperature sensor connector 3. see DTC SPN 111 FMI 3 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information 1. Read DTCs using the DST or SERVICE ADVISOR. Ignition ON.5 L & 6.0 V: Open in loss of coolant temperature input sensor circuit OR Faulty ECU connection OR Faulty ECU Below 4.132 4 Loss of Coolant Temperature Open Ground Test NOTE: For wiring and theory of operation information. Ignition OFF 2. engine OFF 5. Install jumper wire between loss of coolant temperature sensor harness connector input terminal and a good chassis ground 4. Ignition ON. SPN 111 FMI 3 reoccurs: GO TO 4 SPN 111 FMI 4 occurs: Faulty loss of coolant temperature sensor connector OR Faulty loss of coolant temperature sensor – – –1/1 04 160 . Install a jumper wire between both terminals in the loss of coolant temperature sensor harness connector 4. 5 L & 6.133 CTM331 (09APR02) 04-160-133 4.Trouble Code Diagnostics and Tests 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=293 . The sensor’s variable resistance causes the input voltage to the ECU to vary.05 volts.0000069 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-134 4. RG40854.Trouble Code Diagnostics and Tests Level 12 ECU . lower temperatures result in higher voltages. the following will occur: • ECU’s high loss of coolant temperature engine protection feature disabled. For further loss of coolant temperature sensor information. Higher coolant temperatures result in lower loss of coolant temperature input voltages to the ECU.8 L Level 12 Electronic Fuel System 040902 PN=294 . Group 140 earlier in this manual.5 L & 6. It is used to measure the coolant temperature to detect whether there is a loss of coolant. If DTC SPN 111 FMI 4 sets. see MEASURING TEMPERATURE in Section 03.134 ECU HARNESS CONNECTOR Loss of Coolant Temperature Sensor • The loss of coolant temperature sensor is a thermistor (temperature sensitive resistor) mounted in the rear of the cylinder head. DTC SPN 111 FMI 4 will set if: • The loss of coolant temperature input voltage drops below 0.DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low Loss of Coolant Temperature Sensor t Loss of Coolant Temperature Sensor Connector Sensor Ground B A B A Input C1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–24JAN02 RG11981 04 160 . This voltage corresponds to a temperature that is higher than what is physically possible for engine coolant. or poorly positioned terminals.00000C2 –19–19DEC01–1/1 Level 12 ECU . Read DTCs using DST or SERVICE ADVISOR™. Look for dirty. engine OFF 7. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. damaged. see DTC SPN 111 FMI 4 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information 1. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. INTERMITTENT FAULT DIAGNOSTICS.DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low Continued RG40854.8 L Level 12 Electronic Fuel System 040902 PN=295 . Ignition ON. Make note of any DTCs. then clear all DTCs 6. SPN 111 FMI 4 reoccurs: GO TO 3 SPN 111 FMI 4 does not reoccur: Problem is intermittent. and any connectors in between them. 04 160 . 2. earlier in this Group.Trouble Code Diagnostics and Tests Level 12 ECU . engine OFF 3. see DTC SPN 111 FMI 4 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information Perform a preliminary inspection of the ECU connector. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-135 4. the loss of coolant temperature sensor connector. Ignition ON. Read DTCs using DST or SERVICE ADVISOR™. 5. If no other codes are present. For instructions on connecting to the DST or SERVICE ADVISOR™.5 L & 6. This will ensure that terminal damage does not occur. Connect the DST or SERVICE ADVISOR™. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Start the ECU communication software 4.135 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. 5 L & 6. Ignition OFF 2.8 L Level 12 Electronic Fuel System 040902 PN=296 . Read DTCs using DST or SERVICE ADVISOR. Disconnect loss of coolant temperature sensor connector 3.136 CTM331 (09APR02) 04-160-136 4. DTC SPN 111 FMI 4 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information 1.Trouble Code Diagnostics and Tests 3 Loss of Coolant Temperature Sensor Test NOTE: For wiring and theory of operation information. SPN 111 FMI 4 reoccurs: Short to ground in loss of coolant temperature sensor input circuit OR Faulty ECU SPN 111 FMI 3 occurs: Faulty loss of coolant temperature sensor – – –1/1 04 160 . Ignition ON 4. Trouble Code Diagnostics and Tests 04 160 .5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=297 .137 CTM331 (09APR02) 04-160-137 4. RG40854. the following will occur: • Vehicle battery may be drained because ECU will not power down.138 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. DTC SPN 158 FMI 17 will set if: • ECU detects voltage is on the switched voltage input wire to the ECU. Group 210 of this manual. If DTC SPN 158 FMI 17 sets.8 L Level 12 Electronic Fuel System 040902 PN=298 .0000066 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-138 4.Trouble Code Diagnostics and Tests Level 12 ECU .DTC SPN 158 FMI 17 ECU Power Down Error Battery Ignition Switch VSW 30 A VBAT K1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 A2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11982 04 160 .5 L & 6. For wiring on other applications. see APPLICATION SPECIFICATIONS in Section 06. Make note of any DTCs. see DTC SPN 158 FMI 17 ECU POWER DOWN ERROR supporting information.DTC SPN 158 FMI 17 ECU Power Down Error Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Look for dirty.0000109 –19–15JAN02–1/1 Level 12 ECU . 2. then back ON 7. This will ensure that terminal damage does not occur. or poorly positioned terminals. and any connectors in between them. 04 160 . Cycle ignition OFF for 10 seconds. Start the ECU communication software 4.8 L Level 12 Electronic Fuel System 040902 PN=299 . then clear all DTCs 6. For instructions on connecting to the DST or SERVICE ADVISOR™. Read DTCs using DST or SERVICE ADVISOR™.5 L & 6. 1. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. Ignition ON. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. see DTC SPN 158 FMI 17 ECU POWER DOWN ERROR supporting information. 5. SPN 158 FMI 17 reoccurs: GO TO 3 SPN 158 FMI 17 does not reoccur: Problem is intermittent. ignition power circuit. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-139 4. Perform a preliminary inspection of the ECU connector.139 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. Connect the DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU .Continued RG40854.DTC SPN 158 FMI 17 ECU Power Down Error . engine OFF 3. If no other codes are present. Read DTCs using the DST or SERVICE ADVISOR™. damaged. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. 8 L Level 12 Electronic Fuel System 040902 PN=300 . Measurement above 3. Disconnect the ECU connector 3. measure voltage between terminal A2 the ECU wiring harness connector and a good chassis ground.5 L & 6. Ignition ON. see DTC SPN 158 FMI 17 ECU POWER DOWN ERROR supporting information. engine OFF 4. 1.0 V: Faulty ECU connection OR Faulty ECU 04 160 . Ignition OFF 2. Using a multimeter.140 – – –1/1 CTM331 (09APR02) 04-160-140 4.Trouble Code Diagnostics and Tests 3 Wiring Test NOTE: For wiring and theory of operation information.0 V: Faulty ignition switch circuit OR ECU key-on power supply shorted to voltage OR Faulty ignition switch Measurement below 3. 141 CTM331 (09APR02) 04-160-141 4.Trouble Code Diagnostics and Tests 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=301 .5 L & 6. see APPLICATION SPECIFICATIONS in Section 06. the following will occur: • The ECU will use a "limp-home" fuel temperature value of -20°C (-4°F) during cranking.142 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. If DTC SPN 174 FMI 3 sets. Group 210 of this manual for the high fuel temperature input voltage specification. Group 210 of this manual. This voltage corresponds to a temperature that is lower than what is physically possible for fuel temperature.DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High Fuel Temp Sensor t Fuel Temp Connector B A B A Sensor Ground Fuel Temp Input C3 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–08JAN02 RG11988 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 04 160 . Group 140 of this manual. see APPLICATION SPECIFICATIONS in Section 06. For more fuel temperature sensor information.8 L Level 12 Electronic Fuel System 040902 PN=302 . The ECU uses the fuel temperature sensor input to adjust the fuel delivery for the variations in fuel density caused by varying fuel temperatures. For wiring on other applications. – For other applications. RG40854. Higher fuel temperatures result in lower fuel temperature input voltages to the ECU. Fuel Temperature Sensor • The fuel temperature sensor is a thermistor (temperature sensitive resistor) located on the injection pump fuel outlet housing.Trouble Code Diagnostics and Tests Level 12 ECU . The fuel temperature sensor’s variable resistance causes the input voltage to the ECU to vary.0000062 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-142 4.9 volts. see MEASURING TEMPERATURE in Section 03. • Engine power will be slightly derated. – For OEM engine applications. the high fuel temperature input voltage specification is 4. lower temperatures result in higher voltages. DTC SPN 174 FMI 3 will set if: • The fuel temperature input voltage goes above the sensor’s high voltage specification. and 40°C (104°F) during running.5 L & 6. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-143 4. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU .8 L Level 12 Electronic Fuel System 040902 PN=303 .DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.9 V: Problem is intermittent. see INTERMITTENT FAULT DIAGNOSTICS.5 L & 6. the high fuel temperature input voltage specification is 4. and sensor location information.143 – – –1/1 2 Intermittent Fault Test NOTE: For wiring. Ignition ON. 4.DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High . 1. see DTC SPN 174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. see APPLICATION SPECIFICATIONS in Section 06. theory of operation.9 volts and above. the fuel temperature sensor connector. NOTE: On OEM applications. see DTC SPN 174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. This will ensure that terminal damage does not occur. engine OFF 3. Perform a preliminary inspection of the ECU connector. If no other codes are present. and any connectors in between them. engine running 5. or poorly positioned terminals. 2. damaged. For instructions on connecting to the DST or SERVICE ADVISOR™.00000F3 –19–07JAN02–1/1 Level 12 ECU . Look for dirty. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. 04 160 . Connect the DST or SERVICE ADVISOR™. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring.9 V or greater: GO TO 3 Below 4. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Group 210 of this manual. and sensor location information. theory of operation. Ignition ON. earlier in this Group.Continued RG40854. For fuel temperature input voltage specifications on other applications. Start the ECU communication software 4. For fuel temperature input voltage specifications on other applications. 1. For fuel temperature input voltage specifications on other applications. Above 0. Above 0.1 V: Faulty fuel temperature sensor connector OR Faulty fuel temperature sensor NOTE: On OEM applications. the low fuel temperature input voltage specification is 0. 04 160 . Ignition ON. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR. Ignition OFF 2. Install jumper wire between fuel temperature sensor harness connector input terminal and a good chassis ground 4. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.1 V: GO TO 4 At or below 0. 1.1 V: Open in fuel temperature input sensor circuit OR Faulty ECU connection OR Faulty ECU 0. see APPLICATION SPECIFICATIONS in Section 06. Disconnect fuel temperature sensor connector 3.8 L Level 12 Electronic Fuel System 040902 PN=304 . theory of operation.5 L & 6. Remove jumper wire between both terminals 3. engine OFF 5. Group 210 of this manual.1 volts and below.Trouble Code Diagnostics and Tests 3 Fuel Temperature Sensor and Connector Test NOTE: For wiring. engine OFF 5.1 volts and below. see DTC SPN 174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. and sensor location information. Ignition ON. Ignition OFF 2. the low fuel temperature input voltage specification is 0. Group 210 of this manual. Install a jumper wire between both terminals in the fuel temperature sensor harness connector 4.1 V or below: Open in fuel temperature sensor ground circuit OR Faulty ECU connection OR Faulty ECU NOTE: On OEM applications. theory of operation. see APPLICATION SPECIFICATIONS in Section 06.144 – – –1/1 4 Fuel Temperature Open Ground Test NOTE: For wiring. – – –1/1 CTM331 (09APR02) 04-160-144 4. and sensor location information. see DTC SPN 174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=305 .Trouble Code Diagnostics and Tests 04 160 .145 CTM331 (09APR02) 04-160-145 4. see MEASURING TEMPERATURE in Section 03.8 L Level 12 Electronic Fuel System 040902 PN=306 . For more fuel temperature sensor information.Trouble Code Diagnostics and Tests Level 12 ECU . RG40854.DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low Fuel Temp Sensor t Fuel Temp Connector B A B A Sensor Ground Fuel Temp Input C3 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–08JAN02 RG11988 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 04 160 . If DTC SPN 174 FMI 4 sets.0000064 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-146 4. and 40°C (104°F) during running.1 volts. Group 140 of this manual.5 L & 6. The ECU uses the fuel temperature sensor input to adjust the fuel delivery for the variations in fuel density caused by varying fuel temperatures. lower temperatures result in higher voltages. the following will occur: • The ECU will use a "limp-home" fuel temperature value of -20°C (-4°F) during cranking. – For OEM engine applications. the low fuel temperature input voltage specification is 0. DTC SPN 174 FMI 4 will set if: • The fuel temperature input voltage goes above the sensor’s low voltage specification. see APPLICATION SPECIFICATIONS in Section 06. Group 210 of this manual for the low fuel temperature input voltage specification. • Engine power will be slightly derated. Higher fuel temperatures result in lower fuel temperature input voltages to the ECU. Fuel Temperature Sensor • The fuel temperature sensor is a thermistor (temperature sensitive resistor) located on the injection pump fuel outlet housing. – For other applications. This voltage corresponds to a temperature that is higher than what is physically possible for fuel temperature. The fuel temperature sensor’s variable resistance causes the input voltage to the ECU to vary.146 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. Group 210 of this manual. For wiring on other applications. see APPLICATION SPECIFICATIONS in Section 06. and sensor location information. Perform a preliminary inspection of the ECU connector.1 V: Problem is intermittent. For instructions on connecting to the DST or SERVICE ADVISOR™.00000F2 –19–07JAN02–1/1 Level 12 ECU . Connect the DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU .147 – – –1/1 2 Intermittent Fault Test NOTE: For wiring. engine OFF 3. Start the ECU communication software 4.1V. 2. damaged. Look for dirty. theory of operation. see DTC SPN 174 FMI 4 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information. This will ensure that terminal damage does not occur. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. earlier in this Group. Ignition ON. engine OFF 5.5 L & 6. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.1 V or below: GO TO 3 Above 0.DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.8 L Level 12 Electronic Fuel System 040902 PN=307 . Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR™ 0.DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low . For the low voltage specification on other applications. see DTC SPN 174 FMI 4 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information. the fuel temperature sensor connector. NOTE: For OEM engine applications. 04 160 . 1. and sensor location information. and any connectors in between them.Continued RG40854. see INTERMITTENT FAULT DIAGNOSTICS. or poorly positioned terminals. If no other codes are present. see APPLICATION SPECIFICATIONS in Section 06. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-147 4. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring. theory of operation. Group 210 of this manual. the low fuel temperature input voltage specification is 0. Ignition ON. 9V. Ignition ON 4.Trouble Code Diagnostics and Tests 3 Fuel Temperature Sensor Test NOTE: For wiring. For the high voltage specification on other applications.148 – – –1/1 CTM331 (09APR02) 04-160-148 4. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.5 L & 6. Below 4.8 L Level 12 Electronic Fuel System 040902 PN=308 . seeDTC SPN 174 FMI 4 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information. theory of operation. Disconnect fuel temperature sensor connector 3. see APPLICATION SPECIFICATIONS in Section 06. the high fuel temperature input voltage specification is 4. Ignition OFF 2. Group 210 of this manual. and sensor location information.9 V or greater: Faulty fuel temperature sensor NOTE: For OEM engine applications. 04 160 . 1.9 V: Short to ground in fuel temperature sensor input circuit OR Faulty ECU 4. Trouble Code Diagnostics and Tests 04 160 .149 CTM331 (09APR02) 04-160-149 4.8 L Level 12 Electronic Fuel System 040902 PN=309 .5 L & 6. For non-OEM applications.8 L Level 12 Electronic Fuel System 040902 PN=310 . For wiring on other applications. Group 210 of this manual. the following will occur: • Engine protection is enabled. the engine derates 2% per minute until the engine is running at 80% of full power. – With Shutdown Feature: No shutdown available for this code. Group 140 of this manual.Trouble Code Diagnostics and Tests Level 12 ECU . DTC SPN 174 FMI 16 will set if: • The ECU senses fuel temperature on OEM applications above 120°C (248°F). If DTC SPN 174 FMI 16 sets. see APPLICATION SPECIFICATIONS in Section 06. RG40854.150 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. see APPLICATION SPECIFICATIONS in Section 06. Group 210 of this manual. – With Derate Feature: On OEM applications. see MEASURING TEMPERATURE in Section 03. The ECU uses the fuel temperature sensor input to adjust the fuel delivery for the variations in fuel density caused by varying fuel temperatures. For more fuel temperature sensor information.DTC SPN 174 FMI 16 Fuel Temperature Moderately High Fuel Temp Sensor t Fuel Temp Connector B A B A Sensor Ground Fuel Temp Input C3 D3 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–08JAN02 RG11988 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 04 160 . Group 140 of this manual.5 L & 6. For fuel temperature specifications on other applications. The fuel temperature sensor’s variable resistance causes the input voltage to the ECU to vary. Group 210 of this manual.0000061 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-150 4. See ENGINE PROTECTION in Section 03. see APPLICATION SPECIFICATIONS in Section 06. Fuel Temperature Sensor • The fuel temperature sensor is a thermistor (temperature sensitive resistor) located on the injection pump fuel outlet housing. lower temperatures result in higher voltages. Higher fuel temperatures result in lower fuel temperature input voltages to the ECU. – – –1/1 CTM331 (09APR02) 04-160-151 4.5 L & 6. – – –1/1 3 Fuel Supply Pressure Check NOTE: For wiring and theory of operation information. Repair and retest.8 L Level 12 Electronic Fuel System 040902 PN=311 . See CHECK FUEL SUPPLY PRESSURE in Section 04.151 2 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Ensure that the fuel level in the fuel tank is not extremely low 2. or poorly positioned terminals. see DTC SPN 174 FMI 16 FUEL TEMPERATURE MODERATELY HIGH supporting information Determine fuel supply pressure. Ensure that fuel cooler is clean No problems found: GO TO 2 Problem found: Repair and retest – – –1/1 04 160 . the fuel temperature sensor connector. This will ensure that terminal damage does not occur.DTC SPN 174 FMI 16 Fuel Temperature Moderately High . Use JT07328 Connector Adapter Test Kit to make measurements in connectors. See F1 . damaged. Fuel pressure within specification: GO TO 4 Fuel pressure below specification: Determine cause of low fuel supply pressure. and any connectors in between them.00000F5 –19–08JAN02–1/1 Level 12 ECU . Group 150 of this manual.Trouble Code Diagnostics and Tests Level 12 ECU .Continued RG40854.FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE in Section 04. No faulty connection(s): GO TO 3 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Look for dirty. see DTC SPN 174 FMI 16 FUEL TEMPERATURE MODERATELY HIGH supporting information Perform a preliminary inspection of the ECU connector. Group 150 of this manual.DTC SPN 174 FMI 16 Fuel Temperature Moderately High Diagnostic Procedure – – –1/1 1 DTC SPN 174 FMI 16 Preliminary Check Before using this diagnostic procedure: 1. see DTC SPN 174 FMI 16 FUEL TEMPERATURE MODERATELY supporting information. Check return fuel lines for restriction between fuel tank and: • Overflow valve on injection pump • Fuel leak off line at injection nozzles Fuel return lines NOT restricted: Faulty fuel cooler OR Faulty injection pump Restriction found in either fuel return line: Determine the cause of restriction Repair and retest – – –1/1 04 160 .152 CTM331 (09APR02) 04-160-152 4.8 L Level 12 Electronic Fuel System 040902 PN=312 .Trouble Code Diagnostics and Tests 4 Fuel Return Lines Restriction Check NOTE: For wiring and theory of operation information.5 L & 6. Trouble Code Diagnostics and Tests 04 160 .153 CTM331 (09APR02) 04-160-153 4.8 L Level 12 Electronic Fuel System 040902 PN=313 .5 L & 6. SERVICE ADVISOR is a trademark of Deere & Company RG40854. the following will occur: • The ECU shuts fuel off until engine speed is below 2800 rpm. monitor DTCs on the active code display parameter. If there are other codes.5 L & 6.Trouble Code Diagnostics and Tests Level 12 ECU . For wiring on other applications. see APPLICATION SPECIFICATIONS in Section 06. • If there are no other stored or active DTCs.DTC SPN 190 FMI 0 Engine Overspeed Extreme Crank Position Sensor Crank Sensor Connector Crank Position Return B A B A Crank Position Input B2 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–23JAN02 RG11984 ECU HARNESS CONNECTOR 04 160 . The ECU uses the crank position input to determine engine speed and precise piston position in relation to the firing order. If DTC SPN 190 FMI 0 sets: • With DTC SPN 190 FMI 0.0000148 –19–11FEB02–1/1 CTM331 (09APR02) 04-160-154 4. The missing teeth help the ECU to determine Top-Dead-Center (TDC). clear DTC SPN 190 FMI 0 and monitor codes to see if DTC SPN 190 FMI 0 reoccurs. there may or not be a problem with the electronic control system.154 NOTE: Wiring schematic shows OEM engine applications only. behind the pressed-on crank gear. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. To find DTC list. Crank Position Sensor • The crank position sensor is located on the front of the crankshaft. Group 210 of this manual.8 L Level 12 Electronic Fuel System 040902 PN=314 . Using the DST or SERVICE ADVISOR™. go to the appropriate diagnostic procedure. The crank timing wheel is composed of 46 evenly spaced teeth and 2 missing teeth. DTC SPN 190 FMI 0 will set if: • The ECU detects that engine speed exceeds 3400 rpm. see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU earlier in this Group. If DTC SPN 190 FMI 0 sets. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=315 . It is an inductive type pickup sensor that detects teeth on the crank timing wheel. see APPLICATION SPECIFICATIONS in Section 06. Using the DST or SERVICE ADVISOR™. there may or not be a problem with the electronic control system. If DTC SPN 190 FMI 16 sets: • With DTC SPN 190 FMI 16. To find DTC list. For wiring on other applications. If DTC SPN 190 FMI 16 sets.DTC SPN 190 FMI 16 Engine Overspeed Moderate Crank Position Sensor Crank Sensor Connector Crank Position Return B A B A Crank Position Input B2 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–23JAN02 RG11984 ECU HARNESS CONNECTOR NOTE: Wiring schematic shows OEM engine applications only. Group 210 of this manual. If there are other codes. behind the pressed-on crank gear. • If there are no other stored or active DTCs. go to the appropriate diagnostic procedure. clear DTC SPN 190 FMI 16 and monitor codes to see if DTC SPN 190 FMI 16 reoccurs. The crank timing wheel is composed of 46 evenly spaced teeth and 2 missing teeth. The missing teeth help the ECU to determine Top-Dead-Center (TDC). The ECU uses the crank position input to determine engine speed and precise piston position in relation to the firing order. see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU earlier in this Group.0000149 –19–11FEB02–1/1 CTM331 (09APR02) 04-160-155 4. the following will occur: • The ECU shuts fuel off until engine speed is below 2800 rpm.Trouble Code Diagnostics and Tests Level 12 ECU . DTC SPN 190 FMI 16 will set if: • The ECU detects that engine speed is higher than 3000 rpm. monitor DTCs on the active code display parameter. 04 160 .155 SERVICE ADVISOR is a trademark of Deere & Company RG40854. Crank Position Sensor • The crank position sensor is located on the front of the crankshaft. the following will occur: • The ECU will use default values for the sensors that use sensor supply input voltage.5 volts on the ECU 5 volt sensor supply circuit.000005C –19–06DEC01–1/1 CTM331 (09APR02) 04-160-156 4. In addition. Group 210 of this manual.Trouble Code Diagnostics and Tests Level 12 ECU .DTC SPN 620 FMI 3 Sensor Supply Voltage High A1 A2 A3 Analog Throttle (A) Sensor Analog Throttle (B) Sensor Oil Pressure Sensor E2 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . see APPLICATION SPECIFICATIONS in Section 06.8 L Level 12 Electronic Fuel System 040902 RG11983 C O N N E C T O R –19–24JAN02 PN=316 . The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECU’s memory to determine the value of the parameter the sensor was measuring. DTC SPN 620 FMI 3 will set if: • The ECU detects a voltage that is higher than 5. the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings.156 NOTE: Wiring schematic shows OEM engine applications only. RG40854. If DTC SPN 620 FMI 3 sets. For wiring on other applications.5 L & 6. Sensor Supply Voltage • The ECU supplies voltage to a few different sensors depending on the application. SPN 620 FMI 3 reoccurs: GO TO 3 SPN 620 FMI 3 does not reoccur: Problem is intermittent. If no other codes are present. Perform a preliminary inspection of the ECU connector. see DTC SPN 620 FMI 3 SENSOR SUPPLY VOLTAGE HIGH supporting information. then clear all DTCs 6. or poorly positioned terminals. This will ensure that terminal damage does not occur.DTC SPN 620 FMI 3 Sensor Supply Voltage High . SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-157 4.5 L & 6. Look for dirty. see INTERMITTENT FAULT DIAGNOSTICS. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. see DTC SPN 620 FMI 3 SENSOR SUPPLY VOLTAGE HIGH supporting information. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=317 .DTC SPN 620 FMI 3 Sensor Supply Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Make note of any DTCs. Read DTCs using DST or SERVICE ADVISOR™. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. 04 160 .00000F6 –19–08JAN02–1/1 Level 12 ECU .157 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. Ignition ON. 1. damaged. 2. 5. engine OFF 3. Read DTCs using the DST or SERVICE ADVISOR™. Connect the DST or SERVICE ADVISOR™. earlier in this Group. Start the ECU communication software 4. For instructions on connecting to the DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU . engine OFF 7. Ignition ON.Continued RG40854. 000 ohms: Faulty ECU connector OR Faulty ECU Less than 20.5 L & 6. measure resistance between terminal E2 in the harness end of the ECU connector and all other terminals in the harness end of the ECU connector.8 L Level 12 Electronic Fuel System 040902 PN=318 .Trouble Code Diagnostics and Tests 3 Sensor Supply Wire Check for Short NOTE: For wiring and theory of operation information. see DTC SPN 620 FMI 3 SENSOR SUPPLY VOLTAGE HIGH supporting information. 1. Ignition OFF 2.158 CTM331 (09APR02) 04-160-158 4. Disconnect ECU connector 3.000 ohms: Short to voltage in sensor supply wire – – –1/1 04 160 . Using multimeter. Greater than 20. 159 CTM331 (09APR02) 04-160-159 4.8 L Level 12 Electronic Fuel System 040902 PN=319 .5 L & 6.Trouble Code Diagnostics and Tests 04 160 . 160 NOTE: Wiring schematic shows OEM engine applications only.Trouble Code Diagnostics and Tests Level 12 ECU . If DTC 620 FMI 4 sets. DTC 620 FMI 4 will set if: • The ECU detects a voltage that is lower than 4. For wiring on other applications.8 L Level 12 Electronic Fuel System 040902 RG11983 C O N N E C T O R –19–24JAN02 PN=320 . RG40854. Sensor Supply Voltage • The ECU supplies voltage to a few different sensors depending on the application. see APPLICATION SPECIFICATIONS in Section 06. the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings.DTC SPN 620 FMI 4 Sensor Supply Voltage Low A1 A2 A3 Analog Throttle (A) Sensor Analog Throttle (B) Sensor Oil Pressure Sensor E2 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . Group 210 of this manual. The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECU’s memory to determine the value of the parameter the sensor was measuring.44 volts on the ECU 5 volt sensor supply circuit. the following will occur: • The ECU will use default values for the sensors that use sensor supply input voltage. In addition.5 L & 6.000005E –19–06DEC01–1/1 CTM331 (09APR02) 04-160-160 4. Disconnect all sensors that receive their 5V supply from terminal E2 of the ECU 8. 04 160 . For instructions on connecting to the DST or SERVICE ADVISOR™. Read DTCs using DST or SERVICE ADVISOR™. Perform a preliminary inspection of the ECU connector.00000F7 –19–08JAN02–1/1 Level 12 ECU .Continued RG40854. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Make note of any DTCs. Ignition ON. 1. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. see DTC SPN 620 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. Look for dirty.161 – – –1/1 2 Sensor Check NOTE: For wiring and theory of operation information. This will ensure that terminal damage does not occur. engine running 9. then clear all DTCs 6.DTC SPN 620 FMI 4 Sensor Supply Voltage Low .8 L Level 12 Electronic Fuel System 040902 PN=321 . see DTC SPN 620 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. 2. Start the ECU communication software 4. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. 5.DTC SPN 620 FMI 4 Sensor Supply Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.5 L & 6. Read DTCs using the DST or SERVICE ADVISOR™. SPN 620 FMI 4 reoccurs: GO TO 4 SPN 620 FMI 4 does not reoccur: GO TO 3 SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-161 4. engine OFF 3. damaged. or poorly positioned terminals. Connect the DST or SERVICE ADVISOR™. Ignition OFF 7. Ignition ON.Trouble Code Diagnostics and Tests Level 12 ECU . see DTC SPN 620 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. While reconnecting each sensor one at a time. measure resistance between terminal D3 in the harness end of the ECU connector and: • A good chassis ground • Terminal J2 in the harness end of the ECU connector Greater than 20.Trouble Code Diagnostics and Tests 3 Intermittent Fault Test NOTE: For wiring and theory of operation information. If no other codes are present.162 4 Sensor Supply Short to Ground Check NOTE: For wiring and theory of operation information.5 L & 6. Ignition ON. Disconnect the ECU connector 3. – – –1/1 04 160 . 1. earlier in this Group. engine OFF 2. Ignition OFF 2.000 ohms: Faulty ECU connector OR Faulty ECU Less than 20. 1. Using a multimeter.000 ohms: Sensor 5 volt supply circuit shorted to ground – – –1/1 CTM331 (09APR02) 04-160-162 4. monitor DTCs using the DST or SERVICE ADVISOR.8 L Level 12 Electronic Fuel System 040902 PN=322 . SPN 620 FMI 4 reoccurs: Faulty sensor Replace and retest SPN 620 FMI 4 does not reoccur: Problem is intermittent. see DTC SPN 620 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. see INTERMITTENT FAULT DIAGNOSTICS. 8 L Level 12 Electronic Fuel System 040902 PN=323 .163 CTM331 (09APR02) 04-160-163 4.5 L & 6.Trouble Code Diagnostics and Tests 04 160 . RG40854. the following will occur: • The engine will not start or run.5 L & 6.000014B –19–13FEB02–1/1 CTM331 (09APR02) 04-160-164 4.DTC SPN 627 FMI 4 ECU Unswitched Power Missing Battery Ignition Switch VSW 30 A VBAT K1 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 A2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–14DEC01 RG11982 04 160 .164 ECU HARNESS CONNECTOR DTC SPN 627 FMI 4 will set if: • The ECU does not detect battery voltage. If DTC SPN 627 FMI 4 sets.8 L Level 12 Electronic Fuel System 040902 PN=324 .Trouble Code Diagnostics and Tests Level 12 ECU . Start the ECU communication software 4. If no other codes are present. see DTC SPN 627 FMI 4 ECU UNSWITCHED POWER MISSING supporting information. Make notes of any DTCs. 2. see DTC SPN 620 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.DTC SPN 627 FMI 4 ECU Unswitched Power Missing Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. 1. Connect the DST or SERVICE ADVISOR™. Read DTCs using the DST or SERVICE ADVISOR™. earlier in this Group. or poorly positioned terminals. For instructions on connecting to the DST or SERVICE ADVISOR™. 5. Perform a preliminary inspection of the ECU connector. This will ensure that terminal damage does not occur. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-165 4. Look for dirty. engine OFF 3. SPN 627 FMI 4 reoccurs: GO TO 3 SPN 627 FMI 4 does not reoccur: Problem is intermittent.165 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. then clear all DTCs 6. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.8 L Level 12 Electronic Fuel System 040902 PN=325 .000014C –19–13FEB02–1/1 Level 12 ECU .Trouble Code Diagnostics and Tests Level 12 ECU .Continued RG40854.5 L & 6. damaged. engine running 7.DTC SPN 627 FMI 4 ECU Unswitched Power Missing . 04 160 . No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Ignition ON. Ignition ON. Read DTCs using DST or SERVICE ADVISOR™. seeINTERMITTENT FAULT DIAGNOSTICS. Using a multimeter.Trouble Code Diagnostics and Tests 3 ECU and ECU Connector Test NOTE: For wiring and theory of operation information. Disconnect ECU connector 3. Voltage within specification for battery: Faulty ECU power supply fuse OR Faulty ECU connection OR Open or short in ECU power circuit Voltage substantially less than battery voltage: Faulty battery or charging system – – –1/1 CTM331 (09APR02) 04-160-166 4.166 4 Battery Voltage Check NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=326 . measure battery voltage at the battery terminals. see DTC SPN 627 FMI 4 ECU UNSWITCHED POWER MISSING supporting information.5 L & 6. measure voltage between a good chassis ground and terminal K1 Voltage is substantially less than battery voltage: GO TO 4 Voltages are at or near battery voltage on both terminals: Faulty ECU connection OR Faulty ECU – – –1/1 04 160 . 1. see DTC SPN 627 FMI 4 ECU UNSWITCHED POWER MISSING supporting information. Using a multimeter. Ignition OFF 2. 167 CTM331 (09APR02) 04-160-167 4.8 L Level 12 Electronic Fuel System 040902 PN=327 .Trouble Code Diagnostics and Tests 04 160 .5 L & 6. 5 L & 6.DTC SPN 629 FMI 13 ECU Error DTC SPN 629 FMI 13 will set if: • The ECU detects an internal problem. earlier in this Group. Make note of any DTCs. Ignition ON. 1.Trouble Code Diagnostics and Tests Level 12 ECU .8 L Level 12 Electronic Fuel System 040902 PN=328 . RG40854. Verify that controllers on vehicle are in correct location and connected to the correct wiring harness 2. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. If no other codes are present. Read DTCs using DST or SERVICE ADVISOR™. 6.000003C –19–06DEC01–1/1 Level 12 ECU . engine OFF 4. then clear all DTCs 7. If DTC SPN 629 FMI 13 sets. For instructions on connecting to the DST or SERVICE ADVISOR™. Connect the DST or SERVICE ADVISOR™. see DTC SPN 629 FMI 13 ECU ERROR supporting information. 3.168 – – –1/1 1 Intermittent Fault Test NOTE: For wiring and theory of operation information.DTC SPN 629 FMI 13 ECU Error Diagnostic Procedure 04 160 . see INTERMITTENT FAULT DIAGNOSTICS. SPN 629 FMI 13 reoccurs: Faulty ECU SPN 629 FMI 13 does not reoccur: Problem is intermittent. Start the ECU communication software 5. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-168 4. Read DTCs using DST or SERVICE ADVISOR™. engine running or cranking for 15 seconds 8. Ignition ON. the following will occur: • The engine will not start or run. 8 L Level 12 Electronic Fuel System 040902 PN=329 .169 CTM331 (09APR02) 04-160-169 4.Trouble Code Diagnostics and Tests 04 160 .5 L & 6. The crank timing wheel is composed of 46 evenly spaced teeth and 2 missing teeth. Crank Position Sensor • The crank position sensor is located on the front of the crankshaft. Group 210 of this manual.DTC SPN 637 FMI 2 Crank Position Input Noise Crank Position Sensor Crank Sensor Connector Crank Position Return B A B A Crank Position Input B2 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–23JAN02 RG11984 ECU HARNESS CONNECTOR 04 160 . see APPLICATION SPECIFICATIONS in Section 06.0000038 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-170 4. behind the pressed-on crank gear. For wiring on other applications. DTC SPN 637 FMI 2 will set if: • The ECU detects excessive noise (extra pulses) on the crank position input. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The missing teeth help the ECU to determine Top-Dead-Center (TDC). If DTC SPN 637 FMI 2 sets. the following will occur: • Engine probably will not run RG40854.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=330 .170 NOTE: Wiring schematic shows OEM engine applications only.Trouble Code Diagnostics and Tests Level 12 ECU . The ECU uses the crank position input to determine engine speed and precise piston position in relation to the firing order. Read DTCs using DST or SERVICE ADVISOR™. and any other connector.Trouble Code Diagnostics and Tests Level 12 ECU . the crank position sensor connector. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.Continued RG40854. Warm engine 7. 1. Look for dirty. This will ensure that terminal damage does not occur. 04 160 .5 L & 6. Ignition ON. then clear all DTCs 6. engine running 8. see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group. damaged. engine OFF 3. Start the ECU communication software 4. 5. Ignition ON.DTC SPN 637 FMI 2 Crank Position Input Noise .DTC SPN 637 FMI 2 Crank Position Input Noise Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. SPN 637 FMI 2 reoccurs: GO TO 3 SPN 637 FMI 2 does not reoccur: Problem is intermittent. Read DTCs using DST or SERVICE ADVISOR™. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Perform a preliminary inspection of the ECU connector. see DTC SPN 637 FMI 2 CRANK POSITION INPUT NOISE supporting information.00000F8 –19–08JAN02–1/1 Level 12 ECU . Connect the DST or SERVICE ADVISOR™. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Make note of all DTCs.171 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. 2. For instructions on connecting to the DST or SERVICE ADVISOR™. If no other codes are present. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-171 4.8 L Level 12 Electronic Fuel System 040902 PN=331 . see DTC SPN 637 FMI 2 CRANK POSITION INPUT NOISE supporting information. or poorly positioned terminals. 5 L & 6. battery ground connection Corrosion. 1. Things to check: • • • • • All harness connectors Alternator connections Chassis ground connections. particularly the crank sensor wiring • Check wiring for proper pin location in the crank sensor and ECU connectors 2. dirt. This problem may be caused by loose electrical ground or power connections anywhere on the machine.Trouble Code Diagnostics and Tests 3 Crank Signal Noise Test NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=332 . Other possible causes of SPN 637 FMI 2: • Electromagnetic interference (EMI) from an incorrectly installed 2-way radio • Interference from some radar source • Possible broken teeth on the crankshaft timing ring 04 160 . SPN 637 FMI 2 is most likely caused by radiated or conducted electrical "noise" from some part of the machine. or paint can cause intermittent and "noisy" connections Check the wiring for intermittent open and short circuits. see DTC SPN 637 FMI 2 CRANK POSITION INPUT NOISE supporting information.172 – – –1/1 CTM331 (09APR02) 04-160-172 4. Trouble Code Diagnostics and Tests 04 160 .173 CTM331 (09APR02) 04-160-173 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=333 . For wiring on other applications. the following will occur: • Engine probably will not run.000003A –19–06DEC01–1/1 CTM331 (09APR02) 04-160-174 4. The missing teeth help the ECU to determine Top-Dead-Center (TDC).174 NOTE: Wiring schematic shows OEM engine applications only.8 L Level 12 Electronic Fuel System 040902 PN=334 . Group 210 of this manual. If DTC SPN 637 FMI 10 sets.Trouble Code Diagnostics and Tests Level 12 ECU .5 L & 6. The ECU uses the crank position input to determine engine speed and precise piston position in relation to the firing order. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. Crank Position Sensor • The crank position sensor is located on the front of the crankshaft. RG40854. The crank timing wheel is composed of 46 evenly spaced teeth and 2 missing teeth.DTC SPN 637 FMI 10 Crank Position Input Pattern Error Crank Position Sensor Crank Sensor Connector Crank Position Return B A B A Crank Position Input B2 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 D2 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 –19–23JAN02 RG11984 ECU HARNESS CONNECTOR 04 160 . behind the pressed-on crank gear. see APPLICATION SPECIFICATIONS in Section 06. DTC SPN 637 FMI 10 will set if: • The ECU detects an improper pattern on the crank position input. 2. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information. Read DTCs using DST or SERVICE ADVISOR™. Read DTCs using DST or SERVICE ADVISOR™. SPN 637 FMI 10 reoccurs: GO TO 3 SPN 637 FMI 10 does not reoccur: Problem is intermittent. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Perform a preliminary inspection of the ECU connector. Make note of any DTCs. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-175 4. 1. Ignition ON. For instructions on connecting to the DST or SERVICE ADVISOR™. then clear all DTCs 6. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=335 . 5. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. the crank position sensor connector. or poorly positioned terminals. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information. engine running 7.Trouble Code Diagnostics and Tests Level 12 ECU . engine OFF 3.DTC SPN 637 FMI 10 Crank Position Input Pattern Error Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Ignition ON. Connect the DST or SERVICE ADVISOR™. earlier in this Group. Look for dirty.DTC SPN 637 FMI 10 Crank Position Input Pattern Error . see INTERMITTENT FAULT DIAGNOSTICS.5 L & 6. If no other codes are present.000010A –19–15JAN02–1/1 Level 12 ECU .175 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. and any other connector. 04 160 . Start the ECU communication software 4. This will ensure that terminal damage does not occur. damaged.Continued RG40854. Disconnect crank position sensor connector 3. 1. Using a multimeter. Crank position sensor connector and ECU connector still disconnected 3. Using a multimeter measure resistance between terminal B2 in the harness end of the ECU connector and the following: • A good ground • All other terminals in both ECU connectors All measurements greater than 2000 ohms: GO TO 6 Any measurement less than 2000 ohms: Faulty crank position sensor input wiring harness – – –1/1 CTM331 (09APR02) 04-160-176 4. Between 2500 and 3500 ohms: GO TO 4 Below 2500 ohms or above 3500 ohms: Faulty crank position sensor – – –1/1 04 160 . measure resistance between: • Terminal A of the crank position sensor harness connector and terminal B2 in the harness end of the ECU connector • Terminal B of the crank position sensor harness connector and terminal D2 in the harness end of the ECU connector Both measurements 5 ohms or less: GO TO 5 Either measurement greater than 5 ohms: Open in crank position sensor input wire OR Open in crank position sensor return wire OR Terminals A and B in the crank position sensor harness connector possibly inverted – – –1/1 5 Crank Sensor Input Wiring Check NOTE: For wiring and theory of operation information. Ignition OFF 2. Ignition OFF 2.8 L Level 12 Electronic Fuel System 040902 PN=336 .Trouble Code Diagnostics and Tests 3 Crank Position Sensor Test NOTE: For wiring and theory of operation information. measure resistance between both terminals of the crank position sensor. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information. Ignition OFF 2.176 4 Open in Crank Sensor Input and Return Check NOTE: For wiring and theory of operation information. 1. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information. Disconnect ECU connector 4. Using a multimeter. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information.5 L & 6. Disconnect crank position sensor connector 3. 1. crankshaft. or any foreign material on the end of the sensor 4.8 L Level 12 Electronic Fuel System 040902 PN=337 . Using a multimeter measure resistance between terminal D2 in the harness end of the ECU connector and the following: • A good ground • All other terminals in both ECU connectors All measurements greater than 2000 ohms: GO TO 7 Any measurement less than 2000 ohms: Faulty crank position sensor return wiring harness – – –1/1 7 Crank Sensor and Timing Wheel Check NOTE: For wiring and theory of operation information. Ignition OFF 2. 1. Crank position sensor connector and ECU connector still disconnected 3. Remove timing cover 3.5 L & 6. All gears in time: Faulty crank position sensor connector OR Faulty ECU connector OR Faulty ECU One or more gears out of time: Make necessary adjustments to ensure correct timing. Inspect the crank timing wheel notches for burrs or chips All components OK: GO TO 8 Fault found in a component: Repair or replace component as needed 04 160 .177 – – –1/1 8 Gear Timing Check NOTE: For wiring and theory of operation information. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information. See INSTALL CAMSHAFT in Section 02. Check timing between camshaft.5 L & 6. Remove crank position sensor 3.8 L Diesel Engines Base Engine Manual (CTM 104). see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information. – – –1/1 CTM331 (09APR02) 04-160-177 4. 1.5 & 6. corrosion. Ignition OFF 2. see DTC SPN 637 FMI 10 CRANK POSITION INPUT PATTERN ERROR supporting information.Trouble Code Diagnostics and Tests 6 Crank Sensor Return Wiring Check NOTE: For wiring and theory of operation information. 1. Remove crank position sensor from injection pump 2. Inspect sensor for cracks. and injection pump gears.8 L Diesel Engines Base Engine Manual (CTM 104). Group 050 of 4. See INSTALL CAMSHAFT in Group 050 of 4. Trouble Code Diagnostics and Tests Level 12 ECU .DTC SPN 639 FMI 13 CAN Error CAN Low CAN High CAN Shield F1 G1 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S E F G 04 160 . DTC SPN 639 FMI 13 will set if: • The ECU detects a problem communicating on CAN. there are many controllers on CAN.0000036 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-178 4.178 D C A J H B D C E B A F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 C O N N E C T O R Switched Voltage Static Ground K1 K2 K3 Diagnostic Connector B A A C C CAN Terminator NOTE: Wiring schematic shows OEM engine applications only.8 L Level 12 Electronic Fuel System 040902 PN=338 RG11972 –19–14DEC01 B B A C . For wiring on other applications. On some applications. RG40854. see APPLICATION SPECIFICATIONS in Section 06. If DTC SPN 639 FMI 13 sets. Group 210 of this manual. Controller Area Network (CAN) • CAN is the network in which the individual controllers on a machine communicate with each other.5 L & 6. engine operation may or may not be affected. The number of controllers communicating on CAN depends on the application. on other applications. the following will occur: • Depending on the application. the ECU is the only controller on CAN. Start ECU communication software 4.Continued RG40854. Read DTCs using the DST or SERVICE ADVISOR. If no other codes are present.5 L & 6.DTC SPN 639 FMI 13 CAN Error . This will ensure that terminal damage does not occur. engine OFF 3. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Read DTCs using DST or SERVICE ADVISOR™. 04 160 . then clear all DTCs 6. DTC SPN 639 FMI 13 reoccurs: GO TO 3 DTC SPN 639 FMI 13 does not reoccur: Problem is intermittent. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. see INTERMITTENT FAULT DIAGNOSTICS. 5. Ignition ON. 2. Connect the DST or SERVICE ADVISOR™. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-179 4.179 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. see DTC SPN 639 FMI 13 CAN ERROR supporting information 1. or poorly positioned terminals.000010F –19–16JAN02–1/1 Level 12 ECU . damaged. see DTC SPN 639 FMI 13 CAN ERROR supporting information Perform a preliminary inspection of the ECU connector. Make note of all DTCs. Ignition ON 7. Look for dirty. the CAN connections. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.8 L Level 12 Electronic Fuel System 040902 PN=339 . earlier in this Group.Trouble Code Diagnostics and Tests Level 12 ECU . For instructions on connecting to the DST or SERVICE ADVISOR™.DTC SPN 639 FMI 13 CAN Error Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. and any other connector. 8 L Level 12 Electronic Fuel System 040902 PN=340 . Ignition OFF 2. Disconnect ECU connector 3. check those controllers for CAN related DTCs No CAN related DTCs found on other controllers: GO TO 4 Found CAN related DTCs on other controllers: Refer to machine manual to diagnose and repair the cause of DTC.5 L & 6.180 NOTE: For wiring and theory of operation information. measure resistance between•terminals F1 and G1 in the harness end of the ECU connector Between 55 ohms and 65 ohms: Faulty ECU connector OR Faulty ECU Less than 55 ohms or greater than 65 ohms: Open or short in CAN communication circuit – – –1/1 CTM331 (09APR02) 04-160-180 4. see DTC SPN 639 FMI 13 CAN ERROR supporting information 1. see DTC SPN 639 FMI 13 CAN ERROR supporting information If application has other machine controllers communicating on the CAN bus. then determine if DTC SPN 639 FMI 13 reoccurs – – –1/1 4 CAN Resistance Test 04 160 .Trouble Code Diagnostics and Tests 3 Check Other Controllers For CAN Related DTCs NOTE: For wiring and theory of operation information. Using a multimeter. If DTC SPN 898 FMI 9 sets: • Connect the DST or SERVICE ADVISOR™.181 SERVICE ADVISOR is a trademark of Deere & Company RG40854. see DTC SPN 639 FMI 13 CAN ERROR DIAGNOSTIC PROCEDURE earlier in this Group. start the ECU communication software • Read active DTCs and stored DTCs using DST or SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE ADVISOR™. • If no other stored or active CAN or vehicle related DTCs are found.0000114 –19–22JAN02–1/1 CTM331 (09APR02) 04-160-181 4. DTC SPN 898 FMI 9 will set if: • The ECU does not receive the engine speed or torque message over CAN or it is not valid.DTC SPN 898 FMI 9 Vehicle Speed or Torque Message Invalid CAN (Controller Area Network) Vehicle Speed or Torque Message • The CAN (Controller Area Network) transmits the vehicle’s desired engine speed or torque to the ECU from another controller. • With ignition ON and engine OFF. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. the following will occur: • The ECU will default engine speed to low idle. If DTC SPN 639 FMI 13 also occurs.Trouble Code Diagnostics and Tests Level 12 ECU . If DTC SPN 898 FMI 9 sets.8 L Level 12 Electronic Fuel System 040902 PN=341 .5 L & 6. 04 160 . replace the ECU and retest. This will ensure that terminal damage does not occur. If DTC SPN 970 FMI 31 sets. the switch will close. the following will occur: • The ECU will shut the engine down immediately. For wiring on other applications. When the property being RG40854. the voltage is grounded. Group 210 of this manual. NOTE: Wiring schematic shows OEM engine applications only. DTC SPN 970 FMI 31 will set if: • The ECU does not read an input voltage on the auxiliary engine shutdown input wire. the engine shutdown switch is a normally open switch. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.000003E –19–06DEC01–1/1 CTM331 (09APR02) 04-160-182 4. Auxiliary Engine Shutdown Switch • On OEM applications. see APPLICATION SPECIFICATIONS in Section 06.DTC SPN 970 FMI 31 Auxiliary Engine Shutdown Switch Active A1 A2 A3 B1 B2 B3 To External Shutdown Switch Sensor Ground Switch Input D3 A1 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 .8 L Level 12 Electronic Fuel System 040902 RG12047 C O N N E C T O R –19–24JAN02 PN=342 . measured exceeds a certain value.Trouble Code Diagnostics and Tests Level 12 ECU . When the switch is closed. which will cause the ECU to shutdown the engine.182 IMPORTANT: Do not force probes into connector terminals or damage will result.5 L & 6. 5 L & 6. External Fuel Derate Switch • On OEM applications. This will ensure that terminal damage does not occur.000003F –19–06DEC01–1/1 CTM331 (09APR02) 04-160-183 4. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. If DTC SPN 971 FMI 31 sets.183 NOTE: Wiring schematic shows OEM engine applications only.DTC SPN 971 FMI 31 External Engine Derate Switch Active A1 A2 A3 B1 B2 B3 To External Derate Switch Sensor Ground Input D3 C2 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 IMPORTANT: Do not force probes into connector terminals or damage will result. For derates on other applications. the following will occur: • On OEM applications. measured exceeds a certain value. see APPLICATION SPECIFICATIONS in Section 06. For wiring on other applications. Group 210 of this manual. DTC SPN 971 FMI 31 will set if: • The ECU does not read an input voltage. which will cause the ECU to derate the engine.Trouble Code Diagnostics and Tests Level 12 ECU . the switch will close. see APPLICATION SPECIFICATIONS in Section 06. Group 210 of this manual.8 L Level 12 Electronic Fuel System 040902 PN=343 . the external derate switch is a normally open switch. the voltage is grounded. When property being RG40854. When the switch is closed. RG12046 C O N N E C T O R –19–23JAN02 04 160 . the ECU will derate the engine 2% per minute until the engine is running at 80% of full power. the pump control valve will return to a position that ends injection pressure. the following will occur: • Engine performance may be erratic.DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . see FUEL INJECTION PUMP OPERATION in Section 03. the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. Group 130 of this manual.0000040 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-184 4. If DTC SPN 1076 FMI 0 sets. The ECU switches current on and off in order to charge the solenoid. RG40854. By controlling current to the solenoid. it moves a pump control valve into a position that allows for injection pressure to be developed.8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=344 . DTC SPN 1076 FMI 0 will set if: • The ECU determines that the pump control valve takes too long to close. When the current to the solenoid is decreased. When the current to the solenoid is increased. For more operation information.184 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an fuel control solenoid that is controlled by the Engine Control Unit (ECU).Trouble Code Diagnostics and Tests Level 12 ECU .5 L & 6. 185 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. 2. 1. If no other codes are present. engine OFF 3. 04 160 . Make note of any DTCs. Start the ECU communication software 4. Look for dirty. Connect the DST or SERVICE ADVISOR™. then clear all DTCs 5. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-185 4.Trouble Code Diagnostics and Tests Level 12 ECU . Ignition ON. Perform a preliminary inspection of the ECU connector. or poorly positioned terminals. see INTERMITTENT FAULT DIAGNOSTICS. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. SPN 1076 FMI 0 reoccurs: GO TO 3 SPN 1076 FMI 0 does not reoccur: Problem is intermittent. Read DTCs using DST or SERVICE ADVISOR™. see DTC SPN 1076 FMI 0 PUMP CONTROL VALVE CLOSURE TOO LONG supporting information. engine cranking or running 6. damaged. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. see DTC SPN 1076 FMI 0 PUMP CONTROL VALVE CLOSURE TOO LONG supporting information. Ignition ON. earlier in this Group.8 L Level 12 Electronic Fuel System 040902 PN=345 . For instructions on connecting to the DST or SERVICE ADVISOR™. and any other connector.Continued RG40854.5 L & 6. the pump connector. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long .0000124 –19–29JAN02–1/1 Level 12 ECU . SPN 1076 FMI 0 reoccurs: Faulty ECU SPN 1076 FMI 0 does not reoccur: Problem repaired – – –1/1 04 160 . 2. Remove and install new injection pump. engine running.Trouble Code Diagnostics and Tests 3 Injection Pump Check NOTE: For wiring and theory of operation information.186 CTM331 (09APR02) 04-160-186 4. Read DTCs using DST or SERVICE ADVISOR.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=346 . 3. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02. Group 090 of this manual. see DTC SPN 1076 FMI 0 PUMP CONTROL VALVE CLOSURE TOO LONG supporting information. Ignition ON. 1. 8 L Level 12 Electronic Fuel System 040902 PN=347 .Trouble Code Diagnostics and Tests 04 160 .5 L & 6.187 CTM331 (09APR02) 04-160-187 4. the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. Group 130 of this manual. When the current to the solenoid is decreased. it moves a pump control valve into a position that allows for injection pressure to be developed. the following will occur: • Engine performance may be erratic.0000044 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-188 4. RG40854. By controlling current to the solenoid. see FUEL INJECTION PUMP OPERATION in Section 03. The ECU switches current on and off in order to charge the solenoid. For more operation information. the pump control valve will return to a position that ends injection pressure.Trouble Code Diagnostics and Tests Level 12 ECU .8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=348 .DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . If DTC SPN 1076 FMI 1 sets.5 L & 6. DTC SPN 1076 FMI 1 will set if: • The ECU determines that the control valve closes too quickly. When the current to the solenoid is increased.188 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an fuel control solenoid that is controlled by the Engine Control Unit (ECU). then clear all DTCs 5. Perform a preliminary inspection of the ECU connector. SPN 1076 FMI 1 reoccurs: GO TO 3 SPN 1076 FMI 1 does not reoccur: Problem is intermittent. For instructions on connecting to the DST or SERVICE ADVISOR™. and any other connector. damaged. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Look for dirty. the pump connector. Ignition ON. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-189 4. This will ensure that terminal damage does not occur. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. see DTC SPN 1076 FMI 1 PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information. 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=349 . earlier in this Group. Connect the DST or SERVICE ADVISOR™.DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. engine cranking or running 6.DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short . or poorly positioned terminals.0000125 –19–29JAN02–1/1 Level 12 ECU .189 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. Make note of any DTCs. Start the ECU communication software 4.5 L & 6. If no other codes are present. Read DTCs using DST or SERVICE ADVISOR™. engine OFF 3. 2.Trouble Code Diagnostics and Tests Level 12 ECU . see DTC SPN 1076 FMI 1 PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information. see INTERMITTENT FAULT DIAGNOSTICS. 1. Ignition ON.Continued RG40854. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. 1. Remove and install new injection pump. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02. engine OFF 2.Trouble Code Diagnostics and Tests 3 Checking Battery Voltage NOTE: For wiring and theory of operation information. Read the Battery Voltage parameter using the DST or SERVICE ADVISOR.190 NOTE: For wiring and theory of operation information. Ignition ON. 1. Group 090 of this manual.8 L Level 12 Electronic Fuel System 040902 PN=350 .5 L & 6. At or near battery voltage: GO TO 4 Significantly above or below battery voltage: Faulty power supply – – –1/1 4 Injection Pump Check 04 160 . see DTC SPN 1076 FMI 1 PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information. Read DTCs using the DST or SERVICE ADVISOR. 2. see DTC SPN 1076 FMI 1 PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information. engine running. 3. SPN 1076 FMI 1 reoccurs: Faulty ECU SPN 1076 FMI 1 does not reoccur: Problem repaired – – –1/1 CTM331 (09APR02) 04-160-190 4. Ignition ON. 5 L & 6.Trouble Code Diagnostics and Tests 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=351 .191 CTM331 (09APR02) 04-160-191 4. 192 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). DTC SPN 1076 FMI 3 will set if: • The ECU determines that pump solenoid current is higher than normal. If DTC SPN 1076 FMI 3 sets. When the current to the solenoid is increased.8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=352 . see FUEL INJECTION PUMP OPERATION in Section 03. By controlling current to the solenoid.Trouble Code Diagnostics and Tests Level 12 ECU . For more operation information.5 L & 6. the following will occur: • Engine performance may be erratic. When the current to the solenoid is decreased. the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. RG40854. it moves a pump control valve into a position that allows for injection pressure to be developed.DTC SPN 1076 FMI 3 Pump Solenoid Current High Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . the pump control valve will return to a position that ends injection pressure. The ECU switches current on and off in order to charge the solenoid. Group 130 of this manual.0000046 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-192 4. This will ensure that terminal damage does not occur. and any other connector.DTC SPN 1076 FMI 3 Pump Solenoid Current High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Read DTCs using DST or SERVICE ADVISOR™. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Connect the DST or SERVICE ADVISOR™. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. or poorly positioned terminals. engine OFF 3.Continued RG40854.8 L Level 12 Electronic Fuel System 040902 PN=353 .5 L & 6.Trouble Code Diagnostics and Tests Level 12 ECU . SPN 1076 FMI 3 reoccurs: GO TO 3 SPN 1076 FMI 3 does not reoccur: Problem is intermittent. damaged. Start the ECU communication software 4.DTC SPN 1076 FMI 3 Pump Solenoid Current High .0000126 –19–29JAN02–1/1 Level 12 ECU . 2. earlier in this Group. Perform a preliminary inspection of the ECU connector. see INTERMITTENT FAULT DIAGNOSTICS. Ignition ON. Look for dirty.193 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. If no other codes are present. Ignition ON. For instructions on connecting to the DST or SERVICE ADVISOR™. 04 160 . engine cranking or running 6. the pump connector. then clear all DTCs 5. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-193 4. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Make note of any DTCs. see DTC SPN 1076 FMI 3 PUMP SOLENOID CURRENT HIGH supporting information. see DTC SPN 1076 FMI 3 PUMP SOLENOID CURRENT HIGH supporting information. 1. Remove and install new injection pump. measure resistance between Terminal A3 and all other terminals in the ECU connector Measurement greater than 20. Disconnect pump solenoid connector and ECU connector 3. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02. Read DTCs using the DST or SERVICE ADVISOR. Ignition ON. Ignition OFF 2.5 L & 6. Using a multimeter. 1.000 ohms: Short to power in pump solenoid return wire – – –1/1 04 160 . measure resistance between Terminal K2 and all other terminals in the ECU connector Measurement greater than 20.194 4 Pump Solenoid Supply Wire Check NOTE: For wiring and theory of operation information. see DTC SPN 1076 FMI 3 PUMP SOLENOID CURRENT HIGH supporting information. engine running. 1. 1.Trouble Code Diagnostics and Tests 3 Pump Solenoid Return Wire Check NOTE: For wiring and theory of operation information.000 ohms: GO TO 4 Measurement less than 20. 2. Disconnect pump solenoid connector and ECU connector 3. Using a multimeter. see DTC SPN 1076 FMI 3 PUMP SOLENOID CURRENT HIGH supporting information. Ignition OFF 2. Group 090 of this manual. see DTC SPN 1076 FMI 3 PUMP SOLENOID CURRENT HIGH supporting information. SPN 1076 FMI 3 reoccurs: Faulty ECU SPN 1076 FMI 3 does not reoccur: Problem repaired – – –1/1 CTM331 (09APR02) 04-160-194 4.000 ohms: Short to power in pump solenoid supply wire – – –1/1 5 Injection Pump Check NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=354 . 3.000 ohms: GO TO 5 Measurement less than 20. 5 L & 6.195 CTM331 (09APR02) 04-160-195 4.Trouble Code Diagnostics and Tests 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=355 . see FUEL INJECTION PUMP OPERATION in Section 03. The ECU switches current on and off in order to charge the solenoid. If DTC SPN 1076 FMI 5 sets. For more operation information. the following will occur: • Engine will not run.DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . it moves a pump control valve into a position that allows for injection pressure to be developed. Group 130 of this manual. By controlling current to the solenoid.8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=356 . the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. When the current to the solenoid is increased. the pump control valve will return to a position that ends injection pressure. DTC SPN 1076 FMI 5 will set if: • The ECU determines that pump solenoid circuit is open.0000049 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-196 4.5 L & 6. When the current to the solenoid is decreased.196 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU).Trouble Code Diagnostics and Tests Level 12 ECU . RG40854. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Look for dirty. and any other connector. If no other codes are present.DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open . Perform a preliminary inspection of the ECU connector. Make note of any DTCs. see INTERMITTENT FAULT DIAGNOSTICS. 04 160 . see DTC SPN 1076 FMI 5 PUMP SOLENOID CIRCUIT OPEN supporting information.5 L & 6.DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. Read DTCs using DST or SERVICE ADVISOR™. earlier in this Group. Ignition ON. Use JT07328 Connector Adapter Test Kit to make measurements in connectors.8 L Level 12 Electronic Fuel System 040902 PN=357 . Ignition ON. For instructions on connecting to the DST or SERVICE ADVISOR™. then clear all DTCs 5. Connect the DST or SERVICE ADVISOR™. the pump connector. engine cranking or running 6. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-197 4. see DTC SPN 1076 FMI 5 PUMP SOLENOID CIRCUIT OPEN supporting information. or poorly positioned terminals. Start the ECU communication software 4.197 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. This will ensure that terminal damage does not occur. 2.Trouble Code Diagnostics and Tests Level 12 ECU . SPN 1076 FMI 5 reoccurs: GO TO 3 SPN 1076 FMI 5 does not reoccur: Problem is intermittent. engine OFF 3. damaged.000004C –19–06DEC01–1/1 Level 12 ECU .Continued RG40854. 1. Measurement less than 5 ohms: GO TO 4 Measurment 5 ohms or greater: Faulty ECU connector OR Faulty ECU – – –1/1 04 160 . 1. measure resistance between: • Terminal K2 in the ECU connector and terminal A in the pump solenoid connector • Terminal A3 in the ECU connector and terminal B in the pump solenoid connector Both measurements less than 5 ohms: Faulty pump connector OR Faulty injection pump Either measurement greater than 5 ohms: Faulty pump connector OR Faulty ECU connector OR Open in pump solenoid supply wire OR Open in pump solenoid return wire – – –1/1 CTM331 (09APR02) 04-160-198 4. 1. Using a multimeter. Disconnect pump solenoid connector and ECU connector 3. Using a multimeter.Trouble Code Diagnostics and Tests 3 ECU Check NOTE: For wiring and theory of operation information. Ignition OFF 2. see DTC SPN 1076 FMI 5 PUMP SOLENOID CIRCUIT OPEN supporting information. Disconnect ECU connector 3. Ignition OFF.5 L & 6. measure resistance between terminal K2 and terminal A3 of the harness side of the ECU connector.198 4 Injection Pump Wiring Check NOTE: For wiring and theory of operation information. see DTC SPN 1076 FMI 5 PUMP SOLENOID CIRCUIT OPEN supporting information.8 L Level 12 Electronic Fuel System 040902 PN=358 . engine OFF 2. 199 CTM331 (09APR02) 04-160-199 4.Trouble Code Diagnostics and Tests 04 160 .5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=359 . Trouble Code Diagnostics and Tests Level 12 ECU . the ECU has the ability to manage the quantity and timing of fuel delivery to the engine.DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 .5 L & 6. the pump control valve will return to a position that ends injection pressure. The ECU switches current on and off in order to charge the solenoid.000004D –19–06DEC01–1/1 CTM331 (09APR02) 04-160-200 4. For more operation information. If DTC SPN 1076 FMI 6 sets. Group 130 of this manual. When the current to the solenoid is decreased.8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=360 . the following will occur: • ECU will shut engine down immediately. it moves a pump control valve into a position that allows for injection pressure to be developed.200 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). When the current to the solenoid is increased. By controlling current to the solenoid. see FUEL INJECTION PUMP OPERATION in Section 03. DTC SPN 1076 FMI 6 will set if: • The ECU determines that pump solenoid circuit is shorted. RG40854. 1. If no other codes are present. Make note of any DTCs.5 L & 6. Look for dirty. the pump connector. Ignition ON. earlier in this Group. see INTERMITTENT FAULT DIAGNOSTICS.8 L Level 12 Electronic Fuel System 040902 PN=361 .DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted . Use JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. see DTC SPN 1076 FMI 6 PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information. 04 160 .201 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. Read DTCs using DST or SERVICE ADVISOR™.DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. For instructions on connecting to the DST or SERVICE ADVISOR™. Connect the DST or SERVICE ADVISOR™. SPN 1076 FMI 6 reoccurs: GO TO 3 SPN 1076 FMI 6 does not reoccur: Problem is intermittent. engine OFF 3. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group.Trouble Code Diagnostics and Tests Level 12 ECU . 2. or poorly positioned terminals.0000127 –19–29JAN02–1/1 Level 12 ECU . Ignition ON.Continued RG40854. and any other connector. see DTC SPN 1076 FMI 6 PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information. Start the ECU communication software 4. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-201 4. Perform a preliminary inspection of the ECU connector. then clear all DTCs 5. damaged. engine cranking or running 6. 1. see DTC SPN 1076 FMI 6 PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information. 1. measure resistance between terminal K2 of the harness side of the ECU connector and: • A good ground • All other terminals in the ECU connector Measurement greater than 20.Trouble Code Diagnostics and Tests 3 Pump Solenoid Supply Circuit Check NOTE: For wiring and theory of operation information.000 ohms: GO TO 4 Measurement less than 20. Disconnect pump solenoid connector and ECU connector 3. see DTC SPN 1076 FMI 6 PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information. Remove and install new injection pump. SPN 1076 FMI 6 reoccurs: Faulty ECU SPN 1076 FMI 6 does not reoccur: Problem repaired – – –1/1 CTM331 (09APR02) 04-160-202 4. Ignition ON.5 L & 6.000 ohms: GO TO 5 Measurement less than 20. 2. see DTC SPN 1076 FMI 6 PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.202 4 Pump Solenoid Return Circuit Check NOTE: For wiring and theory of operation information. Using a multimeter. Ignition OFF 2. Disconnect pump solenoid connector and ECU connector 3.000 ohms: Pump solenoid return wire shorted – – –1/1 5 Injection Pump Check NOTE: For wiring and theory of operation information. engine running. Read DTCs using DST or SERVICE ADVISOR. Group 090 of this manual. measure resistance between terminal A3 of the harness side of the ECU connector and: • A good ground • All other terminals in the ECU connector Measurement greater than 20. 3. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02.8 L Level 12 Electronic Fuel System 040902 PN=362 . 1.000 ohms: Pump solenoid supply wire shorted – – –1/1 04 160 . Ignition OFF 2. Using a multimeter. 203 CTM331 (09APR02) 04-160-203 4.Trouble Code Diagnostics and Tests 04 160 .5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=363 . the following will occur: • Engine performance may be erratic. By controlling current to the solenoid. see FUEL INJECTION PUMP OPERATION in Section 03. When the current to the solenoid is increased.DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 . the pump control valve will return to a position that ends injection pressure. The ECU switches current on and off in order to charge the solenoid. DTC SPN 1076 FMI 7 will set if: • The ECU determines that it can not detect the closure of the pump control valve.Trouble Code Diagnostics and Tests Level 12 ECU .000004F –19–06DEC01–1/1 CTM331 (09APR02) 04-160-204 4.204 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. For more operation information. If DTC SPN 1076 FMI 7 sets. RG40854. it moves a pump control valve into a position that allows for injection pressure to be developed. Group 130 of this manual.8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=364 .5 L & 6. When the current to the solenoid is decreased. 1.Trouble Code Diagnostics and Tests Level 12 ECU .DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. or poorly positioned terminals. Start the ECU communication software 4. For instructions on connecting to the DST or SERVICE ADVISOR™. and any other connector. Perform a preliminary inspection of the ECU connector. 2. Look for dirty. engine OFF 3. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group.205 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.0000050 –19–06DEC01–1/1 Level 12 ECU . Ignition ON. If no other codes are present. Connect the DST or SERVICE ADVISOR™. then clear all DTCs 5.5 L & 6.DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected Continued RG40854. SPN 1076 FMI 7 reoccurs: GO TO 3 SPN 1076 FMI 7 does not reoccur: Problem is intermittent. Read DTCs using the DST or SERVICE ADVISOR™. the pump connector. 04 160 . Make note of any DTCs. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. damaged. see DTC SPN 1076 FMI 7 PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information.8 L Level 12 Electronic Fuel System 040902 PN=365 . This will ensure that terminal damage does not occur. Ignition ON. engine cranking or running 6. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-205 4. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. see DTC SPN 1076 FMI 7 PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information. see INTERMITTENT FAULT DIAGNOSTICS. earlier in this Group. engine running. see DTC SPN 1076 FMI 7 PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information. 3. SPN 1076 FMI 7 reoccurs: Faulty ECU SPN 1076 FMI 7 does not reoccur: Problem repaired – – –1/1 04 160 . Group 090 of this manual.206 CTM331 (09APR02) 04-160-206 4. 2. Read DTCs using the DST or SERVICE ADVISOR.Trouble Code Diagnostics and Tests 3 Injection Pump Check NOTE: For wiring and theory of operation information. Remove and install new injection pump. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02. 1.8 L Level 12 Electronic Fuel System 040902 PN=366 .5 L & 6. Ignition ON. 5 L & 6.Trouble Code Diagnostics and Tests 04 160 .207 CTM331 (09APR02) 04-160-207 4.8 L Level 12 Electronic Fuel System 040902 PN=367 . For more operation information. If DTC SPN 1076 FMI 10 sets. DTC SPN 1076 FMI 10 will set if: • Pump solenoid circuit is moderately shorted to power. the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. Group 130 of this manual.DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 04 160 .0000051 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-208 4. it moves a pump control valve into a position that allows for injection pressure to be developed. When the current to the solenoid is decreased. When the current to the solenoid is increased. RG40854.8 L Level 12 Electronic Fuel System 040902 RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R PN=368 . the pump control valve will return to a position that ends injection pressure. see FUEL INJECTION PUMP OPERATION in Section 03. By controlling current to the solenoid.5 L & 6.208 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). the following will occur: • ECU will derate engine to 50% of full power immediately.Trouble Code Diagnostics and Tests Level 12 ECU . The ECU switches current on and off in order to charge the solenoid. or poorly positioned terminals. damaged. Read DTCs using DST or SERVICE ADVISOR™. Start the ECU communication software 4. If no other codes are present.5 L & 6. Ignition ON. Ignition ON. Look for dirty. Perform a preliminary inspection of the ECU connector. Make note of any DTCs.8 L Level 12 Electronic Fuel System 040902 PN=369 . Use JT07328 Connector Adapter Test Kit to make measurements in connectors.DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.Trouble Code Diagnostics and Tests Level 12 ECU . and any other connector. then clear all DTCs 5. 04 160 . For instructions on connecting to the DST or SERVICE ADVISOR™.DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted Continued RG40854. see DTC SPN 1076 FMI 10 PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information. see DTC SPN 1076 FMI 10 PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information. Connect the DST or SERVICE ADVISOR™. engine OFF 3. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-209 4. This will ensure that terminal damage does not occur.0000050 –19–06DEC01–1/1 Level 12 ECU . see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. earlier in this Group. the pump connector. 2. see INTERMITTENT FAULT DIAGNOSTICS. SPN 1076 FMI 10 reoccurs: GO TO 3 SPN 1076 FMI 10 does not reoccur: Problem is intermittent. 1.209 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. engine cranking or running 6. 3. see DTC SPN 1076 FMI 10 PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information. Read DTCs using the DST or SERVICE ADVISOR. Disconnect pump solenoid connector and ECU connector 3. engine running. Ignition OFF 2. see DTC SPN 1076 FMI 10 PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information. Using a multimeter.000 ohms: GO TO 5 Measurement less than 20.210 4 Pump Solenoid Return Circuit Check NOTE: For wiring and theory of operation information. Disconnect pump solenoid connector and ECU connector 3.Trouble Code Diagnostics and Tests 3 Pump Solenoid Supply Circuit Check NOTE: For wiring and theory of operation information. 1. Group 090 of this manual. Remove and install new injection pump.000 ohms: Pump solenoid return wire shorted – – –1/1 5 Injection Pump Check NOTE: For wiring and theory of operation information. Using a multimeter.000 ohms: GO TO 4 Measurement less than 20. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02. measure resistance between terminal K2 of the harness side of the ECU connector and: • A good ground • All other terminals in the ECU connector Measurement greater than 20.000 ohms: Pump solenoid supply wire shorted – – –1/1 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=370 . SPN 1076 FMI 10 reoccurs: Faulty ECU SPN 1076 FMI 10 does not reoccur: Problem repaired – – –1/1 CTM331 (09APR02) 04-160-210 4. 1. Ignition OFF 2. 2. see DTC SPN 1076 FMI 10 PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information. Ignition ON.5 L & 6. measure resistance between terminal A3 of the harness side of the ECU connector and: • A good ground • All other terminals in the ECU connector Measurement greater than 20. 1. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=371 .211 CTM331 (09APR02) 04-160-211 4.Trouble Code Diagnostics and Tests 04 160 . 8 L Level 12 Electronic Fuel System 040902 PN=372 RG12044 C O N N E C T O R –19–23JAN02 .5 volts on the ECU 5 volt sensor supply circuit. The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECU’s memory to determine the value of the parameter the sensor was measuring. the following will occur: • The ECU will use default values for the sensors that use sensor supply input voltage. If DTC 1079 FMI 3 sets. In addition.DTC SPN 1079 FMI 3 Sensor Supply Voltage High Analog Throttle (A) Sensor Connector Analog Throttle (A) Sensor A B C A B C Sensor Return Sensor 5V D3 E2 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S Analog Throttle (A) Input B3 04 160 . the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings.Trouble Code Diagnostics and Tests Level 12 ECU .0000052 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-212 4. RG40854.5 L & 6.212 Sensor Supply Voltage • The ECU supplies voltage to a few different sensors depending on the application. DTC 1079 FMI 3 will set if: • The ECU detects a voltage that is higher than 5. Connect the DST or SERVICE ADVISOR™. Ignition ON. This will ensure that terminal damage does not occur. For instructions on connecting to the DST or SERVICE ADVISOR™. engine OFF 6.Continued RG40854. damaged. see DTC SPN 1079 FMI 3 SENSOR SUPPLY VOLTAGE HIGH supporting information. Look for dirty. then clear all DTCs 5. SPN 1079 FMI 3 reoccur: GO TO 3 SPN 1079 FMI 3 does not reoccur: Problem is intermittent. Ignition ON. see INTERMITTENT FAULT DIAGNOSTICS. see DTC SPN 1079 FMI 3 SENSOR SUPPLY VOLTAGE HIGH supporting information.8 L Level 12 Electronic Fuel System 040902 PN=373 . Start the ECU communication software 4. or poorly positioned terminals. 04 160 . 1. engine OFF 3.DTC SPN 1079 FMI 3 Sensor Supply Voltage High . Perform a preliminary inspection of the ECU connector.213 – – –1/1 2 Intermittent Fault Test NOTE: For wiring and theory of operation information.5 L & 6. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information. If no other codes are present. 2.000010E –19–16JAN02–1/1 Level 12 ECU .DTC SPN 1079 FMI 3 Sensor Supply Voltage High Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Make notes of any DTCs. SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-213 4. and any connectors in between. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. the analog throttle (A) connector. Read DTCs using DST or SERVICE ADVISOR™.Trouble Code Diagnostics and Tests Level 12 ECU . earlier in this Group. DTC SPN 1079 FMI 3 SENSOR SUPPLY VOLTAGE HIGH supporting information.5 L & 6. Using a multimeter.Trouble Code Diagnostics and Tests 3 Sensor Supply Wire Check for Short NOTE: For wiring and theory of operation information.000 ohms: Faulty ECU connector OR Faulty ECU Less than 20. Disconnect ECU connector 3.214 CTM331 (09APR02) 04-160-214 4. 1. measure resistance between terminal E2 the harness end of the ECU connector and all other terminals in the harness end of the ECU connector Greater than 20.8 L Level 12 Electronic Fuel System 040902 PN=374 .000 ohms: Short to voltage in sensor supply wire – – –1/1 04 160 . Ignition OFF 2. Trouble Code Diagnostics and Tests 04 160 .5 L & 6.215 CTM331 (09APR02) 04-160-215 4.8 L Level 12 Electronic Fuel System 040902 PN=375 . RG40854.Trouble Code Diagnostics and Tests Level 12 ECU . the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. In addition. DTC 1079 FMI 4 will set if: • The ECU detects a voltage that is lower than 4.216 Sensor Supply Voltage • The ECU supplies voltage to a few different sensors depending on the application. If DTC 1079 FMI 4 sets. the following will occur: • The ECU will use default values for the sensors that use sensor supply input voltage.5 L & 6.DTC SPN 1079 FMI 4 Sensor Supply Voltage Low Analog Throttle (A) Sensor Connector Analog Throttle (A) Sensor A B C A B C Sensor Return Sensor 5V D3 E2 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 E C U H A R N E S S Analog Throttle (A) Input B3 04 160 .0000054 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-216 4.44 volts on the ECU 5 volt sensor supply circuit. The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECU’s memory to determine the value of the parameter the sensor was measuring.8 L Level 12 Electronic Fuel System 040902 PN=376 RG12044 C O N N E C T O R –19–23JAN02 . Look for dirty. 2. damaged. see DTC SPN 1079 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. Disconnect all of the sensors that receive their 5 V supply from terminal E2 in the ECU connector.DTC SPN 1079 FMI 4 Sensor Supply Voltage Low Diagnostic Procedure – – –1/1 1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.DTC SPN 1079 FMI 4 Sensor Supply Voltage Low . SPN 1079 FMI 4 reoccurs: GO TO 4 SPN 1079 FMI 4 does not reoccur: GO TO 3 SERVICE ADVISOR is a trademark of Deere & Company – – –1/1 CTM331 (09APR02) 04-160-217 4. Make note of any DTCs. This will ensure that terminal damage does not occur.Continued RG40854. or poorly positioned terminals. see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. Perform a preliminary inspection of the ECU connector. the analog throttle (A) connector.Trouble Code Diagnostics and Tests Level 12 ECU . engine running 8. Ignition ON. see DTC SPN 1079 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s) NOTE: For wiring and theory of operation information.8 L Level 12 Electronic Fuel System 040902 PN=377 . 7. 04 160 . then clear all DTCs 5. Ignition ON. Read DTCs using DST or SERVICE ADVISOR™. Ignition OFF 6. 1.5 L & 6. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Connect the DST or SERVICE ADVISOR™. Start the ECU communication software 4. engine OFF 3. For instructions on connecting to the DST or SERVICE ADVISOR™.000010D –19–16JAN02–1/1 Level 12 ECU .217 – – –1/1 2 Sensor Check NOTE: For wiring and theory of operation information. and any connectors in between. see INTERMITTENT FAULT DIAGNOSTICS. see DTC SPN 1079 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information.8 L Level 12 Electronic Fuel System 040902 PN=378 . measure resistance individually between terminal E2 in the harness end of the ECU connector and: • A good chassis ground • Terminal J2 in the harness end of the ECU connector • Terminal D3 in the harness end of the ECU connector Greater than 20.Trouble Code Diagnostics and Tests 3 Intermittent Fault Test NOTE: For wiring and theory of operation information.218 4 Sensor Supply Short to Ground Check NOTE: For wiring and theory of operation information. While reconnecting each of the sensors one at a time. Using a multimeter. Ignition OFF 2. 1. – – –1/1 04 160 .000 ohms: Sensor 5 volt supply circuit shorted to a ground – – –1/1 CTM331 (09APR02) 04-160-218 4. If no other codes are present. SPN 1079 FMI 4 reoccurs: Sensor that reset the DTC is faulty Replace and retest SPN 1079 FMI 4 does not reoccur: Problem is intermittent.000 ohms: Faulty ECU connector OR Faulty ECU Less than 20.5 L & 6. Ignition ON 2. 1. earlier in this Group. Disconnect ECU connector 3. read DTCs using the DST or SERVICE ADVISOR. see DTC SPN 1079 FMI 4 SENSOR SUPPLY VOLTAGE LOW supporting information. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=379 .219 CTM331 (09APR02) 04-160-219 4.Trouble Code Diagnostics and Tests 04 160 . it will derate (according to relating DTC) the engine for 30 seconds and will shut the engine down. high loss of coolant temperature. DTC SPN 1109 FMI 31 will set if: • • • • The The The The ECU ECU ECU ECU detects detects detects detects low oil pressure. the following will occur: RG40854.DTC SPN 1109 FMI 31 Engine Protection Shutdown Warning Engine Shutdown Warning: • This code informs the operator that the ECU will shut the engine down because it has detected a condition such as low oil pressure.0000056 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-220 4. the engine will be derated.220 • If the ECU has engine protection with shutdown. see DTC SPN 110 FMI 0 ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE DIAGNOSTIC PROCEDURE earlier in this Group of the manual. a high fuel temperature. or a faulty injection pump. Prior to shutdown. low coolant level.Trouble Code Diagnostics and Tests Level 12 ECU . • If DTC SPN 111 FMI 0 is active. a high loss of coolant temperature. • If DTC SPN 110 FMI 0 is active. If DTC SPN 1109 FMI 31 sets. see DTC SPN 174 FMI 16 FUEL TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. high fuel temperature. 04 160 . see DTC SPN 111 FMI 0 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. • If DTC SPN 174 FMI 16 is active. the ECU has shut the engine down within 30 seconds. a high engine coolant temperature. If the ECU is programmed with engine protection with shutdown.8 L Level 12 Electronic Fuel System 040902 PN=380 . If DTC 1109 FMI 31 sets: • If DTC SPN 100 FMI 1 is active.5 L & 6. see DTC SPN 100 FMI 1 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE earlier in this Group of the manual. high engine coolant temperature. see DTC SPN 110 FMI 0 ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE DIAGNOSTIC PROCEDURE earlier in this Group of the manual.0000057 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-221 4. or low coolant level.8 L Level 12 Electronic Fuel System 040902 PN=381 . a high engine coolant temperature. If DTC 1110 FMI 31 sets: • If DTC SPN 100 FMI 1 is active. high loss of coolant temperature. DTC SPN 1110 FMI 31 will set if: • • • • The The The The ECU ECU ECU ECU detects detects detects detects low oil pressure. see DTC SPN 111 FMI 0 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. 04 160 . • If DTC SPN 174 FMI 16 is active. the ECU has shut the engine down. a high loss of coolant temperature. the following will occur: • The ECU will have shut the engine down. • If DTC SPN 110 FMI 0 is active. see DTC SPN 100 FMI 1 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE earlier in this Group of the manual. see DTC SPN 174 FMI 16 FUEL TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. a high fuel temperature.DTC SPN 1110 FMI 31 Engine Protection Shutdown Engine Protection Shutdown: • This code informs the operator that the ECU shut the engine down because it has detected a condition such low oil pressure. If the ECU is programmed with engine protection with shutdown. high engine coolant temperature.221 If DTC SPN 1110 FMI 31 sets. • If DTC SPN 111 FMI 0 is active.Trouble Code Diagnostics and Tests Level 12 ECU .5 L & 6. RG40854. see DTC SPN 111 FMI 0 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. high loss of coolant temperature. a high engine coolant temperature. If DTC SPN 174 FMI 16 is active.5 L & 6. high coolant temperature. • – DTC SPN 100 FMI 18 ENGINE OIL PRESSURE MODERATELY LOW DIAGNOSTIC PROCEDURE If DTC SPN 105 FMI 16 is active. or DTC SPN 110 FMI 16 is active. see one of the following procedures earlier in this Group of the manual: – DTC SPN 100 FMI 1 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE • • RG40854. DTC SPN 110 FMI 15. high manifold air temperature. high manifold air temperature. see one of the following procedures earlier in this Group of the manual: – DTC SPN 110 FMI 0 ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE DIAGNOSTIC PROCEDURE – DTC SPN 110 FMI 15 ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE DIAGNOSTIC PROCEDURE – DTC SPN 110 FMI 16 ENGINE COOLANT TEMPERATURE HIGH MODERATELY SEVERE DIAGNOSTIC PROCEDURE If DTC SPN 111 FMI 0 is active. a high fuel temperature. see DTC SPN 174 FMI 16 FUEL TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual.8 L Level 12 Electronic Fuel System 040902 PN=382 . or high fuel temperature.DTC SPN 1569 FMI 31 Fuel Derate Fuel Derate • The fuel derate trouble code is set to indicate that the ECU has detected a condition such as low oil pressure.0000058 –19–06DEC01–1/1 CTM331 (09APR02) 04-160-222 4. DTC SPN 1569 FMI 31 will set if: • • • • • The The The The The ECU ECU ECU ECU ECU detects detects detects detects detects low oil pressure. a high loss of coolant temperature. If the ECU detects one of these conditions.Trouble Code Diagnostics and Tests Level 12 ECU .222 If DTC SPN 1569 FMI 31 sets. • 04 160 . If DTC SPN 110 FMI 0. see DTC SPN 105 FMI 16 MANIFOLD AIR TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. the following will occur: • The ECU will limit the amount of fuel available to the engine in an attempt to protect the engine. it will begin to derate the amount of fuel delivered to the engine. If DTC SPN 1569 FMI 31 sets: • If DTC SPN 100 FMI 1 or DTC SPN 100 FMI 18 is active. RG11985 –19–20DEC01 Pump Solenoid Supply C O N N E C T O R 04 160 .8 L Level 12 Electronic Fuel System 040902 PN=383 . the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. see FUEL INJECTION PUMP OPERATION in Section 03.5 L & 6.DTC SPN 2000 FMI 6 Internal ECU Failure Pump Solenoid A1 A2 A3 Pump Solenoid Connector Pump Solenoid Return B A B A B1 B2 B3 C1 C2 C3 D1 D2 D3 E C U H A R N E S S A3 K2 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 Stanadyne DE10 Injection Pump • The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). For more operation information. Group 130 of this manual. the pump control valve will return to a position that ends injection pressure.000005A –19–06DEC01–1/1 CTM331 (09APR02) 04-160-223 4. If DTC SPN 2000 FMI 6 sets. The ECU switches current on and off in order to charge the solenoid.223 RG40854. the following will occur: • Engine shuts down immediately If DTC SPN 2000 FMI 6 sets: • Replace the ECU and retest. it moves a pump control valve into a position that allows for injection pressure to be developed. DTC SPN 2000 FMI 6 will set if: • ECU has detected a short in the ECU that causes an extremely high current at the injection pump. By controlling current to the solenoid.Trouble Code Diagnostics and Tests Level 12 ECU . When the current to the solenoid is decreased. When the current to the solenoid is increased. 5 L & 6.Trouble Code Diagnostics and Tests Level 12 ECU . go to the appropriate diagnostic procedure. the following will occur: RG40854. DTC SPN 2000 FMI 13 will set if: • The ECU determines that it.000005B –19–06DEC01–1/1 CTM331 (09APR02) 04-160-224 4. OR another controller on the machine is not the right controller for the particular machine.DTC SPN 2000 FMI 13 Security Violation Security Violation • When the ignition is first turned on. all of the controllers on the machine communicate with each other to make sure that all controllers are correct for the particular machine. 04 160 . If DTC SPN 2000 FMI 13 sets: • If one of the controllers on the machine has just been replaced.8 L Level 12 Electronic Fuel System 040902 PN=384 .224 • The ECU will allow the engine to start. check to see if any of the controllers have active or stored CAN related DTCs. If DTC SPN 2000 FMI 13 sets. • If all controllers on the machine are the correct part numbers. make sure the correct controller was installed. but will only allow low idle engine speed. If they do. . . . . . . . . . . . . . .05-170-1 Fuel System Repair and Adjustment Service Equipment and Tools . . . . . . . . . .05-170-9 05 Group 180—Diagnostic Service Tools Electronic Fuel System Diagnostic Tools. . . . . . . .05-170-4 Control System Repair and Adjustment Essential Tools . . . . . . . . . .Section 05 Tools and Other Materials Contents Page Group 170—Electronic Fuel/Control System Repair Tools and Other Materials Fuel System Repair and Adjustment Essential Tools . .8 L Level 12 Electronic Fuel System 040902 PN=1 . . . . . . . . . . . . . . . .05-170-3 Fuel System Repair and Adjustment Other Materials . . . . . . . . . . . . . . . . . . . .5 L & 6. . . . . . . . . . . . . . . . .05-170-5 Control System Repair and Adjustment Other Materials . . . . . . .05-180-1 CTM331 (09APR02) 05-1 4. . . . . . . . . . . . . Contents 05 CTM331 (09APR02) 05-2 4.8 L Level 12 Electronic Fuel System 040902 PN=2 .5 L & 6. .000020F –19–27NOV01–2/10 RG12020 –UN–19NOV01 DE10 Injection Pump Timing Pin . . . JDG1571 Used to lock flywheel at No. . . . .Group 170 Electronic Fuel/Control System Repair Tools and Other Materials Fuel System Repair and Adjustment Essential Tools NOTE: Order tools according to information given in the U. . . . . This timing pin MUST be used on engine applications using the tapered-nose crankshaft due to the higher torque specification for damper retaining cap screw. JDG1559 Used for static lock pin timing during installation of injection pump.000020F –19–27NOV01–1/10 Injection Pump Drive Gear Puller . . . . . . . . . . . . . 1 TDC for injection pump timing. . JDG1560 05 170 1 OUO1080. . JDG1560 Remove drive gear from tapered shaft of injection pump. .5 L & 6. . JDG1571 Continued on next page OUO1080. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).000020F –19–27NOV01–4/10 CTM331 (09APR02) 05-170-1 4.8 L Level 12 Electronic Fuel System 040902 PN=387 RG12031 –UN–20DEC01 . SERVICEGARD is a trademark of Deere & Company RG12017 –UN–16NOV01 OUO1080. . .S. . . . . JDG1559 OUO1080. . . . . . . . . .000020F –19–27NOV01–3/10 Timing Pin . . . . . . . . . . . . .5 L & 6. . . . . JDG1515-1 Use with slide hammer to remove injection nozzles.8 L Level 12 Electronic Fuel System 040902 PN=388 . JDE39 05 170 2 OUO1080. . . . . JDE39 Clean injection nozzle bore in cylinder head. . . JDG1521 OUO1080. . . . . . . . . JDG1515-1 OUO1080. . . . . JDG1522 Continued on next page OUO1080.Electronic Fuel/Control System Repair Tools and Other Materials RG11741 –UN–24MAY01 Injection Nozzle Puller .000020F –19–27NOV01–6/10 RG11742 –UN–24MAY01 Spring Chamber Cap Wrench .000020F –19–27NOV01–5/10 RG5084 –UN–23AUG88 Nozzle Bore Cleaning Tool . . JDG1521 Used to remove the spring chamber cap on RSN nozzles. . . . . .000020F –19–27NOV01–7/10 RG12023 –UN–27NOV01 Pressure Adjusting Screw Tool . .000020F –19–27NOV01–8/10 CTM331 (09APR02) 05-170-2 4. . . . . . . . . . JDG1522 Used to adjust opening pressure on RSN nozzles. . S. . SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). . .5 L & 6. . Some tools may be available from a local supplier. JD258 (JD-258) Used to install carbon stop seal in injection nozzle groove. . . . . JDG1515-2 Used to loosen or tighten lock nut of pressure adjusting screws. . .000020F –19–27NOV01–9/10 Nozzle Carbon Stop Seal Installer . . . . . . . .8 L Level 12 Electronic Fuel System 040902 PN=389 . . . . .000020F –19–27NOV01–10/10 Fuel System Repair and Adjustment Service Equipment and Tools NOTE: Order tools according to information given in the U.0000210 –19–27NOV01–1/3 CTM331 (09APR02) 05-170-3 4. . .Electronic Fuel/Control System Repair Tools and Other Materials JDG15152 –UN–13JUN01 Pressure Adjusting Screw Lock Nut Wrench . . OUO1080. . SERVICEGARD is a trademark of Deere & Company Continued on next page OUO1080. . –UN–22JUL92 RG6254 JD258 (JD-258) 05 170 3 OUO1080. . . . . . . . LOCTITE is a registered trademark of Loctite Corp. . . . . . .8 L Level 12 Electronic Fuel System 040902 PN=390 CD30307 –UN–07MAR95 . . . JT25510 OUO1080. JT25510 Check nozzle opening pressure. KJD10109 OUO1080. OUO1080.0000210 –19–27NOV01–3/3 Fuel System Repair and Adjustment Other Materials Number Name Use T43512 (U.KJD10109 To connect injection nozzle to BOSCH tester. . . . .0000211 –19–27NOV01–1/1 CTM331 (09APR02) 05-170-4 4. . BOSCH) . . . .S.) TY9473 (Canadian) 242 (LOCTITE®) Thread Lock and Sealer (Medium Strength) Apply to fuel supply pump mounting screws and fuel line fittings.Electronic Fuel/Control System Repair Tools and Other Materials Injection Nozzle Tester (R. .5 L & 6. .0000210 –19–27NOV01–2/3 CD30308 –UN–08MAR95 05 170 4 Fuel Pressure Line . . . . . .0000003 –19–12MAR02–3/17 METRI-PACK™ Crimping Tool . . . . . .JDG364 Used to extract WEATHER PACK™ terminals from electrical connectors. . . . Continued on next page RG40854. . .8 L Level 12 Electronic Fuel System 040902 RW25542A RW25542A PN=391 . .0000003 –19–12MAR02–4/17 CTM331 (09APR02) 05-170-5 4. . . . . . . JDG865 Used to crimp METRI-PACK™ male and female terminals on 14-20 gauge wires. . 05 170 5 WEATHER PACK is a trademark of Packard Electric RG40854. .0000003 –19–12MAR02–2/17 WEATHER PACK™ Crimping Tool . . . . –UN–07MAR02 WEATHER PACK is a trademark of Packard Electric RG40854. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). . . . .5 L & 6. . . . . .S. JDG783 Used to crimp WEATHER PACK™ male and female terminals on 14-20 gauge wires. . . . . . –UN–07MAR02 METRI-PACK is a trademark of Packard Electric Inc. This tool crimps both the wire and the seal retainer at the same time.Electronic Fuel/Control System Repair Tools and Other Materials Control System Repair and Adjustment Essential Tools NOTE: Order tools according to information given in the U.0000003 –19–12MAR02–1/17 Terminal Extraction Tool . SERVICEGARD is a trademark of Deere & Company RW25539 –UN–28AUG96 RG40854. 0000003 –19–12MAR02–7/17 CTM331 (09APR02) 05-170-6 4. and YAZAKI male and female terminals on 12-20 gauge wires. . . .Electronic Fuel/Control System Repair Tools and Other Materials Packard Crimper . . . This tool crimps the wire and the seal retainer separately. .Mate-N-Lock terminal extraction tool. . . METRIPACK. JDG145 Electrician’s Pliers. . JDG143 . . JDG155 This kit is assembled with the most commonly used terminal extraction tools used to repair wiring harnesses on John Deere applications.Sure-Seal terminal insertion tool. . . JDG146 . . . Continued on next page RG40854. JDG139 . . . . .8 L Level 12 Electronic Fuel System 040902 RG11686 –UN–13FEB01 PN=392 RW25558 –UN–29AUG96 .Universal Crimping Pliers.Holding Plate. . . . .Deutsch 6-8 gauge terminal extraction/insertion tool.Carrying Case. JDG144 . . JDG140 .0000003 –19–12MAR02–5/17 Technician’s Electrical Repair Kit . . . JDG145 Used to cut. .CPC Blade Type terminal extraction tool. . . . . SUMITOMO. . . .Mate-N-Lock terminal extraction tool. . . . . JDG707 Used to crimp WEATHER PACK. strip.5 L & 6.CPC and Metrimate terminal extraction tool. JDG142 . and splice wires. RG11679 –UN–05FEB01 05 170 6 RG40854. . . . RG40854. . . . . . JDG141 . . This kit includes the following: JDG107 . . .0000003 –19–12MAR02–6/17 Electrician’s Pliers . . and JDG785 . . . 280-Series.0000003 –19–12MAR02–9/17 METRI-PACK™ Extractor (Narrow) .Electronic Fuel/Control System Repair Tools and Other Materials Technician’s Electrical Repair Kit . and 630-Series METRI-PACK™ connectors. .CPC Blade Type terminal extraction tool. .CPC and Metrimate terminal extraction tool.0000003 –19–12MAR02–10/17 CTM331 (09APR02) 05-170-7 4. .Narrow. . . . . . JDG777 Used to remove terminals from 150-Series METRI-PACK™. METRI-PACK is a trademark of Packard Electric Inc. . . . 05 170 7 METRI-PACK is a trademark of Packard Electric Inc. This kit includes the following: JDG140 . JT07195B This kit is assembled with the most commonly used terminal extraction tools used to repair wiring harnesses on John Deere applications. SUMITOMO. JDG141 . . RG40854. JDG777 METRI-PACK terminal extraction tool .5 L & 6. . .0000003 –19–12MAR02–8/17 RW25541 –UN–20AUG96 RW25558 –UN–29AUG96 METRI-PACK™ Extractor (Wide) . . . JDG364 WEATHERPACK terminal extraction tool. .Deutsch 16-18 gauge terminal extraction/insertion tool.Wide. JDG362 . JDG776 Used to remove terminals from 56-Series. . .Deutsch 6-8 gauge terminal extraction/insertion tool.8 L Level 12 Electronic Fuel System 040902 PN=393 . . JDG361 . Continued on next page RG40854. RW25541 –UN–20AUG96 RG40854. . JDG776 Metripack terminal extraction tool .Deutsch 12-14 gauge terminal extraction/insertion tool. . . . . and YAZAKI connectors. . . . and JDG785 . Electronic Fuel/Control System Repair Tools and Other Materials DEUTSCH™ Electrical Repair Tool Kit . . . RG10740 –UN–31MAY00 RG40854. . . . . JDG362 Extracts wire. . . . . .0000003 –19–12MAR02–12/17 05 170 8 16—18 Gauge Extractor (Set of Two) . . . . . .0000003 –19–12MAR02–16/17 CTM331 (09APR02) 05-170-8 4. . RG40854.0000003 –19–12MAR02–15/17 Terminal Extraction Tool . RG40854. . . . . . . . . .5 L & 6. . . . . FKM10457 Continued on next page RG40854. . . . . . . FKM10457 Used to extract terminals from ECU connector. .0000003 –19–12MAR02–13/17 20—24 Gauge Extractor (Set of Two) . JDG361 Extracts wire. . . . . . . . RG40854. JDG363 Extracts wire. . . . . . JDG360 Install DEUTSCH™ contacts DEUTSCH is a trademark of Deutsch Co. . .8 L Level 12 Electronic Fuel System 040902 PN=394 RW25540 .JDG359 Repair DEUTSCH electrical connector bodies. . .0000003 –19–12MAR02–11/17 12—14 Gauge Extractor (Set of Two) . . .0000003 –19–12MAR02–14/17 Crimping Tool. . . . . –UN–06SEP96 JDG359 DEUTSCH is a trademark of Deutsch Company RG40854. . . . . . . S. .) High Temperature Grease Pipe Sealant Sensor O-rings.JDG144 Used to crimp wire terminal ends for ECU connector. Apply to threads of oil pressure sensor. .S. JDG144 RG40854. . .8 L Level 12 Electronic Fuel System 040902 PN=395 . . .0000003 –19–12MAR02–17/17 Control System Repair and Adjustment Other Materials Number Name Use JDT405 (U. .5 L & 6. . . Lubricant Insulate electrical connectors 05 170 9 LOCTITE is a registered trademark of Loctite Corp. . . . . .Electronic Fuel/Control System Repair Tools and Other Materials RG10739 –UN–26MAY00 Crimping Pliers . . .0000215 –19–27NOV01–1/1 CTM331 (09APR02) 05-170-9 4. .) TY9375 (U.) TY9480 (Canadian) 592 (LOCTITE®) AT66865 (U. .S. . . . . OUO1080. 8 L Level 12 Electronic Fuel System 040902 PN=396 .5 L & 6.Electronic Fuel/Control System Repair Tools and Other Materials 05 170 10 CTM331 (09APR02) 05-170-10 4. Group 180 Diagnostic Service Tools Electronic Fuel System Diagnostic Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD™ Catalog or in the European Microfiche Tool Catalog (MTC) unless otherwise noted. SERVICEGARD is a trademark of Deere & Company. RG40854,0000002 –19–09APR02–1/9 Fuel System Cap Plug Kit . . . . . . . . . . . . . . . . JDG998 Used to protect the fuel system from dirt and debris when disconnecting fuel system components during fuel transfer pump pressure check. –UN–20MAY98 05 180 1 JDG998 RG40854,0000002 –19–09APR02–2/9 RG5162 –UN–23AUG88 Universal Pressure Test Kit . . . . . . . . . . . . . . . JT05412 Used for testing engine oil pressure, intake manifold pressure (turbo boost), and fuel supply pump pressure. JT05412 Continued on next page RG40854,0000002 –19–09APR02–3/9 CTM331 (09APR02) 05-180-1 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 RG8518 PN=397 Diagnostic Service Tools ECU Communication Software Kit. . . . . . . . . . . JDIS122 Please refer to your John Deere Dealer website for information on obtaining the latest version of software. –UN–26NOV97 JDIS122 RG40854,0000002 –19–09APR02–4/9 05 180 2 NOTE: Available from John Deere Distribution Service Center (DSC). United States and Canadian Agricultural dealers DO NOT ORDER without first contacting your Branch or TAM. RG40854,0000002 –19–09APR02–5/9 ECU Communication Hardware Kit . . . . . . . . . . JDIS121 Used with JDIS122 - ECU Communication Software Kit. Together, the kits enable a Windows (’95 or ’98) or NT compatible computer to read information from the Engine Control Unit (ECU). The computer must be at least a 486/66 with 8 MB of RAM and an IEEE 1284 compliant parallel port. –UN–09JUL01 RG8554 RG40854,0000002 –19–09APR02–6/9 NOTE: Available from John Deere Distribution Service Center (DSC). United States and Canadian Agricultural dealers DO NOT ORDER without first contacting your Branch or TAM. Continued on next page RG40854,0000002 –19–09APR02–7/9 CTM331 (09APR02) 05-180-2 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=398 RG11747 Diagnostic Service Tools Digital Multimeter . . . . . . . . . . . . . . . . . . . . JT07306 Test electrical components for voltage, resistance, current flow, or temperature. It is especially good for measuring low voltage or high resistance circuits. –UN–19JUN00 RG40854,0000002 –19–09APR02–8/9 Connector Adapter Test Kit . . . . . . . . . . . . . . . JT07328 Used with JT05791 Digital Multimeter to make voltage and resistance measurements in control system wiring harness connectors. Can also be used to test terminals for proper fit. 05 180 3 –UN–26NOV97 JT07328 RG40854,0000002 –19–09APR02–9/9 CTM331 (09APR02) 05-180-3 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 RG8803 PN=399 RG11126 Diagnostic Service Tools 05 180 4 CTM331 (09APR02) 05-180-4 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=400 Section 06 Specifications Contents Page Page Group 200—Repair Specifications Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1 Metric Bolt and Cap Screw Torque Values . . .06-200-2 General OEM Engine Specifications . . . . . . . .06-200-3 Electronic Fuel System Repair and Adjustment Specifications . . . . . . . . . . . . . .06-200-4 Electronic Engine Control Repair and Adjustment Specifications . . . . . . . . . . . . . .06-200-5 Group 210—Diagnostic Specifications Group 150/160 Electronic Fuel System Diagnostic Specifications . . . . . . . . . . . . . . .06-210-1 Application Specifications . . . . . . . . . . . . . . . .06-210-3 Backhoes - Sensor Specifications . . . . . . . . . .06-210-4 Backhoes - Torque Curve Selection . . . . . . . .06-210-4 Backhoes - Governor Mode Selection . . . . . . .06-210-5 Backhoes - ECU Terminal Identification . . . . .06-210-5 Crawlers - Sensor Specifications. . . . . . . . . . .06-210-6 Crawlers - Torque Curve Selection . . . . . . . . .06-210-7 Crawlers - Governor Mode Selection. . . . . . . .06-210-7 Crawlers - ECU Terminal Identification . . . . . .06-210-8 Excavators - Sensor Specifications . . . . . . . .06-210-10 Excavators - Torque Curve Selection . . . . . .06-210-11 Excavators - Governor Mode Selection . . . . .06-210-11 Excavators - ECU Terminal Identification . . .06-210-12 Forwarders - Sensor Specifications . . . . . . . .06-210-14 Forwarders - Torque Curve Selection . . . . . .06-210-16 Forwarders - Governor Mode Selection. . . . .06-210-16 Forwarders - ECU Terminal Identification . . .06-210-17 Harvesters - Sensor Specifications . . . . . . . .06-210-18 Harvesters - Torque Curve Selection . . . . . .06-210-19 Harvesters - Governor Mode Selection . . . . .06-210-19 Harvesters - ECU Terminal Identification. . . .06-210-20 OEM Engines - Sensor Specifications . . . . . .06-210-22 OEM Engines - Torque Curve Selection . . . .06-210-24 OEM Engines - Governor Mode Selection. . .06-210-24 OEM Engines - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-25 OEM Engines - Electronic Control System Wiring Diagram . . . . . . . . . . . . . . . . . . . . .06-210-26 OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-28 Skidders - Sensor Specifications . . . . . . . . . .06-210-30 Skidders - Torque Curve Selection . . . . . . . .06-210-31 CTM331 (09APR02) Skidders - Governor Mode Selection . . . . . . .06-210-31 Skidders - ECU Terminal Identification . . . . .06-210-32 Telehandlers - Sensor Specifications . . . . . .06-210-34 Telehandlers - Torque Curve Selection . . . . .06-210-35 Telehandlers - Governor Mode Selection . . .06-210-35 Telehandlers - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-36 06 06-1 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=1 Contents 06 CTM331 (09APR02) 06-2 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=2 Group 200 Repair Specifications Unified Inch Bolt and Cap Screw Torque Values 06 200 1 DX,TORQ1 –19–20JUL94–1/1 CTM331 (09APR02) 06-200-1 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=403 TS1656 –19–02APR97 Repair Specifications Metric Bolt and Cap Screw Torque Values 06 200 2 DX,TORQ2 –19–20JUL94–1/1 CTM331 (09APR02) 06-200-2 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=404 TS1657 –19–02APR97 Repair Specifications General OEM Engine Specifications ITEM 4045TF275 Number of Cylinders Bore Stroke Displacement Compression Ratio Max. Crank Pressure Governor Regulation (Industrial) Governor Regulation (Generator) Oil Pressure At Rated Speed, Full Load (± 15 psi) Oil Pressure At Low Idle (Minimum) Length Width Height Weight 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 7—10 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 4045HF275 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 7—10 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 6068TF275 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 7—10 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1119 mm (43.9 in.) 623 mm (24.5 in.) 1012 mm (39.9 in.) 587 kg (1290 lb) 6068HF275 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 7—10 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1123 mm (44.2 in.) 623 mm (24.5 in.) 1015 mm (40.0 in.) 587 kg (1290 lb) 06 200 3 DPSG,OUO1004,102 –19–19NOV01–1/1 CTM331 (09APR02) 06-200-3 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=405 Repair Specifications Electronic Fuel System Repair and Adjustment Specifications Item Measurement Specification Final Fuel Filter Bracket-to-Cylinder Head Final Fuel Filter Mounting Base-to-Bracket Primary Fuel Filter Bracket-to-Cylinder Head and Alternator Primary Fuel Filter/Water Bowl Mounting Base-to-Bracket Fuel Supply Pump Torque 73 N•m (54 lb-ft) Torque 73 N•m (54 lb-ft) Torque 73 N•m (54 lb-ft) Torque 50 N•m (36 lb-ft) Pressure 28—41 kPa (0.41 bar) (4—6 psi) 30 N•m (22 lb-ft) 25 N•m (19 lb-ft) 195 N•m (145 lb-ft) 27 N•m (20 lb-ft) 9.28—0.5 L & 6.0000212 –19–27NOV01–1/2 CTM331 (09APR02) 06-200-4 4.8 L Level 12 Electronic Fuel System 040902 PN=406 .5 lb-ft) Fuel Supply Pump Cap Screws Injection Pump Mounting Stud Nuts Injection Pump Gear Mounting Nut 06 200 4 Torque Torque Torque Torque Injection Pump Fuel Delivery (Pressure) Lines Injection Pump Timing Pin Plug Fuel Injection Nozzle Nozzle Torque Return Leakage at 10 300 kPa (103 bar) (1500 psi) 1 to 14 drops (maximum) within 30 seconds Fuel Injection Nozzle Rate Shaping Nozzle Opening Pressure for Setting (New or Reconditioned) Opening Pressure for Checking (New or Reconditioned) Opening Pressure for Setting (Used) Opening Pressure for Checking (Used) 24 400—24 900 kPa (244—249 bar) (3540—3620 psi) 24 100 kPa (241 bar) (3500 psi) Min 23 000—23 600 kPa (230—236 bar) (3340—3420 psi) 21 800 kPa (218 bar) (3170 psi) Min Continued on next page OUO1080.5 N•m (7. 0000216 –19–27NOV01–1/1 CTM331 (09APR02) 06-200-5 4.8 L Level 12 Electronic Fuel System 040902 PN=407 .) 27 N•m (20 lb-ft) 27 N•m (20 lb-ft) Fuel Injection Pump Return Line Fuel Injection Nozzle Delivery Lines Torque Torque OUO1080.5 lb-ft) Fuel Injection Nozzle Hold-Down Clamp Cap Screws Fuel Leak-Off Line Hex Nut Torque 40 N•m (30 lb-ft) Torque 5 N•m (3.5 L & 6.0000212 –19–27NOV01–2/2 Electronic Engine Control Repair and Adjustment Specifications Item Measurement Specification 06 200 5 Coolant Temperature Sensor in Thermostat Housing Coolant Temperature Sensor in Cylinder Head Crankshaft Position Sensor Oil Pressure Sensor Manifold Air Temperature Sensor Fuel Temperature Sensor Fuel Heater Torque 15 N•m (11 lb-ft) Torque 35 N•m (26 lb-ft) Torque Torque Torque Torque Torque 14 N•m (10 lb-ft) 15 N•m (11 lb-ft) 10 N•m (7 lb-ft) 13—18 N•m (10—13 lb-ft) 9 N•m (7 lb-ft) OUO1080.Repair Specifications Item Measurement Specification Rate Shaping Nozzle Opening pressure difference between cylinders 700 kPa (7 bar) (100 psi) Max Fuel Injection Nozzle Pressure Adjusting Screw Lock Nut Lift Adjusting Screw Lock Nut Torque 10 N•m (7 lb-ft) Torque 5 N•m (3.7 lb-ft) (44 lb-in. 8 L Level 12 Electronic Fuel System 040902 PN=408 .5 L & 6.Repair Specifications 06 200 6 CTM331 (09APR02) 06-200-6 4. 5 psi) 15 kPa (0.Group 210 Diagnostic Specifications Group 150/160 Electronic Fuel System Diagnostic Specifications Item Measurement Specification Fuel Supply Pump Static Pressure 25—30 kPa (0.5 L/min (0.5—4.30 bar) (3.25—0.8 L Level 12 Electronic Fuel System 040902 PN=409 .OUO1004.42 gpm) Fuel Supply Pump DPSG.15 bar) (2.34 bar) (3—5 psi) 1.21—0.0 psi) Fuel Supply Pump Minimum Static Pressure at 850 rpm Engine Speed Minimum Positive Pressure at 2400 rpm Engine Speed Minimum Flow at 2400 rpm Engine Speed Fuel Supply Pump 21—34 kPa (0.2762 –19–17MAY00–1/1 06 210 1 CTM331 (09APR02) 06-210-1 4.5 L & 6. 8 L Level 12 Electronic Fuel System 040902 PN=410 .Diagnostic Specifications 06 210 2 CTM331 (09APR02) 06-210-2 4.5 L & 6. See Vehicle • Forwarders – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring . 06 210 3 RG40854.Diagnostic Specifications Application Specifications Below is an overview of the specfications listed for applications in the next few pages.See Vehicle • Crawlers – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring .See Vehicle manual. manual.5L & 6.See Vehicle • Excavators – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring .See Vehicle manual. • OEM Engines – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Electronic Control System Wiring Diagram – 4. • Backhoes – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring .5 L & 6. • Telehandlers – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring .See Vehicle • Harvesters – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring . manual.0000128 –19–29JAN02–1/1 CTM331 (09APR02) 06-210-3 4.8 L Level 12 Electronic Fuel System 040902 PN=411 .See Vehicle manual. manual. manual.8L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram • Skidders – Sensor Specifications – Torque Curve Selection – Governor Mode Selection – ECU Terminal Identification – Vehicle Wiring . 9 Volts Below 0. If no other throttle is available. pressure.8 L Level 12 Electronic Fuel System 040902 PN=412 . High MAT engine protection is disabled.000013B –19–30JAN02–1/1 CTM331 (09APR02) 06-210-4 4.7 Volts Below 0. Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4.Sensor Specifications The specifications shown below are voltage. High fuel temperature engine protection is disabled.Diagnostic Specifications Backhoes . High ECT engine protection is disabled.1 Volts Exceeds 4. High MAT engine protection is disabled.1 Volts Exceeds 113°C (235°F) Derate If no other throttle is available. High ECT engine protection is disabled.9 Volts Below 0.9 Volts Below 0.1 Volts Exceeds 120°C (248°F) 06 210 4 RG40854.3 Volts Above 4.000013A –19–30JAN02–1/1 Backhoes .Torque Curve Selection Torque Curve Selection for Backhoes Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal operation SERVICE ADVISOR is a trademark of Deere & Company RG40854. High fuel temperature engine protection is disabled. Sensor Specifications for Backhoes Sensor Analog Throttle (A) Measured Sensor Parameter High Input Voltage Low Input Voltage Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Most Severe Temperature Out of Range Value Above 4. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 2% per minute until engine runs at 80% of full power. and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor. engine will run at idle speed.5 L & 6. engine will run at idle speed. ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B3 B2 D2 A3 K2 C3 B1 D1 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa N/Aa Changes with each sensor Changes with each sensor B A B B A A A A 06 210 5 N/A = Not Applicable RG40854.8 L Level 12 Electronic Fuel System 040902 PN=413 .000013F –19–30JAN02–1/1 CTM331 (09APR02) 06-210-5 4.Governor Mode Selection Desired Speed Governor Selection for Backhoes Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal droop Max.000013E –19–30JAN02–1/1 Backhoes .Diagnostic Specifications Backhoes . Speed Governor Selection for Backhoes Mode Selected on DST or SERVICE ADVISOR™ 9 Conditions: Normal droop SERVICE ADVISOR is a trademark of Deere & Company RG40854.5 L & 6. If no other throttle is available.9 Volts Below 0. Low oil pressure engine protection is disabled.5 L & 6. High ECT engine protection is disabled.Sensor Specifications The specifications shown below are voltage. High loss of coolant temperature engine protection is disabled.9 Volts Below 0. pressure.Diagnostic Specifications Crawlers .9 Volts Below 0. and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor.25 Volts Below an extremely low engine oil pressure.9 Volts Below 0.05 Volts Exceeds 124°C (255°F) Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4. High fuel temperature engine protection is disabled.5 Volts Below 0.05 Volts Exceeds 113°C (235°F) Derate If no other throttle is available. ECU derates engine 2% per minute until engine runs at 80% of full power. Sensor Specifications for Crawlers Sensor Analog Throttle (A) Measured Sensor Parameter High Input Voltage Low Input Voltage Oil Pressure High Input Voltage Low Input Voltage Extremely Low Pressure Out of Range Value Above 4.8 L Level 12 Electronic Fuel System 040902 PN=414 . High loss of coolant temperature engine protection is disabled. Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage Engine Coolant Temperature (ECT) 06 210 6 High Input Voltage Low Input Voltage Most Severe Temperature Loss of Coolant Temperature High Input Voltage Low Input Voltage Extremely High Temperature Exceeds 4.75 Volts Below 0.25 Volts Above 4.05 Volts Exceeds 120°C (248°F) RG40854.05 Volts Exceeds 4. ECU derates engine 20% per minute until engine runs at 60% of full power. ECU derates engine 20% per minute until engine runs at 60% of full power. Above 4. engine will run at idle speed. High MAT engine protection is disabled. High MAT engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power.0000132 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-6 4. High ECT engine protection is disabled. engine will run at idle speed. This pressure increases with engine speed. Low oil pressure engine protection is disabled. 0000134 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-7 4.Torque Curve Selection Torque Curve Selection for Crawlers Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal operation SERVICE ADVISOR is a trademark of Deere & Company RG40854.8 L Level 12 Electronic Fuel System 040902 PN=415 .Governor Mode Selection Desired Speed Governor Selection for Crawlers Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal droop Max. Speed Governor Selection for Excavators Mode Selected on DST or SERVICE ADVISOR™ 9 Conditions: Normal droop 06 210 7 SERVICE ADVISOR is a trademark of Deere & Company RG40854.0000135 –19–30JAN02–1/1 Crawlers .Diagnostic Specifications Crawlers .5 L & 6. 0000137 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-8 4.8 L Level 12 Electronic Fuel System 040902 PN=416 .ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input Loss of Coolant Temperature a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B3 B2 D2 A3 K2 C3 B1 D1 F3 C1 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa N/Aa Changes with each sensor Changes with each sensor B A B B A A A A B A N/A = Not Applicable 06 210 8 RG40854.5 L & 6.Diagnostic Specifications Crawlers . 8 L Level 12 Electronic Fuel System 040902 PN=417 .5 L & 6.Diagnostic Specifications 06 210 9 CTM331 (09APR02) 06-210-9 4. 5 L & 6. High fuel temperature engine protection is disabled. Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Most Severe Temperature Exceeds 4. ECU derates engine 2% per minute until engine runs at 80% of full power. High ECT engine protection is disabled. and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor.Sensor Specifications The specifications shown below are voltage. pressure.1 Volts Exceeds 88°C (190°F) Derate High MAT engine protection is disabled.000012E –19–30JAN02–1/1 CTM331 (09APR02) 06-210-10 4. ECU derates engine 4% per minute until engine runs at 90% of full power.9 Volts Below 0. ECU derates engine 20% per minute until engine runs at 75% of full power.1 Volts Exceeds 120°C (248°F) RG40854. High ECT engine protection is disabled.1 Volts Exceeds 115°C (239°F) Moderately Severe Temperature Exceeds 113°C (235°F) Least Severe Temperature 06 210 10 Exceeds 110°C (230°F) Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 95% of full power.Diagnostic Specifications Excavators .8 L Level 12 Electronic Fuel System 040902 PN=418 . ECU derates engine 2% per minute until engine runs at 80% of full power. High MAT engine protection is disabled.9 Volts Below 0. Sensor Specifications for Excavators Sensor Manifold Air Temperature (MAT) Measured Sensor Parameter High Input Voltage Low Input Voltage Moderately High Temperature Out of Range Value Above 4.9 Volts Below 0. 000012F –19–30JAN02–1/1 Excavators .8 L Level 12 Electronic Fuel System 040902 PN=419 .5 L & 6.0000131 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-11 4.Torque Curve Selection Torque Curve Selection for Excavators Torque Curve # on DST or SERVICE ADVISOR™ 1 2 Conditions for Torque Curve Normal operation Altitude Derate SERVICE ADVISOR is a trademark of Deere & Company RG40854. Speed Governor Selection for Excavators Mode Selected on DST or SERVICE ADVISOR™ 9 Conditions: Normal droop SERVICE ADVISOR is a trademark of Deere & Company RG40854.Governor Mode Selection Desired Speed Governor Selection for Excavators Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal droop 06 210 11 Max.Diagnostic Specifications Excavators . 8 L Level 12 Electronic Fuel System 040902 PN=420 .5 L & 6.Diagnostic Specifications Excavators .0000130 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-12 4.ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low Sensor Ground Throttle Reference Throttle Input Throttle Ground Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input a ECU Terminal # A2 K1 J2 G1 F1 D3 F3 B3 C1 B2 D2 A3 K2 C3 B1 D1 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor N/Aa N/Aa N/Aa A B B A A A A N/A = Not Applicable 06 210 12 RG40854. 5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=421 .Diagnostic Specifications 06 210 13 CTM331 (09APR02) 06-210-13 4. pressure.5 L & 6.0000158 –19–21FEB02–1/2 06 210 14 CTM331 (09APR02) 06-210-14 4. Continued on next page RG40854.8 L Level 12 Electronic Fuel System 040902 PN=422 . and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor.Sensor Specifications The specifications shown below are voltage.Diagnostic Specifications Forwarders . High fuel temperature engine protection is disabled.5 L & 6. engine will run at idle speed. ECU derates engine 20% per minute until engine runs at 60% of full power. engine will run at idle speed. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 20% per minute until engine runs at 60% of full power.1 Volts Exceeds 88°C (190°F) Derate If no other throttle is available.3 Volts Pressure goes below an engine speed dependent value. If no other throttle is available. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled.9 Volts Below 0.3 Volts Above 4. ECU derates engine 2% per minute until engine runs at 80% of full power. High ECT engine protection is disabled. High MAT engine protection is disabled. Above 4.5 Volts Below 0.0000158 –19–21FEB02–2/2 CTM331 (09APR02) 06-210-15 4. High ECT engine protection is disabled. If no other throttle is available.1 Volts Exceeds 115°C (239°F) Moderately Severe Temperature Exceeds 110°C (230°F) Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4.9 Volts Below 0. ECU derates engine 2% per minute until engine runs at 80% of full power.Diagnostic Specifications Sensor Specifications for Forwarders Sensor Analog Throttle (A) (1010 Forwarders ONLY) Measured Sensor Parameter High Input Voltage Low Input Voltage Analog Throttle (B) (1010 Forwarders ONLY) High Input Voltage Low Input Voltage Oil Pressure High Input Voltage Low Input Voltage Extremely Low Pressure Out of Range Value Above 4. High MAT engine protection is disabled. 06 210 15 Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage Moderately High Temperature Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Most Severe Temperature Exceeds 4.8 L Level 12 Electronic Fuel System 040902 PN=423 .1 Volts Exceeds 120°C (248°F) RG40854. High fuel temperature engine protection is disabled.7 Volts Below 0.7 Volts Below 0. engine will run at idle speed.3 Volts Above 4. If no other throttle is available.9 Volts Below 0. engine will run at idle speed. Speed Governor Selection for Forwarders Mode Selected on DST or SERVICE ADVISOR™ 9 06 210 16 Conditions: Normal droop SERVICE ADVISOR is a trademark of Deere & Company RG40854.8 L Level 12 Electronic Fuel System 040902 PN=424 .Governor Mode Selection Desired Speed Governor Selection for Forwarders Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal droop Max.5 L & 6.0000159 –19–21FEB02–1/1 Forwarders .Diagnostic Specifications Forwarders .000015A –19–21FEB02–1/1 CTM331 (09APR02) 06-210-16 4.Torque Curve Selection Torque Curve Selection for Forwarders Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal Operation SERVICE ADVISOR is a trademark of Deere & Company RG40854. ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input (1010 Forwarders ONLY) Analog Throttle (B) Input (1010 Forwarders ONLY) Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 F2 B2 D2 A3 K2 C3 B1 D1 F3 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B B A B B A A A A B N/A = Not Applicable 06 210 17 RG40854.Diagnostic Specifications Forwarders .5 L & 6.000015B –19–21FEB02–1/1 CTM331 (09APR02) 06-210-17 4.8 L Level 12 Electronic Fuel System 040902 PN=425 . Diagnostic Specifications Harvesters - Sensor Specifications The specifications shown below are voltage, pressure, and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor. Sensor Specifications for Harvesters Sensor Oil Pressure Measured Sensor Parameter High Input Voltage Low Input Voltage Extremely Low Pressure Out of Range Value Above 4.5 Volts Below 0.3 Volts Pressure goes below an engine speed dependent value. Above 4.9 Volts Below 0.1 Volts Exceeds 88°C (190°F) Derate Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. ECU derates engine 20% per minute until engine runs at 60% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 20% per minute until engine runs at 60% of full power. ECU derates engine 2% per minute until engine runs at 80% of full power. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage Moderately High Temperature Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Exceeds 4.9 Volts Below 0.1 Volts Exceeds 115°C (239°F) 06 210 18 Most Severe Temperature Moderately Severe Temperature Exceeds 110°C (230°F) Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4.9 Volts Below 0.1 Volts Exceeds 120°C (248°F) RG40854,0000167 –19–21FEB02–1/1 CTM331 (09APR02) 06-210-18 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=426 Diagnostic Specifications Harvesters - Torque Curve Selection Torque Curve Selection for Harvesters Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal operation SERVICE ADVISOR is a trademark of Deere & Company RG40854,0000166 –19–21FEB02–1/1 Harvesters - Governor Mode Selection Desired Speed Governor Selection for Harvesters Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal droop Max. Speed Governor Selection for Harvesters Mode Selected on DST or SERVICE ADVISOR™ 9 Conditions: Normal droop 06 210 19 SERVICE ADVISOR is a trademark of Deere & Company RG40854,0000165 –19–21FEB02–1/1 CTM331 (09APR02) 06-210-19 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=427 Diagnostic Specifications Harvesters - ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B2 D2 A3 K2 C3 B1 D1 F3 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor A B B A A A A B N/A = Not Applicable 06 210 20 RG40854,0000164 –19–21FEB02–1/1 CTM331 (09APR02) 06-210-20 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=428 Diagnostic Specifications 06 210 21 CTM331 (09APR02) 06-210-21 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=429 Diagnostic Specifications OEM Engines - Sensor Specifications The specifications shown below are voltage, pressure, and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor. Continued on next page RG40854,0000129 –19–29JAN02–1/3 06 210 22 CTM331 (09APR02) 06-210-22 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=430 Diagnostic Specifications Sensor Specifications for OEM Engines Sensor Analog Throttle (A) Measured Sensor Parameter High Input Voltage Low Input Voltage Analog Throttle (B) High Input Voltage Low Input Voltage Oil Pressure High Input Voltage Low Input Voltage Extremely Low Pressure Out of Range Value Above 4.7 Volts Below 0.3 Volts Above 4.7 Volts Below 0.3 Volts Above 4.5 Volts Below 0.3 Volts Below an extremely low engine oil pressure. This pressure increases with engine speed. Below a moderately low engine oil pressure. This pressure increases with engine speed. Above 4.9 Volts Below 0.1 Volts H engines: Exceeds 100°C (212°F) T engines: Exceeds 120°C (248°F) Exceeds 4.9 Volts Below 0.05 Volts Exceeds 118°C (244°F) Derate If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. ECU derates engine 60% per minute until engine runs at 40% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 60% per minute until engine runs at 40% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 2% per minute until engine runs at 95% of full power. High fuel temperature engine protection is disabled. 06 210 23 Moderately Low Pressure Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage Moderately High Temperature Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Most Severe Temperature Moderately Severe Temperature Exceeds 113°C (235°F) Least Severe Temperature Exceeds 108°C (226°F) Fuel Temperature High Input Voltage Exceeds 4.9 Volts Continued on next page RG40854,0000129 –19–29JAN02–2/3 CTM331 (09APR02) 06-210-23 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=431 Diagnostic Specifications Sensor Specifications for OEM Engines Low Input Voltage Moderately High Temperature Below 0.1 Volts Exceeds 120°C (248°F) High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. RG40854,0000129 –19–29JAN02–3/3 OEM Engines - Torque Curve Selection Torque Curve Selection for OEM Engines Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal Curve 06 210 24 SERVICE ADVISOR is a trademark of Deere & Company RG40854,000012A –19–29JAN02–1/1 OEM Engines - Governor Mode Selection Desired Speed Governor Selection for OEM Engines Mode Selected on DST or SERVICE ADVISOR™ 0 10 Conditions Normal Droop Isochronous Droop Max. Speed Governor Selection for OEM Engines Mode Selected on DST or SERVICE ADVISOR™ 0 9 10 Conditions: Normal Droop Gen Sets ONLY: Above 93% throttle at 1800 RPM Isochronous Droop SERVICE ADVISOR is a trademark of Deere & Company RG40854,000012B –19–29JAN02–1/1 CTM331 (09APR02) 06-210-24 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=432 Diagnostic Specifications OEM Engines - ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Analog Throttle (B) Input Multi-state Throttle Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input Auxiliary Engine Shutdown Switch Input External Engine Derate Switch Input a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 F2 C1 B2 D2 A3 K2 C3 B1 D1 F3 A1 C2 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B B B A B B A A A A B May change by application May change by application 06 210 25 N/A = Not Applicable RG40854,000012C –19–29JAN02–1/1 CTM331 (09APR02) 06-210-25 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=433 Diagnostic Specifications OEM Engines - Electronic Control System Wiring Diagram RG11986 –19–19DEC01 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 914 911 012 914 911 911 B1 Oil Pressure Sensor Clean Side Increase A Pressure C 911 B2 Fuel Temp B3 Coolant Temp B4 MAT B5 Engine Crank Sensor Y1 Fuel Control Solenoid A B t B 914 Sensor Return B t Twisted Pair B A 463 911 448 447 493 Inject Lo 491 Inject Hi B A A A B 904 012 905 020 012 911 012 914 467 461 428 F3 C3 B1 D3 D1 E2 Excitation Voltage (+5V) D2 B2 Sensor Return K2 A3 = Options On 12V ECUs And Included On All 24V ECUs A2 Switched Battery A1 C2 J3 F2 Cruise CANC. RES./External Derate 981 954 913 911 012 914 John Deere Level 12 (12V or 24V) Engine Control Unit (ECU) A ECU Connector K3 429 A1 941 H3 H2 H1 E1 G2 B3 C1 G3 E3 936 955 923 915 474 918 947 473 439 J1 417 K1 022 J2 050 CAN L CAN H F1 G1 904 905 020 012 905 904 012 012 012 062 050 B A Override Shut DN/Blink Codes 936 Resume Coast/Bump DN Secondary Analog Throttle SAE J1939/11 3-Way Deutsch Term Spare - Sourcing Driver 2 Twisted Shielded Pair 904 905 020 85 87 87A 955 Set Accel/Bump Up Air Heated Wait Lamp A B C 022 Unswitched Battery A B C 904 905 020 020 K1 Fuel Pump Supply Relay F02 10A Cruise On/ISOC. GOV. 923 Cruse Brake/Bump Enable External Shutdown 86 30 Resume Coast Analog Throttle 911 012 914 High/Low Idle Bump Enable 020 Bump DN Set Accel Bump Up Air Heater 050 050 System Ground SAE J1939/11 3-Way Deutsch Connector Located Near ECU 072 X11 J H G F E D C B A 050 905 904 X10 X6 T A B C D E F G H J K L M N O P Q R S T U V W X W X L A N R H K 429 417 Instrument Panel Connector X9 Fuel Heater A 050 Auxillary Connector 050 050 SE2 SE2 SE2 SE2 SE2 SE2 SE2 050 Diagnostic Connector 050 050 X7 UT UT SE2 050 X3 B SE3- Focus 12 (ECU) SE4- Fuel Heater Option RG40854,0000121 –19–28JAN02–1/1 CTM331 (09APR02) 06-210-26 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 002 Unswitched Battery Cruse Brake Tachometer Fault Lamp SE2 PN=434 5 L & 6.Diagnostic Specifications 06 210 27 CTM331 (09APR02) 06-210-27 4.8 L Level 12 Electronic Fuel System 040902 PN=435 . 5 L & 6.Diagnostic Specifications OEM Engines .5L & 6.0000122 –19–28JAN02–1/1 CTM331 (09APR02) 06-210-28 4.8L Instrument Panel/Engine Start Components Electrical Wiring Diagram RG11987 –19–19DEC01 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 Starter Relay Solenoid 002 BAT 412 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V X1 UT 002 BAT Ignition Switch 422 914 911 012 412 012 002 BAT 002 BAT 422 002 012 911 012 S1 X3 Instrument Panel Connector B S A X02 A Wiring Supplied With JD Alternator 012 X3 Instrument Panel Connector 002 422 Accessory Off Run Start Run ST D X3 Instrument Panel Connector V 904 U F 905 020 Back Light Options 24V Back Light Option 24V Regulator P M C 24V 911 002 002 911 022 032 B BAT IGN G 412 012 A 10A B +12V 022 022 002 032 ACC J X03 PC GND 411 442 925 929 929 925 442 929 925 442 929 925 442 929 925 442 929 925 442 904 905 050 411 050 411 050 411 050 411 050 OUTPUT +12V OR +24V +12V OR +24V +12V OR +24V +12V OR +24V +12V OR +24V Back Lighting Back Lighting Back Lighting Back Lighting +12V OR +24V Back Lighting A BAT 936 409 955 923 2 Coil High Idle A B A B A 947 390 Ohm Low Idle 1300 Ohm 918 911 Back Lighting Starter Relay 12V OR 24V C S IGN C A 050 411 Twisted Shielded Pair A 5A 020 Out Coil KST Off B Bump Up Off Bump Down A Idle Switch High Idle Low Idle A Idle (CW) Full Throttle POT A B C All B Off B Off Override Shutdown A P1 C B A D F F P2 D A B C F P3 D A B C F P4 D A B C F P5 D A B C A H E P6 D C G B F 012 A B C 12V Back Light Option B A B C A B C Data + Data + Data - Data + Data - Data + Data - Data + Data - 915 474 SPG SPG SPG SPG SPG 050 050 002 022 442 050 Remote On/Off Plug Bump Enable Bump Down 442 050 411 947 918 915 474 442 050 411 442 050 411 442 050 411 442 050 411 442 411 Bump Up 442 925 925 925 925 925 A B 020 905 904 032 B TVP (12V OR 24V) ALT 12V Start Motor 12V SPG S B Data + Data - Data - N1 G1 M1 X5 A 929 929 929 929 929 B 12V S4 Override Shutdown Momentary GND F1 Speed Select Momentary Bump Enable Momentary Bump Enable Off Bump OFF Enable Analog Throttle Air Heater Wait Lamp S2 S3 S5 Dimmer Option A B A B X3 Instrument Panel E Connector 050 SPG 947 918 915 474 C B A C B A SAE J1939/11 3-Way Deutsch Conn Back Light No Dimmer Back Light Dimmer High (CW) Low 050 050 002 X4 Single Point Ground 050 022 SAE J1939/11 3-Way Deutsch Term SE4 UT SE1-Engine Start Components SE3 SE3 SE3 SE3 SE3 SE3 SE3 SE3 050 SPG SE2-Control Panel 050 SPG 050 SPG RG40854.4.8 L Level 12 Electronic Fuel System 040902 PN=436 . 8 L Level 12 Electronic Fuel System 040902 PN=437 .5 L & 6.Diagnostic Specifications 06 210 29 CTM331 (09APR02) 06-210-29 4. High ECT engine protection is disabled. ECU derates engine 20% per minute until engine runs at 60% of full power.1 Volts Exceeds 120°C (248°F) RG40854.000016C –19–21FEB02–1/1 CTM331 (09APR02) 06-210-30 4.8 L Level 12 Electronic Fuel System 040902 PN=438 . ECU derates engine 2% per minute until engine runs at 80% of full power. Low oil pressure engine protection is disabled.Sensor Specifications The specifications shown below are voltage. ECU derates engine 2% per minute until engine runs at 80% of full power.3 Volts Exceeds 88°C (190°F) Derate If no other throttle is available. High MAT engine protection is disabled. High MAT engine protection is disabled. engine will run at idle speed. Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage Moderately High Temperature 06 210 30 Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Most Severe Temperature Exceeds 4. pressure.9 Volts Below 0. Above 4.3 Volts Exceeds 115°C (239°F) Moderately Severe Temperature Exceeds 110°C (230°F) Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4.5 L & 6. engine will run at idle speed. High ECT engine protection is disabled.3 Volts Above 4. High fuel temperature engine protection is disabled. ECU derates engine 20% per minute until engine runs at 60% of full power.9 Volts Below 0.5 Volts Below 0. Low oil pressure engine protection is disabled. and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor.7 Volts Below 0.3 Volts Pressure goes below an engine speed dependent value.9 Volts Below 0. If no other throttle is available. High fuel temperature engine protection is disabled.Diagnostic Specifications Skidders . Sensor Specifications for Skidders Sensor Analog Throttle (A) Measured Sensor Parameter High Input Voltage Low Input Voltage Oil Pressure High Input Voltage Low Input Voltage Extremely Low Pressure Out of Range Value Above 4. ECU derates engine 2% per minute until engine runs at 80% of full power. 8 L Level 12 Electronic Fuel System 040902 PN=439 .5 L & 6.000016F –19–21FEB02–1/1 CTM331 (09APR02) 06-210-31 4.Torque Curve Selection Torque Curve Selection for Skidders Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal operation SERVICE ADVISOR is a trademark of Deere & Company RG40854.Diagnostic Specifications Skidders . Speed Governor Selection for Skidders Mode Selected on DST or SERVICE ADVISOR™ 9 Conditions: Normal droop 06 210 31 SERVICE ADVISOR is a trademark of Deere & Company RG40854.000016D –19–21FEB02–1/1 Skidders .Governor Mode Selection Desired Speed Governor Selection for Skidders Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal droop Max. 5 L & 6.ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Multi-state Throttle Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 C1 B2 D2 A3 K2 C3 B1 D1 F3 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B B A B B A A A A B N/A = Not Applicable 06 210 32 RG40854.0000170 –19–21FEB02–1/1 CTM331 (09APR02) 06-210-32 4.Diagnostic Specifications Skidders .8 L Level 12 Electronic Fuel System 040902 PN=440 . Diagnostic Specifications 06 210 33 CTM331 (09APR02) 06-210-33 4.5 L & 6.8 L Level 12 Electronic Fuel System 040902 PN=441 . 5 L & 6. engine will run at idle speed. High ECT engine protection is disabled. High fuel temperature engine protection is disabled. Engine Coolant Temperature (ECT) High Input Voltage Low Input Voltage Most Severe Temperature 06 210 34 Moderately Severe Temperature Exceeds 113°C (235°F) Least Severe Temperature Exceeds 108°C (226°F) Fuel Temperature High Input Voltage Low Input Voltage Moderately High Temperature Exceeds 4. ECU derates engine 2% per minute until engine runs at 80% of full power.1 Volts Exceeds 118°C (244°F) Derate If no other throttle is available. Sensor Specifications for Telehandlers Sensor Analog Throttle (A) Measured Sensor Parameter High Input Voltage Low Input Voltage Oil Pressure Switch Low Input Voltage Extremely Low Pressure Out of Range Value Above 4. Input circuit is grounded when engine is running at a minimum engine speed. High fuel temperature engine protection is disabled.Diagnostic Specifications Telehandlers .9 Volts Below 0.7 Volts Below 0. ECU derates engine 2% per minute until engine runs at 80% of full power. and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor. High MAT engine protection is disabled. ECU derates engine 20% per minute until engine runs at 60% of full power. No derate Manifold Air Temperature (MAT) High Input Voltage Low Input Voltage High MAT engine protection is disabled.9 Volts Below 0. No derate. pressure.8 L Level 12 Electronic Fuel System 040902 PN=442 .3 Volts Input circuit is grounded at key ON with no engine speed.1 Volts Exceeds 120°C (248°F) RG40854.1 Volts Exceeds 4. Above 4.9 Volts Below 0. engine will run at idle speed. High ECT engine protection is disabled.Sensor Specifications The specifications shown below are voltage. ECU derates engine 20% per minute until engine runs at 40% of full power.0000140 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-34 4. If no other throttle is available. 5 L & 6.Torque Curve Selection Torque Curve Selection for Telehandlers Torque Curve # on DST or SERVICE ADVISOR™ 1 Conditions for Torque Curve Normal Operation SERVICE ADVISOR is a trademark of Deere & Company RG40854.Diagnostic Specifications Telehandlers .8 L Level 12 Electronic Fuel System 040902 PN=443 . Speed Governor Selection for Telehandlers Mode Selected on DST or SERVICE ADVISOR™ 9 Conditions: Normal droop 06 210 35 SERVICE ADVISOR is a trademark of Deere & Company RG40854.0000141 –19–30JAN02–1/1 Telehandlers .0000142 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-35 4.Governor Mode Selection Desired Speed Governor Selection for Telehandlers Mode Selected on DST or SERVICE ADVISOR™ 0 Conditions Normal Droop Max. N/A = Not Applicable 06 210 36 RG40854.8 L Level 12 Electronic Fuel System 040902 PN=444 .ECU Terminal Identification ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input a ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 B2 D2 A3 K2 C3 B1 D1 C1 Sensor Connector Terminal# N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B A B B A A A A Refer to vehicle manual for this.5 L & 6.Diagnostic Specifications Telehandlers .0000143 –19–30JAN02–1/1 CTM331 (09APR02) 06-210-36 4. . . . . . . . . . . . . .04-160-24 F401 . . . . . . . . . . . . pull type. . . . . . .8 L Level 12 Electronic Fuel System 040902 B Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Replace . . . . . . . . . . . . . .06-210-3 Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4E3 . . .5 L & 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-12 METRI-PACK. . . . . . . . . . . . . . . . . . . . . . . . 04-150-53 C CAN definition of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Telehandlers . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4E0 . . . . . . . . . .04-160-13 Diagnostics ACP-Err/Bus EP . .04-150-32 Tests Excavator torque curve change . . . . . . . . . . . . . repair . .04-150-36 EE-error. . . .04-160-12 Active vs. . . . . . .04-160-15 Clearing engine codes . . . . . . . . . . . . . . . . . . . .04-160-28 Diagnostic procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Skidders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-10 Viewing active codes . .04-150-50 Fuel supply quality . . . . . . intake Diagnostic check. . . . . .02-110-14 Remove blade terminals from connector body . . . . . . . . . . . . . . . . . . .03-140-5 Remove and install . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 4. . . . . . . . . . . . . . . . . . . . . . .04-160-24 F402 . . . . . . . . . . . . . . . . . .03-140-12 Air in fuel test . . .04-160-22 2-digit codes . . . . . . . . . . . . . . . . . .04-160-16 Derate programs Application specifications . .04-160-24 F403 . . . .03-140-11 Check Fuel supply pressure. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Cruise control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12 Diagnostic Scan Tool (DST) Data parameter description . . .03-140-13 Diagnostic Gauge Clearing stored codes .04-160-19 Diagnostic Trouble Codes (DTCs) Active engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4ED. . . . . . . . . . .06-210-3 Forwarders . . . . . . . . . . . . inactive . . . . . .04-150-56 D Data parameter description . . . . . .04-160-12 Viewing stored codes . . . . . . . . . .02-110-4 Application specifications Backhoes . . . . . . .04-150-36 Engine configuration parameters. . . . . . . . . . . . . . . .04-150-42 Operation .02-110-11 Controller Area Network (CAN). . . . . . . . . . . . . . . . . . . . . . . . .02-110-17 General information. . . . . operation. . . . . . . . . . . . . . . . . . .04-160-24 F4A7 . .06-210-3 OEM engines . . .04-150-49 Air temperature sensor Operation . . . . . . . . . .03-140-6 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36 Does not communicate with ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-9 CTM331 (09APR02) Indx 1 Index-1 PN=1 . . . . . . . . . . . . . . . . . . .06-210-3 Operation .Index Page Page A Air heater. . . . . . . . . . . . . . electrical AMP . . . . . . . . . . . . . . . . 02-090-26.04-150-36 ACP-Err/Bus Error . . . . . . . . . . . . . .03-140-2 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-15 Blinking Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-47 Circuit malfunctions Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-11 Coolant.04-160-24 F400 .04-160-13 Clearing stored codes . . .04-160-27 Listing of . . . . . . . . .04-160-24 F4EA . . . . . . . . . . . . . .04-160-5 Connectors. . . . . . . . . . . .02-110-2 Crank sensor Operation . . . . . . . . . . . . . .04-160-24 Other F4A0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20 DEUTSCH. . . . . .04-160-16 Diagnostics ECU does not communicate with DST . . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Bleed fuel system . . . . . . . . . . . . . . . .03-140-12 Cylinder misfire test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36 ACP-Err/No Addr . . . . . . . . . . . . . . . . . . . . .01-002-1 Coolant temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22 SPN/FMI codes .02-110-6 METRI-PACK.03-140-15 Diagnosing intermittent faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Harvesters . . . . . . . . . . . . . . . . push type . . . . . . . . . . . . . . . . . . . . .04-160-4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-92 SPN 0100 FMI 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0091 FMI 10 . . . . . . . . . . . . . . . . . . . . . .04-160-86 CTM331 (09APR02) SPN 0091 FMI 09 . . . . . . . . . . .04-160-86 SPN 0028 FMI 04 . . . . . . . . . . . . . . . . .04-160-183 SPN 1076 FMI 00 . . . . . . .04-160-86 SPN 0029 FMI 14 . . . .04-160-24 F474 . . . . . . . . . . .04-160-24 F477 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F416 . .04-160-188 SPN 1076 FMI 03 . . . . . . . . . . .03-140-15 2-Digit codes DTC 11 . . . . . . . . . . . . . . . . . . . .04-160-24 F494 . . . . . . .04-160-102 SPN 0105 FMI 03 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-174 SPN 0639 FMI 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0091 FMI 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-126 SPN 0111 FMI 00 . . . .04-160-138 SPN 0174 FMI 03 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-216 SPN 1109 FMI 31 . .04-160-24 F475 . . . . . . . . . . . . . . . . . . . . . . . .04-160-223 SPN 2000 FMI 13 . . . . . . . . . . . . . . . . . . . . . .04-160-24 F48B . . . . . . . . . . . . . . . . . .04-160-182 SPN 0971 FMI 31 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F464 . .04-160-24 F413 . . .04-160-24 F465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-88 SPN 0100 FMI 03 . . . . . . . . . .04-160-24 F430 . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F460 . . . . . . . . . . . . . . . .04-160-24 F432 . . . . . . . . . . . . . . . . .04-160-24 F476 . . . . . . . .04-160-150 SPN 0190 FMI 00 . . . .04-160-24 F49A . . . .04-160-204 SPN 1079 FMI 03 . . . . . . . . . . . . .04-160-24 F446 . . . . . . . . . . . . . . . . .04-160-120 SPN 0110 FMI 15 . . . . . . . . . . . . .04-160-108 SPN 0105 FMI 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F463 . . . . . . .04-160-24 F429 . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F426 . . . . . . .04-160-184 SPN 1076 FMI 01 . . . . . . . . . . . . . . .04-160-24 F459 . . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0100 FMI 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F461 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F492 . . .04-160-212 SPN 1079 FMI 04 . . . . . . . . . . . . . . . . .04-160-196 SPN 1076 FMI 06 .04-160-24 F405 . . . . . . . . .04-160-200 SPN 1076 FMI 07 . . . . . . . . . . . . . . . . .04-160-128 SPN 0111 FMI 03 . . . . . . . .04-160-142 SPN 0174 FMI 04 . . . . . . . . . .04-160-24 F470 . . . . . . . . . . . . . . . . . . . . . . . .04-160-112 SPN 0110 FMI 00 . . . . . . . .04-160-24 F424 . . . . . .04-160-222 SPN 2000 FMI 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-220 SPN 1110 FMI 31 . . . . .04-160-168 SPN 0637 FMI 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F439 . . . . . . . . . . . . . . . . . . . . .04-160-24 F414 . . . . . . . . . . . . .04-160-154 SPN 0190 FMI 16 . . . .04-160-160 SPN 0627 FMI 04 . . . . . . . . . .04-160-24 F493 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F425 . .04-160-116 SPN 0110 FMI 04 . . . . . .04-160-24 F417 . . . . . . . . . . . . . . . . . . . . . . . .04-160-155 SPN 0620 FMI 03 . . .04-160-12 Warning light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 12 . . . . . . . . . . . . . . . . . . . . . .04-160-130 SPN 0111 FMI 04 . . . . . . . . . . . . . . . . . . . . . . . .04-160-224 Stored engine codes . .04-160-156 SPN 0620 FMI 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-104 SPN 0105 FMI 04 . . . . . . . . . . . .04-160-86 SPN 0029 FMI 03 . . . . . . . . . . . . . .04-160-24 F418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 Index-2 PN=2 . . . . . . . . . . . . . .04-160-178 SPN 0898 FMI 09 . . .04-160-134 SPN 0158 FMI 17 . . . . . . . . . . . . . . . . . .04-160-24 F415 . . .04-160-192 SPN 1076 FMI 05 . . . . . . . .04-160-24 F491 .04-160-170 SPN 0637 FMI 10 . . . . . . . . .04-160-114 SPN 0110 FMI 03 . . . . . . .04-160-24 SPN/FMI SPN 0028 FMI 03 . . . . . . . . . . . . . .04-160-86 SPN 0091 FMI 04 . . .04-160-24 F423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 L & 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F436 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0029 FMI 04 . . . . . . . . . . . . . . . . . .04-160-24 F411 . . . . . . . . . . . . . . . . . . .04-160-24 F420 . . .04-160-181 SPN 0970 FMI 31 . . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0091 FMI 14 . . . . . . . . . . . .04-160-146 SPN 0174 FMI 16 . . . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0091 FMI 07 . . . . . . . . . . . . . . .04-160-24 F422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-221 SPN 1569 FMI 31 .04-160-124 SPN 0110 FMI 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F421 . .Index Page Page Indx 2 F404 . . . . . . . . . . . . . . . . . . . .04-160-86 SPN 0091 FMI 03 . . .04-160-24 F428 . .04-160-96 SPN 0100 FMI 18 . . . . . . . . . . . . . . . .04-160-24 F445 . . . . . . . . . . . . . .04-160-164 SPN 0629 FMI 13 . . . . . . . . . . .03-140-10 Repair and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-29 Supply system check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 81 . . .04-150-16 Engine idles poorly . . . . . . . . .04-160-24 DTC 55 . . . . . . . . . . . . . . . . . .Index Page Page DTC 13 . . . . . . . . . . . . . . . . . . . .04-150-32 CTM331 (09APR02) ECU does not communicate with Service ADVISOR. . . . . . . . . . .5 L & 6. . . . .02-110-20 DEUTSCH . . . . . . . . . . . . . . . .04-150-11 Engine emits excessive black or gray exhaust smoke . . . . . . . . . . . . . . . . .04-160-24 DTC 84 . . . . . . .04-150-32 Engine cranks/won’t start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 37 . . . . . . . . . . .04-160-24 DTC 76 . . .04-160-24 DTC 71 . . . . . .01-002-1 Digital multimeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-14 Definition of. . . . . .03-140-5 Monitoring engine parameters. . . .04-160-24 DTC 64 . . . . . . .03-140-14 Measuring engine speed . . . . . . . . . . . . . . . .03-140-12 Derating . . . . how to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 88 . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 68 . . . . . . . . . . . . . . . . . . .04-150-22 Engine misfires/runs irregularly .04-150-2 Engine does not develop full power . . .03-140-13 Excavator throttle operation . .06-210-26 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 77 . . . . . . . . . . . . . . . . . . 02-110-14 WEATHERPACK . . . . . . . . . . . . . . . . .04-160-24 DTC 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Cruise control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 24 . . . . . . . . . . . . . .03-140-2 E ECU Definition of. . . . . . . . . . . . .04-160-2 DST Connecting to . . . . . . . . . . . . . . . . . . . .03-140-8 CAN throttle operation. . . . . . . . .04-150-29 Fuel in oil . . . . . . . . . . . . . . . .04-160-24 DTC 32 . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 42 . . .04-160-5 Electrical Concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-7 Engine will not crank . . . . . . . . . . . . . . . . . .04-160-1 Electrical connectors AMP . . . . . . . . . . . . . . . . . . . . . . . . .04-150-26 Observable Abnormal engine noise . . .04-160-24 DTC 23 . . . . .04-160-24 DTC 82 .03-140-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 Indx 3 Index-3 PN=3 . . . . . . . . . .04-160-24 DTC 39 . . . . . . . . . . .03-140-13 Engine protection . . . . . .04-160-24 DTC 74 .04-160-24 DTC 14 . . . . . . . . . . . . .04-160-24 DTC 21 . . . . . . . . . . . . . . . . . . . . . . .02-110-17 General information. . .04-150-36 ECU does not communicate with DST . . . . . . . . .04-150-22 OEM wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Troubleshooting . . . . . . . .04-150-23 Analog Throttle (B) does not respond . .04-160-24 DTC 19 . . . . . .04-150-19 Engine emits excessive white exhaust smoke . . . . . . . . . . . .03-140-12 Analog throttle operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-2 DTC Definition of. . . . . .03-140-8 Governor modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Measuring temperature . .04-160-24 DTC 72 . . .04-160-24 DTC 16 . . . . . . . . . . . . . . . . . . . .03-140-9 Measuring pressure . . . . . . . . . .04-160-24 DTC 65 . . . . . . . . . . . . . .04-160-24 DTC 15 . . . . . . . . . . . .02-110-6 Electronic control system Air heater operation . . . . .04-160-24 DTC 26 . . . .04-160-24 DTC 75 . . . . . .04-160-24 DTC 73 . . . . . . . . .04-150-25 ECU does not communicate with Diagnostic Gauge . . . . . . . .02-110-12. . . . . . . . . . . . . . . . . . . . . .03-140-3 4. . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 Diagnostics Air heater check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-6 METRI-PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Malfunctions . . . . .04-160-24 DTC 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-8 Electrical insulating compound . . . . . . . . . . . . . . . . . . . . . . . . .02-110-1 Electrical circuit Diagnosis . . . . . . . . . . . . . . . .04-160-24 DTC 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-42 Fuel system Excessive fuel consumption. .04-160-24 DTC 22 . . . . . .04-160-24 DTC 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 63 . . . . . . . . . . . . . . . . .04-160-24 DTC 38 . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Fuel injection nozzles Adjustment . .04-150-2 Engine does not develop full power . . . . . .04-150-29 Supply system check. . . . . . . . . . . . . . . . . . . .03-140-2 Governor mode Application specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-001-2 Engine configuration parameters . . . . . . .02-090-11 Static timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 CTM331 (09APR02) Indx 4 Seal installation. . . . . . . . . . . . . . . . . . . . . .02-090-10 Operation . . . .04-150-50 Fuel supply quality check . . . . . clean . definition of.02-090-23 Bore. . . . . . .02-110-4 G Glossary of terms Electronic control system . . . .03-140-15 Engine cranks/won’t start . . . . . . . . . . . . . . . . . . . . . .02-090-20 Fuel injection pump Inspect . . . . . .03-140-3 Overview. . .02-090-25 Opening pressure test. . . . . . . . . . . . . . . . . . . . . . . .02-110-7 4. . . . . . . . . . . . . . .02-090-1 Supply pressure specifications . .03-130-2 Relieve pressure . . . . . .04-150-42 Operation . . . . . . . . . . . . . . . . . theory of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-26. . . . . . . . . . . . . . . . . . . . . . . . .02-090-1 Operation . . . . . . . . . . . . .01-002-3 Fuel drain back test . . . . . . . .Index Page Page Multi-state throttle operation . .03-130-6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Diagnose malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-001-4 Model designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-11 Engine emits excessive black or gray exhaust smoke . . . . . . . . . . .04-150-51 Install . . . . . . . . . . . . . . . . . . . . . .04-150-16 Engine idles poorly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-14 H Heater. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-26 Fuel drain back test . . . . . . . . . . . . . .02-090-19 Valve seat checking . . . . . . . . . . . . abnormal . . . . . . . . . .04-160-10 Engine Control Unit (ECU) Operation. . . . . . . .04-150-22 F FMI. . . . . . . . . . .04-150-56 Diagnostics Excessive fuel consumption. . . . . . . . . . . . . . . . . . . . .02-090-2 Replace . . . . .03-140-4 Pump solenoid . . . . . using with electrical components . . . . . . . . . . .04-150-47 General information. . . . . . . . . . . . .03-130-4 Remove . . . . . . . . . .04-150-49 Bleed . . . . . . . . . . . . . . . . . .04-150-48 Fuel supply pressure check . . . . . .03-140-10 Repair and adjustment . . . . . . . . . . . . . . . . . . . . . . . . theory of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9 Fuel system Air in fuel test . . . .02-090-7 Fuel heater Replace . . . . . . . . . . . . . . . . . . . . . . .04-150-29 Fuel in oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-21 Operation . . . . . . . . . . . . . . . . . . .03-140-9 Engine Application charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-001-1 Serial number plate. . . . . . . . . . .03-140-2 Fuel Bio-Diesel . . . . . . . . . . . . . . 04-150-53 Cylinder misfire test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20 Valve stem and guide wear checking . . . . . . . . . . . . .02-090-10 Fuel supply pump Bench test. . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Operation. . . . .5 L & 6. .01-002-2 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 Index-4 PN=4 . . . . . . . . . . . . . . . . .04-150-19 Engine emits excessive white exhaust smoke . .02-090-6 Exploded view (primary) . . . . . . . . . . . . . . .03-130-8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-1 Fuel temperature sensor Operation . . . . .02-090-13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Remove and install . . . . . . . . . . . . . . . . . . .04-150-7 Engine noise.04-150-22 Engine misfires/runs irregularly. . . air intake Diagnostic check. . . . . .02-090-5 Operation . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Lubricity . . . . . . .03-140-12 High pressure washer. . . . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Replace .04-150-23 Engine Protection . . . . . .02-090-22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-13 Engine will not crank . . . . . . . . .04-150-30 Disassemble . . . . . .06-210-3 Operation . .02-090-13 Operation . . . . .04-150-48 Fuel filter Exploded view (final). . . . . . . . . . . . . . .02-110-1 Self-diagnosis . . .02-090-24 Spray pattern test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Fuel temperature. . . . . . . . . . . how to use . . . . . . . . . . . . . . . . . . . . .Index Page Page I Inch torque values . . . . . . . . . . .02-110-4 MAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-14 Data parameter description . . . . . . .03-140-9 Instrument panel (OEM) Blinking codes. . . . . . . .06-210-19 4. . . . . .03-140-6 Oil pressure . . . . . . . . . . . . . . .02-090-25 Remove . . . . . . . . . . . . . .04-150-36 Viewing active codes . . . . . . . . . . . . . . . . . .04-160-16 Diagnostics ECU does not communicate with Sevice ADVISOR. . . . . . . . .02-090-18 Diagnose malfunctions . .04-160-12 Wiring diagram . . . . . . .02-110-4 Loss of coolant temperature . . . . . . . .03-140-6 Remove and install . . . . . . . . . . . .03-140-7 Loss of coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Solenoid operation . . . . . . .04-160-19 Specifications Backhoes ECU terminal identification. . . . . .03-140-9 Fuel temperature. . operation Coolant temperature .03-140-12 Intermittent fault. . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Crank position. . . . . . . . . . . .02-110-4 Oil pressure . . . . . .02-110-3 CTM331 (09APR02) Index-5 PN=5 . . .06-200-2 Misfire test. . .06-210-7 Excavators ECU terminal identification. . . . . . . . . . . . . . . . . . . . . .03-140-6 Replace . . . . . . . . . . . . . . . . . .06-210-5 Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-16 Sensors . definition of . . .03-140-8 Replace . . . . . . . . . . .04-150-32 Tests Excavator torque curve change . . . . . . . . . . . . . . . . . . . . .04-160-28 S Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-3 Harvesters ECU terminal identification. . . . . . . .06-210-8 Governor mode selection.02-090-18 Clean . . . . . . .04-160-12 Viewing stored codes . . . . . . .06-210-7 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-28 Intake air heater Diagnostic check. . .02-090-16 Injection pump Operation . . . . . .02-110-2 Lubricants. . .06-210-19 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-14 Torque curve selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-001-2 Service ADVISOR Conecting to . . . . . . . . . .06-210-10 Torque curve selection . . . . . . . . . . . . . . . . . . . . . .06-210-4 Torque curve selection . . . . . . .06-210-11 Sensors . . . .03-140-6 Manifold air temperature . . . . . . . . . . . . . . . . . . . . . . . . . cylinder Cylinder misfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-15 Clearing stored codes . . . . . . . . . . . . . . . . . .04-150-56 Multimeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-18 Torque curve selection . . .02-090-22 Install . . . . . . . . .5 L & 6. . . . . . . . . . . . . . . . .02-110-2 Crank position. . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Diagnostic gauge diagnostics . . . . . .03-140-2 Metric torque values . . . . . . . . . .06-210-4 Crawlers ECU terminal identification. .06-200-1 Injection nozzles Bore. . . . . . . . . . . . . . . . . . .04-150-30 Disassemble .04-150-42 Operation . . . . . . . . . . . . . . . . .06-210-17 Governor mode selection. . . . . . . . . .06-210-12 Governor mode selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2 O Oil pressure sensor Operation . .02-110-2 Manifold air temperature . . . . . . . . . . . . . . . . . . . . . .01-002-1 Indx 5 M Manifold air temperature sensor Operation . . . . . . . . . . . . .06-210-1 General OEM engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Serial number plate . . . . . . . . . . . . . . . . . . . . . . . . .06-210-20 Governor mode selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-11 Forwarders ECU terminal identification. . . . . . . . . . . . . replace Coolant temperature . . . . . . . . . . . . clean . . . . . . . . . . . . . . . . . . .06-210-16 Fuel supply pressure. . . . . . . . . . . . . . . . . . . . .06-210-6 Torque curve selection . . . . . . . . . . . . . . . . diagnosing. . . . . . . .06-210-5 Governor mode selection. . . . . . .8 L Level 12 Electronic Fuel System 040902 L Loss of coolant temperature sensor Operation . . . . . . . . . .04-160-85 Throttle. . . . .Excavator throttle reference voltage high . . . . . . . . . . . . .03-140-8 Excavator . . .04-160-54 T11 . . .04-150-42 Air in fuel . . . . . . . . . .06-210-31 Sensors . . .Multi-state throttle input voltage out of range. . . . . . . . . . . . . . . . . . . . .04-150-56 Excavator torque curve change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-47 Fuel supply system check . . . . . .04-150-48 Fuel supply pressure. . . . . . .04-150-50 Fuel supply quality check . . . . . . . . . . . . .04-150-26 Throttle DTCs Listing of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-24 Instrument panel wiring diagram . . . . . . . . . . . . . . . .04-160-78 T19 . . . . . . .Analog throttle (A) input low . . . . . . . . .06-210-28 Torque curve selection .Excavator throttle ground voltage low . . . . . . . . . . . . . . . . . operation Analog .04-160-81 T20 . . . . . . . . . . . . . . . . . .Analog throttle (B) input low . . . . . .Excavator throttle input voltage high . . . . . . . . . . . . . . . . . . . . .06-210-26 Index-6 4. . . . . . . . . . . . . . .06-210-31 Telehandlers ECU terminal identification. . . . . . . . . . . . . . . . . .Analog throttle (A) input voltage out of range.06-200-2 Trouble codes Diagnostic procedure . . . . . . . .04-160-38 T04 . .06-210-22 Start components wiring diagram. . . . . . . .5 L & 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Throttle calibration aborted . . . . . . . . . . . .06-210-30 Torque curve selection . . .06-210-32 Governor mode selection. . . . . . . . . . . . . . . . . . . . . . . .Analog throttle (B) input high . . . . . . . . . . . . . .05-180-1 Torque curve selection Application specifications . . . . . . . . . . . . . . . . .06-210-35 Speed governing . . . . . . . . .03-140-8 Multi-state . . . . . . . . . .03-140-8 Tools Electronic Fuel System Diagnostic . . . . . . . . . . . . . . .Multi-state throttle input low . . . . . . . . . .06-210-34 Torque curve selection .04-160-42 T05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Excavator throttle input voltage low . . . . . . . . . . . . . . .06-210-28 Sensors . . . . . . . . . . . . . . . . . . . . . . . .04-160-34 T03 . . . . . . . . . .06-200-1 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-84 T23 .04-160-29. . . . .04-160-74 T16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-28 T Test Air heater check . . . . . . . .03-140-14 SPN. .04-160-83 T22 . . . . . . .Excavator throttle reference voltage low . . . . . . . . . . . . . . . . . .04-160-66 T14 . . . .04-160-70 CTM331 (09APR02) T15 . . . . . . . . . . . . . . . . . . . . . . .Index Page Page OEM engines ECU terminal identification. . . . . . .06-210-26 Skidders ECU terminal identification. . . . . .04-150-49 Cylinder misfire . . . . . . . . . .03-140-2 Start components Wiring diagram . . .Multi-state throttle input high . . . . . . . . . . . . .04-160-22 Indx 6 W Wiring diagram Instrument panel (OEM) . . . . . . . . . . . . .06-210-28 OEM engines . .04-160-82 T21 . . . . . . .06-210-3 Excavator change test. . . . . . . . . .04-160-50 T07 . . . . . . .04-160-46 T06 . . . . . . . . . . .8 L Level 12 Electronic Fuel System 040902 PN=6 . . . . . . . . . . . . . . . . . . . . . . . .Throttle not calibrated properly . . . . . . .06-210-24 Wiring diagram . . . . . . . . . . . . . . . .03-140-14 Torque values Inch. .06-210-36 Governor mode selection. . . . . . . . . . . . . . . . . . . .04-160-27 Listing of . . . . .Excavator throttle ground voltage high . . . . . .04-160-58 T12 . . . . . . . . . . .CAN throttle invalid .06-210-25 Governor mode selection. .Analog throttle (A) input high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-30 T02 . .04-160-19 Operation .04-160-19 Fuel drain back . . . . . . . . . . . . . . . .Throttle input voltage below lower calibration limit . . . .06-210-35 Sensors . . . . . . . . . . . . . . . . . . . . . . . definition of . 04-160-86 T01 . . . . . . . . . . .03-140-8 CAN . . . . . .04-160-62 T13 . . . . . . .