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PowerTech® 4.5 & 6.8 L DieselEngines—Level 12 Electronic Fuel
CTM331 09APR02 (English)
COMPONENT TECHNICAL MANUAL
System with DE10 Pump
POWERTECH 4.5L & 6.8LDiesel Engines
Level 12 ElectronicFuel System With
Stanadyne DE10 Pump
TECHNICAL MANUALPOWERTECH 4.5 L & 6.8 L Diesel
Engines—Level 12 Electronic FuelSystem with DE10 Pump
CTM331 09APR02 (ENGLISH)
For complete service information also see:
POWERTECH 4.5 L and 6.8 L DieselEngines—Base Engine . . . . . . . . . . . . . . . . . CTM104Alternators and Starter Motors. . . . . . . . . . . CTM77OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems
LITHO IN U.S.A.
Introduction
OUO1080,00001FE –19–16NOV01–1/1
Forward
This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.
This manual (CTM331) covers only Level 12 ElectronicFuel 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 baseengine, mechanical fuel system, level 4 electronic fuelsystem 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 provideadditional information on electronic fuel systems asneeded.
Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.
This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.
Use this component technical manual in conjunctionwith the machine technical manual. An applicationlisting in Section 01, Group 001 identifiesproduct-model/component type-model relationship. Seethe machine technical manual for information on
component removal and installation, and gainingaccess to the components.
Information is organized in sections and groups for thevarious components requiring service instruction.Section 05 summarizes all applicable essential tools,service equipment and tools, other materials needed todo the job, and service parts kits. Section 06summarizes all specifications, wear tolerances, andtorque values.
Before beginning diagnosis or repair on an engine,clean the engine.
This manual contains SI Metric units of measurefollowed immediately by the U.S. customary units ofmeasure. Most hardware on these engines is metricsized.
Some components of this engine may be servicedwithout removing the engine from the machine. Referto the specific machine technical manual forinformation on components that can be servicedwithout removing the engine from the machine and forengine removal and installation procedures.
Read each block of material completely beforeperforming service to check for differences inprocedures or specifications. Follow only theprocedures that apply to the engine model number youare working on. If only one procedure is given, thatprocedure applies to all the engines in the manual.
CALIFORNIA PROPOSITION 65 WARNINGDiesel engine exhaust and some of its constituentsare known to the State of California to causecancer, birth defects and other reproductive harm.
CTM331 (09APR02) 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Introduction
DPSG,OUO1004,129 –19–15MAY98–1/1
POWERTECH 4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10Pump
RG
1193
1–U
N–0
6NO
V01
Right Side of Engine
RG
1193
2–U
N–0
6NO
V01
Left Side of Engine
POWERTECH is a registered trademark of Deere & Company
CTM331 (09APR02) 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=3
Introduction
CTM331 (09APR02) 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=4
Contents01
SECTION 01—General InformationGroup 000—SafetyGroup 001—Engine IdentificationGroup 002—Fuels
02SECTION 02—Repair and AdjustmentsGroup 090—Electronic Fuel System Repair and
AdjustmentsGroup 110—Electrical Engine Control Repair and
Adjustment
SECTION 03—Theory of OperationGroup 130—Electronic Fuel System OperationGroup 140—Electronic Control System Operation
SECTION 04—Diagnostics
03
Group 150—Observable Diagnostics and TestsGroup 160—Trouble Code Diagnostics and Tests
SECTION 05—Tools and Other MaterialsGroup 170—Electronic Fuel/Control System Repair
Tools and Other MaterialsGroup 180—Diagnostic Service Tools
SECTION 06—SpecificationsGroup 200—Repair SpecificationsGroup 210—Diagnostic Specifications
04
05
All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.
06
COPYRIGHT 2002DEERE & COMPANY
Moline, IllinoisAll rights reserved
A John Deere ILLUSTRUCTION Manual
INDX
CTM331 (09APR02) i 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=1
Contents
01
02
03
04
05
06
INDX
CTM331 (09APR02) ii 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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01
Section 01General Information
Contents
Page
Group 000—Safety . . . . . . . . . . . . . . . . . . . .01-000-1
Group 001—Engine IdentificationEngine Model Designation. . . . . . . . . . . . . . . .01-001-1Engine Serial Number Plate Information . . . . .01-001-2OEM Engine Option Code Label . . . . . . . . . . .01-001-3Information Relative to Emissions
Regulations . . . . . . . . . . . . . . . . . . . . . . . . .01-001-3Engine Application Charts . . . . . . . . . . . . . . . .01-001-4
Group 002—FuelsLubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2Dieselscan Fuel Analysis. . . . . . . . . . . . . . . . .01-002-2Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-3
CTM331 (09APR02) 01-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Contents
01
CTM331 (09APR02) 01-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Group 000Safety
010001
DX,FLAME –19–29SEP98–1/1
Handle Fluids Safely—Avoid Fires
TS
227
–UN
–23A
UG
88
When you work around fuel, do not smoke or work nearheaters or other fire hazards.
Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burnspontaneously.
DX,FIRE3 –19–16APR92–1/1
Handle Starting Fluid Safely
TS
1356
–UN
–18M
AR
92
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keepstarting fluid away from batteries and cables.
To prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected location.
Do not incinerate or puncture a starting fluid container.
DX,FIRE2 –19–03MAR93–1/1
Prepare for Emergencies
TS
291
–UN
–23A
UG
88
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.
CTM331 (09APR02) 01-000-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=9
Safety
01000
2
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X98
11–U
N–2
3AU
G88
Escaping fluid under pressure can penetrate the skincausing serious injury.
Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.
Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.
DX,WEAR –19–10SEP90–1/1
Wear Protective Clothing
TS
206
–UN
–23A
UG
88
Wear close fitting clothing and safety equipmentappropriate to the job.
Prolonged exposure to loud noise can cause impairmentor loss of hearing.
Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.
Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.
CTM331 (09APR02) 01-000-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=10
Safety
010003
DX,LOOSE –19–04JUN90–1/1
Service Machines Safely
TS
228
–UN
–23A
UG
88
Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.
Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.
DX,AIR –19–17FEB99–1/1
Work In Ventilated Area
TS
220
–UN
–23A
UG
88
Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.
If you do not have an exhaust pipe extension, open thedoors and get outside air into the area
DX,CLEAN –19–04JUN90–1/1
Work in Clean Area
T66
42E
J–U
N–1
8OC
T88
Before starting a job:
• Clean work area and machine.• Make sure you have all necessary tools to do your job.• Have the right parts on hand.• Read all instructions thoroughly; do not attempt
shortcuts.
CTM331 (09APR02) 01-000-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=11
Safety
01000
4
DX,PAINT –19–19JUL01–1/1
Remove Paint Before Welding or Heating
TS
220
–UN
–23A
UG
88
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 76 mm (3 in.) from area tobe affected by heating.
• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.
Do not use a chlorinated solvent in areas where weldingwill take place.
Do all work in an area that is well ventilated to carry toxicfumes and dust away.
Dispose of paint and solvent properly.
DX,TORCH –19–03MAR93–1/1
Avoid Heating Near Pressurized Fluid Lines
TS
953
–UN
–15M
AY
90Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines can beaccidentally cut when heat goes beyond the immediateflame area.
CTM331 (09APR02) 01-000-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=12
Safety
010005
DX,LIGHT –19–04JUN90–1/1
Illuminate Work Area Safely
TS
223
–UN
–23A
UG
88
Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.
DX,SAFE,TOOLS –19–10OCT97–1/1
Construct Dealer-Made Tools Safely
LX10
1674
9–U
N–0
1JU
L97
Faulty or broken tools can result in serious injury. Whenconstructing tools, use proper, quality materials, and goodworkmanship.
Do not weld tools unless you have the proper equipmentand experience to perform the job.
CTM331 (09APR02) 01-000-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=13
Safety
01000
6
DX,SERV –19–17FEB99–1/1
Practice Safe Maintenance
TS
218
–UN
–23A
UG
88
Understand service procedure before doing work. Keeparea clean and dry.
Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.
Securely support any machine elements that must beraised for service work.
Keep all parts in good condition and properly installed. Fixdamage immediately. Replace worn or broken parts.Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery groundcable (—) before making adjustments on electricalsystems or welding on machine.
On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.
DX,REPAIR –19–17FEB99–1/1
Use Proper Tools
TS
779
–UN
–08N
OV
89Use tools appropriate to the work. Makeshift tools andprocedures can create safety hazards.
Use power tools only to loosen threaded parts andfasteners.
For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.
Use only service parts meeting John Deere specifications.
CTM331 (09APR02) 01-000-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=14
Safety
010007
DX,DRAIN –19–03MAR93–1/1
Dispose of Waste Properly
TS
1133
–UN
–26N
OV
90
Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.
Do not pour waste onto the ground, down a drain, or intoany water source.
Air conditioning refrigerants escaping into the air candamage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.
DX,LIVE –19–25SEP92–1/1
Live With Safety
TS
231
–19–
07O
CT
88
Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.
CTM331 (09APR02) 01-000-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Safety
01000
8
CTM331 (09APR02) 01-000-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Group 001Engine Identification
010011
OUO1080,00001FA –19–15NOV01–1/1
Engine Model Designation
John Deere Engine Model—4045 and 6068 Engines
John Deere engine model designation includes number ofcylinders, displacement in liters, aspiration, user code, andapplication code. For example:
4045TF275 Engine4 ................................................................ Number of cylinders4.5 ............................................................. Liter displacementT ............................................................... Aspiration codeF ............................................................... User code275 ............................................................ POWERTECH application codeAspiration CodeD ............................................................... Naturally aspiratedT ............................................................... Turbocharged, no aftercoolingA ............................................................... Turbocharged and Air-to-Coolant AftercooledH ............................................................... Turbocharged and Air-to-Air AftercooledUser Factory CodeAT ............................................................. Agritalia srl (Vittoria, Sicily, Italy)CQ ............................................................ John Deere Brazil (Horizontina, Brazil)DW ............................................................ John Deere Davenport Works (Davenport, Iowa)E ............................................................... John Deere Ottumwa Works (Ottumwa, Iowa)F ............................................................... OEM (Outside Equipment Manufacturers)FF ............................................................. Deere-Hitachi (Kernersville, North Carolina)FG ............................................................. Goldoni S.P.A. (Modena, Italy)FM ............................................................ Marine EnginesH ............................................................... John Deere Harvester Works (East Moline, Illinois)KV ............................................................. John Deere Commercial Worksite Products (Knoxville, Tennessee)L ................................................................ John Deere Werke Mannheim (Germany)LA ............................................................. John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)LV ............................................................. John Deere Commercial Products (Augusta, Georgia)N ............................................................... John Deere Des Moines Works (Des Moines, Iowa)P ............................................................... Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)PY ............................................................. Larson & Toubro Ltd. (Pune, India)RW ............................................................ John Deere Waterloo Tractor Works (Waterloo, Iowa)T ............................................................... John Deere Dubuque Works (Dubuque, Iowa)T8 ............................................................. Cameco Industries (Thibodaux, Louisiana)TJ .............................................................. Timberjack (Deere) (Sweden/Finland/Canada)YC ............................................................. John Deere Jialian Harvester Co. Limited (China)Z ............................................................... John Deere WERKE Zweibrucken (Germany)Application Code001, etc. .................................................... See ENGINE APPLICATION CHARTS, later in this Group
POWERTECH is a registered trademark of Deere & Company
CTM331 (09APR02) 01-001-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=17
Engine Identification
01001
2
OUO1080,00001FB –19–15NOV01–1/1
Engine Serial Number Plate Information
RG
1181
6–U
N–1
5NO
V01
Engine Serial Number Plate
RG
9060
–UN
–16M
AR
98
Dubuque Engine Serial Number Plate
RG
1194
9–U
N–0
7NO
V01
Saran Engine Serial Number Plate
RG
1194
8–U
N–0
6NO
V01
Torreon Engine Serial Number Plate
A—Engine Serial Number PlateB—Engine Serial NumberC—Engine Application DataD—Coefficient of Absorption (Saran Engines Only)
IMPORTANT: The engine serial number plate (A) canbe easily destroyed. Before “hot tank”cleaning the block, remove the plate.
Engine Serial Number (B)
Each engine has a 13-digit John Deere engine serialnumber identifying the producing factory, engine modeldesignation, and a 6-digit sequential number. Thefollowing is an example:
CD4045T000000CD .......................... Factory producing engine4045T ..................... Engine model designation000000 ................... Sequential serial numberFactory Code (Engine Manufacturer)T0 ........................... Dubuque, IowaCD .......................... Saran, FrancePE .......................... Torreon, MexicoJ0 ........................... Rosario, ArgentinaEngine Model Designation4045T ..................... Definition explained previously. See ENGINE
MODEL DESIGNATION earlier in this group.Sequential Number000000 ................... 6-digit sequential serial number
Engine Application Data (C)
The second line of information on the serial number plateidentifies the engine/machine or OEM relationship. SeeENGINE APPLICATION CHARTS later in this group.
Coefficient of Absorption (D) — (Saran-Built EnginesOnly)
The second line of information on the Saran serial numberplate also contains the coefficient of absorption value forsmoke emissions.
CTM331 (09APR02) 01-001-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=18
Engine Identification
010013
OUO1080,000020E –19–26NOV01–1/1
OEM Engine Option Code Label
RG
1202
7–U
N–0
3DE
C01
An option code label is secured to the top of the valvecover and identifies the factory installed options on eachOEM engine to ensure correct parts acquisition.
Always provide option code information and engine basecode when ordering repair parts. A listing of option codesis given in parts catalogs and operator’s manuals.
NOTE: Before “hot tank” cleaning, ensure that optioncodes are recorded elsewhere.
OUO1080,0000035 –19–29AUG01–1/1
Information Relative to Emissions Regulations
Depending on the final destination, engines can meetthe emissions regulations according to the USEnvironmental Protection Agency (EPA), California AirResources Board (CARB) and for Europe, theDirective 97/68/EC relating the measures against theemissions of particles and gaseous pollutant frominternal combustion engines. Such engines are called“CERTIFIED” and receive an emission label stuck onthe engine.
The regulations prohibit tampering with theemission-related components listed below which wouldrender that component inoperative or to make anyadjustment on the engine beyond publishedspecifications. It is also illegal to install a part or
component where the principle effect of thatcomponent is to bypass, defeat, or render inoperativeany engine component or device which would affectthe engine’s conformance to the emission regulations.To summarize, it is illegal to do anything exceptreturn the engine to its original publishedspecifications.
List of emission-related components:
• Fuel injection system• Intake manifold• Turbocharger• Charge air cooling system• Piston
CTM331 (09APR02) 01-001-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=19
Engine Identification
01001
4
OUO1089,0000205 –19–09NOV01–1/1
Engine Application Charts
JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT
Machine Model Engine Model
Dubuque
310G Backhoe Loader (XXXXXX—) PE4045DT058, T04045DT058
310G Backhoe Loader (Alt Comp) (XXXXXX—) PE4045TT088, T04045TT088
310SG Backhoe Loader (XXXXXX—) PE4045TT089, T04045TT089
315SG Backhoe Loader (XXXXXX—)
450H Crawler Dozer (Alt Comp) (XXXXXX—) PE4045TT084, T04045TT084
450H Crawler Dozer (Nat Asp) (XXXXXX—) PE4045DT058, T04045DT058
450H LGP Crawler Dozer (XXXXXX—) PE4045TT085, T04045TT085
550H Crawler Dozer (XXXXXX—) PE4045TT087, T04045TT087
550H LGP Crawler Dozer (XXXXXX—) PE4045TT086, T04045TT086
Saltillo, Mexico
120C Excavator PE4045HP050
160C LC Excavator PE4045HP051
Timberjack
810 Forwarder CD4045HTJ01
1010 (1058) Forwarder T04045HTJ76
1410 (1458) Forwarder CD6068HTJ02
770 (863) Harvester CD4045HTJ03
1070 (1063) Harvester CD6068HTJ03
JOHN DEERE AGRICULTURAL EQUIPMENT
Machine Model Engine Model
Zweibrucken, Germany
3800 TeleHandler CD4045HZ050
JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)
CD4045TF275
PE4045HF275
CD4045TF275
PE4045TF275
CD6068HF275
PE6068HF275
CD6068TF275
PE6068TF275
CTM331 (09APR02) 01-001-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=20
Group 002Fuels
010021
DPSG,OUO1004,2761 –19–16MAY00–1/1
Lubricants and Coolant
NOTE: Refer to Section 01, Group 002 of CTM104 BaseEngine Manual for information on lubricants andcoolants.
OUOD002,0000171 –19–18DEC01–1/1
Diesel Fuel
Consult your local fuel distributor for properties of thediesel fuel available in your area.
In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 arerecommended.
Required fuel properties
In all cases, the fuel must meet the followingproperties:
Cetane number of 45 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20°C (-4°F) or elevations above1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5°C (9°F) below the expected low temperature.
Fuel lubricity should pass a minimum load level of3100 grams as measured by ASTM D6078 or,maximum scar diameter of 0.45 mm as measured byASTM D6079.
Sulfur content:
• Diesel fuel quality and fuel sulfur content mustcomply with all existing regulations for the area inwhich the engine operates.
• Sulfur content less than 0.05% (500 ppm) ispreferred.
• If diesel fuel with sulfur content greater than 0.05%(500 ppm) is used, crankcse oil service intervalsmay be affected. (See recommendation for DieselEngine Oil.)
• DO NOT use diesel fuel with sulfur content greaterthan 1.0%.
IMPORTANT: DO NOT mix used engine oil or anyother type of lubricating oil withdiesel fuel.
CTM331 (09APR02) 01-002-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=21
Fuels
01002
2
RG41183,0000046 –19–18DEC01–1/1
Bio-Diesel Fuel
Consult your local fuel distributor for properties of thebio-diesel fuel available in your area.
Bio-diesel fuels may be used ONLY if the bio-dieselfuel properties meet the latest edition of ASTM PS121,DIN 51606 or equivalent specification.
It has been found that bio-diesel fuels may improvelubricity in concentrations up to a 5% blend inpetroleum diesel fuel.
When using a blend of bio-diesel fuel, the engine oillevel must be checked daily when the air temperatureis -10°C (14°F) or lower. If the oil becomes diluted withfuel, shorten oil change intervals accordingly.
IMPORTANT: Raw pressed vegetable oils are NOTacceptable for use for fuel in anyconcentration in John Deereengines.
These oils do not burn completely,and will cause engine failure byleaving deposits on injectors and inthe combustion chamber.
A major environmental benefit of bio-diesel fuel is itsability to biodegrade. This makes proper storage andhandling of bio-diesel fuel especially important. Areasof concern include:
• Quality of new fuel• Water content of the fuel• Problems due to aging of the fuel
Potential problems resulting from deficiencies in theabove areas when using bio-diesel fuel inconcentrations above 5% may lead to the followingsymptoms:
• Power loss and deterioration of performance• Fuel leakage• Corrosion of fuel injection equipment• Coked and/or blocked injector nozzles, resulting in
engine misfire• Filter plugging• Lacquering and/or seizure of internal components• Sludge and sediments• Reduced service life of engine components
DX,FUEL6 –19–06DEC00–1/1
Dieselscan Fuel Analysis
DIESELSCAN is a John Deere fuel sampling program tohelp you monitor the quality of your fuel source. It verifiesfuel type, cleanliness, water content, suitability for coldweather operation, and if fuel is within ASTMspecifications. Check with your John Deere dealer foravailability of DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
CTM331 (09APR02) 01-002-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=22
Fuels
010023
OUOD002,0000179 –19–18DEC01–1/1
Lubricity of Diesel Fuel
Diesel fuel must have adequate lubricity to ensureproper operation and durability of fuel injection systemcomponents.
Diesel fuels for highway use in the United States andCanada require sulfur content less than 0.05% (500ppm).
Diesel fuel in the European Union requires sulfurcontent less than 0.05% (500 ppm).
Experience shows that some low sulfur diesel fuelsmay have inadequate lubricity and their use mayreduce performance in fuel injection systems due toinadequate lubrication of injection pump components.The lower concentration of aromatic compounds inthese fuels also adversely affects injection pump sealsand may result in leaks.
Use of low lubricity diesel fuels may also causeaccelerated wear, injection nozzle erosion or corrosion,engine speed instability, hard starting, low power, andengine smoke.
Fuel lubricity should pass a minimum load level of3100 gram as measured by the ASTM D6078 ormaximum scar diameter of 0.45 mm as measured byASTM D6079.
ASTM D975 and EN 590 specifications do not requirefuels to pass a fuel lubricity test.
If fuel of low or unknown lubricity is used, add JohnDeere PREMIUM DIESEL FUEL CONDITIONER (orequivalent) at the specified concentration.
CTM331 (09APR02) 01-002-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=23
Fuels
01002
4
CTM331 (09APR02) 01-002-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=24
Section 02Repair and AdjustmentsContents 02
Page Page
Group 090—Electronic Fuel System Repair and Remove Blade Terminals from ConnectorAdjustments Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11
Fuel System—General Information . . . . . . . . .02-090-1 Repair (Pull Type) METRI-PACKRelieve Fuel System Pressure . . . . . . . . . . . .02-090-1 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-12Remove and Install Final Fuel Filter/Water Repair (Push Type) METRI-PACK
Bowl and/or Pre-Filter/Water Bowl Base . . .02-090-2 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-14Fuel Pre-Filter/Water Bowl Assembly Repair DEUTSCH Connectors . . . . . . . . . .02-110-17
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-20Final Fuel Filter Assembly . . . . . . . . . . . . . . . .02-090-6Replace Final Fuel Filter/Water Bowl and
Pre-Filter/Water Bowl. . . . . . . . . . . . . . . . . .02-090-7Remove Fuel Supply Pump. . . . . . . . . . . . . . .02-090-9Install Fuel Supply Pump. . . . . . . . . . . . . . . .02-090-10Injection Pump Static Timing . . . . . . . . . . . . .02-090-10Remove Injection Pump . . . . . . . . . . . . . . . .02-090-11Inspect Injection Pump Drive Gear ID and
Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13Install Injection Pump . . . . . . . . . . . . . . . . . .02-090-13Remove Fuel Injection Nozzles . . . . . . . . . . .02-090-16Clean Fuel Injection Nozzle Bore . . . . . . . . .02-090-18Clean Fuel Injection Nozzles . . . . . . . . . . . . .02-090-18Fuel Injection Nozzle Test . . . . . . . . . . . . . . .02-090-19Disassemble Fuel Injection Nozzles . . . . . . .02-090-22Adjust Fuel Injection Nozzle . . . . . . . . . . . . .02-090-23Install Seals on Fuel Injection Nozzle . . . . . .02-090-24Install Fuel Injection Nozzles . . . . . . . . . . . . .02-090-25Bleed the Fuel System . . . . . . . . . . . . . . . . .02-090-26
Group 110—Electrical Engine Control Repair andAdjustment
Engine Control Unit (ECU) . . . . . . . . . . . . . . .02-110-1Remove and Install Engine Coolant
Temperature Sensor . . . . . . . . . . . . . . . . . .02-110-2Remove and Install Loss of Coolant
Temperature Sensor . . . . . . . . . . . . . . . . . .02-110-2Replace Crankshaft Position Sensor . . . . . . . .02-110-3Remove and Install Oil Pressure Sensor . . . . .02-110-3Remove and Install Manifold Air Temperature
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4Remove and Install Fuel Temperature
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4Remove and Install Fuel Heater . . . . . . . . . . .02-110-5Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-6Use Electrical Insulating Compound . . . . . . . .02-110-6Using High-Pressure Washer . . . . . . . . . . . . .02-110-7Repair WEATHERPACK Connector . . . . . . .02-110-8
CTM331 (09APR02) 02-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=1
Contents
02
CTM331 (09APR02) 02-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Group 090Electronic Fuel System Repair and Adjustments
020901
OUO1089,00001F7 –19–06NOV01–1/1
Fuel System—General Information
Stanadyne DE10 pumps are static lock-pin timedduring installation of the injection pump.
The fuel supply pump is a separate componentmounted on upper right-hand side of engine block andis actuated by a pin in block that rides on enginecamshaft lobe.
Engines may be equipped with an optional fuelpre-filter/water bowl.
All engines are equipped with a round final fuel filterwith water bowl. Hand primer on top of filter element isoptional.
All engines use Stanadyne Rate Shaping Nozzles(RSN).
Field-installed options include fuel heater, water bowland hand fuel primer.
RG,35,JW7625 –19–20NOV97–1/1
Relieve Fuel System Pressure
X98
11–U
N–2
3AU
G88
High Pressure Fluids
CAUTION: Escaping diesel fuel under pressurecan have sufficient force to penetrate the skin,causing serious injury. Before disconnectinglines, be sure to relieve pressure. Beforeapplying pressure to the system, be sure ALLconnections are tight and lines, pipes andhoses are not damaged. Keep hands and bodyaway from pinholes and nozzles which ejectfluid under pressure. Use a piece of cardboardor wood, rather than hands, to search forsuspected leaks.
If ANY fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result. Doctors unfamiliar with this type ofinjury may call the Deere & Company MedicalDepartment in Moline, Illinois, or otherknowledgeable medical source.
Any time the fuel system has been opened up for service(lines disconnected or filters removed), it will be necessaryto bleed air from the system. See BLEED THE FUELSYSTEM in this group.
CTM331 (09APR02) 02-090-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=27
Electronic Fuel System Repair and Adjustments
02090
2
OUO1089,00001F6 –19–06NOV01–1/3
Remove and Install Final Fuel Filter/WaterBowl and/or Pre-Filter/Water Bowl Base
RG
1198
9–U
N–1
5NO
V01
Final Fuel Filter
A—Final Fuel Filter/Water Bowl
Refer to operator’s manual for proper servicing and(hourly) replacement intervals.
Engines are equipped with a final fuel filter/water bowl (A)and may have an optional pre-filter/water bowl.
Final fuel filters/water bowls can be equipped with atransparent (see-through) water collection bowl and/orhand primer on machines equipped with only one filter.
Continued on next page
CTM331 (09APR02) 02-090-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=28
Electronic Fuel System Repair and Adjustments
020903
OUO1089,00001F6 –19–06NOV01–2/3
RG
1202
1–U
N–2
6NO
V01
Final Fuel Filter Base
A—Final Fuel Filter Base
1. Thoroughly clean fuel filter/pre-filter assemblies andsurrounding area to keep from getting dirt and debrisinto fuel system.
2. Connect a drain line to filter drain adapters and drainall fuel from system.
NOTE: The fuel filters are keyed to the filter header. Ifboth pre-filter and final filter are removed, ensurethat they are reinstalled in the correct headers.
3. Remove final fuel filter element and pre-filter/waterbowl, if desired. See REPLACE FINAL FUELFILTER/WATER BOWL AND PRE-FILTER/WATERBOWL, in this group.
NOTE: Pre-filter and final filter fuel lines may beconnected to different filter inlet and outlet portsdepending on engine application. Mark fuel linelocation to aid during assembly. Refer to markingson fuel filter base for fuel inlet/outlet ports, as theyare different between the pre- and final filterbases.
4. Disconnect fuel lines from all ports.
5. Remove final fuel filter base (A).
6. If equipped, remove pre-filter base.
7. Replace parts as necessary.
8. Install mounting brackets and tighten to torquespecifications provided below.
SpecificationFinal Fuel FilterBracket-to-Cylinder Head—Torque 73 N•m (54 lb-ft).............................................................................Final Fuel Filter MountingBase-to-Bracket—Torque 73 N•m (54 lb-ft)................................................Fuel Pre-Filter Bracket-to-CylinderHead and Alternator—Torque 73 N•m (54 lb-ft).........................................Fuel Pre-Filter/Water BowlMounting Base-to-Bracket—Torque 50 N•m (36 lb-ft).............................................................................
CTM331 (09APR02) 02-090-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=29
Continued on next page
Electronic Fuel System Repair and Adjustments
02090
4
OUO1089,00001F6 –19–06NOV01–3/3
9. Install pre-filter and final filter fuel filter/water bowlelements. See REPLACE FINAL FUELFILTER/WATER BOWL AND PRE-FILTER/WATERBOWL, in this group.
10. Connect fuel lines to all ports.
11. Bleed the fuel system. See BLEED THE FUELSYSTEM in this group.
CTM331 (09APR02) 02-090-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=30
Electronic Fuel System Repair and Adjustments
020905
RG,35,JW7623 –19–21JAN02–1/1
Fuel Pre-Filter/Water Bowl Assembly(Optional)
RG
T77
51H
R–U
N–1
9NO
V97
RG
T77
51H
S–U
N–1
9NO
V97
Primary Filter/Water Bowl Assembly
A—Drain AdapterB—PackingC—Cap ScrewD—Water BowlE—Retaining RingF—Filter ElementG—Filter Base with Seal RingH—Vent PlugI—PackingJ—Plug (2 used)K—DiaphragmL—Spring SeatM—SpringN—Spring CoverO—Pump KnobP—Retaining Ring
CTM331 (09APR02) 02-090-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=31
Electronic Fuel System Repair and Adjustments
02090
6
OUO1080,00001FC –19–15NOV01–1/1
Final Fuel Filter Assembly
RG
1201
5–U
N–1
6NO
V01
Final Fuel Filter
1—Retaining Ring2—O-Ring3—Stem4—O-Ring5—Retaining Ring6—Filter7—O-Ring8—O-Ring9—Drain Adapter10—Screw11—O-Ring12—Water Bowl13—Adapter14—O-Ring15—Fuel Heater (Optional)16—O-Ring17—Filter Base18—Primer Assembly (Optional)19—Cap
CTM331 (09APR02) 02-090-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=32
Electronic Fuel System Repair and Adjustments
020907
OUO1089,00001F5 –19–06NOV01–1/2
Replace Final Fuel Filter/Water Bowl andPre-Filter/Water Bowl
RG
1199
0–U
N–1
5NO
V01
Final Fuel Filter Shown
A—Retaining RingB—Filter Element
NOTE: Refer to operator’s manual for proper servicingand (hourly) replacement intervals.
Final fuel filters can be equipped with atransparent (see-through) water bowl and/or handprimer on machines equipped with only one filter.
Replacement of pre- and final fuel filter elementsare similar. Differences will be noted. Make surecorrect embossments on filter elements match theslots in the mounting header.
1. Thoroughly clean fuel filter/water bowl assembly andsurrounding area, if not previously done.
2. Connect a drain line to filter drain adapters and drainall fuel from filters.
NOTE: Lifting up on retaining ring (A) as it is rotatedhelps to get it past raised locators.
3. Firmly grasp the retaining ring (A) and rotate itcounterclockwise 1/4 turn. Remove ring with filterelement (B).
4. Inspect filter mounting base for cleanliness. Clean asrequired.
5. Remove transparent (see-through) water bowl, ifequipped. Drain and clean water bowl. Dry withcompressed air.
6. Install transparent (see-through) water bowl, ifequipped, onto new filter element. Make sure O-ring isproperly installed in the top groove of bowl.
7. Thoroughly inspect filter base dust seal ring. Replaceas needed.
Continued on next page
CTM331 (09APR02) 02-090-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=33
Electronic Fuel System Repair and Adjustments
02090
8
OUO1089,00001F5 –19–06NOV01–2/2
NOTE: The fuel filters must be indexed properly and thekey on canister must be oriented in slot ofmounting base for correct installation.
8. Install new filter element onto mounting base andposition element using a slight rocking motion. Be sureelement is properly indexed on mounting base.
9. Install retaining ring onto mounting base and tightenabout 1/3 turn until ring “snaps” into the detent. DONOT overtighten the retaining ring.
10. Bleed fuel system. See BLEED THE FUEL SYSTEM,in this group.
CTM331 (09APR02) 02-090-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=34
Electronic Fuel System Repair and Adjustments
020909
OUO1089,00001F8 –19–06NOV01–1/1
Remove Fuel Supply Pump
RG
1199
1–U
N–1
5NO
V01
Fuel Supply Pump Lines
RG
9051
–UN
–16M
AR
98
Remove Fuel Supply Pump
RG
1202
2–U
N–2
7NO
V01
Fuel Supply Pump Push Rod
A—Supply Pump Inlet from Fuel TankB—Supply Pump Outlet to Final Fuel FilterC—Cap ScrewsD—Push Rod
IMPORTANT: A backup wrench must always be usedwhen disconnecting fittings or fuel linesfrom supply pump to avoid damage tofittings.
1. Disconnect fuel inlet line (A) and outlet line (B) and capconnections on fuel supply pump and fuel lines to keepdebris out of fuel system.
2. Remove cap screws (C) and remove fuel supply pumpassembly from cylinder block.
NOTE: The fuel supply pump is driven by a push rod (D)that rides on an eccentric camshaft lobe. Thecylinder head must be removed to remove thispush rod.
3. Cover opening on cylinder block to prevent dirt fromentering the engine.
4. Inspect face of pump lever for wear. If lever face isworn flat or concave, replace pump.
CTM331 (09APR02) 02-090-9 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=35
Electronic Fuel System Repair and Adjustments
02090
10
OUO1089,00001FA –19–06NOV01–1/1
Install Fuel Supply Pump
RG
1199
1–U
N–1
5NO
V01
Fuel Supply Pump Lines
A—Supply Pump Inlet from Fuel TankB—Supply Pump Outlet to Final Fuel FilterC—Cap Screws
IMPORTANT: Apply LOCTITE 242 to threads of supplypump mounting cap screws (C) and fuelline fittings when reinstalling supplypump. DO NOT allow sealant to get intofuel system.
1. Install the fuel supply pump to cylinder block withpumping lever resting on top of push rod, using a newO-ring. Tighten cap screws (C) to specifications.
SpecificationFuel Supply Pump Cap Screws—Torque 30 N•m (22 lb-ft).............................................................................
IMPORTANT: ALWAYS use a backup wrench wheninstalling fittings and/or fuel lines ontosupply pump to avoid damage tofittings.
2. Connect supply pump inlet line (A) and outlet line (B)and tighten securely.
3. Bleed fuel system. See BLEED THE FUEL SYSTEM inthis group.
OUO1089,00001FB –19–06NOV01–1/1
Injection Pump Static Timing
Static lock-pin timing is accomplished during installation ofthe injection pump. See INSTALL INJECTION PUMP laterin this group.
CTM331 (09APR02) 02-090-10 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=36
Electronic Fuel System Repair and Adjustments
0209011
OUO1089,00001FE –19–07NOV01–1/2
Remove Injection Pump
RG
1200
2–U
N–1
6NO
V01
Stanadyne DE10 Fuel Injection Pump
RG
1203
6–U
N–2
1JA
N02
JDG1559 Injection Pump Timing Pin
RG
1200
0–U
N–2
1JA
N02
Injection Pump Drive Gear Removal
A—JDG1559 Timing PinB—Injection Pump Drive GearC—Screws (2 used)D—Center Forcing Screw
IMPORTANT: Never steam clean or pour cold wateron a fuel injection pump while the pumpis running or while it is warm. Doing somay cause seizure of internal rotatingpump parts.
1. Clean the fuel injection pump, lines and area aroundthe pump with cleaning solvent or a steam cleaner.
2. Rotate engine to TDC of number 1 cylindercompression stroke and install JDG1571 Timing Pin inflywheel.
3. Before removing injection pump from engine, installJDG1559 Injection Pump Timing Pin (A) into pumptiming pin bore.
4. Remove injection pump drive gear cover (shownremoved). Remove drive gear retaining nut and washerfrom end of pump shaft. Be careful not to let washerfall inside timing gear cover.
5. Attach JDG1560 Drive Gear Puller to injection pumpdrive gear (B) using two screws (C).
6. Evenly tighten the two screws (C) and snugly tightencenter forcing screw (D) against end of pump shaft.
7. Tighten center forcing screw (D) until pump drive gearis free from tapered shaft. Remove JDG1560 Pullerfrom drive gear.
CTM331 (09APR02) 02-090-11 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=37
Continued on next page
Electronic Fuel System Repair and Adjustments
02090
12
OUO1089,00001FE –19–07NOV01–2/2
RG
1200
1–U
N–1
6NO
V01
Injector Pump Electrical Connector Removal
RG
1200
3–U
N–1
6NO
V01
Disconnect Fuel Delivery Lines
A—Temperature Sensor ConnectorB—Fuel Control Solenoid ConnectorC—Fuel Return LineD—Fuel Supply LineE—ClampF—Fuel Delivery LinesG—Nut (3 used)
8. Remove temperature sensor connector (A) and fuelcontrol solenoid connector (B).
IMPORTANT: ALWAYS use a backup wrench whenloosening or tightening fuel deliverylines at fuel injection pump, so that thepump discharge fittings are not altered.This prevents possible internal pumpdamage.
9. Disconnect fuel supply line (D) and return line (C).
10. Remove clamp (E) retaining fuel delivery (pressure)lines (F).
11. Disconnect all fuel delivery lines (F) from injectionpump and install protective caps.
12. Remove three injection pump mounting stud nuts (G).Remove injection pump from mounting studs. Placepump on a clean flat surface and inspect shaft ODand drive gear as outlined later in this group. SeeINSPECT INJECTION PUMP DRIVE GEAR ID ANDSHAFT OD later in this group.
CTM331 (09APR02) 02-090-12 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=38
Electronic Fuel System Repair and Adjustments
0209013
OUO1089,00001FC –19–06NOV01–1/1
Inspect Injection Pump Drive Gear ID and Shaft OD
IMPORTANT: Use a good light source tothoroughly inspect gear ID and shaftOD.
1. Inspect injection pump drive gear ID full 360° formetal transfer as a result of slippage on shaft.
2. Inspect injection pump drive shaft OD full 360° forpresence of metal transfer from gear slippage. Ifthere is clear evidence of metal transfer on pumpshaft OD or in drive gear ID, injection pump anddrive gear MUST BE replaced.
IMPORTANT: When replacing injection pump drivegear or installing a new pump, thetapered surfaces of the pump driveshaft OD and drive gear ID MUST BEcleaned to remove protectivecoatings and oily residue. Use asuitable cleaner that does not leavea residue. Mating surfaces MUST BEASSEMBLED DRY and LUBRICANTSMUST NOT BE USED.
OUO1089,0000204 –19–08NOV01–1/3
Install Injection Pump
B
A
RG
1201
9–U
N–1
9NO
V01
Install Timing Pin
A—JDG1559 Timing PinB—Hole in Drive Shaft
1. Before installing injection pump on engine, installJDG1559 Injection Pump Timing Pin (A) into pumptiming pin bore. Install a small punch or screwdriverinto hole in pump drive shaft (B) and turn shaft untiltiming pin drops into recess in injection pump driveshaft.
Continued on next page
CTM331 (09APR02) 02-090-13 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=39
Electronic Fuel System Repair and Adjustments
02090
14
OUO1089,0000204 –19–08NOV01–2/3
RG
1200
4–U
N–1
6NO
V01
Injection Pump Mounting Stud Nuts
RG
1200
7–U
N–1
6NO
V01
Injection Pump Timing Pin
RG
1200
8–U
N–1
6NO
V01
Injection Pump Gear Installation
A—Injection Pump Mounting Stud Nut (3 used)B—JDG1559 Injection Pump Lock Timing PinC—Gear Mounting NutD—Pump Gear
NOTE: When rotating engine to TDC of compressionstroke on number 1 cylinder, turn engine only indirection of rotation to prevent gear backlash.Backlash of gears is enough to throw the injectionpump timing off by several degrees, resulting inpoor engine performance.
2. Make sure that number 1 cylinder is locked at TDC ofcompression stroke and install JDG1571 Timing Pin inflywheel.
NOTE: Retain JDG1559 Timing Pin (B) in pump duringinstallation.
3. Install injection pump onto mounting studs and tightenthree pump mounting stud nuts (A) to specification.Position drive gear while installing pump.
SpecificationInjection Pump Mounting StudNuts—Torque 25 N•m (19 lb-ft)..................................................................
4. Install injection pump gear (D) on drive shaft. Install,but do not tighten, injection pump gear mounting nut(C).
NOTE: Hold the injection pump gear while applyingtorque to prevent the gear from rotating.
5. Rotate gear counterclockwise (viewed from front ofengine) to remove any backlash, and tighten gearmounting nut to specification.
SpecificationInjection Pump Gear MountingNut—Torque 195 N•m (145 lb-ft)................................................................
6. Install injection pump gear access plate and removetiming pin (B) from pump. Install plug in injection pumptiming pin hole and tighten to specification.
SpecificationInjection Pump Timing Pin Plug—Torque 9.5 N•m (7.5 lb-ft)...........................................................................
7. Remove JDG1571 Timing Pin from flywheel.
CTM331 (09APR02) 02-090-14 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=40
Continued on next page
Electronic Fuel System Repair and Adjustments
0209015
OUO1089,0000204 –19–08NOV01–3/3
RG
1200
1–U
N–1
6NO
V01
Injector Pump Electrical Connectors
RG
1200
3–U
N–1
6NO
V01
Connect Fuel Delivery Lines
RG
1203
5–U
N–1
1JA
N02
A—Temperature Sensor ConnectorB—Fuel Control Solenoid ConnectorC—Fuel Return LineD—Fuel Supply LineE—ClampF—Fuel Delivery LinesG—Nut (3 used)H—Engine Block SideI—Outlet Connection to No. 1 Cylinder
8. Connect injection pump fuel delivery (pressure) lines(F). Beginning with outlet (I) and continuing around thepump head in counterclockwise direction, attach linesin same order as engine firing (1-5-3-6-2-4 on6-cylinder engines and 1-3-4-2 on 4-cylinder engines).
IMPORTANT: ALWAYS use a backup wrench whenloosening or tightening fuel deliverylines at fuel injection pump, so that thepump discharge fittings are not altered.This prevents possible internal pumpdamage.
9. Tighten fuel delivery lines at pump to specification.
SpecificationInjection Pump Fuel Delivery(Pressure) Lines—Torque 27 N•m (20 lb-ft)...............................................
10. Install clamp (E).
11. Connect fuel supply line (D) and fuel return line (C).
12. Install temperature sensor connector (A) and fuelcontrol solenoid connector (B).
13. Bleed air from fuel system as outlined in this group.See BLEED THE FUEL SYSTEM in this group. Startengine, run for several minutes and check entire fuelsystem for leaks.
CTM331 (09APR02) 02-090-15 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=41
Electronic Fuel System Repair and Adjustments
02090
16
OUO1089,00001FF –19–07NOV01–1/4
Remove Fuel Injection Nozzles
RG
1199
3–U
N–1
5NO
V01
Fuel Injection Nozzle
General Nozzle Service Precautions
Before removal, thoroughly remove all dirt from thecylinder head around fuel injection nozzles. Clean withcompressed air to prevent dirt from entering the cylinders.Plug the bore in the cylinder head after each nozzle hasbeen removed. Cap fuel line openings as soon as theyare disconnected.
Immediately fit protective caps over the nozzle tips andthe line connections to avoid handling damage and gettingdebris in fuel system.
Do not bend the fuel delivery lines, as this may affect theirdurability. When loosening the fuel pressure lines, holdmale union of nozzle line stationary with a backup wrench.
OUO1089,00001FF –19–07NOV01–2/4
RG
1199
4–U
N–1
5NO
V01
Fuel Leak-Off Lines
A—Tube Nuts
1. Loosen tube nuts (A) at each nozzle to remove leak-offlines and T-fittings as an assembly.
Continued on next page
CTM331 (09APR02) 02-090-16 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=42
Electronic Fuel System Repair and Adjustments
0209017
OUO1089,00001FF –19–07NOV01–3/4
RG
1199
9–U
N–1
9NO
V01
Fuel Injection Line at Nozzle
2. Disconnect fuel injection line from nozzle using abackup wrench on nozzle connection as shown.
3. Remove cap screw securing nozzle in cylinder headnozzle bore.
OUO1089,00001FF –19–07NOV01–4/4R
G12
018
–UN
–16N
OV
01
Injection Nozzle Puller Set
A—JDG1515-1 Nozzle Puller
4. Pull injection nozzle out of cylinder head usingJDG1515-1 Nozzle Puller (A).
IMPORTANT: Do not use screwdrivers, pry bars, orsimilar tools for this as they mightdamage the injection nozzle beyondrepair.
CTM331 (09APR02) 02-090-17 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=43
Electronic Fuel System Repair and Adjustments
02090
18
RG,35,JW7596 –19–20NOV97–1/1
Clean Fuel Injection Nozzle Bore
RG
7743
–UN
–07N
OV
97
Clean Injection Nozzle BoreA—Nozzle Bore Cleaning Tool
IMPORTANT: Always turn tool clockwise in bore toprevent dulling of cutting edges, evenwhen removing tool from bore.
Clean injection nozzle bore using JDE39 Nozzle BoreCleaning Tool (A). Blow debris from bore usingcompressed air, and plug the bore to prevent entry offoreign material.
OUO1080,00001FD –19–15NOV01–1/1
Clean Fuel Injection Nozzles
RG
1199
5–U
N–1
5NO
V01
Clean Fuel Injection Nozzle
A—Carbon Stop SealB—Upper Sealing Washer
1. Remove carbon stop seal (A) from groove in nozzlebody using razor blade or sharp knife and removeupper sealing washer (B). Discard seal and washer.
2. Place nozzle in solvent or clean diesel fuel, so carbonstop seal groove is submerged, and soak for a while.
IMPORTANT: Do not scrape or disturb the TEFLON
coating on the nozzle body above thecarbon stop seal groove. This coatingwill become discolored during normaloperation, but this is not harmful. Donot use a motor-driven brush to cleannozzle body.
3. After soaking, clean nozzle tip with brass wire brush.Never use a steel wire brush or scraper.
TEFLON is a registered trademark of the DuPont Co.
CTM331 (09APR02) 02-090-18 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=44
Electronic Fuel System Repair and Adjustments
0209019
OUO1089,0000200 –19–07NOV01–1/3
Fuel Injection Nozzle Test
X98
11–U
N–2
3AU
G88
High Pressure Fluid
L307
41–U
N–0
8AU
G89
Fuel Injection Nozzle Test
1—Nozzle Tester2—Pressure Line
CAUTION: The nozzle tip should always bedirected away from the operator. Fuel from thespray orifices can penetrate clothing and skincausing serious personal injury. Enclosing thenozzle in a clear glass beaker is recommended.
Before applying pressure to the nozzle tester,be sure that all connections are tight, and thatthe fittings are not damaged. Fluid escapingfrom a very small hole can be almost invisible.To search for suspected leaks, use a piece ofcardboard or wood, rather than hands.
If ANY fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result.
NOTE: Testing the performance of a nozzle while theengine is running is just a rough test. To obtain atrue check of nozzle performance, use a nozzletester JT25510 (1) and pressure line KJD10109(2).
Use only carefully filtered diesel fuel for testingthe injection nozzles, since dirty fuel will severelydamage the precision parts of a nozzle.
Connect the nozzle to the tester so that the axis of thenozzle forms an angle of approximately 30° to the verticaland the spray of fuel is directed downwards. Check allconnections for leaks. Close the gauge shut-off valve andflush (bleed) the nozzle by operating test pump rapidly.
Continued on next page
CTM331 (09APR02) 02-090-19 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=45
Electronic Fuel System Repair and Adjustments
02090
20
OUO1089,0000200 –19–07NOV01–2/3
Spray Pattern Test
Close gauge shut-off valve and operate the pump lever at60 strokes per minute. If the fuel injection nozzle isworking properly, the fuel should issue through all nozzleorifices in a fine, evenly shaped spray cone. This spraycone is inclined from the centerline of the nozzle body, butshould be distributed. For a better check, place a piece ofpaper or cardboard at a suitable distance below thenozzle and check the appearance of the damp circularspots made by the fuel. Deviations from the regular spraypattern or angle may be due to the complete or partialclogging of a nozzle orifice. In this case the fuel issues ina jet rather than in a fine spray.
Checking Valve Stem and Guide Wear
Connect fuel injection nozzle to the nozzle tester with thetip raised a little higher than its opposite end.Cover the tip and pump the tester to a pressure of10 300 kPa (103 bar) (1500 psi). Keep the pressureconstant and observe how much fuel leaks out of thenozzle return end. After the first drop has formed, countthe drops for 30 seconds and compare with specification.
Fuel Injection Nozzle—SpecificationNozzle—Return Leakage at10 300 kPa (103 bar) (1500 psi) 1 to 14 drops (maximum) within
30 seconds.............
Checking Valve Seat
Connect the nozzle to tester in horizontal position.Operate the pump lever rapidly to bleed the nozzle andallow the valve to seat. Dry the tip of the nozzlethoroughly. Now operate the pump lever slowly until theindicated pressure is approximately 2800 to 3500 kPa(28 to 35 bar) (400 to 500 psi) below opening pressure(see specification for opening pressure). Keep watchingthe nozzle. Under these conditions the fluid should notdrip out of the nozzle tip. However some weeping or lightmoisture on the tip is considered acceptable. Work thepump lever quickly several times in succession to makethe nozzle spray in the normal way. After the last stroke ofthe pump, observe again. If the nozzle is not quiteleakproof, disassemble for servicing.
CTM331 (09APR02) 02-090-20 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=46
Continued on next page
Electronic Fuel System Repair and Adjustments
0209021
OUO1089,0000200 –19–07NOV01–3/3
Opening Pressure Test
NOTE: Absolute opening pressure is less important thanequal opening pressure of all nozzles.
Close gauge shut-off valve and actuate the pump severaltimes to allow the nozzle valve to seat properly. Opengauge shut-off valve. Pump the pressure up to the pointwhere the pressure gauge needle falls rapidly. This point(take reading) is the nozzle valve opening pressure.
Fuel Injection Nozzle—SpecificationRate Shaping Nozzle—OpeningPressure for Setting(New or Reconditioned) 24 400—24 900 kPa
(244—249 bar) (3540—3620 psi).............................................
Opening Pressure for Checking(New or Reconditioned) 24 100 kPa (241 bar) (3500 psi)
Min..........................
Opening Pressure for Setting(Used) 23 000—23 600 kPa
(230—236 bar) (3340—3420 psi)........................................................................
Opening Pressure for Checking(Used) 21 800 kPa (218 bar) (3170 psi)
Min.....................................................
Rate Shaping Nozzle—Openingpressure difference betweencylinders 700 kPa (7 bar) (100 psi) Max.....................................................
If spray pattern, leakage test, and valve wear test aregood but the opening pressure test is unsatisfactory,adjust opening pressure.
CTM331 (09APR02) 02-090-21 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=47
Electronic Fuel System Repair and Adjustments
02090
22
OUO1089,0000201 –19–07NOV01–1/1
Disassemble Fuel Injection Nozzles
RG
1199
6–U
N–1
5NO
V01
RSN Nozzle Disassembly
A—T-FittingB—CapC—O-Ring (2 used)D—RetainerE—Protection CapF—Carbon Stop SealG—Seal WasherH—Protection Cap
NOTE: If all tests prove that the nozzle performs properly,no further service is necessary and the nozzle canbe reinstalled. If an injection nozzle is notoperating properly and must be disassembled forcleaning and/or reconditioning, see your“Stanadyne” dealer.
CTM331 (09APR02) 02-090-22 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=48
Electronic Fuel System Repair and Adjustments
0209023
OUO1089,0000202 –19–07NOV01–1/2
Adjust Fuel Injection Nozzle
X98
11–U
N–2
3AU
G88
High Pressure Fluids
RG
1199
7–U
N–1
5NO
V01
RSN Nozzle Adjust
A—Pressure Adjusting ScrewB—Lift Adjusting ScrewC—Spring Chamber CapD—Lift Adjusting Screw Lock NutE—Pressure Adjusting Screw Lock NutF—Spring Seat
CAUTION: Nozzle tip should always be directedaway from operator. Fuel from spray orificescan penetrate clothing and skin causing seriouspersonal injury. Enclosing nozzle in a glassbeaker is recommended.
Before applying pressure to nozzle tester, besure all connections are tight, and fittings arenot damaged. Fluid escaping from a very smallhole can be almost invisible. Use a piece ofcardboard or wood, rather than hands, tosearch for suspected leaks.
If ANY fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result.
1. Unscrew spring chamber cap (C) using JDG1521Spring Chamber Cap Wrench.
2. Loosen and remove lift adjusting screw lock nut (D).
3. Loosen pressure adjusting screw lock nut (E) usingJDG1515-2 Special Wrench.
4. Connect nozzle to tester, then adjust opening pressureto specifications by turning the pressure adjustingscrew (A). Use JDG1522 Pressure Adjusting ScrewTool.
5. Tighten pressure adjusting screw lock nut (E) tospecification, then recheck opening pressure.
6. Carefully screw lift adjusting screw (B) until it bottomson spring seat (F).
7. Unscrew lift adjusting screw with 7/8 turn.
8. Tighten lift adjusting screw lock nut (D) to specification.
CTM331 (09APR02) 02-090-23 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=49
Continued on next page
Electronic Fuel System Repair and Adjustments
02090
24
OUO1089,0000202 –19–07NOV01–2/2
9. Recheck opening pressure.
Fuel Injection Nozzle—SpecificationPressure Adjusting Screw LockNut—Torque 10 N•m (7 lb-ft)......................................................................Lift Adjusting Screw Lock Nut—Torque 5 N•m (3.5 lb-ft)..............................................................................
RG,35,JW7586 –19–20NOV97–1/1
Install Seals on Fuel Injection Nozzle
RG
9096
–UN
–27M
AR
98
Fuel Injection Nozzle Seals
A—Carbon Stop Seal InstallerB—Carbon Stop SealC—Seal Washer
IMPORTANT: Each time an injection nozzle isremoved from the cylinder head,replace carbon stop seal (B) with a newone.
1. Position JD258 (JD-258) Nozzle Carbon Stop SealInstaller (A) over nozzle tip.
2. Install a new seal washer (C) onto nozzle body.
3. Position a new carbon stop seal (B) on seal installer.Slide the carbon seal until it seats in its groove onnozzle body.
NOTE: If nozzle is not going to be installed at this time,install a No. 16189 Nozzle Protector Cap overnozzle tip. Plug all other openings in nozzle toprevent contamination.
CTM331 (09APR02) 02-090-24 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=50
Electronic Fuel System Repair and Adjustments
0209025
OUO1080,0000200 –19–16NOV01–1/2
Install Fuel Injection Nozzles
RG
1199
8–U
N–1
9NO
V01
Injection Nozzle in Cylinder Head
IMPORTANT: Before installing injection nozzles, makesure nozzles are clean and free from oilor grease.
NOTE: If nozzle bore in cylinder head must be cleaned,use JDE39 Nozzle Bore Cleaning Tool. SeeREMOVE FUEL INJECTION NOZZLES earlier inthis group.
1. Remove plug (if installed previously) from nozzle borein cylinder head and blow out bore with compressedair.
NOTE: Make sure that the sealing surface of the cylinderhead (on which the seal washer will be resting) issmooth and free of damage or dirt. This couldprevent proper sealing. Dirt and roughness couldalso cause nozzle to be distorted when theattaching screw is tightened, making the valvestick.
2. Install nozzle with spacer and clamps in cylinder headusing a slight twisting motion as nozzle is seated inbore. Illustration shows relationship of parts requiredfor proper installation.
3. Align nozzle clamps and install cap screw. Do nottighten cap screw at this stage.
4. Connect fuel pressure line to nozzle. Leave connectionslightly loose until air is bled from system.
5. Tighten nozzle hold-down clamp cap screws tospecifications.
SpecificationFuel Injection Nozzle Hold-DownClamp Cap Screws—Torque 40 N•m (30 lb-ft)...........................................
6. Install leak-off line assembly.
SpecificationFuel Leak-Off Line Hex Nut—Torque 5 N•m (3.7 lb-ft)
(44 lb-in.)..............................................................................
CTM331 (09APR02) 02-090-25 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=51
Continued on next page
Electronic Fuel System Repair and Adjustments
02090
26
OUO1080,0000200 –19–16NOV01–2/2
RG
1199
9–U
N–1
9NO
V01
Nozzle Fuel Pressure Line
7. Bleed air from loose injection line connection. Tightenconnection using two wrenches to the followingspecifications.
SpecificationFuel Injection Nozzle DeliveryLine—Torque 27 N•m (20 lb-ft)...................................................................
See BLEED THE FUEL SYSTEM in this group.
OUO1089,0000203 –19–07NOV01–1/5
Bleed the Fuel System
X98
11–U
N–2
3AU
G88
High Pressure Fluids
CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoidhazards by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.
If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis 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 necessaryto bleed air from the system.
The fuel system may be bled at one of several locations.On some engine applications it may be necessary toconsult your operator’s manual and choose the bestlocation for your engine/machine application.
CTM331 (09APR02) 02-090-26 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=52
Continued on next page
Electronic Fuel System Repair and Adjustments
0209027
OUO1089,0000203 –19–07NOV01–2/5
RG
1180
5–U
N–2
5OC
T01
Final Fuel Filter Bleed Vent Screw
A—Bleed Vent Screw
1. Loosen the air bleed vent screw (A) two full turns byhand on fuel filter base.
OUO1089,0000203 –19–07NOV01–3/5
RG
1180
6–U
N–2
5OC
T01
Fuel Supply Pump Primer LeverB—Primer Lever
2. Operate fuel supply pump prime lever (B) or primerbutton on fuel filter base (if equipped).
3. Tighten bleed plug securely; continue operating primeruntil pumping action is not felt.
4. Start engine and check for leaks.
If engine will not start, it may be necessary to bleed airfrom fuel system at fuel injection pump or injectionnozzles as explained next.
Continued on next page
CTM331 (09APR02) 02-090-27 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=53
Electronic Fuel System Repair and Adjustments
02090
28
OUO1089,0000203 –19–07NOV01–4/5
RG
1180
7–U
N–2
5OC
T01
Fuel Injection Pump Return Line
A—Fuel Return Line
At Fuel Injection Pump
1. Loosen fuel return line (A) at fuel injection pump.
2. Operate fuel supply pump primer lever or primer buttonon fuel filter base (if equipped).
3. As soon as fuel flow is free from air bubbles, tightenfuel return line to specifications. Primer lever isspring-loaded and will return to normal position.
SpecificationFuel Injection Pump ReturnLine—Torque 27 N•m (20 lb-ft)...................................................................
OUO1089,0000203 –19–07NOV01–5/5
RG
1180
8–U
N–2
5OC
T01
Nozzle Fuel Pressure Line
At Fuel Injection Nozzles
1. Place throttle lever in half-throttle position.
IMPORTANT: Always use a backup wrench whenloosening or tightening fuel lines atnozzles and/or injection pump to avoiddamage.
2. Using two open-end wrenches, loosen two fuel lineconnections at injection nozzles.
3. Crank engine over with starter motor for 15 seconds(but do not start engine) until fuel without any airbubbles flows out of loosened connection. Retightenconnection to specifications.
SpecificationFuel Injection Nozzle DeliveryLines—Torque 27 N•m (20 lb-ft).................................................................
4. Repeat procedure for remaining injection nozzles (ifnecessary) until all air has been removed from fuelsystem.
If engine still will not start, see your authorized servicingdealer or engine distributor.
CTM331 (09APR02) 02-090-28 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=54
Group 110Electrical Engine Control Repair and Adjustment
021101
OUO1080,0000201 –19–16NOV01–1/1
Engine Control Unit (ECU)
RG
1200
6–U
N–1
5NO
V01
Engine Control Unit (ECU)
IMPORTANT: DO NOT pressure wash the EngineControl Unit (ECU).
Before welding on engines with ECU,protect the ECU from high-currentdamage as follows:
1. Disconnect ECU-to-vehicle frameground connection.
2. Disconnect all other connectors fromECU. Also disconnect moduleconnector at injector pump.
3. Connect welder ground close towelding point and make sure ECUand other electrical components arenot in the ground path.
NOTE: For diagnosis and testing of the electronic enginecontrol and sensors, refer to Group 150.
IMPORTANT: DO NOT OPEN ENGINE CONTROLUNIT.
NOTE: The sealed ECU assembly is the systemcomponent LEAST likely to fail. Ensure that it isisolated and identified as the defective componentbefore replacing. See operation and test manualfor proper troubleshooting procedures.
The ECU is not repairable. If it is found to be defective,replace it as a unit. Provide the 13-digit engine serialnumber when ordering a new ECU.
IMPORTANT: If an ECU is not programmed identicallywith the original (failed) ECU,misleading diagnostic messages, poorperformance, or engine damage canoccur.
CTM331 (09APR02) 02-110-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=55
Electrical Engine Control Repair and Adjustment
02110
2
OUO1080,0000202 –19–16NOV01–1/1
Remove and Install Engine CoolantTemperature Sensor
RG
1200
9–U
N–1
6NO
V01
Engine Coolant Temperature Sensor
A—Engine Coolant Temperature Sensor
1. Disconnect engine coolant temperature sensor wiringconnector and remove sensor.
2. Coat sensor O-ring with JDT405 High TemperatureGrease and install sensor in thermostat housing.Tighten to specifications.
SpecificationEngine Coolant TemperatureSensor—Torque 15 N•m (11 lb-ft)..............................................................
3. Install sensor wiring connector.
RG40854,000014A –19–11FEB02–1/1
Remove and Install Loss of CoolantTemperature Sensor
RG
1076
6–U
N–2
6MA
Y00
Loss of Coolant Temperature (Rear of Cylinder Head)
A—Loss of Coolant Temperature Sensor
1. Disconnect loss of coolant temperature sensor wiringconnector and remove sensor.
2. Coat sensor O-ring with JDT405 High TemperatureGrease and install sensor in the rear of the cylinderhead. Tighten to specifications.
SpecificationLoss of Coolant TemperatureSensor—Torque 35 N•m (26 lb-ft)..............................................................
3. Install sensor wiring connector.
CTM331 (09APR02) 02-110-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=56
Electrical Engine Control Repair and Adjustment
021103
OUO1080,0000203 –19–16NOV01–1/1
Replace Crankshaft Position Sensor
RG
1201
1–U
N–1
6NO
V01
Crankshaft Position Sensor
A—Crankshaft Position Sensor
1. Disconnect sensor wiring connector.
2. Using a deep well socket, remove crankshaft positionsensor (A).
3. Replace sensor and O-ring in timing gear cover.Tighten sensor to specifications.
SpecificationCrankshaft Position Sensor—Torque 14 N•m (10 lb-ft).............................................................................
4. Install sensor wiring connector.
OUO1080,0000204 –19–16NOV01–1/1
Remove and Install Oil Pressure Sensor
RG
1055
0–U
N–0
2DE
C99
Oil Pressure Sensor
1. Disconnect oil pressure sensor wiring connector(shown disconnected) and remove sensor from cylinderblock.
2. Coat threads of sensor with LOCTITE 592 PipeSealant with TEFLON. Install sensor in oil coolerhousing and tighten to specifications.
SpecificationOil Pressure Sensor—Torque 15 N•m (11 lb-ft).........................................
3. Install sensor wiring connector.
LOCTITE is a registered trademark of Loctite Corp.TEFLON is a registered trademark of Du Pont Co.
CTM331 (09APR02) 02-110-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=57
Electrical Engine Control Repair and Adjustment
02110
4
OUO1080,00001F5 –19–09NOV01–1/1
Remove and Install Manifold Air TemperatureSensor
RG
1201
3–U
N–1
6NO
V01
Manifold Air Temperature Sensor
A—Manifold Air Temperature Sensor
1. Disconnect air temperature sensor wiring connectorand remove sensor (A) from air intake line.
2. Replace O-ring and install sensor in air intake line.Tighten sensor to specifications.
SpecificationManifold Air TemperatureSensor—Torque 10 N•m (7 lb-ft)................................................................
3. Install sensor wiring connector.
OUO1080,00001F6 –19–12NOV01–1/1
Remove and Install Fuel Temperature Sensor
RG
1201
4–U
N–1
6NO
V01
Fuel Temperature Sensor
A— Fuel Temperature Sensor
1. Disconnect fuel temperature sensor wiring connectorand remove sensor (A) from fuel injection pump.
2. Replace O-ring and install sensor into fuel injectionpump and tighten to specifications.
SpecificationFuel Temperature Sensor—Torque 13—18 N•m (10—13 lb-ft)..............................................................
3. Install sensor wiring connector.
CTM331 (09APR02) 02-110-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=58
Electrical Engine Control Repair and Adjustment
021105
OUO1080,00001F7 –19–12NOV01–1/1
Remove and Install Fuel Heater
RG
1201
6–U
N–1
6NO
V01
Fuel Heater
1. Disconnect fuel heater wiring connector and removeheater from filter base.
2. Replace O-ring and install fuel heater in primary fuelfilter inlet port to specifications.
SpecificationFuel Heater—Torque 9 N•m (7 lb-ft)...........................................................
3. Install heater wiring connector.
CTM331 (09APR02) 02-110-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=59
Electrical Engine Control Repair and Adjustment
02110
6
RG,RG34710,1328 –19–23OCT97–1/1
Connectors
Connectors are devices that provide for assembly anddisassembly of systems. Connectors should always beserviced using tools designed for that type of connector. Agood crimp is important to mechanical and electricalsoundness. Repaired connectors should be physicallytested by pulling to be sure the contact is firmly attachedto the conductor.
IMPORTANT: If for some reason the connectors arenot connected, such as when the fuelinjection pump is removed, it isimportant to protect the connectorsfrom debris.
Refer to the procedures which follow for repair of varioustypes of connectors.
RG,RG34710,1335 –19–23OCT97–1/1
Use Electrical Insulating Compound
Apply AT66865 Compound directly to the terminalsbetween the wire seal and connector body. This providesa moisture barrier, especially in wet and humid conditions.
CTM331 (09APR02) 02-110-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=60
Electrical Engine Control Repair and Adjustment
021107
RG,RG34710,1329 –19–23OCT97–1/1
Using High-Pressure Washer
T66
42E
J–U
N–1
8OC
T88
Using High-Pressure Washer
IMPORTANT: Reduce pressure when directingpressurized water at electronic orelectrical components and connectorsas this may cause the components tomalfunction. Always reduce pressure,and spray at a 45 to 90 degree angle.
CTM331 (09APR02) 02-110-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=61
Electrical Engine Control Repair and Adjustment
02110
8
AG,OUOD008,296 –19–06MAR02–1/4
Repair WEATHERPACK Connector
TS
0128
–UN
–23A
UG
88
1. Disconnect WEATHERPACK connector. Remove thetie bands and tape.
2. Open the secondary lock on the back of the connector.
3. Identify wire color/number to the connector cavity.Make sure each wire goes back to the correct cavitylocation.
4. Insert JDG364 Extraction Tool1 over terminal contact inconnector body. Extraction tool needs to be fullyseated to unlock terminal tangs from the connectorbody. When tool is seated, gently pull the wire from theback of the connector. If the wire(s) or terminal(s) arebeing repaired, go to step 5. If the wires and terminalsare OK and only the connector is being replaced, go tostep 9.
5. Using JDG145 Universal Electrical Pliers2, cut off wiredirectly behind the terminal seal crimp. If any part ofthe seal is still on the wire, dispose of it.
6. Using JDG145 Universal Electrical Pliers2, strip 6 mm(1/4 in.) insulation from end of wire.
WEATHERPACK is a trademark of Packard Electric
1 Included in JT07195B Electrical Repair Kit
2Included in JDG155 Electrical Repair Tool Kit
Continued on next page
CTM331 (09APR02) 02-110-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=62
Electrical Engine Control Repair and Adjustment
021109
AG,OUOD008,296 –19–06MAR02–2/4
TS
0136
–UN
–23A
UG
88
7. Select correct size of seal. Slide the seal over the wireinsulation with the smaller diameter side facing the endof the wire. Small diameter side of seal should line upwith the outer edge of the insulation.
IMPORTANT: The seal must fit snug over the cableinsulation without a gap between thecable seal and the insulation.
NOTE: Cable seals are color coded for three sizes ofwire:
• Green - 18—20 Gauge Wire• Gray - 14—16 Gauge Wire• Blue - 10—12 Gauge Wire
AG,OUOD008,296 –19–06MAR02–3/4
TS
1623
–UN
–02N
OV
94
8. Select correct size terminal on wire and crimp inposition with a W-type crimp using a JDG783WEATHER PACK Crimping Tool.
NOTE: Terminals have numbered identification for twosizes of wire:
• #15 - 14—16 Gauge Wire• #19 - 18—20 Gauge Wire
WEATHER PACK is a trademark of Packard Electric Continued on next page
CTM331 (09APR02) 02-110-9 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=63
Electrical Engine Control Repair and Adjustment
02110
10
AG,OUOD008,296 –19–06MAR02–4/4
TS
0130
–UN
–23A
UG
88T
S01
39–U
N–0
2DE
C88
A—SleeveB—Pin
9. Insert terminal into connector. Terminal should clickwhen it is fully seated. Make sure the wire is insertedinto the correct connector cavity.
IMPORTANT: Terminal tangs must be carefully spreadto ensure good seating on connectorbody. If terminal is being reused in anew connector, make sure tangs arespread.
NOTE: Connector bodies are “keyed” for correctterminals. Be sure terminals are correctly aligned.
Correct terminal installation for sleeve (A) and pin(B) is illustrated.
10. Gently pull on wire to insure that the terminal islocked in position.
11. Repair or transfer remaining wires.
12. Close the secondary lock on the back of theconnector.
13. Retape wires and add the required tie bands to theharness.
CTM331 (09APR02) 02-110-10 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=64
Electrical Engine Control Repair and Adjustment
0211011
AG,OUOD008,297 –19–06MAR02–1/1
Remove Blade Terminals from ConnectorBody
RW
4218
–UN
–23A
UG
88
A—Locking TangB—Original Position
NOTE: Use JDG776 Extraction Tool with 56, 280, and630 Series METRI-PACK terminals. Use JDG777Extraction Tool with 150 Series METRI-PACKterminals.
1. Insert JDG776 or JDG777 Terminal Extraction Tool1
into connector body pushing the terminal locking tanginward.
2. Gently pull wire and remove terminal from connector.
3. Adjust the locking tang on the terminal to it’s originalposition before installing into a connector.
1Included in JT07195B Electrical Repair Kit
CTM331 (09APR02) 02-110-11 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=65
Electrical Engine Control Repair and Adjustment
02110
12
AG,OUOD008,298 –19–06MAR02–1/2
Repair (Pull Type) METRI-PACK Connectors
RG
1223
1A–U
N–1
3MA
R02
RG
1223
2A–U
N–1
3MA
R02
RW
1693
5A–U
N–0
5AU
G98
A—ConnectorB—Connector SealC—JDG777 Terminal Extraction ToolD—Terminal Locking TangE—Terminal
1. Disconnect the METRI-PACK connector (A) from theECU.
2. Remove tie bands and tape from the wiring harnessbehind the connector.
3. Identify wire color/number to the connector cavity.Make sure each wire goes back to the correct cavitylocation.
4. Using JDG776 Terminal Extraction Tool (C)1, carefullyremove the connector seal (B) from the back of theconnector.
IMPORTANT: Make sure no damage to the sealoccurs or water and contaminants willcorrode terminals.
NOTE: Extraction tool must be used from the back of theconnector.
5. Using JDG776 Terminal Extraction Tool (C), angle thetip so it slides along the top edge of the connector.Make sure the extraction tool is centered in theconnector cavity and push the tool in until resistance isfelt.
6. With extraction tool inserted into the connector, gentlyrotate tool clockwise and counter-clockwise (no morethan 1/8 turn each direction) to depress the terminallocking tang (D).
7. Remove extraction tool from back of connector.
8. Push wire until terminal has extracted from the front ofthe connector. If terminal does not extract, repeat steps4-6.
METRI-PACK is a trademark of Delphi Packard Electric Systems
1 Included JT07195B Electrical Repair Kit
CTM331 (09APR02) 02-110-12 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=66
Continued on next page
Electrical Engine Control Repair and Adjustment
0211013
AG,OUOD008,298 –19–06MAR02–2/2
RG
1223
4A–U
N–1
3MA
R02
RG
1223
3A–U
N–1
3MA
R02
RW
1693
5A–U
N–0
5AU
G98
D—Terminal Locking TangE—Correct Terminal OrientationF—WireG—JDG783 Terminal Crimping ToolH—JDG707 Terminal Crimping Tool
9. Using JDG145 Universal Electrical Pliers1, cut off wiredirectly behind the terminal.
IMPORTANT: Save as much wire as possible. If only acouple of wires are shorter than therest, all of the strain will be placed onthem. Damage to the harness mayoccur.
10. Using JDG145 Universal Electrical Pliers1, strip 6 mm(1/4 in.) insulation from end of wire.
11. If wire has been removed from the connector, makesure the wire is fed through the connector (F) and inthe correct cavity.
12. Using either JDG783 (G) or JDG707 (H) CrimpingPliers, crimp a new terminal on the wire.
13. Make sure terminal locking tang (D) on new terminalis in outward position. Pull wire back into connectorcavity until terminal locks.
NOTE: Terminal will seat only one way. If terminal doesnot pull into the connector body socket, check forcorrect terminal alignment (E).
14. Push on the wire to make sure terminal is locked intothe connector.
15. Slide the connector seal back into the connector.Make sure seal is in it’s origional position.
16. Retape the wires and add the required tie bands tothe harness.
1Included in JDG155 Electrical Repair Tool Kit
CTM331 (09APR02) 02-110-13 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=67
Electrical Engine Control Repair and Adjustment
02110
14
AG,OUOD008,299 –19–06MAR02–1/3
Repair (Push Type) METRI-PACKConnectors
RW
7713
7–U
N–0
8DE
C98
TS
0136
–UN
–23A
UG
88
A—Connector Secondary LockB—Extraction ToolC—Connector Body SocketD—Terminal
1. Disconnect the METRI-PACK connector. Remove thetie bands and tape.
2. Remove secondary lock (A).
3. Identify wire color/number to the connector cavity.Make sure each wire goes back to the correct cavitylocation.
4. Insert JDG776 or JDG777 Terminal Extraction Tool1
(B) into connector cavity (C) pushing the terminallocking tab inward.
NOTE: Use JDG776 Extraction Tool with 56, 280, and630 Series METRI-PACK terminals. Use JDG777Extraction Tool with 150 Series METRI-PACKterminals.
5. Remove extraction tool and pull wire from the back ofthe connector.
6. Using JDG145 Universal Electrical Pliers2, cut off wiredirectly behind the terminal.
7. Using JDG145 Universal Electrical Pliers2 strip 6 mm(1/4 in.) insulation from end of wire.
8. Select correct size of seal. Slide the seal over the wireinsulation with the smaller diameter side facing the endof the wire. Small diameter side of seal should line upwith the outer edge of the insulation.
METRI-PACK is a trademark of Delphi Packard Electric Systems
1Included in JT07195B Electrical Repair Kit
2Included in JDG155 Electrical Repair Tool Kit
Continued on next page
CTM331 (09APR02) 02-110-14 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=68
Electrical Engine Control Repair and Adjustment
0211015
AG,OUOD008,299 –19–06MAR02–2/3
IMPORTANT: The seal must fit snug over the cableinsulation, without a gap between thecable seal and the insulation.
NOTE: Cable seals are color coded for three sizes ofwire:
• Green - 18—20 Gauge Wire• Gray - 14—16 Gauge Wire• Blue - 10—12 Gauge Wire
9. Select correct size contact for wire.
Continued on next page
CTM331 (09APR02) 02-110-15 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=69
Electrical Engine Control Repair and Adjustment
02110
16
AG,OUOD008,299 –19–06MAR02–3/3
RW
7713
9–U
N–0
7DE
C98
RW
7713
8A–U
N–1
5MA
R02
RW
7714
0A–U
N–1
5MA
R02
A—ContactB—ToolC—Cable SealD—Terminal Locking Tang
10. Crimp contact (A) on wire with a “W” type crimp usingJDG865 Crimping Tool (B).
11. Crimp cable seal (C) on contact using JDG865Crimping Tool (B).
12. Make sure locking tang (D) on the new terminal is inthe outward position.
13. Push terminal into the correct connector cavity untilterminal locks.
14. Gently pull on wire to verify terminal is locked into theconnector.
15. Place the secondary lock back on the connector.
16. Retape the wires and add the required tie bands tothe harness.
CTM331 (09APR02) 02-110-16 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=70
Electrical Engine Control Repair and Adjustment
0211017
AG,OUOD008,304 –19–03NOV99–1/4
Repair DEUTSCH Connectors
RW
7714
2–U
N–0
7DE
C98
A—Handle
1. Disconnect the Deutsch connector. Remove the tiebands and tape.
2. Identify wire color/number to the connector cavity.Make sure each wire goes back to the correct cavitylocation.
3. Select correct size extractor tool for size of wire to beremoved:
• JDG361 Extractor Tool - 12—14 Gauge Wire1
• JDG362 Extractor Tool - 16—18 Gauge Wire1
• JDG363 Extractor Tool - 20 Gauge Wire2
• JDG785 Extractor Tool - 6-8 Gauge Wire3
4. Start inserting the wire into the handle end (A) of thecorrect size extraction tool.
5. Slide extraction tool rearward along wire until tool tipsnaps onto wire.
IMPORTANT: DO NOT twist tool when inserting inconnector.
6. Slide extraction tool along wire into connector bodyuntil tool is positioned over terminal contact.
7. Pull wire from connector body using extraction tool.
8. Using JDG145 Universal Electrical Pliers4 cut off wiredirectly behind the terminal.
9. Using JDG145 Universal Electrical Pliers4, strip 6 mm(1/4 in.) insulation from end of wire.
DEUTSCH is a trademark of Deutsch Company
1Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCHElectrical Repair Kit
2Included in JDG359 DEUTSCH Electrical Repair Kit
3Included in JT07195B Electrical Repair Tool Kit
4Included in JDG155 Electrical Repair Tool Kit
CTM331 (09APR02) 02-110-17 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=71
Continued on next page
Electrical Engine Control Repair and Adjustment
02110
18
AG,OUOD008,304 –19–03NOV99–2/4
TS
117
–UN
–23A
UG
88A—SelectorB—Lock NutC—Adjusting Screw
10. Adjust selector (A) on JDG360 Crimping Tool1 forcorrect wire size .
11. Loosen lock nut (B) and turn adjusting screw (C) inuntil screw stops.
1Included in JDG359 Electrical Repair Kit
AG,OUOD008,304 –19–03NOV99–3/4
TS
0134
–UN
–23A
UG
88
A—TerminalB—CoverC—Lock NutD—Adjusting Screw
12. Insert terminal (A) and turn adjusting screw (D) untilterminal is flush with cover (B).
IMPORTANT: Select correct size terminal to fitconnector body.
13. Tighten lock nut (C).
Continued on next page
CTM331 (09APR02) 02-110-18 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=72
Electrical Engine Control Repair and Adjustment
0211019
AG,OUOD008,304 –19–03NOV99–4/4T
S11
8–U
N–2
3AU
G88
TS
0135
–UN
–23A
UG
88R
W77
141
–UN
–07D
EC
98
14. Insert wire in terminal and crimp until handle contactsstop.
IMPORTANT: Terminal must remain centered betweenindenters while crimping.
15. Release handle and remove terminal.
16. Inspect terminals to ensure all wires are in crimpedbarrel.
IMPORTANT: If all wire strands are not crimped intoterminal, cut off wire at terminal andrepeat terminal installation procedures.
NOTE: Readjust crimping tool for each crimpingprocedure.
17. Push terminal straight into correct connector cavityuntil positive stop is felt.
IMPORTANT: Install terminal in correct connectorcavity using correct size grommet.
18. Gently pull on wire to verify terminal is locked into theconnector.
19. Transfer remaining wires to correct cavity in newconnector.
20. Retape the wires and add the required tie bands tothe harness.
CTM331 (09APR02) 02-110-19 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=73
Electrical Engine Control Repair and Adjustment
02110
20
DPSG,OUO1004,2867 –19–06MAR02–1/2
Repair AMP Connector
RG
1074
2–U
N–3
1MA
Y00
Using AMP Crimping Tool
A—Locator Assembly C—Wire E—Crimping Slot G—Insulation BarrelB—Locator D—Crimping Slot F—Terminal H—Wire Barrel
1. Disconnect AMP connector. Remove the tie bandsand tape.
2. Identify wire color/number to the connector cavity.Make sure the each wire goes back into the correctcavity location.
3. Press JDG1369 Terminal Extraction Tool into faceof connector and remove wire and terminal fromback of connector.
NOTE: Verify wire stripping length and crimp heightbefore using AMP crimping tool. Seeinstructions provided with tool.
4. Strip new wire to length indicated in toolinstructions. Do not nick or cut wire strands.
5. Hold JDG708 AMP Crimping Tool so that the back(wire side) is facing you. Squeeze tool handlestogether and allow them to open fully.
NOTE: See instructions provided with tool todetermine which crimping slot (D or E) to use.
6. Holding the terminal (F) by the mating end, insertthe insulation barrel (G) first, through the front ofthe tool and into the appropriate crimp slot (D or E).
IMPORTANT: Make sure that both sides of theinsulation barrel (G) are startedevenly into the crimping section. DoNOT attempt to crimp an improperlypositioned terminal.
7. Position the terminal so that the open “U” of thewire and insulation barrels (H and G) face the topof the tool. Place the terminal up into the nest sothat the movable locator (B) drops into the slot inthe terminal as shown. Butt the front end of the wirebarrel (H) against the movable locator.
8. Hold the terminal (F) in position and squeeze thetool handles together until ratchet engagessufficiently to hold the terminal in position. DO NOTdeform insulation barrel or wire barrel.
9. Insert stripped wire (C) into terminal insulation andwire barrels until it is butted against the wire stop.
CTM331 (09APR02) 02-110-20 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=74
Continued on next page
Electrical Engine Control Repair and Adjustment
0211021
DPSG,OUO1004,2867 –19–06MAR02–2/2
T11
2335
E–U
N–1
5MA
R02
A—Wire and TerminalB—Locator
10. Hold the wire and terminal (A) in place. Squeeze toolhandles together until ratchet releases. Allow toolhandles to open and remove crimped terminal.
NOTE: The crimped terminal may stick in the crimpingarea. It can be easily removed by pushingdownward on the top of the locator (B).
11. Install wire in correct connector cavity.
12. Retape the wires and add the required tie bands tothe harness.
CTM331 (09APR02) 02-110-21 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=75
Electrical Engine Control Repair and Adjustment
02110
22
CTM331 (09APR02) 02-110-22 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=76
Section 03Theory of Operation
Contents
Page
Group 130—Electronic Fuel System OperationAbout this Group . . . . . . . . . . . . . . . . . . . . . . .03-130-1 03Fuel System Operation . . . . . . . . . . . . . . . . . .03-130-2Fuel Supply Pump Operation . . . . . . . . . . . . .03-130-4Final Fuel Filter Operation. . . . . . . . . . . . . . . .03-130-5Fuel Injection Pump Operation . . . . . . . . . . . .03-130-6Fuel Injection Nozzle Operation. . . . . . . . . . . .03-130-8
Group 140—Electronic Control System OperationAbout This Group . . . . . . . . . . . . . . . . . . . . . .03-140-1Electronic Control System Terminology . . . . . .03-140-2Electronic Control System Operation. . . . . . . .03-140-3Monitoring Engine Parameters . . . . . . . . . . . .03-140-3Electronic Control System Overview . . . . . . . .03-140-4Measuring Temperature . . . . . . . . . . . . . . . . .03-140-5Measuring Pressure . . . . . . . . . . . . . . . . . . . .03-140-7Measuring Throttle Position. . . . . . . . . . . . . . .03-140-8Measuring Engine Speed . . . . . . . . . . . . . . . .03-140-9Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . .03-140-9Engine Control Unit (ECU) . . . . . . . . . . . . . .03-140-10Controller Area Network (CAN) . . . . . . . . . . .03-140-11Cruise Control Operation. . . . . . . . . . . . . . . .03-140-12Intake Air Heater Operation. . . . . . . . . . . . . .03-140-12Engine Protection . . . . . . . . . . . . . . . . . . . . .03-140-13Derate Programs. . . . . . . . . . . . . . . . . . . . . .03-140-13Multiple Torque Curve Selection . . . . . . . . . .03-140-14Governor Droop Mode Selection . . . . . . . . . .03-140-14Engine Control Unit (ECU) Self-Diagnosis. . .03-140-15
CTM331 (09APR02) 03-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=1
Contents
03
CTM331 (09APR02) 03-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Group 130Electronic Fuel System Operation
031301RG40854,000001C –19–03DEC01–1/1
About this Group
In this group, the fuel system information is described inthe following categories:
• Fuel System Operation• Fuel Supply Pump Operation• Final Fuel Filter Operation• Fuel Injection Pump Operation• Fuel Injection Nozzle Operation
CTM331 (09APR02) 03-130-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=79
Electronic Fuel System Operation
03130
2
RG40854,000001D –19–03DEC01–1/2
Fuel System Operation
RG
1195
7–U
N–2
1DE
C01
A—Fuel Tank E—Fuel Injection Pump H—Fuel Leak-off Line K—Injection Pump PressureB—Prefilter F—Overflow Valve I—Tank Pressure Fuel FuelC—Fuel Supply Pump G—Fuel Injection Nozzle J—Supply Pump PressureD—Final Fuel Filter Fuel
The fuel supply pump (C) draws fuel from the tank (A)by pressurizing the fuel. Once the fuel is pressurized inthe fuel supply pump, it travels through the final fuelfilter (D) to the fuel injection pump (E). On some
applications, fuel is routed through a prefilter (B) priorto the fuel supply pump. A water bowl can be includedwith either the prefilter or final fuel filters. Typically, thewater bowl is located at the first filter in the system.
CTM331 (09APR02) 03-130-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=80
Continued on next page
Electronic Fuel System Operation
031303RG40854,000001D –19–03DEC01–2/2
The fuel injection pump raises the required fuelpressure for injection. This high pressure fuel is routedthrough the delivery (pressure) lines to the fuelinjection nozzles (G). If there is excess fuel in theinjection pump, it is released through an overflow valve(F) and returned to tank through the fuel leak-off line(H).
Once the pressure of the fuel inside the injectionnozzle (G) overcomes the nozzle valve, fuel is forced
otu a small orifice in the nozzle tip. This allows for fuelto atomize as it enters the combustion chamber.Excess fuel from the nozzles is routed through the fuelreturn leak-off line and returns to the fuel tank. Onsome applications, the fuel goes through a fuel coolerbefore returning to the fuel tank.
CTM331 (09APR02) 03-130-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=81
Electronic Fuel System Operation
03130
4
RG40854,0000110 –19–16JAN02–1/1
Fuel Supply Pump Operation
RG
9119
–UN
–17A
PR
98
A—Fuel OutletB—Outlet Check ValveC—Inlet Check ValveD—Fuel InletE—Return SpringF—RodG—LeverH—Hand Primer LeverI—Diaphragm
The Sofabex fuel supply pump uses an eccentric lobe onthe engine camshaft to operate the lever (G) on supplypump to pressurize fuel system.
Fuel flows from the fuel tank at gravity pressure to theinlet side (D) of the diaphragm-type pump.
As the lever (G) rides on the high side of the camshaftlobe, the rod (F) pulls diaphragm (I) down. Suctionpressure opens the inlet check valve (C) and fuel is drawninto the pump.
As the camshaft lobe rotates to the low side, the returnspring (E) forces the diaphragm (I) upward. The resultingfuel pressure closes the inlet check valve (C) and opensthe outlet check valve (B), delivering fuel through theoutlet (A) to the injection pump.
A hand primer lever (H) is provided for manually forcingfuel through the system to bleed air from the fuel filter,lines, etc.
CTM331 (09APR02) 03-130-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=82
Electronic Fuel System Operation
031305
RG40854,0000111 –19–16JAN02–1/1
Final Fuel Filter Operation
RG
9090
–UN
–27M
AR
98
A—Bleed ScrewB—Fuel OutletC—Fuel InletD—Filter ElementE—Drain PlugF—Primer Pump
Fuel enters the filter at inlet (C), flows through filterelement (D) and exits through outlet (B) to the fuelinjection pump. The 5 micron filter element is housed in asediment bowl attached to the base with a threadedretaining ring.
Since water and contaminants settle at the bottom of thesediment bowl, a drain plug (E) is provided. On someoptions, a water bowl is attached to the bottom of thesediment bowl.
Air in the system can be expelled through the air ventwhen bleed screw (A) is loosened. Optional priming pump(F) draws fuel from the fuel tank to fill the filter bowl whenthe filter element is changed. The priming pump alsosupplies fuel from the filter to the injection pump.
CTM331 (09APR02) 03-130-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=83
Electronic Fuel System Operation
03130
6
RG40854,0000112 –19–16JAN02–1/2
Fuel Injection Pump Operation
RG
1195
8–U
N–2
0DE
C01
A—Fuel Inlet Fitting D—Cam Ring G—Pump Control Valve J—Fuel Return Fitting/HousingB—Heavy Duty Driveshaft E—Discharge Fitting H—Distributor Rotor Pressure RegulatorC—Transfer Pump F—Fuel Control Solenoid I—Fuel Temperature Sensor
NOTE: The above illustration has been reprinted withpermission from Stanadyne AutomotiveCorporation.
The main components of the Stanadyne DE10 fuelinjection pump are the driveshaft (B), the transferpump (C), cam ring (D) and shoes, distributor rotor(H), pump control valve (G), and fuel control solenoid(F). The crankshaft of the engine drives the driveshaftof the pump using gears between the two components.The rotation of the driveshaft moves the transfer pump,cam shoes and rollers, and distributor shaft since all ofthese components are engaged.
The fuel transfer pump (inside the injection pump)draws fuel from the final filter through the fuel inletfitting (A). With each revolution, it pressurizes fuelbetween 0—1100 kPa (0—11 bar) (0—160 psi)depending on the rotational speed of the pump. Once
the fuel has been pressurized by the transfer pump, itcan travel to three locations: inside the plungers of thecam ring (D), into the injection pump housing cavaties,and recirculated back to the fuel inlet passage.
When the pump control valve is open, it allows thetransfer pump pressurized fuel to enter the highpressure chamber. The Engine Control Unit (ECU)energizes the fuel control solenoid which causes thepump control valve to close. When the pump controlvalve is closed, the plungers in the high pressurechamber create injection pressure because they areforced inward by the rotation of the cam ring. Highpressure fuel is forced through the discharge fittings tothe injection nozzles. When the fuel control solenoid isdeenergized, the pump control valve opens. The fuel inthe high pressure chamber is spilled out of the highpressure chamber into the transfer pump fuel.
CTM331 (09APR02) 03-130-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=84
Continued on next page
Electronic Fuel System Operation
031307RG40854,0000112 –19–16JAN02–2/2
Some of the transfer pump pressure fuel is releasedthrough a port that contains a vent wire into injectionpump housing cavaties. The purpose of housingpressure fuel is to keep the injection pumpcomponents cooled and lubricated. The amount of fuelthat is released into the housing is determined by thesize of the vent wire. The pressure of the housing iscontrolled by the fuel return fitting/pressure regulator(J). If the pressure exceeds the regulator, it will returnfuel to the fuel tank. The ECU monitors the fuel
temperature of the housing through a fuel temperaturesensor (I). For more information on the fueltemperature sensor, see MEASURINGTEMPERATURE in Group 140 of this Section.
The remaining transfer pump pressure fuel travelsthrough a transfer pump regulating valve. This allowsfor fuel to return to injection pump inlet pressure. Itcirculates the fuel back through the transfer pump.
CTM331 (09APR02) 03-130-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=85
Electronic Fuel System Operation
03130
8
RG40854,0000020 –19–03DEC01–1/1
Fuel Injection Nozzle Operation
RG
1195
9–U
N–1
2FE
B02
A—Spray tipB—Carbon stop sealC—Nozzle valveD—Nozzle bodyE—Seal washerF—Connection for injection lineG—Nozzle valve guideH—Union nutI—Spring seatJ—Adjustable pressure springK—Lift adjusting screwL—Lock nut for pressure adjusting screwM—T-fittingN—Lock nut for lift adjusting screwO—Pressure adjusting screwP—Location clampQ—NippleR—Filter screenS—Fuel pressure lineT—Cap
The nozzle spray tip (A) forms an integral unit with nozzlebody (D) from which it cannot be separated. The injectionnozzle is secured in the cylinder head by threesuperimposed spring clamps which press on a locationclamp and a cap screw. The contact pressure is limited bya spacer ring. The nozzle is sealed in the cylinder head atits lower end with a carbon stop seal (B). The top end issealed with seal washer (D). Clamp (P) ensures correctposition of the complete fuel injection nozzle in thecylinder head. The leak-off line is connected by T-fitting(M), which is fitted on the nozzle body and secured a capwith O-ring seal (T).
The fuel injection nozzle works basically in the same wayas a normal spray type nozzle. Its opening pressure isadjusted by the pressure adjusting screw (O). The lift ofnozzle valve (C) is adjusted by screw (K) located inpressure adjusting screw.
The carbon stop seal (B) prevents carbon from collectingaround nozzle in cylinder head. The fuel injection nozzleshave four orifices.
CTM331 (09APR02) 03-130-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=86
Group 140Electronic Control System Operation
031401
RG40854,0000021 –19–03DEC01–1/1
About This Group
In this group, the electronic control system is described inthe 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
CTM331 (09APR02) 03-140-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=87
Electronic Control System Operation
03140
2
RG40854,0000023 –19–03DEC01–1/2
Electronic Control System Terminology
Actuator A device controlled by the (ECU) to perform a certain function.
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt signals.
Boost Air charge pressure in the intake manifold.
CAN Controller Area Network. The electronic pathway network on vehicles that allows communication betweencontrollers.
DTC Diagnostic Trouble Code. A code which is stored in the ECU’s memory when the ECU detects a problem in theelectronic control system.
DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and runspecial tests. The DST consists of an Windows (’95, ’98, 2000) or NT compatible computer and a hardware kitavailable from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. Thesoftware is available to download from your John Deere home page.
Digital A signal which consists of only two-volt levels — usually 0 volts and +5 volts.
ECT Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant. See MEASURINGTEMPERATURE later in this Group for details.
ECU Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine. See ENGINECONTROL UNIT (ECU) later in this Group for details.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system trouble codes accordingto the SAE J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code isthe Suspect Parameter Number (SPN).
J1587/J1708 The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty vehicles. J1587is the software standard. J1708 is the hardware standard.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURINGTEMPERATURE later in this Group for details.
PDM Parallel Data Module. Device used as part of the DST that allows communication with the ECU.
PROM Programmable, Read-Only Memory. The computer chip which contains the calibration information for the enginecontrol system. See ENGINE CONTROL UNIT (ECU) later in this Group for details.
PWM Pulse Width Modulation. A digital signal (not analog) which consists of a pulse generated at a fixed frequency.When an actuator is controlled by a PWM signal, the on time of the signal is increased or decreased (modulated)to increase or decrease the output of the actuator.
RAM Random Access Memory. The portion of computer memory within the ECU which changes as the engine isrunning and is stored while the engine is off. See ENGINE CONTROL UNIT (ECU) later in this Group for details.
SAE Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance and energyresource conservation.
Sensor Device used by the ECU to monitor various engine parameters.
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes accordingto the SAE J1939 Standard. The SPN identifies the system or component that has the failure. The second half ofthe code is the Failure Mode Identifier (FMI).
CTM331 (09APR02) 03-140-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=88
Continued on next page
Electronic Control System Operation
RG40854,0000023 –19–03DEC01–2/2
VBAT Battery voltage or unswitched voltage.
VSW Switched voltage
031403
RG40854,0000022 –19–03DEC01–1/1
Electronic Control System Operation
Engine Starting Mode
When the key is turned to the “ON” position, aswitched power voltage is sent to the ElectronicControl Unit (ECU). This energizes the ECU andallows it to “boot-up” and ready itself for engine start.
NOTE: If a wiring problem prevents the key ON signalfrom getting to the ECU, the engine will notstart.
As soon as the ECU receives an input from thecrankshaft position sensor that the engine is cranking,it will move the pump control valve to the “pressure”position, which will allow injection pressure to bedeveloped. The fuel is delivered to all of the cylinders.To provide cold temperature enrichment, the amount offuel injected is based on the temperature measured by
the Engine Coolant Temperature (ECT) sensor. At thispoint, the engine will start and the ECU will go into therunning mode.
Engine Running Mode
In the running mode, the ECU monitors informationfrom the various sensors, then determines theoptimum amount of fuel to inject and the optimuminjection timing in order to allow the engine to develophigh power while maintaining low exhaust emissionoutput. The ECU controls fuel delivery by energizingand de-engergizing the pump control valve solenoid.When the ECU energizes the solenoid, the pumpcontrol valve closes and injection begins. When thecorrect amount of fuel has been injected, the ECUde-energizes the solenoid, causing the pump controlvalve to open, and fuel injection to stop.
RG40854,0000026 –19–03DEC01–1/1
Monitoring Engine Parameters
In order for the electronic control system to deliver fuelaccording to a given set of operating conditions, thefollowing 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
CTM331 (09APR02) 03-140-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=89
Electronic Control System Operation
03140
4
RG40854,0000024 –19–03DEC01–1/1
Electronic Control System Overview
RG
1196
0–U
N–1
8DE
C01
A—Oil Pressure Sensor D—Crank Position Sensor G—Manifold Air Temperature H—Loss of CoolantB—Pump Control Solenoid E—Fuel Temperature Sensor (MAT) Sensor Temperature SensorC—Engine Control Unit (ECU) F—ECT Sensor
NOTE: Some of the components shown are optionaland not used on all applications.
The electronic control system serves as an enginegovernor by controlling the pump control valve througha solenoid so that fuel is delivered according to agiven set of engine conditions, in precise amounts, andat a precise time in relation to piston position. In order
to achieve this, the engine control system peforms thefollowing funtions:
• Constantly monitors engine operating conditions• Delivery an optimum amount of fuel for operating
conditions• Provides multiple control modes• Performs self-diagnosis
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031405
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Measuring Temperature
RG
1181
9–U
N–1
7AU
G01
The Engine Coolant Temperature (ECT) sensor, Loss ofCoolant Temperature sensor, Manifold Air Temperature(MAT) sensor, and Fuel Temperature sensor arethermistors (temperature sensitive variable resistors). Thesensors’ resistance goes down as the temperature that itis exposed to goes up (negative temperature coefficient).Higher temperatures result in lower voltages and lowertemperatures result in higher voltages. The Engine ControlUnit (ECU) sends 5 volts to the sensor, monitors thevoltage drop across the sensor, and compares the voltagedrop to preprogrammed values in the ECU’s memory inorder to determine temperature. In addition to temperaturesensors, some applications use temperature switches.The loss of coolant temperature switch is an example.Temperature switches close when a specific temperatureis reached.
RG40854,0000025 –19–03DEC01–2/5
RG
1196
3–U
N–2
9JA
N02
A—ECT Sensor
Engine Coolant Temperature (ECT) Sensor
On most applications, the Engine Coolant Temperature(ECT) sensor is located in the thermostat housing (A). Onother applications, it may be located at the rear of thecylinder head.
The ECU monitors coolant temperature for:
• Engine protection purposes. For more information onengine protection and derate programs see, ENGINEPROTECTION or DERATE PROGRAMS later in thisGroup.
• Starting fuel quantity determination — The ECU willadjust the amount of fuel delivered during start-upbased on initial ECT readings.
• Idle speed determination — In order to speed enginewarm-up, the ECU will increase idle speed after start-upif a low coolant temperature is measured.
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Electronic Control System Operation
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6
RG40854,0000025 –19–03DEC01–3/5
RG
1076
6–U
N–2
6MA
Y00
A—Loss of Coolant Temperature Sensor
Loss of Coolant Temperature Sensor
The Loss of Coolant Temperature sensor is located in therear of the cylinder head (A) on some applications usingthis engine.
The ECU monitors loss of coolant temperature for engineprotection purposes. For more information on engineprotection and derate programs see, ENGINEPROTECTION or DERATE PROGRAMS later in thisGroup.
RG40854,0000025 –19–03DEC01–4/5
RG
1196
4–U
N–2
9JA
N02
A—MAT Sensor
Manifold Air Temperature (MAT) Sensor
The Manifold Air Temperature (MAT) sensor is located inthe cross over tube (A) or in the intake manifold. The MATsensor measures intake air temperature to help the ECUcalculate the correct fueling and for cold starting. TheECU also monitors manifold air temperature for engineprotection purposes. For more information on engineprotection and derate programs, see ENGINEPROTECTION or DERATE PROGRAMS later in thisGroup. This sensor is optional and is not included on allapplications.
Continued on next page
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RG
1196
2–U
N–2
9JA
N02
A—Fuel Temperature Sensor
Fuel Temperature Sensor
The fuel temperature sensor (A) is located on top of theinjection pump. It measures the temperature of the fuel inthe injection pump that is going through the overflowvalve. The temperature is used to help the ECU tocalculate the correct amount of fueling rENGINEPROTECTION or DERATE PROGRAMS laster in thisGroup.
RG40854,0000027 –19–03DEC01–1/2
Measuring Pressure
RG
1182
0–U
N–1
7AU
G01
The system’s pressure sensors are 3 wire variableresistors. As the pressure changes, sensor resistancechanges. The ECU sends a 5 volt reference voltage to thesensor, monitors the voltage returning on the sensorsignal wire, and compares the voltage drop topreprogrammed values in the ECU’s memory to determinepressure. In addition to pressure sensors, someapplications use pressure switches. Pressure switchesclose when a specific pressure is reached.
Continued on next page
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RG
1196
1–U
N–2
9JA
N02
A—Oil Pressure Sensor
Oil Pressure Sensor
The oil pressure sensor is an optional sensor located inthe main engine galley (A). The ECU monitors oilpressure for engine protection purposes. For moreinformation on engine protection and derate programssee, ENGINE PROTECTION or DERATE PROGRAMSlater in this Group.
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Measuring Throttle Position
The 4.5 L and 6.8 L engines have the option of operatingwith a analog throttle position sensor output signal or CANthrottle. On some applications, multiple throttles are used.
Analog Throttle
An analog throttle signal comes from a potentiometer-typesensor. The ECU converts the voltage returning from thepotentiometer into a percent of full throttle signal.
Multi-State Throttle
The multi-state throttle is used when a few fixed enginespeeds are desired.
CAN Throttle
CAN throttle is information sent to the ECU by anothercontroller over CAN of the desired throttle position.
Excavator Throttle
The Excavator uses an analog throttle signal that comefrom a potentiometer-type sensor. The throttle informationis sent to the ECU by the Pump and Valve controller. TheECU must convert the voltage into percent throttle.
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Electronic Control System Operation
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Measuring Engine Speed
RG
1196
5–U
N–2
9JA
N02
A—Crank Position Sensor
Crank Position Sensor
The crank position sensor operates by detecting notcheson their respective timing wheels. When a notch on thetiming wheel is directly under the sensor, a voltage signalis induced. The ECU monitors this voltage signal todetermine the position of the timing wheel. The sensor islocated on the front of the crankshaft, behind thepressed-on crank gear.
The crank position sensor (A) is located on the front of thecrankshaft. It is an inductive type pickup sensor thatdetects teeth on the crank timing wheel. The ECU usesthe crank position input to determine engine speed.
RG40854,0000115 –19–24JAN02–1/1
Pump Solenoid
A
RG
1196
6–U
N–2
9JA
N02
A—Pump Solenoid Connector
Located on the end of the injection pump, the pumpsolenoid (A) controls the movement of the pump controlvalve. This controls the quantity of fuel delivered to theengine. When the Engine Control Unit (ECU) supplies nocurrent to the solenoid, the valve does not move. Thus,the injection pump delivers no fuel. When the ECUsupplies current to the solenoid, the pump control valvecloses off the high injection chamber. This allows fuel tobe delivered from the injection pump. The quantity of fuelis determined by various sensors in the control systemand messages sent to the ECU.
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Electronic Control System Operation
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RG40854,0000029 –19–03DEC01–1/2
Engine Control Unit (ECU)
ECU Connector
F3F2F1
G1
H1J1
K1
G2
H2J2
K2
G3
H3J3
K3
A3A2A1
B1
C1D1
E1
B2
C2D2
E2
B3
C3
D3
E3
RG
1196
7–1
9–19
DE
C01
The Engine Control Unit (ECU) is the “brains” of theElectronic Control System. The ECU is aself-contained unit containing electronic circuitry andcomputer software which together perform thefollowing functions:
• Converts the electrical signals from the varioussensors into digital signals
• Makes decisions of optimum fuel quantity and timingbased on information from various sensors
• Limits maximum fuel for operation on multiple powercurves
• Controls pump control valve solenoid for desired fueldelivery
• 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 voltagesignals from the various sensors into digital signalsthat the central processing unit can “understand”.
Central Processing Unit (CPU)
The central processing unit performs the mathematicalcomputations and logical functions that are necessaryin controlling injection fuel quantity and injection timing.The CPU controls the pump control solenoid fordesired fuel quantity and timing. It also controls theself diagnostic system.
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Memory
The ECU contains 3 different types of memory:
— Random Access Memory - RAM
The RAM is like the working desk top of the ECU.Data from the various sensors and the results ofvarious calculations are temporarily stored in RAM.Information in RAM is lost when battery voltage to theECU is removed.
— Read Only Memory - ROM
The ROM contains programmed information.Information in ROM can only be read, not changed.ROM information is retained when battery voltage isremoved.
— Electrical Erasable Programmable Read OnlyMemory - EEPROM
The EEPROM contains information programmed in atthe factory including engine specific data, andapplication data. Information in the EEPROM isretained when battery voltage is removed.
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Controller Area Network (CAN)
Controller Area Network (CAN) is used to allowcommunication between other controllers on the engine orvehicle and for connecting to diagnostic software. All ofthe controllers that are required to communicate over CANare connected together using wires forming a bus. J1939is an SAE standard that utilizes CAN.
Just about any type of information can be communicatedover the CAN Bus. This information includes partnumbers, serial numbers, engine speed, fan speed, etc.The engine also uses CAN to talk to other vehiclecontrollers. Depending on the application, information likethrottle position, application requested derates and orengine protection, displaying diagnostic fault codes onvehicle displays, etc. CAN also allows diagnostic softwarelike the Diagnostic Scan Tool (DST) and SERVICEADVISOR to communicate with our engine controller. Allof the information viewed through the software istransferred via the CAN Bus.
SERVICE ADVISOR is a trademark of Deere & Company
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Cruise Control Operation
The ECU is available with and without the cruisecontrol function. It is an off-road cruise control thatmaintains constant engine speed under varying loadconditions. This function is especially intended for fieldapplications where an operator faces the need to turnthe vehicle around at the end of each row. This cruisecontrol allows the driver to use the throttle and/orbrake to turn the vehicle around. When ready toresume field operations, the operator brings the enginespeed above 1300 rpm and activates theCancel/Resume function again to resume cruisespeed. An internal timer gives the operator one minuteto complete the turnaround maneuver.
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
On 12 volt ECUs, the engine speed can be set fromtwo different locations. The primary location wouldnormally be in the cab of the vehicle and is used to seta constant engine speed while the vehicle is beingdriven. The secondary cruise control is normally usedin a location that provides PTO speed control and isused with the engine in “neutral” or out of gear. Bothlocations have the normal cruise control functions.
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Intake Air Heater Operation
An optional function not included in all ECUs, theintake air heater is used to increase intake manifold airtemperature to improve cold starting. When theoperator turns the key from “OFF” to “ON”, the ECUuses the fuel temperature sensor to determine enginetemperature and ambient air temperature, turns on the“Air Heater Indicator” light on the dash, and energizesthe air heater relay.
The air heater relay will in turn energize the air heatercoils located in the intake manifold. The ECU will keepthe air heater relay energized for an amount of timethat is determined by the measured temperatures.When the ECU has determined that the preheat time is
adequate, it will turn off the “Air Heater Indicator” lightand de-energize the air heater relay. If the operatorturns the ignition from “ON” to “START” at this time,the engine will crank and start.
If the operator turns the key from “START” to “ON”without waiting for the “Air Heater Indicator” light toturn off, the ECU will de-energize the air heater relayand a key-off/key-on cycle is required beforepreheating is allowed again.
Anytime the engine cranks but does not start, akey-off/key-on cycle will be required before preheatingis allowed again.
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Engine Protection
Engine protection is necessary to prevent damage toan engine. There are three different engine protectionprograms available in Engine Control Units (ECUs):
• No Protection — The ECU does not have thesoftware to derate or shut the engine down. It is theresponsibility of the operator to react to warninglight(s) on their application. Derating or shutting theengine down may be necessary depending on theDiagnostic Trouble Code (DTC) that is set. Refer tothe operator’s manual to identify this information fora given application.
• Engine Protection WITHOUT Shutdown — TheECU has the capability to derate an engine. It is theresponsibility of the operator to react to warninglight(s) on their application to identify if it isnecessary to shut the engine down. Refer to theoperator’s manual to retrieve this information for agiven application.
• Engine Protection with Shutdown— The ECU willderate the engine for given DTCs. If a DTC that
requires shutdown is set, the ECU will severelyderate the engine and shut the engine down in 30seconds. If the problem is corrected within the 30second delay period, the power will increase at aparticular rate until full power is reached.
Shutdown Override Feature
NOTE: Holding the shutdown override switchcontinuously “ON” will not reset the 30 secondtimer.
The engine protection shutdowns can be overriddenfor 30 seconds at a time. This can be used to move avehicle to a safe location. Each time the switch ispushed, the shutdown timer is reset to 30 seconds,and the engine will run in a derated power mode. SeeAPPLICATION SPECIFICATIONS in Section 06,Group 210 of this manual for engine protectionfeatures on different sensors on your application.
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Derate Programs
The Electronic Control Unit (ECU) will derate theamount of fuel that is delivered to the engine whensensor inputs exceed normal operating ranges. ADiagnostic Trouble Code (DTC) always accompanies a
fuel derate. See APPLICATION SPECIFICATIONS inSection 06, Group 210 of this manual for sensorderate specifications on your application.
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Multiple Torque Curve Selection
RG
8552
–19–
18S
EP
98
The ECU has the ability to limit the maximum fuel quantitysuch that multiple torque curves can be individuallyselected while the engine is running. The selection ofmultiple torque curves is determined by either switchinputs into the ECU’s torque curve select terminal, or bymessages from other controllers on the machine’sController Area Network (CAN). In most applications, onetorque curve is used for “normal” operation. Several otherderated torque curves will be used to protect vehicleaxles, hitches, and transmissions, etc. under certainoperating conditions.
For example: a machine can choose multiple torquecurves using simple switching arrangement. A simpleon/off toggle switch and resistor can be used to switchbetween torque curve 1 (maximum power), and any of theother torque curves. When the switch is open, the ECUwill command torque curve 1. When the switch is closed,the ECU will command one of the other curves dependingon the resistance in the line. See APPLICATIONSPECIFICATIONS in Section 06, Group 210 of thismanual and refer to the corresponding torque curveselection for your application.
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Governor Droop Mode Selection
The electronic control system provides all-speedgoverning. The Engine Control Unit (ECU) controls theengine speed based on the analog throttle input.
The ECU also has the ability to provide normal andisochronous (0%) droop. The normal droop gives adrop in engine speed with an increase in load or anincrease in engine speed with a decrease in load.When in isochronous, the droop is set at 0%, and
there is a no change in engine speed with changingloads until engine’s torque limit is reached. The factorylow idle speed is always set for isochronous governing.Droop selection can be determined by engine speed,load, and cruise control depending on the application.See APPLICATION SPECIFICATIONS in Section 06,Group 210 of this manual and refer to thecorresponding governor droop mode for yourapplication.
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Engine Control Unit (ECU) Self-Diagnosis
The Engine Control Unit (ECU) has the ability to detectproblems internally and in the electronic controlsystem. This includes determining if any sensor inputvoltages are too high or too low. If the ECU detects aproblem with the electronic control system, aDiagnostic Trouble Code (DTC) specific to the failedsystem will be stored in the ECU’s memory.
There are two types of DTCs:
• Active• Stored
Active DTCs indicate that the failure is occurring.These type of failures are sometimes called “hard”failures.
Stored DTCs indicate that a failure has occurred in thepast, but is not currently occurring. This type of DTCcan be caused by an “intermittent” failure. These couldbe problems such as a bad connection or a wireintermittently shorting to ground.
There are several different methods for displaying bothstored and active DTCs from the ECU.
NOTE: If the Diagnostic Scan Tool (DST) or SERVICEADVISOR is used to read a sensor voltageand calculated value, and there is an activeDTC for that sensor, the calculated value forthat sensor will be the “limp home” value andthe voltage will be the actual sensor voltage.Use the voltage during diagnostics unlessotherwise directed by a diagnostic chart.
There are several different methods of displaying bothstored and active DTCs from the ECU.
SPN/FMI CODES
SPN/FMI codes are written from the SAE J1939standard as a two part code. The first part is called the
Suspect Parameter Number (SPN). Typically, itcontains between 2 and 4 digits. The SPN identifiesthe system or the component that has the failure; forexample SPN 110 indicates a failure in the enginecoolant temperature circuit. The second part of thecode is called the Failure Mode Identifier (FMI) code.The FMI contains 2 digits. The FMI identifies the typeof failure that has occurred; for example FMI 3indicates value above normal. In order to determinethe exact failure, both the SPN and FMI are required.Combining SPN 110 with FMI 3 yields engine coolanttemperature input voltage high. To find out the equ
On all applications with the Level 12 Engine ControlUnit (ECU), the ECU transmits SPN/FMI codes overthe Controller Area Network (CAN). This allows forservice tools such as the DST, SERVICE ADVISOR,and the Diagnostic Gauge to display active and storedDTCs. In CTM 331, the diagnostic procedures aretitled by SPN/FMI codes.
2-DIGIT CODES
Some applications do not display engine codes as anSPN/FMI. In most of these cases, the code isdisplayed as a 2-digit code. An example of a 2-digitcode is 18 for engine coolant temperature inputvoltage high. If used on an application with multiplecontrollers, ECU may be displayed in front of thenumbers, such as ECU 018. A 2-digit code may beseen on SERVICE ADVISOR, the on-board display,or when the code is blinked for various reasons. In thismanual, it will be necessary to convert these codes tothe SPN/FMI code in order to follow the correctdiagnostic procedure. See LISTING OF DIAGNOSTICTROUBLE CODES (DTCS) ON ECU in Group 160 ofthis manual.
OTHER CODES
SERVICE ADVISOR is a trademark of Deere & Company
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If codes are not displayed as SPN/FMI or as 2-digitcodes, there may be another format that theapplication is using. For example on someapplications, the code F455 is displayed for enginecoolant temperature input voltage high. This may beseen on some applications within SERVICEADVISOR. In this manual, it is necessary to convertthis format of code into an SPN/FMI code to ensurethat the correct diagnostic procedure is followed. SeeLISTING OF DIAGNOSTIC TROUBLE CODES(DTCS) ON ECU
WARNING LAMP
On some applications, there is a warning lamp that isused when a code becomes active. Typically, a solid
light indicates that the ECU is taking extrememeasures to protect the engine, and a blinking lightindicates that the ECU has detected a fault and engineperformance may be affected. Refer to Operator’sManual for a given application for more detailedinformation.
CLEARING STORED DTCS
Stored DTCs can be cleared through the DiagnosticScan Tool (DST) or SERVICE ADVISOR. Refer tothe vehicle machine manual or see CLEARINGSTORED DTCS ON DIAGNOSTIC GAUGE in Group160 later in this manual to determine how to clear thecode reader.
SERVICE ADVISOR is a trademark of Deere & Company
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Section 04Diagnostics
Contents
Page Page
Group 150—Observable Diagnostics and Tests Level 12 ECU - D1 - ECU Does NotAbout This Group of the Manual . . . . . . . . . . .04-150-1 Communicate with DST or SERVICELevel 12 ECU - E1 - Engine Cranks/Won’t ADVISOR Diagnostic Procedure . . . . . . .04-150-33
Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-2 Level 12 ECU - D2 - Diagnostic GaugeLevel 12 ECU - E1 - Engine Cranks/Won’t Does Not Communicate With ECU . . . . . .04-150-36
Start Diagnostic Procedure . . . . . . . . . . . . .04-150-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-37Level 12 ECU - E2 - Engine Misfires/Runs Level 12 ECU - D2 - Diagnostic Gauge Does 04
Irregularly. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-7 Not Communicate With ECU DiagnosticLevel 12 ECU - E2 - Engine Misfires/Runs Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-37
Irregularly Diagnostic Procedure . . . . . . . . .04-150-7 Level 12 ECU - A1 - Intake Air HeaterLevel 12 ECU - E3 - Engine Does Not Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-42
Develop Full Power . . . . . . . . . . . . . . . . . .04-150-11 Level 12 ECU - A1 - Intake Air Heater CheckLevel 12 ECU - E3 - Engine Does Not - Continued . . . . . . . . . . . . . . . . . . . . . . . .04-150-43
Develop Full Power Diagnostic Level 12 ECU - A1 - Intake Air Heater CheckProcedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-11 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-44
Level 12 ECU - E4 - Engine Emits Check Fuel Supply Quality . . . . . . . . . . . . . .04-150-47Excessive White Exhaust Smoke. . . . . . . .04-150-16 Test for Fuel Drain Back . . . . . . . . . . . . . . . .04-150-48
Level 12 ECU - E4 - Engine Emits Test for Air in Fuel . . . . . . . . . . . . . . . . . . . .04-150-49Excessive White Exhaust Smoke Diagnostic Check Fuel Supply Pressure . . . . . . . . . . . . .04-150-50Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-16 Bench Test Fuel Supply Pump . . . . . . . . . . .04-150-51
Level 12 ECU - E5 - Engine Emits Bleed the Fuel System . . . . . . . . . . . . . . . . .04-150-53Excessive Black Or Gray Smoke . . . . . . . .04-150-19 Test for Cylinder Misfire (Engine
Level 12 ECU - E5 - Engine Emits Running) . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-56Excessive Black Or Gray Smoke DiagnosticProcedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19 Group 160—Trouble Code Diagnostics and Tests
Level 12 ECU - E6 - Engine Will Not About this Group of the Manual. . . . . . . . . . . .04-160-1Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Electrical Concepts . . . . . . . . . . . . . . . . . . . . .04-160-1
Level 12 ECU - E7 - Engine Idles Poorly . . .04-150-22 Using a Digital Multimeter . . . . . . . . . . . . . . . .04-160-2Level 12 ECU - E8 - Abnormal Engine Electrical Circuit Malfunctions . . . . . . . . . . . . .04-160-2
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-23 Troubleshooting Circuit Malfunctions . . . . . . . .04-160-5Level 12 ECU - E9 - Analog Throttle (B) Engine Configuration Data Parameters on
Does Not Respond . . . . . . . . . . . . . . . . . .04-150-25 Diagnostic Gauge . . . . . . . . . . . . . . . . . . .04-160-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-26 Viewing Active DTCs on Diagnostic
Level 12 ECU - F1 - Fuel Supply System Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12Check Diagnostic Procedure . . . . . . . . . . .04-150-26 Viewing Stored DTCs on Diagnostic
Level 12 ECU - F2 - Excessive Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12Consumption . . . . . . . . . . . . . . . . . . . . . . .04-150-29 Clearing Stored DTCs on Diagnostic
Level 12 ECU - F3 - Fuel in Oil. . . . . . . . . . .04-150-29 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13Level 12 ECU - F5 - Fuel Injection Nozzle Connecting to Diagnostic Scan Tool (DST) or
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 SERVICE ADVISOR . . . . . . . . . . . . . . . .04-160-14Level 12 ECU - D1 - ECU Does Not Blinking DTCs . . . . . . . . . . . . . . . . . . . . . . . .04-160-15
Communicate With DST or SERVICE Data Parameter Description . . . . . . . . . . . . .04-160-16ADVISOR . . . . . . . . . . . . . . . . . . . . . . . .04-150-32 Engine Test Instructions - Excavator
Level 12 ECU - D1 - ECU Does Not Torque Curve Change Test . . . . . . . . . . . .04-160-19Communicate With DST or SERVICE
Continued on next pageADVISOR - Continued . . . . . . . . . . . . . .04-150-33
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Contents
Page Page
Diagnostic Trouble Codes (DTCs) . . . . . . . . .04-160-20 Level 12 ECU - T13 - Excavator ThrottleGround Voltage High . . . . . . . . . . . . . . . . .04-160-66Listing of Diagnostic Trouble Codes (DTCs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-67on ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22
Level 12 ECU - T13 - Excavator ThrottleDiagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-27Ground Voltage High DiagnosticIntermittent Fault Diagnostics . . . . . . . . . . . .04-160-28Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-67Listing of Throttle Codes . . . . . . . . . . . . . . . .04-160-29
Level 12 ECU - T14 - Excavator ThrottleLevel 12 ECU - T1 - Multi-state ThrottleGround Voltage Low . . . . . . . . . . . . . . . . .04-160-70Input High . . . . . . . . . . . . . . . . . . . . . . . . .04-160-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-31
Level 12 ECU - T14 - Excavator ThrottleLevel 12 ECU - T1 - Multi-State ThrottleGround Voltage Low DiagnosticInput High Diagnostic Procedure . . . . . . . .04-160-31Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-71Level 12 ECU - T2 - Multi-state Throttle
Level 12 ECU - T15 - Excavator ThrottleInput Low. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-34Input Voltage High . . . . . . . . . . . . . . . . . . .04-160-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-35
Level 12 ECU - T15 - Excavator ThrottleLevel 12 ECU - T2 - Multi-State ThrottleInput Voltage High - Continued . . . . . . . . .04-160-75Input Low Diagnostic Procedure . . . . . . . .04-160-35
Level 12 ECU - T15 - Excavator Throttle
04
Level 12 ECU - T3 - Analog Throttle (A)Input Voltage High DiagnosticInput High . . . . . . . . . . . . . . . . . . . . . . . . .04-160-38Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-39
Level 12 ECU - T16 - Excavator ThrottleLevel 12 ECU - T3 - Analog Throttle (A)Input Voltage Low . . . . . . . . . . . . . . . . . . .04-160-78Input High Diagnostic Procedure . . . . . . . .04-160-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-79Level 12 ECU - T4 - Analog Throttle (A)
Level 12 ECU - T16 - Excavator ThrottleInput Low. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-42Input Voltage Low Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-43Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-79Level 12 ECU - T4 - Analog Throttle (A)
Level 12 ECU - T19 - Throttle Not CalibratedInput Low Diagnostic Procedure . . . . . . . .04-160-43Properly . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-81Level 12 ECU - T5 - Analog Throttle (B)
Level 12 ECU - T20 - Throttle InputInput High . . . . . . . . . . . . . . . . . . . . . . . . .04-160-46Voltage Below Lower Calibration Limit . . . .04-160-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-47
Level 12 ECU - T21 - Throttle CalibrationLevel 12 ECU - T5 - Analog Throttle (B)
Aborted . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-83Input High Diagnostic Procedure . . . . . . . .04-160-47
Level 12 ECU - T22 - Analog Throttle (A)Level 12 ECU - T6 - Analog Throttle (B)
Input Voltage Out of Range . . . . . . . . . . . .04-160-84Input Low. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-50 Level 12 ECU - T23 - Multi-state Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 Input Voltage Out of Range . . . . . . . . . . . .04-160-85
Level 12 ECU - T6 - Analog Throttle (B) Level 12 ECU - DTC SPN 28, 29, 91 FMIInput Low Diagnostic Procedure . . . . . . . .04-160-51 3, 4, 7, 9, 10, 13, 14 . . . . . . . . . . . . . . . . .04-160-86
Level 12 ECU - T7 - CAN Throttle Invalid . . .04-160-54 Level 12 ECU - DTC SPN 100 FMI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-55 Engine Oil Pressure Extremely Low. . . . . .04-160-88
Level 12 ECU - T7 - CAN Throttle Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-55 Level 12 ECU - DTC SPN 100 FMI 1 Engine
Level 12 ECU - T11 - Excavator Throttle Oil Pressure Extremely Low DiagnosticReference Voltage High. . . . . . . . . . . . . . .04-160-58 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-59 Level 12 ECU - DTC SPN 100 FMI 3
Level 12 ECU - T11 - Excavator Throttle Engine Oil Pressure Input Voltage High. . .04-160-92Reference Voltage High Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-93Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-59 Level 12 ECU - DTC SPN 100 FMI 3 Engine
Level 12 ECU - T12 - Excavator Throttle Oil Pressure Input Voltage High DiagnosticReference Voltage Low . . . . . . . . . . . . . . .04-160-62 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-63 Level 12 ECU - DTC SPN 100 FMI 4
Level 12 ECU - T12 - Excavator Throttle Engine Oil Pressure Input Voltage Low . . .04-160-96Reference Voltage Low Diagnostic
Continued on next pageProcedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-63
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Contents
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-98 Level 12 ECU - DTC SPN 110 FMI 15Engine Coolant Temperature High LeastLevel 12 ECU - DTC SPN 100 FMI 4 EngineSevere . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-124Oil Pressure Input Voltage Low Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-125Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-98
Level 12 ECU - DTC SPN 110 FMI 15Level 12 ECU - DTC SPN 100 FMI 18Engine Coolant Temperature High LeastEngine Oil Pressure Moderately Low . . . .04-160-102Severe Diagnostic Procedure. . . . . . . . . .04-160-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-103
Level 12 ECU - DTC SPN 110 FMI 16Level 12 ECU - DTC SPN 100 FMI 18Engine Coolant Temperature High ModeratelyEngine Oil Pressure Moderately Low DiagnosticSevere . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-126Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-127Level 12 ECU - DTC SPN 105 FMI 3
Level 12 ECU - DTC SPN 110 FMI 16Manifold Air Temperature Input VoltageEngine Coolant Temperature HighHigh. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-104Moderately Severe Diagnostic 04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-105Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-127Level 12 ECU - DTC SPN 105 FMI 3
Level 12 ECU - DTC SPN 111 FMI 0 LossManifold Air Temperature Input Voltageof Coolant Temperature ExtremelyHigh Diagnostic Procedure . . . . . . . . . . .04-160-105High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-128Level 12 ECU - DTC SPN 105 FMI 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-129Manifold Air Temperature Input Voltage
Level 12 ECU - DTC SPN 111 FMI 0 Loss ofLow . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-108Coolant Temperature Extremely High Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-109Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-129Level 12 ECU - DTC SPN 105 FMI 4
Level 12 ECU - DTC SPN 111 FMI 3 LossManifold Air Temperature Input Voltageof Coolant Temperature Input VoltageLow Diagnostic Procedure . . . . . . . . . . . .04-160-109High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-130Level 12 ECU - DTC SPN 105 FMI 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-131Manifold Air Temperature Moderately
Level 12 ECU - DTC SPN 111 FMI 3 Loss ofHigh. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-112Coolant Temperature Input Voltage High Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-113Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-131Level 12 ECU - DTC SPN 105 FMI 16
Level 12 ECU - DTC SPN 111 FMI 4 LossManifold Air Temperature Moderately High
of Coolant Temperature Input VoltageDiagnostic Procedure. . . . . . . . . . . . . . . .04-160-113
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-134Level 12 ECU - DTC SPN 110 FMI 0
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-135Engine Coolant Temperature High Most Level 12 ECU - DTC SPN 111 FMI 4 Loss ofSevere . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-114 Coolant Temperature Input Voltage Low Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-115 Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-135
Level 12 ECU - DTC SPN 110 FMI 0 Engine Level 12 ECU - DTC SPN 158 FMI 17Coolant Temperature High Most Severe Diagnostic ECU Power Down Error. . . . . . . . . . . . . .04-160-138Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-139
Level 12 ECU - DTC SPN 110 FMI 3 Level 12 ECU - DTC SPN 158 FMI 17Engine Coolant Temperature Input Voltage ECU Power Down Error DiagnosticHigh. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-116 Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-117 Level 12 ECU - DTC SPN 174 FMI 3 Fuel
Level 12 ECU - DTC SPN 110 FMI 3 Engine Temperature Input Voltage High . . . . . . .04-160-142Coolant Temperature Input Voltage High Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-143Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-117 Level 12 ECU - DTC SPN 174 FMI 3 Fuel
Level 12 ECU - DTC SPN 110 FMI 4 Temperature Input Voltage High DiagnosticEngine Coolant Temperature Input Voltage Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-143Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-120 Level 12 ECU - DTC SPN 174 FMI 4 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-121 Temperature Input Voltage Low. . . . . . . .04-160-146
Level 12 ECU - DTC SPN 110 FMI 4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-147Coolant Temperature Input Voltage Low Diagnostic
Continued on next pageProcedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-121
CTM331 (09APR02) 04-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Contents
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Level 12 ECU - DTC SPN 174 FMI 4 Fuel Level 12 ECU - DTC SPN 898 FMI 9Vehicle Speed or Torque MessageTemperature Input Voltage Low DiagnosticInvalid . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-181Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-147
Level 12 ECU - DTC SPN 970 FMI 31Level 12 ECU - DTC SPN 174 FMI 16Auxiliary Engine Shutdown SwitchFuel Temperature Moderately High . . . . .04-160-150Active . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-151
Level 12 ECU - DTC SPN 971 FMI 31Level 12 ECU - DTC SPN 174 FMI 16 FuelExternal Engine Derate Switch Active . . .04-160-183Temperature Moderately High Diagnostic
Level 12 ECU - DTC SPN 1076 FMI 0Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-151Pump Control Valve Closure TooLevel 12 ECU - DTC SPN 190 FMI 0 EngineLong . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-184Overspeed Extreme. . . . . . . . . . . . . . . . .04-160-154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-185Level 12 ECU - DTC SPN 190 FMI 16
Level 12 ECU - DTC SPN 1076 FMI 0 PumpEngine Overspeed Moderate . . . . . . . . . .04-160-155Control Valve Closure Too Long DiagnosticLevel 12 ECU - DTC SPN 620 FMI 3Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-185Sensor Supply Voltage High . . . . . . . . . .04-160-156
Level 12 ECU - DTC SPN 1076 FMI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-157Pump Control Valve Closure Too
04
Level 12 ECU - DTC SPN 620 FMI 3Short . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-188Sensor Supply Voltage High Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-189Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-157
Level 12 ECU - DTC SPN 1076 FMI 1 PumpLevel 12 ECU - DTC SPN 620 FMI 4Control Valve Closure Too Short DiagnosticSensor Supply Voltage Low. . . . . . . . . . .04-160-160Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-161
Level 12 ECU - DTC SPN 1076 FMI 3Level 12 ECU - DTC SPN 620 FMI 4Pump Solenoid Current High . . . . . . . . . .04-160-192Sensor Supply Voltage Low Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-193Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-161
Level 12 ECU - DTC SPN 1076 FMI 3Level 12 ECU - DTC SPN 627 FMI 4 ECUPump Solenoid Current High DiagnosticUnswitched Power Missing . . . . . . . . . . .04-160-164Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-165
Level 12 ECU - DTC SPN 1076 FMI 5Level 12 ECU - DTC SPN 627 FMI 4 ECUPump Solenoid Circuit Open . . . . . . . . . .04-160-196
Unswitched Power Missing Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-197
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-165Level 12 ECU - DTC SPN 1076 FMI 5
Level 12 ECU - DTC SPN 629 FMI 13Pump Solenoid Circuit Open Diagnostic
ECU Error . . . . . . . . . . . . . . . . . . . . . . . .04-160-168 Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-197Level 12 ECU - DTC SPN 629 FMI 13 Level 12 ECU - DTC SPN 1076 FMI 6
ECU Error Diagnostic Procedure . . . . . . .04-160-168 Pump Solenoid Circuit SeverelyLevel 12 ECU - DTC SPN 637 FMI 2 Shorted . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-200
Crank Position Input Noise . . . . . . . . . . .04-160-170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-171 Level 12 ECU - DTC SPN 1076 FMI 6 Pump
Level 12 ECU - DTC SPN 637 FMI 2 Solenoid Circuit Severely Shorted DiagnosticCrank Position Input Noise Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-201Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-171 Level 12 ECU - DTC SPN 1076 FMI 7
Level 12 ECU - DTC SPN 637 FMI 10 Pump Control Valve Closure NotCrank Position Input Pattern Error . . . . . .04-160-174 Detected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-205
Level 12 ECU - DTC SPN 637 FMI 10 Level 12 ECU - DTC SPN 1076 FMI 7 PumpCrank Position Input Pattern Error Diagnostic Control Valve Closure Not Detected DiagnosticProcedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-175 Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-205
Level 12 ECU - DTC SPN 639 FMI 13 Level 12 ECU - DTC SPN 1076 FMI 10CAN Error . . . . . . . . . . . . . . . . . . . . . . . .04-160-178 Pump Solenoid Circuit Moderately. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-179 Shorted . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-208
Level 12 ECU - DTC SPN 639 FMI 13Continued on next pageCAN Error Diagnostic Procedure . . . . . . .04-160-179
CTM331 (09APR02) 04-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Contents
Page
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-209Level 12 ECU - DTC SPN 1076 FMI 10
Pump Solenoid Circuit Moderately ShortedDiagnostic Procedure. . . . . . . . . . . . . . . .04-160-209
Level 12 ECU - DTC SPN 1079 FMI 3Sensor Supply Voltage High . . . . . . . . . .04-160-212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-213
Level 12 ECU - DTC SPN 1079 FMI 3Sensor Supply Voltage High DiagnosticProcedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-213
Level 12 ECU - DTC SPN 1079 FMI 4Sensor Supply Voltage Low. . . . . . . . . . .04-160-216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-217
Level 12 ECU - DTC SPN 1079 FMI 4 04Sensor Supply Voltage Low DiagnosticProcedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-217
Level 12 ECU - DTC SPN 1109 FMI 31Engine Protection Shutdown Warning . . .04-160-220
Level 12 ECU - DTC SPN 1110 FMI 31Engine Protection Shutdown . . . . . . . . . .04-160-221
Level 12 ECU - DTC SPN 1569 FMI 31 FuelDerate . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-222
Level 12 ECU - DTC SPN 2000 FMI 6Internal ECU Failure . . . . . . . . . . . . . . . .04-160-223
Level 12 ECU - DTC SPN 2000 FMI 13Security Violation . . . . . . . . . . . . . . . . . . .04-160-224
CTM331 (09APR02) 04-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Contents
04
CTM331 (09APR02) 04-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Group 150Observable Diagnostics and Tests
041501
RG40854,0000113 –19–16JAN02–1/1
About This Group of the Manual
This section of the manual contains necessaryinformation for observable diagnostics and fuel-relatedtest procedures. Use this information in conjunctionwith the 4.5 L & 6.8 L Diesel Engines Base EngineManual (CTM 104). Group 150 is divided into twoareas: diagnosing malfunctions and test procedures.The diagnosing malfunctions area is further dividedinto the following headings, containing the followingobservable symptoms:
NOTE: Follow the diagnostic procedure of an active orstored DTC before pursuing any observablediagnostic procedure.
NOTE: To diagnose observable symptoms on engineswith a mechanical fuel system, see 4.5 L & 6.8L Diesel Engines Mechanical Fuel SystemsManual (CTM 207).
• (E) Diagnosing General Engine Malfunctions:– E1 - Engine cranks/won’t start– E2 - Engine misfires/runs irregularly– E3 - Engine does not develop full power– E4 - Engine emits excessive white exhaust smoke– E5 - Engine emits excessive black or gray smoke– E6 - Engine will not crank– E7 - Engine idles poorly– E8 - Abnormal engine noise– E9 - Analog Throttle (B) Does Not Respond
• (F) Diagnosing Fuel System Malfunctions:
– F1 - Fuel supply system check– F2 - Excessive fuel consumption– F3 - Fuel in oil– F5 - Fuel injector nozzle check
• (D) Diagnosing Diagnostic Software Malfunctions:– D1 - ECU does not communicate with DST or
SERVICE ADVISOR– D2 - Diagnostic Gauge Does Not Communicate
With ECU• (A) Diagnosing Intake Air Heater Malfunctions:
– A1 - Intake Air Heater CheckProcedures for diagnosing some of the abovesymptoms are formatted such that a test or repair isrecommended, then based on the results another testor repair is recommended. Other symptoms areformatted in a symptom - problem - solution format. Inthese symptoms, the problems are arranged in themost likely or easiest to check first. Symptomsarranged in both formats refer to testing procedures inthe second part of this section. The second part of thissection manual contains the following testingprocedures:
• 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)
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-150-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=105
Observable Diagnostics and Tests
RG40854,00000D3 –19–02JAN02–1/1
Level 12 ECU - E1 - Engine Cranks/Won’t Start
NOTE: This procedure applies to engines with JohnDeere Engine Control Units (ECUs). Thisprocedure should be used if engine crankingspeed is OK, but engine will not start or only
starts after prolonged cranking. If engine willnot crank, see E6 - ENGINE WILL NOTCRANK later in this Group.
04150
2
– – –1/1
Level 12 ECU - E1 - Engine Cranks/Won’t Start Diagnostic Procedure
– – –1/1
1 E1 - PreliminaryCheck
Before using this diagnostic procedure:
1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITYlater in this Group.
2. Ensure that engine cranking speed is OK. See TEST ENGINE CRANKING SPEEDin Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
3. Ensure that oil viscosity is correct.
4. 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. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST 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. Crank engine for 15 seconds
5. Read DTCs using DST or SERVICE ADVISOR.
No active DTCs present:GO TO 3
Active DTC(s) present:Diagnose DTCs. If any ofthe DTCs have a SPN637, diagnose them first.
Can not communicatewith ECU:See D1 - ECU DOESNOT COMMUNICATEWITH DST OR SERVICEADVISOR DIAGNOSTICPROCEDURE later in thisGroup.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-150-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=106
Observable Diagnostics and Tests
– – –1/1
3 Crank PositionSensor Indicator Test
1. Start cranking engine
2. Using the DST or SERVICE ADVISOR, read the Crank Position Noise parameterwhile cranking.
NOTE: For an explanation of this parameter, see DATA PARAMETERDESCRIPTION in Group 160.
Crank Position Noiseabove 0:GO TO 4
Crank Position Noise is0:GO TO 5
041503
– – –1/1
4 Vehicle WiringInspection Check
Inspect the vehicle for possible failures that can cause either of the followingconditions:
1. Bad electrical connections
2. Damaged engine speed sensor
3. EMI from improperly installed radio equipment, or other electronic devices
4. Once problem is found, repair and retest.
– – –1/1
5 Fuel Present atInjection NozzlesCheck
Perform following procedure to check for fuel at injection nozzle:
CAUTION: Escaping fluid under pressure can penetrate the skin causingserious injury. Keep hands and body away from pinholes and nozzleswhich could inject fluids under high pressure.
If ANY fluid is injected into the skin, it must be surgically removed withina few hours by a doctor familiar with this type of injury or gangrene mayresult. Doctors unfamiliar with this type of injury may call the Deere andCompany Medical Department in Moline, Illinois, or other knowledgeablemedical source.
1. Using two open-end wrenches, loosen fuel line connection at one of the injectionnozzles.
2. Crank engine while monitoring loosened connection for consistent squirts of fuel.
3. Retighten connection at nozzle to specification.
SpecificationFuel Injection Nozzle Delivery Lines—Torque 27 N•m (20 lb-ft)....................................................................................................
Consistent squirts offuel observed:GO TO 7
Don’t observeconsistent squirts offuel:GO TO 6
CTM331 (09APR02) 04-150-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=107
Observable Diagnostics and Tests
– – –1/1
6 Fuel Supply SystemCheck
Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECKDIAGNOSTIC PROCEDURE later in this Group. Repair problem and retest.
Fuel supply system isOK:GO TO 7
Fuel supply systemproblem found:Repair fuel supply systemproblem and retest.
04150
4
– – –1/1
7 Intake and ExhaustRestrictions Test
Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND EXHAUSTRESTRICTIONS in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines BaseEngine Manual (CTM 104).
All componentsoperating correctly:GO TO 8
Restrictions are found:Repair faulty componentand retest.
– – –1/1
8 Compression Test Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE inSection 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual (CTM104).
Compression pressureis within specification:GO TO 9
Compression pressureis not withinspecification:GO TO 10
– – –1/1
9 Fuel Injection NozzlesCheck
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in thisGroup.
Injection nozzles OK:Faulty injection pump.
Faulty injectionnozzle(s) found:Repair or replaceinjection nozzle(s)
CTM331 (09APR02) 04-150-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=108
Observable Diagnostics and Tests
– – –1/1
10 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves.
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUELINJECTION NOZZLES in Section 02, Group 090 of this manual.
2. Retest the compression pressure.
Compression pressureis within specification:GO TO 13
Compression pressureis not withinspecification:GO TO 11
041505
– – –1/1
11 Valve Lash Check Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
Valve lash is withinspecification:GO TO 12
Valve lash on one ormore valves out ofspecification:Adjust valve lash andretest.
– – –1/1
12 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Section 02, Group 020 of 4.5 L & 6.8L Diesel Engines Base Engine Manual (CTM104).
Lift on all valves withinspecification:GO TO 13
Valve lift on one ormore valves is out ofspecification: Resetclearance to specificationafter measuring lift. SeeCHECK AND ADJUSTVALVE CLEARANCE inSection 02, Group 020 of4.5 L & 6.8 L DieselEngines Base EngineManual (CTM104).
CTM331 (09APR02) 04-150-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=109
Observable Diagnostics and Tests
– – –1/1
13 Pistons, Rings,Cylinder LinersCheck
At this point, the most likely cause of the low engine compression pressure is one ofthe following failures in the pistons, rings, and/or cylinder liners or in the valve guides.Check the most likely items as needed.
• 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 withpistons, rings, and/orliners or valve guides:Repair problem asnecessary.
04150
6
CTM331 (09APR02) 04-150-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=110
Observable Diagnostics and Tests
RG40854,00000D4 –19–02JAN02–1/1
Level 12 ECU - E2 - Engine Misfires/Runs Irregularly
– – –1/1
Level 12 ECU - E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
041507
– – –1/1
1 E2 - PreliminaryCheck
Before using this diagnostic procedure, make the following checks that could cause orbe mistaken as miss/rough running:
1. Check for intake manifold air leaks
2. Check for mechanical problems
3. Check for transmission problems
4. Check engine accessories, such as A/C, cycling on and off
5. Check for electromegnetic interference (EMI) from improperly installed radios, etc.
No problems found:GO TO 2
Problem found:Repair and retest
– – –1/1
2 Active DTC Test 1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST 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. Ignition ON, engine idling
5. Read DTCs using DST or SERVICE ADVISOR.
No active DTCs:GO TO 3
Active DTCs present:Diagnose DTCs. If any ofthe DTCs have a SPN637, diagnose them first
SERVICE ADVISOR is a trademark of Deere & Company
– – –1/1
3 Engine PerformanceTest
1. Ignition ON, engine idling.
2. Observe engine performance.
Not running rough:GO TO 4
Running rough:GO TO 6
CTM331 (09APR02) 04-150-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=111
Observable Diagnostics and Tests
– – –1/1
4 Recreate Conditions Operate engine under conditions where the miss/rough running complaint occurs. Running rough:GO TO 5
Not running rough:No problem found, verifycomplaint and try toreproduce conditions ofmiss/rough runningcomplaint.
04150
8
– – –1/1
5 Active DTC Test 1. Ignition ON, engine idling
2. Read DTCs
No active DTCs:GO TO 6
Active DTCs present:Diagnose DTCs. If any ofthe DTCs have a SPN637, diagnose them first.
– – –1/1
6 Head Gasket FailureCheck
Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES inSection 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual(CTM104).
No sign of head gasketfailure:GO TO 7
Signs of head gasketfailure found:Replace head gasket andretest.
– – –1/1
7 Cylinder MisfireCheck
Check cylinders for misfire. See TEST FOR CYLINDER MISFIRE (ENGINERUNNING) later in this Group.
Single cylinder misfire:GO TO 8
Random or all cylindermisfire:See F1 - FUEL SUPPLYSYSTEM CHECKDIAGNOSTICPROCEDURE later in thisGroup.
CTM331 (09APR02) 04-150-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=112
Observable Diagnostics and Tests
– – –1/1
8 CompressionPressure Check
Check compression pressure. See TEST ENGINE COMPRESSION PRESSURESection 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual(CTM104).
Compression pressureis within specification:GO TO 9
Compression pressureis not withinspecification:GO TO 11
041509
– – –1/1
9 Fuel Delivery LineCheck
Perform the following steps to determine if fuel delivery lines are restricted:
1. Disconnect the suspected fuel delivery line on the injection nozzle end and injectionpump end.
2. Force air through one end of the delivery line.
3. If the delivery line is not restricted, the compressed air should flow freely out theother side.
4. If air does not flow freely, there are restrictions in the fuel line.
Lines are not restricted:GO TO 10
Lines are restricted:Repair or replace linesand retest.
– – –1/1
10 Fuel Injection NozzleCheck
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in thisGroup.
Injection nozzles testOK:Faulty injection pump
Faulty injectionnozzle(s) found:Repair or replaceinjection nozzles.
– – –1/1
11 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves.
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUELINJECTION NOZZLES in Section 02, Group 090 of this manual.
2. Retest the compression pressure.
Compression pressureis within specification:GO TO 14
Compression pressureis not withinspecification:GO TO 12
CTM331 (09APR02) 04-150-9 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=113
Observable Diagnostics and Tests
– – –1/1
12 Valve Lash Check Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
Valve lash is withinspecification:GO TO 13
Valve lash on one ormore valves out ofspecification:Adjust valve lash andretest.
04150
10
– – –1/1
13 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5L &6.8L Diesel Engines Base Engine Manual (CTM104).
Lift on all valves withinspecification:GO TO 14
Valve lift on one ormore valves is out ofspecification: Resetclearance to specificationafter measuring lift. SeeCHECK AND ADJUSTVALVE CLEARANCE inSection 02, Group 020 of4.5 L & 6.8 L DieselEngines Base EngineManual (CTM104).
– – –1/1
14 Pistons, Rings,Cylinder LinersCheck
At this point, the most likely cause of the low engine compression pressure is one ofthe following failures in the pistons, rings, and/or cylinder liners or in the valve guides.Check the most likely items as needed.
• 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 withpistons, rings, and/orliners or valve guides:Repair problem asnecessary.
CTM331 (09APR02) 04-150-10 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=114
Observable Diagnostics and Tests
RG40854,00000D5 –19–02JAN02–1/1
Level 12 ECU - E3 - Engine Does Not Develop Full Power
– – –1/1
Level 12 ECU - E3 - Engine Does Not Develop Full Power Diagnostic Procedure
0415011
– – –1/1
1 E3 - PreliminaryCheck
Before using this diagnostic procedure, 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
– – –1/1
2 Active DTC Test 1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST 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. Ignition ON, engine OFF
5. Read DTCs using DST or SERVICE ADVISOR.
NOTE: On some DTCs, the ECU derates fuel in order to protect the engine.
No DTCs present:GO TO 3
DTCs present:Go to appropriatediagnostic procedure.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-150-11 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=115
Observable Diagnostics and Tests
04150
12
– – –1/1
3 Exhaust EmissionTest
1. Operate engine at full load rated speed.
2. Under these conditions, determine type of exhaust emitted.
Small amount or noexhaust smoke:GO TO 4
Heavy white exhaustsmoke:See E4 - ENGINE EMITSEXCESSIVE WHITEEXHAUST SMOKEDIAGNOSTICPROCEDURE later in thisGroup.
Heavy black or grayexhaust smoke:See E5 - ENGINE EMITSEXCESSIVE BLACK orGRAY EXHAUSTSMOKE DIAGNOSTICPROCEDURE later in thisGroup.
– – –1/1
4 Torque CurveSelection Check
The ECU on 4.5L & 6.8L diesel engines has the ability to operate on multiple torquecurves. To check that the engine is operating on the correct torque curve under theoperating conditions where there is a low power complaint:
1. Recreate the conditions of the low power complaint.
2. Read the Torque Curve parameter on the DST or SERVICE ADVISOR.
NOTE: For an explanation of this parameter, see DATA PARAMETERDESCRIPTION in Group 160.
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. SeeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual andrefer to the corresponding torque curve for your application.
Correct torque curvenumber displayed forcorrespondingoperating conditions:GO TO 5
Incorrect torque curvenumber displayed forcorrespondingoperating conditions:Refer to machine manualto determine componentsthat if faulty could preventthe correct torque curvefrom being selectedORFaulty torque curve selectwiring
– – –1/1
5 Governor DroopMode SelectionCheck
1. Operate engine and attempt to recreate the low power condition.
2. Read the Desired Speed Governor parameter and the Maximum Speed Governorparameter using the DST or SERVICE ADVISOR.
NOTE: For an explanation of this parameter, see DATA PARAMETERDESCRIPTION in Group 160.
3. Compare governor selection to the appropriate governor mode chart. SeeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual andrefer to the corresponding maximum speed and desired speed governor curves foryour application.
Correct governorselection:GO TO 6
Incorrect governorselection:Refer to machine manualto determine componentsthat if faulty could preventthe correct governor frombeing selectedORFaulty governor selectwiring
CTM331 (09APR02) 04-150-12 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=116
Observable Diagnostics and Tests
– – –1/1
6 Throttle Test 1. Operate engine at full load rated speed.
2. Read the Percent Throttle parameter using the DST or SERVICE ADVISOR.
NOTE: For an explanation of this parameter, see DATA PARAMETERDESCRIPTION in Group 160.
97% or above:GO TO 7
Below 97%:Refer to machine manualand perform the throttlecalibration procedure;then retest.
0415013
– – –1/1
7 Turbocharger BoostPressure Check
Check the Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE(TURBOCHARGER BOOST/POWER CHECK) in Section 04, Group 150 of 4.5 L & 6.8L Diesel Engines Base Engine Manual (CTM 104).
Intake manifoldpressure within rangeor above, compared toboost specification:GO TO 8
Intake manifoldpressure below rangecompared to boostspecification:GO TO 9
– – –1/1
8 Fuel Supply SystemCheck with NormalBoost Pressure
Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECKDIAGNOSTIC PROCEDURE later in this Group.
Fuel supply system isOK:Engine appears to bedelivering full power.Check for vehicleproblems that couldcause an excessive loadon the engine.
Fuel supply systemproblem found:Repair fuel supply systemproblem and retest.
– – –1/1
9 CompressionPressure Check
Check compression pressure. See TEST ENGINE COMPRESSION PRESSURESection 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual(CTM104).
Compression pressureis within specification:GO TO 10
Compression pressureis not withinspecification:GO TO 13
CTM331 (09APR02) 04-150-13 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=117
Observable Diagnostics and Tests
– – –1/1
10 Checking PotentialCauses of LowBoost Pressure
Check for the following that can cause reduced boost pressure:
1. Restricted air cleaner
2. Intake air leak
3. Exhaust air leak
4. Restriction in exhaust
5. Faulty turbocharger. See TURBOCHARGER INSPECTION in Section 02, Group080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
None of the aboveproblems found:GO TO 11
Problem found:Repair problem andretest.
04150
14
– – –1/1
11 Fuel Supply SystemCheck with LowBoost Pressure
Check the fuel supply system. F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTICPROCEDURE later in this Group.
Fuel supply system isOK:GO TO 12
Fuel supply systemproblem found:Repair fuel supply systemproblem and retest.
– – –1/1
12 Fuel InjectionNozzles Test
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in thisGroup.
Injection nozzles testOK:Faulty injection pumpORFaulty ECU
Faulty injectionnozzle(s) found:Repair or replace faultyinjection nozzles.
– – –1/1
13 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves.
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUELINJECTION NOZZLES in Section 02, Group 090 of this manual.
2. Retest the compression pressure.
Compression pressureis within specification:GO TO 16
Compression pressureis not withinspecification:GO TO 14
CTM331 (09APR02) 04-150-14 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=118
Observable Diagnostics and Tests
– – –1/1
14 Valve Lash Check 1. Ensure there are no engine mechanical problems and that there isn’t somethingdrawing excessive engine power
2. Ensure that valve lash is correctly adjusted. See CHECK AND ADJUST VALVECLEARANCE in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines BaseEngine Manual (CTM 104).
Valve clearance withinspecification:GO TO 15
Valve clearance out ofspecification:Adjust valves tospecification and retest.
0415015
– – –1/1
15 Valve Lift Check Check valve lift. 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 withinspecification:GO TO 16
Valve lift on one ormore valves is out ofspecification: Resetclearance to specificationafter measuring lift. SeeCHECK AND ADJUSTVALVE CLEARANCE inSection 02, Group 020 of4.5 L & 6.8 L DieselEngines Base EngineManual (CTM104).
– – –1/1
16 Pistons, Rings,Cylinder LinersCheck
At this point, the most likely cause of the low engine compression pressure is one ofthe following failures in the pistons, rings, and/or cylinder liners or in the valve guides.Check the most likely items as needed.
• 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 withpistons, rings, and/orliners or valve guides:Repair problem asnecessary.
CTM331 (09APR02) 04-150-15 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=119
Observable Diagnostics and Tests
RG40854,00000D6 –19–02JAN02–1/1
Level 12 ECU - E4 - Engine Emits Excessive White Exhaust Smoke
04150
16
– – –1/1
Level 12 ECU - E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure
NOTE: This procedure should be used if the engine emits excessive white exhaust smoke. This type of smokecauses a burning sensation to the eyes. If engine emits a less heavy, bluish exhaust smoke see 4.5L/6.8L - L1 -EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual(CTM 104).
– – –1/1
1 E4 - PreliminaryCheck
Before using this diagnostic procedure:
• Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY laterin this Group.
• Ensure engine coolant temperature is not extremely low.
No problems found:GO TO 2
Problem found:Repair and retest
– – –1/1
2 Head Gasket FailureTest
Check for a failed head gasket. See CHECK FOR HEAD GASKET FAILURES inGroup 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No signs of head gasketfailure:GO TO 3
Signs of head gasketfailure are found:See CHECK FOR HEADGASKET FAILURES inGroup 020 of 4.5 L & 6.8L Diesel Engines BaseEngine Manual (CTM104).
– – –1/1
3 CompressionPressure Check
Check compression pressure. See TEST ENGINE COMPRESSION PRESSURESection 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual(CTM104).
Compression pressureis within specification:GO TO 4
Compression pressureis not withinspecification:GO TO 6
CTM331 (09APR02) 04-150-16 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=120
Observable Diagnostics and Tests
– – –1/1
4 Fuel Supply PressureCheck
Check fuel pressure. See CHECK FUEL SUPPLY PRESSURE later in this Group. Fuel pressure withinspecification:GO TO 5
Fuel pressure belowspecification:Check fuel supplysystem. See F1 - FUELSUPPLY SYSTEMCHECK DIAGNOSTICPROCEDURE later in thisGroup.
0415017
– – –1/1
5 Fuel Injection NozzleCheck
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in thisGroup.
Injection nozzles testgood:Faulty injection pump
Faulty injectionnozzle(s) found:Repair or replaceinjection nozzles
– – –1/1
6 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves.
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUELINJECTION NOZZLES in Section 02, Group 090 of this manual.
2. Retest the compression pressure.
Compression pressureis within specification:GO TO 9
Compression pressureis not withinspecification:GO TO 7
– – –1/1
7 Valve Lash Check 1. Ensure there are no engine mechanical problems and that there isn’t somethingdrawing excessive engine power
2. Ensure that valve lash is correctly adjusted. See CHECK AND ADJUST VALVECLEARANCE in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines BaseEngine Manual (CTM 104).
Valve clearance withinspecification:GO TO 8
Valve clearance out ofspecification:Adjust valves tospecification and retest.
CTM331 (09APR02) 04-150-17 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=121
Observable Diagnostics and Tests
04150
18
– – –1/1
8 Valve Lift Check Check valve lift. 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 withinspecification:GO TO 9
Valve lift on one ormore valves is out ofspecification: Resetclearance to specificationafter measuring lift. SeeCHECK AND ADJUSTVALVE CLEARANCE inSection 02, Group 020 of4.5 L & 6.8 L DieselEngines Base EngineManual (CTM104).
– – –1/1
9 Pistons, Rings,Cylinder Liners Check
At this point, the most likely cause of the low engine compression pressure is one ofthe following failures in the pistons, rings, and/or cylinder liners or in the valve guides.Check the most likely items as needed.
• 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 withpistons, rings, and/orliners or valve guides:Repair problem asnecessary.
CTM331 (09APR02) 04-150-18 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=122
Observable Diagnostics and Tests
RG40854,00000D7 –19–02JAN02–1/1
Level 12 ECU - E5 - Engine Emits Excessive Black Or Gray Smoke
0415019
– – –1/1
Level 12 ECU - E5 - Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure
NOTE: This procedure should be used if the engine emits excessive black or gray smoke. If engine emits a lessheavy, bluish exhaust smoke see 4.5L/6.8L - L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of4.5 L & 6.8 L Diesel Engines Base Manual (CTM 104).
– – –1/1
1 E5 - PreliminaryCheck
Before using this diagnostic procedure, check the following:
• Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY laterin this Group.
• 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.
– – –1/1
2 Torque Curve Check NOTE: This check is only required for Excavators. For all other applications, GO TO 3 .
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR in Group 160 later in this manual.
2. With the engine running, read the Torque Curve parameter using the DST orSERVICE ADVISOR.
NOTE: For an explanation of this parameter, see DATA PARAMETERDESCRIPTION in Group 160.
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. SeeEXCAVATORS - TORQUE CURVE SELECTION in Section 06, Group 210 of thismanual.
Correct torque curvenumber displayed:GO TO 3
Incorrect torque curvenumber displayed:Adjust torque curve usingDST or SERVICEADVISOR. See ENGINETEST INSTRUCTIONS -EXCAVATOR TORQUECURVE CHANGE TESTin Section 4, Group 160of this manual.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-150-19 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=123
Observable Diagnostics and Tests
– – –1/1
3 Air Intake andExhaust Test
Check for intake and exhaust restrictions and air leaks. See CHECK FOR INTAKEAND EXHAUST RESTRICTIONS , TEST FOR INTAKE AIR LEAKS and CHECK FOREXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04, Group 150 of 4.5L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No restrictions or leaksfound:GO TO 4
Restrictions or leaksfound:Repair or replacecomponents asnecessary.
04150
20
– – –1/1
4 Turbocharger Check Check for turbocharger failure. See TURBOCHARGER INSPECTION in Section 02,Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No turbocharger failurefound:GO TO 5
Turbocharger failurefound:Follow appropriate repairprocedure in Group 080of 4.5 L & 6.8 L DieselEngines Base EngineManual (CTM104).
– – –1/1
5 Valve Lash Check Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 of4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
Valve lash on all valveswithin specification:GO TO 6
Valve lash on one ormore valves out ofspecification:Adjust valve lash andretest
– – –1/1
6 Fuel Return LineCheck
Check for restricted fuel return line and fitting. No restriction found:GO TO 7
Restriction found:Repair and restest.
CTM331 (09APR02) 04-150-20 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=124
Observable Diagnostics and Tests
– – –1/1
7 Fuel Injection NozzleCheck
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in thisGroup.
Injection nozzles testgood:Faulty injection pump
Faulty injectionnozzle(s) found:Repair or replaceinjection nozzles
0415021
CTM331 (09APR02) 04-150-21 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=125
Observable Diagnostics and Tests
04150
22
RG40854,00000D8 –19–02JAN02–1/1
Level 12 ECU - E6 - Engine Will Not Crank
Symptom Problem Solution
Level 12 ECU - E6 - Engine Will Weak battery Replace battery.Not Crank
Corroded or loose battery Clean battery terminals andconnections connections.
Defective main switch or start safety Repair switch as required.switch
Starter solenoid defective Replace solenoid.
Starter defective Replace starter.
Start circuit defective Check wiring, fuses, and relays.
Engine is seized up Check by rotating engine by hand.
RG40854,00000DA –19–02JAN02–1/1
Level 12 ECU - E7 - Engine Idles Poorly
Symptom Problem Solution
Level 12 ECU - E7 - Engine Idles Poor fuel quality Drain fuel and replace with qualityPoorly fuel of the proper grade.
Air leak on suction side of air intake Check hose and pipe connectionssystem for tightness; repair as required. See
AIR INTAKE AND EXHAUSTSYSTEM SPECIFICATIONS inSection 06, Group 200 of 4.5 L & 6.8L Diesel Engines Base EngineManual (CTM 104).
Electronic control system problem or See E2 - ENGINE MISFIRES/RUNSbasic engine problem IRREGULARLY DIAGNOSTIC
PROCEDURE earlier in this Group.
CTM331 (09APR02) 04-150-22 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=126
Observable Diagnostics and Tests
0415023
RG40854,00000DB –19–02JAN02–1/2
Level 12 ECU - E8 - Abnormal Engine Noise
Symptom Problem Solution
Level 12 ECU - E8 - Abnormal Worn main or connecting rod Determine bearing clearance. SeeEngine Noise bearings CYLINDER BLOCK, LINERS,
PISTONS, AND RODSSPECIFICATIONS in Section 06,Group 200 or CRANKSHAFT , MAINBEARINGS, AND FLYWHEELSPECIFICATIONS in Section 06,Group 200 of 4.5 L & 6.8 L DieselEngines Base Engine Manual (CTM104).
Excessive crankshaft end play Check crankshaft end play. SeeCHECK CRANKSHAFT END PLAYin Section 02, Group 040 of 4.5 L &6.8 L Diesel Engines Base EngineManual (CTM 104).
Loose main bearing caps Check bearing clearance; replacebearings and bearing cap screws asrequired. See CRANKSHAFT , MAINBEARINGS, AND FLYWHEELSPECIFICATIONS in Section 06,Group 200 of 4.5 L & 6.8 L DieselEngines Base Engine Manual (CTM104).
Worn connecting rod bushings and Inspect piston pins and bushings.piston pins See INSPECT PISTON PINS AND
BUSHINGS in Section 02, Group030 of 4.5 & 6.8 L Diesel EnginesBase Engine Manual (CTM 104).
Scored pistons Inspect pistons. See PRELIMINARYLINER, PISTON, AND RODCHECKS in Section 02, Group 030of 4.5 L & 6.8 L Diesel EnginesBase Engine Manual (CTM 104).
Worn timing gears or excess back Check timing gear back lash. Seelash MEASURE TIMING GEAR
BACKLASH in Section 02, Group050 of 4.5 L & 6.8 L Diesel EnginesBase Engine Manual (CTM 104).
CTM331 (09APR02) 04-150-23 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=127
Continued on next page
Observable Diagnostics and Tests
04150
24
RG40854,00000DB –19–02JAN02–2/2
Symptom Problem Solution
Excessive valve clearance Check and adjust valve clearance.See CHECK AND ADJUST VALVECLEARANCE in Section 02, Group020 of 4.5 L & 6.8 L Diesel EnginesBase Engine Manual (CTM 104).
Worn camshaft Inspect camshaft. See VISUALLYINSPECT CAMSHAFT in Section 02,Group 050 of 4.5 & 6.8 L DieselEngines Base Engine Manual (CTM104).
Worn rocker arm shaft(s) Inspect rocker arm shafts. SeeDISASSEMBLE AND INSPECTROCKER ARM SHAFT ASSEMBLYin Section 02, Group 020 of 4.5 L &6.8 L Diesel Engines Base EngineManual (CTM 104).
Insufficient engine lubrication See 4.5L/6.8L - L2 - ENGINE OILPRESSURE LOW in Section 04,Group 150 of 4.5 & 6.8 L DieselEngines Base Engine Manual (CTM104).
Turbocharger noise See TURBOCHARGERINSPECTION in Section 02, Group080 of 4.5 L & 6.8 L Diesel EnginesBase Engine Manual (CTM 104).
CTM331 (09APR02) 04-150-24 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=128
Observable Diagnostics and Tests
0415025
RG40854,0000145 –19–11FEB02–1/1
Level 12 ECU - E9 - Analog Throttle (B) DoesNot Respond
NOTE: This procedure is necessary for OEM applicationsonly. For other applications, check for DiagnosticTrouble Codes (DTCs) and follow thecorresponding procedure.
Symptom Problem Solution
Level 12 ECU - E9 - Analog Active DTC Check Read DTCs on DST or SERVICEThrottle (B) Does Not Respond ADVISOR. Go to the diagnostic
procedure for the correspondingDTC.
Analog Throttle (B) Check See T6 - ANALOG THROTTLE (B)INPUT LOW DIAGNOSTICPROCEDURE in Group 160 of thismanual.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-150-25 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=129
Observable Diagnostics and Tests
RG40854,00000DD –19–02JAN02–1/1
Level 12 ECU - F1 - Fuel Supply System Check
– – –1/1
Level 12 ECU - F1 - Fuel Supply System Check Diagnostic Procedure
04150
26
– – –1/1
1 F1 - PreliminaryCheck
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
Before using this diagnostic procedure:
• Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY afterthis Group.
• Inspect all fuel lines and fittings for ruptures or leaks.• If fuel system has recently been opened, bleed fuel system. See BLEED THE FUEL
SYSTEM later in this Group.
No problem found:GO TO 2
Problem found:Repair and retest.
– – –1/1
2 Air In Fuel Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
No air found in fuelsystem:GO TO 3
Air found in fuelsystem:Bleed fuel system. SeeBLEED THE FUELSYSTEM later in thisGroup.
– – –1/1
3 Fuel Supply PressureCheck
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in thisGroup.
Pressure withinspecification:GO TO 7
Pressure is belowspecification:GO TO 4
CTM331 (09APR02) 04-150-26 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=130
Observable Diagnostics and Tests
– – –1/1
4 Fuel Filter Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
1. Replace final fuel filter and retest.
2. Replace prefilter (if equipped) and retest.
3. Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in thisGroup.
Pressure withinspecification:Problem resolved
Pressure belowspecification:GO TO 5
0415027
– – –1/1
5 Fuel Supply LinesCheck
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
Remove fuel supply lines and determine if there are any internal restrictions.
No restrictions found:GO TO 6
Restrictions found:Repair or replacecomponents as needed.
– – –1/1
6 Fuel Supply PumpCheck
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
At this point, the most likely cause for low fuel pressure is a failure in the fuel supplypump. See BENCH TEST FUEL SUPPLY PUMP later in this Group.
– – –1/1
7 Return Fuel Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
1. Disconnect fuel line from injection pump overflow valve.
2. Loosen overflow valve from injection pump.
3. Turn ignition switch to “ON” position.
4. Operate hand primer on fuel supply pump until fuel flows out the overflow valvefitting location. If fuel flow out the hole cannot be obtained, retighten all fittings.
Good fuel flow out ofloose overflow valve:No fuel supply problemfound.
NOT good fuel flow orno flow out of looseoverflow valve:GO TO 8
CTM331 (09APR02) 04-150-27 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=131
Observable Diagnostics and Tests
04150
28
– – –1/1
8 RestrictedPre-Injection FuelLine Check
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION inSection 03, Group 130 earlier in this manual.
This check will help determine if the pre-injection fuel line is restricted.
• Disconnect fuel line from the final filter to the injection pump.• Force air through the fuel line.
No restrictions found:No fuel supply problemsfound.Return to diagnosticprocedure earlier in thisGroup for:E1 - ENGINECRANKS/WON’T STARTDIAGNOSTICPROCEDUREORE3 - ENGINE DOES NOTDEVELOP FULL POWERDIAGNOSTICPROCEDURE
Restrictions found:Repair or replacecomponents as needed.
CTM331 (09APR02) 04-150-28 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=132
Observable Diagnostics and Tests
0415029
RG40854,00000DE –19–02JAN02–1/1
Level 12 ECU - F2 - Excessive Fuel Consumption
Symptom Problem Solution
Level 12 ECU - F2 - Excessive Poor fuel quality Drain fuel and replace with qualityFuel Consumption fuel of the proper grade.
Engine overloaded Reduce engine load
Air cleaner restricted or dirty Replace air cleaner element asrequired.
Compression too low Determine cause of low compressionand repair as required.
Leaks in fuel supply system Locate source of leak and repair asrequired.
RG40854,00000DF –19–02JAN02–1/1
Level 12 ECU - F3 - Fuel in Oil
Symptom Problem Solution
Level 12 ECU - F3 - Fuel in Oil Faulty injection pump front seal Replace front seal.
CTM331 (09APR02) 04-150-29 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=133
Observable Diagnostics and Tests
04150
30
RG40854,0000001 –19–06MAR02–1/2
Level 12 ECU - F5 - Fuel Injection Nozzle Check
The Level 12 ECU - F5 - Fuel Injection Nozzle Checkprovides a list of possible failures and there solutions.This list below provides references to assist in thediagnosis and repair of the nozzle.
• Operation - See FUEL INJECTION NOZZLEOPERATION in Section 03, Group 130 of thismanual.
• Removal - See REMOVE FUEL INJECTIONNOZZLES in Section 02, Group 090 of this manual.
• Cleaning - See CLEAN FUEL INJECTIONNOZZLES and CLEAN FUEL INJECTION NOZZLEBORE in Section 02, Group 090 of this manual.
• Performance Tests - See FUEL INJECTIONNOZZLE TEST in Section 02, Group 090 of thismanual.
• Disassembly - See DISASSEMBLE FUELINJECTION NOZZLES in Section 02, Group 090 ofthis manual.
• Adjusting - See ADJUST FUEL INJECTIONNOZZLE in Section 02, Group 090 of this manual.
• Installing Seals - See INSTALL SEALS ON FUELINJECTION NOZZLE in Section 02, Group 090 ofthis manual.
• Installation - See INSTALL FUEL INJECTIONNOZZLES in Section 02, Group 090 of this manual.
Symptom Problem Solution
Failed Carbon Stop Seal Washer Nozzle replaced without using new Clean groove and install new sealseal or washer and washer.
Carbon stop seal groove not cleaned Clean greave and install new seal.when new seal was installed.
Incorrect Opening Pressure Improper adjustment Adjust opening pressure. See FUELINJECTION NOZZLE TEST inSection 02, Group 090 of thismanual.
Broken spring Replace spring
Nozzle Will Not Open Plugged orifices Clean orifices.
Chipped orifices Replace injection nozzle
Bottomed lift screw Adjust lift screw.
Poor Spray Pattern Plugged orifices Clean orifices.
Chipped orifices Replace injection nozzle
Cracked nozzle tip Replace injection nozzle.
Poor Atomization Plugged orifice Clean orifice.
Chipped orifice Replace injection nozzle
Cracked nozzle tip Replace injection nozzle.
CTM331 (09APR02) 04-150-30 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=134
Continued on next page
Observable Diagnostics and Tests
0415031
RG40854,0000001 –19–06MAR02–2/2
Symptom Problem Solution
Seat Leakage Deposits in seat area Clean seat.
Valve seat eroded or pitted Lap valve to seat. Replace nozzle asnecessary.
Tip seat pitted Lap tip to seat. Replace nozzle asnecessary.
Valve not free See FUEL INJECTION NOZZLETEST in Section 02, Group 090 ofthis manual.
Distorted body Replace injection nozzle
Cracked tip Replace injection nozzle
High Leak-Off Wear or scratched at guide Lap valve to guide. Replace nozzleas necessary.
Low Leak-Off Varnish on valve Clean Guide Area
Insufficient clearance Clean nozzle. Lap valve to guide.Replace injection nozzle asnecessary.
CTM331 (09APR02) 04-150-31 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=135
Observable Diagnostics and Tests
04150
32
RG40854,00000E0 –19–02JAN02–1/1
Level 12 ECU - D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR
CAN Low
CAN High
CAN Shield
BA
C
DCEBA
Switched Voltage
CAN Terminator
Static Ground
DiagnosticConnector
DC
BJ
HG
F
E
B A A B
CC
A
F1
G1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
2–1
9–14
DE
C01
This diagnostic procedure should be used ifcommunication between the Diagnostic Scan Tool(DST) or SERVICE ADVISOR and the Engine Control
Unit (ECU) cannot be established. For moreinformation on CAN, see CONTROLLER AREANETWORK (CAN) in Group 130 earlier in this manual.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-150-32 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=136
Observable Diagnostics and Tests
RG40854,00000E9 –19–04JAN02–1/1
Level 12 ECU - D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR -Continued
SERVICE ADVISOR is a trademark of Deere & Company
– – –1/1
Level 12 ECU - D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR Diagnostic Procedure
SERVICE ADVISOR is a trademark of Deere & Company
0415033
– – –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.
NOTE: For wiring and theory of operation, see D1 - ECU DOES NOT COMMUNICATEWITH DST OR SERVICE ADVISOR supporting information
Perform a preliminary inspection of the ECU connector, the diagnostic connector, andall connections in between. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR in Group 160 later in this manual.
2. Make sure all communication cables are properly connected
3. Ignition ON, engine OFF
4. Start the ECU Communication Software
DST or ServiceADVISOR does notcommunicate with ECU:GO TO 3
DST or ServiceADVISORcommunicates withECU: Problem isintermittent. If no othercodes are present, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
– – –1/1
3 Sensor Voltage Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. Disconnect ECT sensor
3. Ignition ON
4. Using a multimeter, measure the voltage between both terminals of the selectedsensor harness connector
3.0 V or above:GO TO 5
Below 3.0 V:GO TO 4
CTM331 (09APR02) 04-150-33 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=137
Observable Diagnostics and Tests
– – –1/1
4 Power Supply Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. Disconnect ECU connector
3. Ignition ON
4. Using a multimeter, measure the voltage between a good ground and terminal A2 inthe harness end of the ECU connector
3.0 V or above:Faulty ECU power fuseORFaulty ECU power wiringORFaulty ECU
Below 3.0 V:Key-on signal wire openor shorted to groundORFaulty ignition switchORFaulty key-on power fuse
04150
34
– – –1/1
5 PDM Power LightTest
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition ON
2. Observe the power light on the Parallel Data Module (PDM)
Green power light ON:GO TO 8
Red power light orpower light OFF:GO TO 6
– – –1/1
6 Open in DiagnosticGround ConnectorWire Test
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector
3. Ignition ON
4. Using a multimeter, measure voltage between switched voltage terminal and groundterminal of the harness end of the diagnostic connector
Substantially less thanbattery voltage:GO TO 7
At or near batteryvoltage:Faulty diagnosticconnectorORFaulty diagnostic cableORFaulty Parallel Port DataModule (PDM)
– – –1/1
7 HarnessPower/Ground WireChecks
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector
3. Probe the ground terminal in the harness side of the diagnostic connector with atest light connected to battery voltage.
Light ON:Faulty diagnosticconnectorOROpen or short in powerwire
Light OFF:Faulty diagnosticconnectorOROpen ground wire
CTM331 (09APR02) 04-150-34 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=138
Observable Diagnostics and Tests
– – –1/1
8 Open in HarnessCircuit Test
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. Disconnect ECU connector and diagnostic cable from the diagnostic connector
3. Using a multimeter, measure resistance on the harness end of both connectorsbetween:
• CAN low terminal D in the diagnostic connector and terminal F1 in the ECUconnector
• CAN high terminal C in the diagnostic connector and terminal G1 in the ECUconnector
Both measurements 5ohms or less:GO TO 9
One or moremeasurements greaterthan 5 ohms:Open in harness circuit
0415035
– – –1/1
9 CAN Resistance Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. ECU and diagnostic connector still disconnected.
3. Using a multimeter, measure resistance between terminals C and D in the harnessend of the diagnostic connector.
Between 45 - 75 ohms:GO TO 10
Less than 45 or greaterthan 75 ohms:Faulty or missing CANterminator connectorOROpen or short in CANwiring harness
– – –1/1
10 CAN High and LowVoltage Test
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOTCOMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
1. Ignition OFF
2. Reconnect ECU connector
3. Ignition ON, engine OFF
4. Using a multimeter, measure voltage between a good chassis ground and :
• Terminal C in the diagnostic connector• Terminal D in the diagnostic connector
Both measurementsbetween 1.5 - 3.5 volts:Faulty ECU/Cab HarnessconnectionORFaulty diagnostic cableORFaulty diagnosticconnectorORFaulty Parallel Port DataModule (PDM)ORFaulty diagnosticsoftware/computerconfigurationORFaulty ECU
Either measurementless than 1.5 or greaterthan 3.5 volts:CAN wiring shorted toground or voltageORFaulty ECU
CTM331 (09APR02) 04-150-35 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=139
Observable Diagnostics and Tests
04150
36
RG40854,00000E2 –19–02JAN02–1/1
Level 12 ECU - D2 - Diagnostic Gauge Does Not Communicate With ECU
CAN Low F1
G1
BA
C
BGFED
Switched VoltageStatic Ground
Diagnostic GaugeConnector
CAN High
CAN Shield
B A A B
CC
CAN Terminator
AH
BG
CF
DE
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
3–1
9–14
DE
C01
NOTE: For more information on CAN, seeCONTROLLER AREA NETWORK (CAN) inGroup 130 earlier in this manual.
Internal Diagnostic Gauge Errors
• The D2 - Diagnostic Gauge Does Not CommunicateWith ECU diagnostic procedure should be followed if
the diagnostic gauge shows the following errorcodes or it can not communicate with the ECU:– EE-error– ACP-Err/No Addr– ACP-Err/Bus EP– ACP-Err/Bus Error
CTM331 (09APR02) 04-150-36 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=140
Observable Diagnostics and Tests
RG40854,0000147 –19–11FEB02–1/1
Level 12 ECU - D2 - Diagnostic Gauge Does Not Communicate With ECU - Continued
– – –1/1
Level 12 ECU - D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure
0415037
– – –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.
NOTE: For wiring and theory of operation, see D2 - DIAGNOSTIC GAUGE DOESNOT COMMUNICATE WITH ECU supporting information.
Perform a preliminary inspection of the ECU connector, the diagnostic gaugeconnector, and all connections in between. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. Ignition ON
Error or no power foundin diagnostic gauge:GO TO 3
No error found andpower present indiagnostic gauge:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
CTM331 (09APR02) 04-150-37 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=141
Observable Diagnostics and Tests
04150
38
– – –1/1
3 Sensor Voltage Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. Disconnect any of the following:
• Fuel temperature sensor• MAT sensor• ECT sensor
3. Ignition ON
4. Using a multimeter, measure the voltage between both terminals of the selectedsensor harness connector.
3.0 V or above:GO TO 5
Below 3.0 V:GO TO 4
– – –1/1
4 Power Supply Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Ignition ON
4. Using a multimeter, measure the voltage between a good ground and terminal A2 inthe harness end of the ECU connector.
3.0 V or above:Faulty ECU power fuseORFaulty ECU power wiringORFaulty ECU
Below 3.0 V:Key-on signal wire openor short to groundORFaulty ignition switchORFaulty key-on power fuse
– – –1/1
5 Diagnostic GaugePower Test
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition ON
2. View diagnostic gauge
Gauge has power:GO TO 8
Gauge does not havepower:GO TO 6
– – –1/1
6 Open in DiagnosticGround ConnectorWire Test
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU DIAGNOSTIC PROCEDURE supporting information.
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector
3. Ignition ON
4. Using a multimeter, measure voltage between switched voltage terminal and groundterminal of the harness end of the diagnostic connector
Substantially less thanbattery voltage:GO TO 7
At or near batteryvoltage:Faulty diagnosticconnectorORFaulty diagnostic cableORFaulty Parallel Port DataModule (PDM)
CTM331 (09APR02) 04-150-38 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=142
Observable Diagnostics and Tests
– – –1/1
7 HarnessPower/Ground WireChecks
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector
3. Probe the ground terminal in the harness side of the diagnostic connector with atest light connected to battery voltage.
Light ON:Faulty diagnosticconnectorOROpen or short in powerwire
Light OFF:Faulty diagnosticconnectorOROpen ground wire
0415039
– – –1/1
8 Open in HarnessCircuit Test
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. Disconnect the ECU connector and the diagnostic cable from the diagnosticconnector.
3. Using a multimeter, measure resistance on the harness end of both connectorsbetween:
• Terminal B in the diagnostic gauge connector and terminal F1 in the ECUconnector.
• Terminal G in the diagnostic gauge connector and terminal G1 in the ECUconnector.
All measurements 5ohms or less:GO TO 9
One or moremeasurements greaterthan 5 ohms:Open in harness circuitORConnector terminals inwrong position
– – –1/1
9 CAN Resistance Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. ECU and diagnostic connectors still disconnected.
3. Using a multimeter, measure resistance between terminals B and G in the harnessend of the diagnostic connector.
Between 45-75 ohms:GO TO 10
Less than 45 or greaterthan 75 ohms:Faulty or missing CANterminator connector(s)OROpen or short in CANwiring harness
CTM331 (09APR02) 04-150-39 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=143
Observable Diagnostics and Tests
04150
40
– – –1/1
10 CAN High and LowVoltage Test
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOTCOMMUNICATE WITH ECU supporting information.
1. Ignition OFF
2. Reconnect ECU connector
3. Ignition ON
4. 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 measurementsbetween 1.5 - 3.5 V:Faulty ECU connectionORFaulty diagnostic gaugeconnectionORFaulty diagnosticsoftware/computerconfigurationORFaulty ECU
Either measurementless than 1.5 V orgreater than 3.5 V:CAN wiring shorted toground or powerORFaulty ECU
CTM331 (09APR02) 04-150-40 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=144
Observable Diagnostics and Tests
0415041
CTM331 (09APR02) 04-150-41 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=145
Observable Diagnostics and Tests
04150
42
RG40854,00000E6 –19–03JAN02–1/1
Level 12 ECU - A1 - Intake Air Heater Check
Switched Voltage
Air HeaterIndicator Light
Air Heater Relay Enable
G2
K3
K1 K2 K3
J3
H3
G3
F3
J2
H2
G2
F2
J1
H1
G1
F1
E1 E2 E3
D3
C3
B3
A3
D2
C2
B2
A2
D1
C1
B1
A1
CONNECTOR
ECU
HARNESS
RG
1204
9–1
9–23
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For non-OEM engine wiringinformation, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Intake Air Heater
The intake air heater is located between the intakepipe and intake manifold. Its function is to heat theintake air during cold starting conditions. Its operationtime is dependent on the fuel temperature that theECU detects at key-on. The table on thecorresponding page explains this relationship.
When the ECU sends battery voltage to the air heaterrelay, the solenoid in the relay activates, and the airheater turns ON. At this time, the ECU will illuminatethe air heater indicator light. When the ECU stopssending battery voltage, the solenoid deactivates, andthe air heater turns OFF. At this time, the ECU will turnthe air heater indicator light OFF.
To ensure full utilization of the intake air heater, theoperator should wait until the light goes out beforestarting the engine. Anytime the engine cranks butdoes not start, a key-off/key-on cycle will be requiredbefore preheating is allowed again.
CTM331 (09APR02) 04-150-42 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=146
Observable Diagnostics and Tests
0415043
RG40854,00000E7 –19–04JAN02–1/1
Level 12 ECU - A1 - Intake Air Heater Check - Continued
NOTE: The table below is for OEM applicationsONLY. For specifications on other applications,see APPLICATION SPECIFICATIONS inSection 06, Group 210 of this manual.
Intake Air Heater Operating ConditionsIntake Air Heater Operation
Fuel Temperature Operation Time
-5°C (23°F) 5 seconds
-10°C (14°F) 15 seconds
-15°C (5°F) 20 seconds
-20°C (-4°F) 30 seconds
-25°C (-13°F) and below 30 seconds
CTM331 (09APR02) 04-150-43 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=147
Observable Diagnostics and Tests
RG40854,00000EB –19–04JAN02–1/1
Level 12 ECU - A1 - Intake Air Heater Check - Continued
– – –1/1
Level 12 ECU - A1 - Intake Air Heater Check Diagnostic Procedure
NOTE: The air heater indicator light is the same light that trouble codes are displayed on. If the light stays on past25 seconds, check for trouble codes or a short to ground in the air heater indicator light wire.
04150
44
– – –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.
NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATERCHECK supporting information
Perform a preliminary inspection of the ECU connector, air heater relay connector, airheater connector, and all connections in between. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Air Heater IndicatorLight Check
NOTE: Do not run engine during this diagnostic procedure.
NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATERCHECK supporting information
1. Key ON, engine OFF
2. Verify that the air heater indicator light is working
Light works:GO TO 3
Light does not work:Faulty air heater indicatorlight wiringORFaulty air heater indicatorlight
CTM331 (09APR02) 04-150-44 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=148
Observable Diagnostics and Tests
0415045
– – –1/1
3 Active DTC Test NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATERCHECK supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST 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 appropriatediagnostic procedure
SERVICE ADVISOR is a trademark of Deere & Company
– – –1/1
4 Fuel TemperatureCheck
NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKEAIR 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-relatedproblem found
– – –1/1
5 Voltage at Air HeaterCheck
NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKEAIR HEATER CHECK supporting information
1. Key OFF
2. Using a multimeter, measure the voltage between the air heater power stud and agood chassis ground while turning key ON (engine OFF)
NOTE: Voltage must be read as key is turned ON
At or near batteryvoltage:GO TO 6
No voltage detected:GO TO 7
– – –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 relatedproblem found
Temperature does notincreaseFaulty air heater
CTM331 (09APR02) 04-150-45 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=149
Observable Diagnostics and Tests
04150
46
– – –1/1
7 Air Heater RelayCheck
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 relayORFaulty wire between relayand heaterORFaulty air heater relay
Relay does not click:Faulty air heater enablewireORFaulty relay groundORFaulty relay
CTM331 (09APR02) 04-150-46 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=150
Observable Diagnostics and Tests
0415047
RG40854,00000EC –19–04JAN02–1/1
Check Fuel Supply Quality
RG
1196
9–U
N–2
3JA
N02
The quality of diesel fuel affects engine performance.Check your operators manual for correct fuelspecifications.
Poor quality or contaminated fuel will make the enginehard 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 forserviceability. If filter is equipped with a water bowl,empty and clean water bowl.
2. Start engine and operate under load, observingengine performance.
3. Ignition OFF, engine off
4. Disconnect fuel line from inlet side of prefilter (ifequipped) or inlet side of final filter on engineswithout prefilter.
5. Connect a hose to inlet port.
6. Submerge hose in a container of clean, goodquality fuel meeting engine specifications.
7. Operate engine under load and observeperformance.
If performance improves, fuel is contaminated ornot of the proper grade. Check fuel source.
CTM331 (09APR02) 04-150-47 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=151
Observable Diagnostics and Tests
04150
48
RG40854,00000EE –19–04JAN02–1/1
Test for Fuel Drain Back
Fuel draining back through the fuel system may causehard starting. This procedure will determine if air isentering the system at connections and allowing fuel tosiphon back to the fuel tank.
1. Disconnect fuel supply and return lines at fuel tank.
IMPORTANT: Fuel return line MUST extend below fuellevel in fuel tank before performing thistest. Fill fuel tank if necessary.
2. Drain all fuel from the system, including the fuel supplypump, 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 100kPa (1 bar) (14.5 psi) when performing this test.
4. Using a low pressure air source, pressurize the fuelsystem at the fuel supply line.
5. Apply liquid soap and water solution to all joints andconnections in the fuel system and inspect for leaks.
NOTE: Connections may allow air to enter the systemwithout 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 thefollowing morning.
CTM331 (09APR02) 04-150-48 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=152
Observable Diagnostics and Tests
0415049
RG40854,00000EF –19–04JAN02–1/1
Test for Air in Fuel
RG
1197
0–U
N–2
3JA
N02
NOTE: If engine cranks but won’t start, see BLEEDTHE FUEL SYSTEM later in this Group.
Air in the fuel system will make the engine hard tostart, run rough, misfire or produce low power.Additionally, it can cause excessive smoke andknocking.
Whenever the fuel system is opened for repair, it mustbe bled to remove any air that has entered the system.
1. Disconnect hose from end of fuel leak-off lineassembly. Connect a clear plastic hose to end ofleak-off line assembly and place opposite end ofhose in a suitable container filled with fuel asshown.
2. Operate engine and check for air bubbles incontainer. If bubbles are present, bleed the fuelsystem and repeat test. See BLEED THE FUELSYSTEM later in this Group.
3. If bubbles are still present, check the following:
• Check for loose fuel fittings from the suction side ofthe fuel supply pump to the fuel tank to include alllines and filters.
• Check fuel tank suction tube (if equipped) andwelded joints for cracks or holes.
Perform any necessary repairs, bleed fuel system andrepeat test.
CTM331 (09APR02) 04-150-49 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=153
Observable Diagnostics and Tests
04150
50
RG40854,00000F9 –19–15JAN02–1/1
Check Fuel Supply Pressure
RG
7946
–UN
–15J
AN
98
IMPORTANT: Before disconnecting any fuel line,completely clean any debris fromaround the fitting. DO NOT allow debristo enter fuel line.
1. Remove plug on final fuel filter base.
2. Install test equipment as shown.
3. Start engine. Fuel pump should maintain minimumpositive pressure listed below. If pressure is low,replace filter element and recheck pressure.
SpecificationFuel Supply Pump—StaticPressure 25—30 kPa (0.25—0.30 bar)
(3.5—4.5 psi).......................................................
Fuel Supply Pump—MinimumStatic Pressure at 850 rpmEngine Speed 15 kPa (0.15 bar) (2.0 psi)..................................................Fuel Supply Pump—MinimumPositive Pressure at 2400 rpmEngine Speed 21—34 kPa (0.21—0.34 bar)
(3—5 psi)...............................................
Fuel Supply Pump—MinimumFlow at 2400 rpm Engine Speed 1.5 L/min (0.42 gpm).............................
CTM331 (09APR02) 04-150-50 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=154
Observable Diagnostics and Tests
0415051
RG40854,0000146 –19–11FEB02–1/3
Bench Test Fuel Supply Pump
RG
9052
–UN
–16M
AR
98
Fuel Supply Pump with Metal Cover
A—LeverB—Outlet Side of PumpC—Inlet Side of PumpD—Primer Lever
The following bench tests can be performed on a supplypump installed on the engine when the pump is suspectedto be defective. See CHECK FUEL SUPPLY PRESSUREin Section 04, Group 150.
Perform the Vacuum/Pressure Test and Leakage Test,listed below. Replace the supply pump if either test showsthe pump to be defective. There is no repair procedure.
Vacuum/Pressure Test
NOTE: This test will give a good indication of condition ofboth the inlet and outlet valves, as well as thediaphragm. The numerical values obtained onboth the vacuum and pressure sides are notimportant; rather it is the needle movement that isimportant (very slow for a good pump; very fast ornot 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. Releaselever and at the same time observe gauge:
• The gauge needle should read the same value eachtime, and then very slowly return to “0”. Thisindicates that the inlet valve and diaphragm are ingood condition. Proceed to next step.
• If the gauge needle does not move at all, or if theneedle rapidly returns to “0”, the pump is defectiveand must be replaced.
4. Remove vacuum/pressure gauge and install onto outletside of pump (B).
5. Move primer lever all the way to upward position.Release lever and at same time observe gaugereading:
CTM331 (09APR02) 04-150-51 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=155
Continued on next page
Observable Diagnostics and Tests
04150
52
RG40854,0000146 –19–11FEB02–2/3
• The gauge needle should initially read 28—41 kPa(0.28—0.41 bar) (4—6 psi), then return to “0” veryslowly. This indicates that the outlet valve anddiaphragm are in good condition. Supply pump isoperating properly and should be reinstalled onengine.
SpecificationFuel Supply Pump—Pressure 28—41 kPa (0.28—0.41 bar)
(4—6 psi)......................
• If the gauge needle initially reads same value asabove and then returns immediately back to “0”, thepump is defective and must be replaced.
RG40854,0000146 –19–11FEB02–3/3
RG
9052
–UN
–16M
AR
98
Fuel Supply Pump with Metal Cover
A—LeverB—Outlet Side of PumpC—Inlet Side of PumpD—Primer Lever
Leakage Test
The leakage test should be performed if a supply pump issuspected of leaking fuel externally, or internally into theengine crankcase.
1. Install an air line on inlet side of pump (C) and apply140 kPa (1.4 bar) (20 psi) pressure.
2. Hold finger over outlet side of pump (B) or install aplug. Submerge pump into a container of clean dieselfuel.
• If air bubbles occur around banded connectionholding the two halves of pump together (indicatingleakage), replace pump.
• If the diaphragm is bad, there will be leakagethrough vent holes (if equipped) and around therocker arm. Replace pump as necessary.
CTM331 (09APR02) 04-150-52 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=156
Observable Diagnostics and Tests
0415053
RG40854,00000F0 –19–04JAN02–1/5
Bleed the Fuel System
X98
11–U
N–2
3AU
G88
CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoidhazards by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.
If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis 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 necessaryto bleed air from the system.
The fuel system may be bled at one of several locations.On some engine applications it may be necessary toconsult your operator’s manual and choose the bestlocation for your engine/machine application.
RG40854,00000F0 –19–04JAN02–2/5
RG
1180
5–U
N–2
5OC
T01
A—Bleed Vent Screw
1. Loosen the air bleed vent screw (A) two full turns byhand on fuel filter base.
Continued on next page
CTM331 (09APR02) 04-150-53 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=157
Observable Diagnostics and Tests
04150
54
RG40854,00000F0 –19–04JAN02–3/5
RG
1180
6–U
N–2
5OC
T01
B—Primer Lever
2. Operate fuel supply pump prime lever (B) or primerbutton on fuel filter base (if equipped).
3. Tighten bleed plug securely; continue operating primeruntil pumping action is not felt.
4. Start engine and check for leaks.
If engine will not start, it may be necessary to bleed airfrom fuel system at fuel injection pump or injectionnozzles as explained next.
RG40854,00000F0 –19–04JAN02–4/5
RG
1180
7–U
N–2
5OC
T01
A—Fuel Return Line
At Fuel Injection Pump
1. Loosen fuel return line (A) at fuel injection pump.
2. Operate fuel supply pump primer lever or primer buttonon fuel filter base (if equipped).
3. As soon as fuel flow is free from air bubbles, tightenfuel return line to specifications. Primer lever isspring-loaded and will return to normal position.
SpecificationFuel Injection Pump ReturnLine—Torque 27 N•m (20 lb-ft)...................................................................
Continued on next page
CTM331 (09APR02) 04-150-54 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=158
Observable Diagnostics and Tests
0415055
RG40854,00000F0 –19–04JAN02–5/5
RG
1180
8–U
N–2
5OC
T01
Nozzle Fuel Pressure Line
At Fuel Injection Nozzles
1. Place throttle lever in half-throttle position.
IMPORTANT: Always use a backup wrench whenloosening or tightening fuel lines atnozzles and/or injection pump to avoiddamage.
2. Using two open-end wrenches, loosen two fuel lineconnections at injection nozzles.
3. Crank engine over with starter motor for 15 seconds(but do not start engine) until fuel free from bubblesflows out of loosened connection. Retighten connectionto specifications.
SpecificationFuel Injection Nozzle DeliveryLines—Torque 27 N•m (20 lb-ft).................................................................
4. Repeat procedure for remaining injection nozzles (ifnecessary) until all air has been removed from fuelsystem.
If engine still will not start, see your authorized servicingdealer or engine distributor.
CTM331 (09APR02) 04-150-55 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=159
Observable Diagnostics and Tests
04150
56
RG40854,00000F1 –19–04JAN02–1/1
Test for Cylinder Misfire (Engine Running)
CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Keephands and body away from pinholes andnozzles which could inject fluids under highpressure.
If ANY fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type of injury organgrene may result. Doctors unfamiliar withthis type of injury may call the Deere &Company Medical Department in Moline, Illinois,or other knowledgeable medical source.
1. Operate engine at intermediate speed with no load.
2. Place a shop towel around nozzle-to-line connection toabsorb escaping fuel.
3. Slowly loosen the fuel pressure line at one of thenozzles until fuel escapes at the connection (fuel notopening nozzle valve).
• If engine speed changes, the cylinder is probablyworking satisfactory.
• If engine speed does not change, a cylinder is faulty.
4. Tighten fuel lines to specifications.
SpecificationFuel Injection Nozzle DeliveryLines—Torque 27 N•m (20 lb-ft).................................................................
5. Repeat test for each remaining cylinder.
6. Remove faulty injection nozzles and repair as required.See F5 - FUEL INJECTION NOZZLE CHECK earlier inthis Group.
CTM331 (09APR02) 04-150-56 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=160
Group 160Trouble Code Diagnostics and Tests
041601
RG40854,00000FA –19–15JAN02–1/1
About this Group of the Manual
This section of the manual contains necessaryinformation to diagnose the electronic control system.Use this information in conjunction with the 4.5 L & 6.8L Diesel Engines Base Engine Manual (CTM104).
See the 4.5 L & 6.8 L Diesel Engines Base EngineManual (CTM 104) for:
• Removal of base engine components• Base engine repair procedures• Base engine disassembly• Base engine inspection• Base engine assembly
Parts such as sensors, actuators, connectors, andwiring harnesses are serviceable and available.
To help diagnose electronic control system problems,Section 06, Group 210 DIAGNOSTIC
SPECIFICATIONS contains useful information, such asECU terminal identification and a system wiringschematic.
IMPORTANT: Under NO circumstances, should theEngine Control Unit (ECU) beopened.
NOTE: Instruction is given throughout the diagnosticcharts to make resistance and voltagemeasurements in the ECU connector. Notethat these measurements are always made inthe harness end of the connector.Measurements should never be made in theECU end of the connection.
RG40854,00000FB –19–15JAN02–1/1
Electrical Concepts
Tests will include making measurements of voltage andresistance and making checks for open circuits and shortcircuits. An understanding of the following concepts isrequired to use the diagnostic procedures:
• Voltage (volts)• Current (amps)• Resistance (ohms)• Open Circuit• Short Circuit
CTM331 (09APR02) 04-160-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=161
Trouble Code Diagnostics and Tests
04160
2
RG40854,00000FC –19–15JAN02–1/1
Using a Digital Multimeter
RG
1112
6–U
N–1
9JU
N00
Digital Multimeter
It is recommended that a digital multimeter (JT07306 orequivalent with an analog display) be used to make therequired measurements in the diagnostic procedures. Aknowledge of the operation of the particular meter used isassumed.
Instructions for measuring voltages take the followingform:
• Measure voltage from Point A (+) to Point (B) (-)
In this example, the positive test lead from the volt-ohminput of the meter should be connected to Point A and thenegative test lead from the common input of the metershould be connected to Point B.
Unless otherwise stated, all voltage measurements aredirect current (D.C.).
In making a resistance measurement, be careful to usethe correct resistance range on the meter. Disconnectappropriate connectors or turn off key switch, as directedby diagnostic procedures later in this group.
RG40854,00000FD –19–15JAN02–1/6
Electrical Circuit Malfunctions
Circuit Malfunctions
There are four major circuit malfunctions. They are:
1. High-resistance circuit
2. Open circuit
3. Grounded circuit
4. Shorted circuit
CTM331 (09APR02) 04-160-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=162
Continued on next page
Trouble Code Diagnostics and Tests
RG40854,00000FD –19–15JAN02–2/6
RG9891 –UN–06JAN99
High Resistance Circuit
A—Unwanted Resistance
Definition of Circuit Malfunctions
1. High Resistance Circuit:
A circuit having unwanted resistance (A) thatcauses a voltage drop and reduces current flow.
041603
RG40854,00000FD –19–15JAN02–3/6
RG9892 –UN–06JAN99
Open Circuit
A—Break or Separation inCircuit
2. Open Circuit:A circuit having a break or a separation (A) thatprevents current from flowing in the circuit.
RG40854,00000FD –19–15JAN02–4/6
RG9893 –UN–06JAN99
Grounded Circuit
A—Voltage Wire in Contactwith Machine Frame
3. Grounded Circuit:A voltage wire in contact with the machine frame(A), providing continuity with the battery groundterminal.
CTM331 (09APR02) 04-160-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=163
Continued on next page
Trouble Code Diagnostics and Tests
04160
4
RG40854,00000FD –19–15JAN02–5/6
RG
9894
–UN
–06J
AN
99
Shorted Circuit
4. Shorted Circuit:A wire-to-wire contact of two adjacent wires thatprovides unwanted continuity between the twowires. The following are types of short circuits:• Voltage wire shorted to another voltage wire
(wires of equal or unequal voltage).• Voltage wire shorted to a sensor signal wire
(wires of unequal voltage).• Voltage wire shorted to a ground wire (wires of
battery voltage or regulated voltage, shorted to a
ground wire connecting a component to thebattery negative terminal).
• Ground wire shorted to another ground wire(wires of zero voltage).
NOTE: This type of short does not create anobservable malfunction. Therefore, no furtherexplanation for trouble shooting is necessary.
RG40854,00000FD –19–15JAN02–6/6
RG9895 –UN–06JAN99
Locations of Circuit Malfunctions
A—Controlling Switch B—Load
Locations of Circuit Malfunctions:
In a “Simple Electrical Circuit” the circuit malfunctionsoccur at only three locations. They are:
1. Before the controlling switch (A).
2. Between the controlling switch (A) and the load (B).
3. After the load (B).
Electrical components can become faulty with thesame four circuit malfunctions. Sometimes componentmalfunctions can easily be confused with circuit
malfunctions. Therefore, care must be exercised whenisolating the cause of the problem.
Example: A component may not operate beforedisconnecting an electrical connection, but it operatesafter reconnecting the connector.
Reason: Oxidation of the terminals created “HighResistance” and a voltage drop that prevents theproper amount of current flow to the component.Disconnecting and reconnecting the connector,removed some oxidation and re-established goodcontinuity through the connector.
CTM331 (09APR02) 04-160-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=164
Trouble Code Diagnostics and Tests
041605
RG40854,00000FE –19–15JAN02–1/4
Troubleshooting Circuit MalfunctionsRG9896 –UN–06JAN99
Troubleshooting Circuit Malfunctions
A—Battery D—Unwanted Resistance G—Circuit Connector I—Load (Lamp)B—Switch E—Circuit Connector H—Component Terminal J—GroundC—Component Terminal F—Open Circuit
1. High Resistance Circuit:
A “High Resistance” circuit can result in slow, dimor no component operation (for example: loose,corroded, dirty or oily terminals, gauge of wire toosmall or broken strands of wire).
2. Open Circuit:
An “Open” circuit results in no component operationbecause the circuit is incomplete (for example:broken wire, terminals disconnected, openprotective device or open switch).
Do the following to isolate the location of a “HighResistance” or “Open” circuit:
a. With the controlling switch (B) closed (on) andthe load (I) connected into the circuit, check for
proper voltage at a location easily accessiblebetween (C) and (H).
• If voltage is low, move toward the voltagesource (A) to locate the point of voltage drop.
• If voltage is correct, move toward the load (I)and ground terminal (J) to locate the voltagedrop.
NOTE: The example shows high resistance (D)between (C) and (E) and the open circuit (F)between (E) and (G).
b. Repair the circuit as required.
c. Perform an operational check-out on thecomponent after completing the repair.
Continued on next page
CTM331 (09APR02) 04-160-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=165
Trouble Code Diagnostics and Tests
04160
6
RG40854,00000FE –19–15JAN02–2/4
RG9897 –UN–06JAN99
Ground Circuit
A—Fuse “A” Terminal C—Switch E—Wire Terminal G—Component TerminalB—Fuse “B” Terminal D—Component Terminal F—Grounded Circuit H—Load (Lamp)
3. Ground Circuit:
A “Grounded” circuit (F) results in no componentoperation and the fuse or circuit breaker opens (forexample: a power wire contacting the machineframe, chassis or component housing).
Do the following to isolate the location of a“Grounded” circuit:
a. Switch (C) must be open (off). Check forcontinuity to ground between (B) and (C).
• If there is continuity, there is a groundedcircuit between (B) and (C). Repair the circuit.
• No continuity, go to step b.
b. Disconnect the load (H) at component terminal(G).
c. With the controlling switch (C) open (off), checkfor continuity to ground between (D) and (E).
• If there is continuity, there is a groundedcircuit between (D) and (E). Repair the circuit.
NOTE: The example is grounded between (D) and (E)at (F).
• Perform an operational check-out on thecomponent after completing the repair.
Continued on next page
CTM331 (09APR02) 04-160-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=166
Trouble Code Diagnostics and Tests
041607
RG40854,00000FE –19–15JAN02–3/4
RG
9898
–UN
–06J
AN
99
Shorted Circuit
4. Shorted Circuit:
Machines equipped with several electronic controldevices contain wiring harnesses that can becomeshorted by one of the following ways shown above.
1. Battery wire from fuse (F1) is shorted at (A) toanother battery wire after switch (Sw.2).• Result: Lamp (E1) is on all of the time.
2. Battery wire from fuse (F1) is shorted at (B) toanother battery wire after switches (Sw.1 & 2).• Result: Both lamps (E1 & E2) operate on
either switch (Sw. 1 or 2).
3. Battery wire from fuse (F1) is shorted at (C) to aground wire.• Result: Fuse (F1) opens after closing switch
(Sw. 1)
4. Battery wire from switch (Sw. 2) is shorted at (D)to a regulated voltage wire.• Result: The sensor signal voltage is distorted.1
5. Battery wire from switch (Sw. 2) is shorted at (E)to the sensor signal voltage wire.• Result: The sensor signal is distorted.1
6. Battery wire from switch (Sw. 2) is shorted at (F)to the sensor ground wire.
• Result: Fuse (F2) opens after closing switch(Sw. 2) and the sensor signal is distorted.1
7. Controller regulated voltage wire is shorted at(G) to the sensor signal voltage wire.• Result: The sensor signal is distorted.
8. Controller regulated voltage wire is shorted at(H) to the sensor ground wire.• Result: The sensor signal is distorted.1
9. Sensor voltage wire is shorted at (I) to thesensor ground wire.• Result: The sensor signal is distorted.1
Do the following to isolate a “Shorted Circuit:”
a. Review the machine electrical schematic toidentify the circuits for the component that doesnot operate.
b. Disconnect the components at each end of thecircuits, to single out the affected wires.
c. To prevent damage to connector terminals,obtain mating connector terminals from repairparts. DO NOT force meter probes intoconnector terminals.
1The sensor signal voltage goes out of range and a fault code maybe restored. The controller may shut down or provide limitedoperation for its function.
CTM331 (09APR02) 04-160-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=167
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Trouble Code Diagnostics and Tests
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8
RG40854,00000FE –19–15JAN02–4/4
d. Connect the meter leads across two of the affectedcircuits. The meter should show no continuitybetween the two circuits. Repeat the check acrossanother combination of two circuits until all affectedcircuits have been checked.
e. Then, connect a meter lead to each affected circuitone at a time and touch the other meter leads to allterminals in the connector. The meter should showno continuity between any two circuits.
Example: A 37 pin connector contains three wiresto a sensor. With one meter probe attached to eachof the three wires, one at a time, touch the othermeter probe to the remaining 36 wires. If there iscontinuity between any two wires, the circuit isshorted. Repair the circuit.
f. Alternate Method to Check for Shorted Circuit.
With the components disconnected at each end ofthe suspected circuits, turn the key switch on.
Connect one meter lead to a good frame ground.With the other meter probe, touch each of thesuspected circuits one at a time. If there is a voltagereading, the circuit is shorted to another voltagewire. Repair the circuit.
g. Repair the “Shorted Circuit” as follows:
• Wires not in a loom: Wrap individual wires withelectrical tape or replace the damaged wire andband as required.
• Wires in a loom: If hot spots exist in shorted areaof the harness, replace the harness. If hot sportsare not noticeable, install a new wire of propergauge between the last two connections. Use tiebands to secure the wire to outside of theharness.
h. Perform an operational check-out on the componentafter completing the repair.
CTM331 (09APR02) 04-160-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=168
Trouble Code Diagnostics and Tests
041609
CTM331 (09APR02) 04-160-9 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=169
Trouble Code Diagnostics and Tests
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10
RG40854,00000FF –19–15JAN02–1/2
Engine Configuration Data Parameters onDiagnostic Gauge
RG
1164
7–1
9–19
JAN
01R
G10
031
–UN
–28O
CT
99
A—Diagnostic GaugeB—Touch SwitchesC—Lights
Accessing Engine Configuration Data Parameters:
1. Scroll through the main menu of engine parameters bypressing either the right or the left touch switch
2. Select “E-Config” sub-menu by simultaneouslypressing the right and the left touch switch.
3. Scroll through the “E-Config”sub-menu to view EngineConfiguration Parameters by pressing either the rightor the left touch switch until desired parameter isfound. The numbers next to the parameters correspondto the number on the graph.
4. In order to exit “E-Config” sub-menu, simultaneouslypress the right and left touch switch
Continued on next page
CTM331 (09APR02) 04-160-10 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Trouble Code Diagnostics and Tests
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RG40854,00000FF –19–15JAN02–2/2
Engine Configuration Parameter Description
Parameter Displayed on Units DescriptionDiagnostic Gauge
Speed 1 RPM Stationary low idle speed of engine which includes influences due to enginetemperature and other stationary changes. This is point 1 on the engineconfiguration map.
Torque 1 % Torque 1 equals the desired torque of the ECU divided by the reference torque.
Speed 2 RPM Engine speed at point 2 of the engine configuration map. This is defined as thekick-in point for which torque is reduced to zero.
Torque 2 % Torque 2 equals the desired torque of the ECU divided by the reference torque.
Speed 3 RPM Engine speed at point 3 of the engine configuration map. Points 3, 4, and 5 areoptional and can be located anywhere between points 1 and 2.
Torque 3 % Torque 3 equals the desired torque of the ECU divided by the reference torque.
Speed 4 RPM Engine speed at point 4 of the engine configuration map. Points 3, 4, and 5 areoptional and can be located anywhere between points 1 and 2.
Torque 4 % Torque 4 equals the desired torque of the ECU divided by the reference torque.
Speed 5 RPM Engine speed at point 5 of the configuration map. Points 3, 4, and 5 are optionaland can be located anywhere between points 1 and 2.
Torque 5 % Torque 5 equals the desired torque of the ECU divided by the reference torque.
Speed 6 RPM Engine speed of high idle.
Torque 6 % Torque 6 equals the desired torque of the ECU divided by the reference torque.
Gov Gain % Equals the change of torque between points 2 and 6 divided by the change ofengine speed between points 2 and 6.
Ref Torque Nm (ft-lbs) This parameter is the 100% reference value for all defined indicated engine torqueparameters. It is only defined once and doesn’t change if a difference engine torquemap becomes valid.
Speed 7 RPM The maximum engine speed above point 6 allowed by the engine control during amomentary high idle override. This duration is limited by the maximum momentaryoverride time limit.
Time Limit sec The maximum time limit allowed to override the engine’s high idle speed.
Lo Limit RPM The minimum engine speed that the engine will allow when operating in a speedcontrol/limit mode
Hi Limit RPM The maximum engine speed that the engine will allow when operating in a speedcontrol/limit mode.
Low Limit % The minimum engine torque that the engine will allow when operating in a torquecontrol/limit mode.
Hi Limit % The maximum engine torque that the engine will allow when operating in a torquecontrol/limit mode.
CTM331 (09APR02) 04-160-11 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=171
Trouble Code Diagnostics and Tests
04160
12
RG40854,0000100 –19–15JAN02–1/1
Viewing Active DTCs on Diagnostic Gauge
RG
1003
1–U
N–2
8OC
T99
A—Diagnostic GaugeB—Touch SwitchesC—Lights
Accessing Active Diagnostic Trouble Codes (DTCs):
1. Scroll through the main menu of engine parameters bypressing either the right or the left touch switch
2. Select “SrvcCode” sub-menu by simultaneouslypressing the right and the left touch switch.
3. Scroll through the “SrvcCode ”sub-menu to view activeDTCs by pressing either the right or the left touchswitch until all codes are found.
4. In order to exit “SrvcCode” sub menu, simultaneouslypress the right and left touch switch
DPSG,OUOD007,2842 –19–21OCT99–1/1
Viewing Stored DTCs on Diagnostic Gauge
RG
1003
1–U
N–2
8OC
T99
A—Diagnostic GaugeB—Touch SwitchesC—Lights
Accessing Stored Diagnostic Trouble Codes (DTCs):
1. Scroll through the main menu of engine parameters bypressing either the right or the left touch switch
2. Select “StorCode” sub-menu by simultaneouslypressing the right and the left touch switch.
3. Scroll through the “StorCode”sub-menu to view storedDTCs by pressing either the right or the left touchswitch until all codes are found.
NOTE: If “No Data” is on the gauge, there are no storedcodes.
4. In order to exit “StorCode”sub menu, simultaneouslypress the right and left touch switch
CTM331 (09APR02) 04-160-12 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=172
Trouble Code Diagnostics and Tests
0416013
RG40854,000006A –19–23JAN01–1/1
Clearing Stored DTCs on Diagnostic Gauge
RG
1003
1–U
N–2
8OC
T99
A—Diagnostic GaugeB—Touch SwitchesC—Lights
Clearing Stored Diagnostic Trouble Codes (DTCs):
1. Scroll through the main menu of engine parameters bypressing either the right or the left touch switch
2. Select “StorCode” sub-menu by simultaneouslypressing the right and the left touch switch.
3. Scroll through the “StorCode”sub-menu to view storedDTCs by pressing either the right or the left touchswitch until all codes are found.
NOTE: If “No Data” is on the gauge, there are no storedcodes.
4. In order to clear codes, simultaneously press the rightand left switch for at least 8 seconds
NOTE: If the switches are held for less than 8 seconds,the sub menu will be exited.
5. If display reads “***********”, press the right switch forat least 8 seconds.
NOTE: If the switch is held for less than 8 seconds, thesub menu will be exited.
6. If the display reads “*Send* **DM3 *”, the codes arenow cleared. In order to exit “StorCode” sub menu,simultaneously press the right and left touch switch
CTM331 (09APR02) 04-160-13 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=173
Trouble Code Diagnostics and Tests
04160
14
RG40854,0000101 –19–15JAN02–1/2
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR
RG
1173
7A–U
N–1
8MA
Y01
Connecting to the DST or SERVICE ADVISOR
A—Diagnostic Connector Mate C—MagiKey E—25 Pin MagiKey Connector G—PC ConnectorB—John Deere Controller D—26 Pin MagiKey Connector F—PC Cable
Cable
JDIS121 - ECU communication Hardware Kit isrequired to connect the DST or SERVICE ADVISORto the ECU. Please refer to your John Deere Dealerwebsite for obtaining the latest version of software.
The diagnostic connector is a black, circular connectorwith a square mounting flange and a dust cap. Thereare nine available pins. Depending on application, thelocation of the diagnostic connector may vary. OnOEM the connector is located near the ECU on theengine wiring harness.
1. Locate diagnostic connector on engine and removedust cap.
2. Connect John Deere Controller Cable (B) to thediagnostic connector on the engine harness usingthe diagnostic connector mate (A).
3. Connect the other end of the John Deere ControllerCable (B) to the MagiKey (C) module at the 26 pinMagiKey connector (D).
4. Connect the PC cable (F) to the MagiKey (C)module at the 25 pin MagiKey connector (E).
5. Connect the PC cable (F) to the computer with theDiagnostic Scan Tool (DST) or SERVICEADVISOR installed through the PC connector (G).
6. Key ON, engine off or running, verify that powerlight on MagiKey is illuminated green.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-14 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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7. Start the diagnostic software and select theappropriate application.
8. Connect to the application. The CAN light on theMagiKey should illuminate red when the connectionto the ECU is made.
9. If DST or SERVICE ADVISOR does not connectsee D1 - ECU DOES NOT COMMUNICATE WITHDST OR SERVICE ADVISOR DIAGNOSTICPROCEDURE in Group 150 of this manual.
10. Replace the dust cap on the diagnostic connector.
0416015
SERVICE ADVISOR is a trademark of Deere & Company
RG40854,0000102 –19–15JAN02–1/1
Blinking DTCs
On OEM applications that have a Fault Lamp, the ECUhas the ability to display DTCs using blinkingsequence of the fault lamp. To retrieve DTCs from theECU using the “blink code” method:
NOTE: The ECU blinks the codes in 2-digit codesonly. In order to convert the codes to SPN/FMIcodes, see LISTING OF DIAGNOSTICTROUBLE CODES (DTCS) ON ECU later inthis Group.
1. Turn the ignition switch “ON”.
2. Hold Override Shutdown Switch for a few seconds
3. The Fault Lamp will begin to flash a code number.For example, flash three times...short pause...flashtwo times...long pause. This example is code 32.
4. The ECU begins the flashing sequence by flashinga code 32, this indicates the start of blinking activecodes. If there are any active DTCs, the ECU willflash it’s 2–digit number. If there is more than oneactive DTC, the ECU will flash each code innumerical order. If there are no active DTCs, theFault Lamp will flash a code 88.
5. Following the active codes, the Fault Lamp willflash a code 33, this indicates the start of blinkingstored codes. If there are any stored DTCs, theFault Lamp will flash it’s 2–digit number. If there ismore than one stored DTC, the ECU will flash eachcode in numerical order. If there are no storedDTCs, the Fault Lamp will flash a code 88.
6. Once complete, the above sequence will berepeated.
7. When complete, turn ignition “OFF”
As an example, if an engine had an active DTC 18and stored DTC 53, the flashing sequence would be:
• flash three times...short pause• flash two times...long pause• flash one time...short pause• flash eight times...long pause• flash three times...short pause• flash three times...long pause• flash five times...short pause• flash three times
CTM331 (09APR02) 04-160-15 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=175
Trouble Code Diagnostics and Tests
04160
16
RG40854,0000103 –19–15JAN02–1/3
Data Parameter Description
Following is a list of the data parameters that can be readon the Diagnostic Scan Tool (DST) or ServiceADVISOR. The DST consists of a Windows (’95 or ’98)or NT compatible computer, JDIS121 ECUCommunication Hardware Kit, and the ECUCommunication Software Kit, available from John Deere.Included in the list below is a brief description of eachparameter, the range of possible readings, and eachparameter’s unit of measurement.
Parameter Units Description
Air Heater Time Remaining sec Amount of time the air heater will continue to heat the air prior to starting.
Analog Throttle (A) Input Voltage (OEM) volts Voltage from analog throttle (A) position sensor (potentiometer) on OEMapplications ONLY.
Analog Throttle (A) Input Voltage volts Voltage from analog throttle (A) position sensor (potentiometer) on non-OEMapplications.
Analog Throttle (B) Input Voltage (OEM) volts Voltage from analog throttle (B) position sensor (potentiometer) on OEMapplications ONLY.
Analog Throttle (B) Input Voltage volts Voltage from analog throttle (B) position sensor (potentiometer) on non-OEMapplications.
Analog Throttle (C) Input Voltage volts Voltage from analog throttle (C) position sensor (potentiometer).
Battery Voltage volts Switched battery voltage may vary depending on application
Crank Position Input Noise Indicator % "0" reading means that there is NO noise. Between 0—100, the noise on thecrank sensor signal becomes progressively worse. When 100 is reached, atrouble code is thrown.
Crank Position Sensor Speed rpm The speed of the crank timing wheel.
Desired Speed Governor Curve N/Aa The mode selected is dependent on the application. See APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual and refer to thecorresponding desired speed governor curve for your application.
ECU Boot Block Part Number N/Aa Part number for the Engine Control Unit (ECU) boot block.
ECU Configuration File Part Number N/Aa Part number for the configuration file in the ECU.
ECU EOL Data Part Number N/Aa Part number for the data programmed into the ECU at the end of the assemblyline. EOL = End of Line
aN/A = Not Applicable
Service ADVISOR is a trademark of Deere & Company Continued on next page
CTM331 (09APR02) 04-160-16 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
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Trouble Code Diagnostics and Tests
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Parameter Units Description
ECU Part Number N/Aa Part number for the Engine Control Unit (ECU) hardware.
ECU Serial Number N/Aa Serial number for the Engine Control Unit (ECU).
ECU Software Assembly Part Number N/Aa Part number for the Engine Control Unit (ECU) software assembly.
ECU Software Part Number N/Aa Part number for the Engine Control Unit (ECU) operating software.
Engine Coolant Temperature °C Engine Coolant Temperature value.(°F)
NOTE: If there is an active fault for the ECT circuit, the ECT will be displayedas NA
Engine Coolant Temperature Input volts Engine Coolant Temperature sensor input voltage to the ECUVoltage
Engine Hourmeter hr Total hours the ECU has run on an engine.-min-sec
Engine Load at Current Speed % Percentage of load on the engine at a given speed.
Engine Model Number N/Aa The model number for the engine.
Engine Oil Pressure kPa Engine Oil pressure value(psi)
Engine Serial Number N/Aa Serial number for the engine.
Engine Speed rpm The speed that the crank sensor detects the crank timing wheel to be movingat.
Fuel Mode N/Aa This code explains the operation mode of the engine.
Fuel System Part Number N/Aa The part number for the fuel system used on the engine.
Fuel System Serial Number N/Aa The serial number for the fuel system used on the engine.
Fuel Temperature °C Fuel temperature value.(°F) NOTE: If there is an active fault for the fuel temperature circuit, the fuel
temperature will be displayed as NA
Fuel Temperature Input Voltage volts Fuel temperature sensor input voltage to the ECU.
Fuel Usage Rate L Total amount of fuel the ECU has commanded the pump control unit to(gal) deliver during the total hours shown by the Engine Hour Meter parameter.
Manifold Air Temperature °C Manifold Air Temperature value.(°F)
NOTE: If there is an active fault for the MAT circuit, MAT will be displayed asNA
aN/A = Not Applicable
Continued on next page
CTM331 (09APR02) 04-160-17 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=177
Trouble Code Diagnostics and Tests
04160
18
RG40854,0000103 –19–15JAN02–3/3
Parameter Units Description
Manifold Air Temperature Input Voltage volts Manifold Air Temperature sensor input voltage to the ECU.
Maximum Speed Governor Curve N/Aa The mode selected is dependent on the application. See APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual and refer to thecorresponding maximum speed governor curve for your application.
Oil Pressure kPa (psi) Oil pressure value.
NOTE: If there is an active fault for the oil pressure circuit, the oil pressurewill be displayed as NA
Oil Pressure Input Voltage volts Oil Pressure sensor input voltage to the ECU
Sensor Supply Voltage volts Voltage that ECU supplies sensors on voltage supply #1
Throttle Type N/Aa Type of throttle(s) active
Throttle Position % Percentage of throttle
Torque Curve Number N/Aa On some applications, the ECU limits the max fuel on multiple torque curves.This displays the torque curve the ECU is currently using to limit maximumfuel. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of thismanual and refer to the corresponding torque curve for your application.
aN/A = Not Applicable
CTM331 (09APR02) 04-160-18 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=178
Trouble Code Diagnostics and Tests
0416019
RG40854,0000171 –19–27FEB02–1/1
Engine Test Instructions - Excavator TorqueCurve Change Test
Torque curve adjustment may be necessary forexcavators operating in high altitude areas. By selectingthe altitude derate option, undesired observable symptomssuch as excessive black smoke can be significantlyreduced or eliminated. Torque curve adjustment can onlybe accomplished with the DST or SERVICE ADVISOR.For instructions on connecting to the DST or SERVICEADVISOR, see CONNECTING TO DIAGNOSTIC SCANTOOL (DST) OR SERVICE ADVISOR in Group 160 laterin this manual.
Performing the Torque Curve High-altitudeAdjustment
1. Ignition ON, engine off.
2. Select Excavator Torque Curve Change Test on theDST or SERVICE ADVISOR.
3. Select the option that corresponds to the desiredoperation.
1. Normal operation2. Altitude derate
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-19 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=179
Trouble Code Diagnostics and Tests
04160
20
RG40854,0000104 –19–15JAN02–1/1
Diagnostic Trouble Codes (DTCs)
There are several different methods of displaying bothstored and active DTCs from the ECU.
SPN/FMI CODES
SPN/FMI codes are written from the SAE J1939standard as a two part code. The first part is called theSuspect Parameter Number (SPN). Typically, itcontains between 2 and 4 digits. The SPN identifiesthe system or the component that has the failure; forexample SPN 110 indicates a failure in the enginecoolant temperature circuit. The second part of thecode is called the Failure Mode Identifier (FMI) code.The FMI contains 2 digits. The FMI identifies the typeof failure that has occurred; for example FMI 3indicates value above normal. In order to determinethe exact failure, both the SPN and FMI are required.Combining SPN 110 with FMI 3 yields engine coolanttemperature input voltage high. To find out the equ
On all applications with the Level 12 Engine ControlUnit (ECU), the ECU transmits SPN/FMI codes overthe Controller Area Network (CAN). This allows forservice tools such as the DST, SERVICE ADVISOR,and the Diagnostic Gauge to display active and storedDTCs. In CTM 331, the diagnostic procedures aretitled by SPN/FMI codes.
2-DIGIT CODES
Some applications do not display engine codes as anSPN/FMI. In most of these cases, the code isdisplayed as a 2-digit code. An example of a 2-digitcode is 18 for engine coolant temperature inputvoltage high. If used on an application with multiplecontrollers, ECU may be displayed in front of thenumbers, such as ECU 018. A 2-digit code may beseen on SERVICE ADVISOR, the on-board display,or when the code is blinked for various reasons. In thismanual, it will be necessary to convert these codes to
the SPN/FMI code in order to follow the correctdiagnostic procedure. See LISTING OF DIAGNOSTICTROUBLE CODES (DTCS) ON ECU in Group 160 ofthis manual.
OTHER CODES
If codes are not displayed as SPN/FMI or as 2-digitcodes, there may be another format that theapplication is using. For example on someapplications, the code F455 is displayed for enginecoolant temperature input voltage high. This may beseen on some applications within SERVICEADVISOR. In this manual, it is necessary to convertthis format of code into an SPN/FMI code to ensurethat the correct diagnostic procedure is followed. SeeLISTING OF DIAGNOSTIC TROUBLE CODES(DTCS) ON ECU
WARNING LAMP
On some applications, there is a warning lamp that isused when a code becomes active. When a code isactive, this lamp will either blink or stay on solid.Typically, a solid light indicates that the ECU is takingextreme measures to protect the engine, and ablinking light indicates that the ECU has detected afault and engine performance may be affected. Referto Operator’s Manual for a given application for moredetailed information.
CLEARING STORED DTCS
Stored DTCs can be cleared through the OEMinstrument panel, through the Diagnostic Scan Tool(DST) or SERVICE ADVISOR. For more informationon clearing DTCs using the diagnostic code reader onthe instrument panel, see CLEARING STORED DTCSON DIAGNOSTIC GAUGE earlier in this Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-20 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=180
Trouble Code Diagnostics and Tests
0416021
CTM331 (09APR02) 04-160-21 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=181
Trouble Code Diagnostics and Tests
04160
22
RG40854,0000106 –19–15JAN02–1/5
Listing of Diagnostic Trouble Codes (DTCs)on ECU
Ascending SPN/FMI Codes
DTC’s Listing in Ascending SPN/FMI CodesSPN FMI Definition28 3 See LISTING OF THROTTLE CODES later in this Group.
4 See LISTING OF THROTTLE CODES later in this Group.29 3 See LISTING OF THROTTLE CODES later in this Group.
4 See LISTING OF THROTTLE CODES later in this Group.14 See LISTING OF THROTTLE CODES later in this Group.
91 3 See LISTING OF THROTTLE CODES later in this Group.4 See LISTING OF THROTTLE CODES later in this Group.7 See LISTING OF THROTTLE CODES later in this Group.10 See LISTING OF THROTTLE CODES later in this Group.13 See LISTING OF THROTTLE CODES later in this Group.14 See LISTING OF THROTTLE CODES later in this Group.
100 1 Engine Oil Pressure Extremely Low3 Engine Oil Pressure Input Voltage High4 Engine Oil Pressure Input Voltage Low18 Engine Oil Pressure Moderately Low
105 3 Manifold Air Temperature Input Voltage High4 Manifold Air Temperature Input Voltage Low16 Manifold Air Temperature Moderately High
110 0 Engine Coolant Temperature High Most Severe3 Engine Coolant Temperature Input Voltage High4 Engine Coolant Temperature Input Voltage Low15 Engine Coolant Temperature High Least Severe16 Engine Coolant Temperature High Moderately Severe
111 0 Loss of Coolant Temperature Extremely High3 Loss of Coolant Temperature Input Voltage High4 Loss of Coolant Temperature Input Voltage Low
158 17 ECU Power Down Error174 3 Fuel Temperature Input Voltage High
4 Fuel Temperature Input Voltage Low16 Fuel Temperature Moderately High
190 0 Engine Overspeed Extreme190 16 Engine Overspeed Moderate620 3 Sensor Supply Voltage High
4 Sensor Supply Voltage Low627 4 ECU Unswitched Power Missing629 13 ECU Error637 2 Crank Position Input Noise
10 Crank Position Input Pattern Error639 13 CAN Error898 9 Vehicle Speed Invalid/Missing970 31 Auxiliary Engine Shutdown Switch Active971 31 External Engine Derate Switch Active1076 0 Pump Control Valve Closure Too Long
1 Pump Control Valve Closure Too Short3 Pump Solenoid Current High5 Pump Solenoid Circuit Open6 Pump Solenoid Circuit Severely Shorted
CTM331 (09APR02) 04-160-22 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=182
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Trouble Code Diagnostics and Tests
RG40854,0000106 –19–15JAN02–2/5
7 Pump Control Valve Closure Not Detected10 Pump Solenoid Circuit Moderately Shorted
1079 3 Sensor Supply Voltage High4 Sensor Supply Voltage Low
1109 31 Engine Shutdown Warning1110 31 Engine Shutdown1569 31 Fuel Derate2000 6 Internal ECU Failure2000 13 Security Violation
0416023
Continued on next page
CTM331 (09APR02) 04-160-23 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=183
Trouble Code Diagnostics and Tests
04160
24
RG40854,0000106 –19–15JAN02–3/5
Ascending 2-Digit/Other Codes
DTC’s Listing in Ascending 2-Digit Codes2-Digit/Other SPN FMI Definition
Code11 See LISTING OF THROTTLE CODES later in this Group.12 See LISTING OF THROTTLE CODES later in this Group.13 See LISTING OF THROTTLE CODES later in this Group.14 See LISTING OF THROTTLE CODES later in this Group.15 LISTING OF THROTTLE CODES later in this Group.16 See LISTING OF THROTTLE CODES later in this Group.18 110 3 Engine Coolant Temperature Input Voltage High19 110 4 Engine Coolant Temperature Input Voltage Low21 620 3 Sensor Supply Voltage High
1079 3 Sensor Supply Voltage High22 620 4 Sensor Supply Voltage Low
1079 4 Sensor Supply Voltage Low23 100 3 Engine Oil Pressure Input Voltage High24 100 4 Engine Oil Pressure Input Voltage Low25 105 3 Manifold Air Temperature Input Voltage High26 105 4 Manifold Air Temperature Input Voltage Low28 629 13 ECU Error32 N/Aa N/Aa When reading blink codes, signifies start of active fault codes.33 N/Aa N/Aa When reading blink codes, signifies start of previously active fault codes.37 174 3 Fuel Temperature Input Voltage High38 174 4 Fuel Temperature Input Voltage Low39 637 2 Crank Position Input Noise
10 Crank Position Input Pattern Error42 190 0 Engine Overspeed Extreme
16 Engine Overspeed Moderate54 158 17 ECU Power Down Error55 639 13 CAN Error62 110 15 Engine Coolant Temperature High Least Severe63 110 16 Engine Coolant Temperature High Moderately Severe64 100 18 Engine Oil Pressure Moderately Low65 100 1 Engine Oil Pressure Extremely Low66 105 16 Manifold Air Temperature Moderately High68 1569 31 Fuel Derate69 110 0 Engine Coolant Temperature High Most Severe71 1076 0 Pump Control Valve Closure Too Long72 1076 1 Pump Control Valve Closure Too Short73 1076 5 Pump Solenoid Circuit Open74 1076 6 Pump Solenoid Circuit Severely Shorted75 1076 7 Pump Control Valve Closure Not Detected76 1076 10 Pump Solenoid Circuit Moderately Shorted77 1076 3 Pump Solenoid Current High78 200 13 Security Violation79 2000 6 Internal ECU Error81 174 16 Fuel Temperature Moderately High82 1110 31 Engine Protection Shutdown83 970 31 Auxilary Engine Shutdown Switch Active84 158 17 ECU Power Down Error
971 31 External Engine Derate Switch ActiveaN/A = Not Applicable
CTM331 (09APR02) 04-160-24 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=184
Continued on next page
Trouble Code Diagnostics and Tests
0416025
RG40854,0000106 –19–15JAN02–4/5
88 N/Aa N/Aa When reading blink codes, signifies that no fault codes are in buffer.F400 See LISTING OF THROTTLE CODES later in this Group.F401 See LISTING OF THROTTLE CODES later in this Group.F402 LISTING OF THROTTLE CODES later in this Group.F403 See LISTING OF THROTTLE CODES later in this Group.F404 See LISTING OF THROTTLE CODES later in this Group.F405 See LISTING OF THROTTLE CODES later in this Group.F411 620 4 Sensor Supply Voltage LowF413 100 1 Engine Oil Pressure Extremely LowF414 620 3 Sensor Supply Voltage High
100 3 Skidders ONLY - Engine Oil Pressure Input Voltage HighF415 100 4 Engine Oil Pressure Input Voltage LowF416 105 3 Manifold Air Temperature Input Voltage HighF417 105 4 Manifold Air Temperature Input Voltage LowF418 105 16 Manifold Air Temperatrue Moderately HighF419 110 0 Engine Coolant Temperature High Most SevereF420 See LISTING OF THROTTLE CODES later in this Group.
110 3 Skidders ONLY - Engine Coolant Temperature Input Voltage HighF421 See LISTING OF THROTTLE CODES later in this Group.
110 4 Skidders ONLY - Engine Coolant Temperature Input Voltage LowF422 110 16 Engine Coolant Temperature High Moderately SevereF423 See LISTING OF THROTTLE CODES later in this Group.
158 17 Skidders ONLY - ECU Power Down ErrorF424 174 3 Fuel Temperature Input Voltage HighF425 See LISTING OF THROTTLE CODES later in this Group.
174 4 Skidders ONLY - Fuel Temperature Input Voltage LowF426 174 16 Fuel Temperature Moderately HighF428 See LISTING OF THROTTLE CODES later in this Group.F429 620 3 Sensor Supply Voltage HighF42A See LISTING OF THROTTLE CODES later in this Group.F430 620 4 Sensor Supply Voltage LowF432 629 13 ECU ErrorF436 637 2 Crank Position Input NoiseF439 637 10 Crank Position Improper PatternF440 100 4 Engine Oil Pressure Input Voltage Low
639 13 Skidders ONLY - CAN ErrorF445 100 3 Engine Oil Pressure Input Voltage HighF446 100 1 Engine Oil Pressure Extremely LowF450 110 4 Engine Coolant Temperature Input Voltage LowF455 110 3 Engine Coolant Temperature Input Voltage HighF457 110 0 Engine Coolant Temperature High Most SevereF459 1076 0 Pump Control Valve Closure Too LongF460 105 4 Manifold Air Temperature Input Voltage Low
1076 1 Skidders ONLY - Pump Control Valve Closure Too ShortF461 1076 3 Pump Solenoid Current HighF462 1076 5 Pump Solenoid Circuit OpenF463 1076 6 Pump Solenoid Circuit Severely ShortedF464 1076 7 Pump Control Valve Closure Not DetectedF465 105 3 Manifold Air Temperature Input Voltage High
1076 10 Skidders ONLY - Pump Solenoid Circuit Moderately ShortedF470 174 4 Fuel Temperature Input Voltage LowF474 174 16 Fuel Temperature Moderately HighF475 174 3 Fuel Temperature Input Voltage High
1569 31 Skidders ONLY - Fuel DerateaN/A = Not Applicable
CTM331 (09APR02) 04-160-25 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=185
Continued on next page
Trouble Code Diagnostics and Tests
04160
26
RG40854,0000106 –19–15JAN02–5/5
F476 2000 6 Internal ECU FailureF477 2000 13 Security ViolationF48A 637 10 Crank Position Input Pattern ErrorF48B 637 2 Crank Position Input NoiseF490 1076 6 Pump Solenoid Circuit Severely ShortedF491 1076 1 Pump Control Valve Closure Too ShortF492 1076 3 Pump Solenoid Current HighF493 1076 7 Pump Control Valve Closure Not DetectedF494 1076 0 Pump Control Valve Closure Too LongF495 1076 5 Pump Solenoid Circuit OpenF49A 1076 10 Pump Solenoid Circuit Moderately ShortedF4A0 111 4 Loss of Coolant Temperature Input Voltage LowF4A5 111 3 Loss of Coolant Temperature Input Voltage HighF4A7 111 0 Loss of Coolant Temperature Extremely HighF4E0 2000 6 Internal ECU FailureF4E3 629 13 ECU ErrorF4EA 158 17 ECU Power Down ErrorF4ED 2000 13 Security Violation
CTM331 (09APR02) 04-160-26 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=186
Trouble Code Diagnostics and Tests
0416027
RG40854,0000105 –19–15JAN02–1/1
Diagnostic Procedure
Diagnosis of the electronic control system should beperformed according to the following procedure:
1. Make sure all engine mechanical and other systemsnot related to the electronic control system areoperating properly.
2. Read and record DTC(s). If an SPN/FMI code is notused, convert the code to SPN/FMI. See LISTINGOF DIAGNOSTIC TROUBLE CODES (DTCS) ONECU earlier in this Group.
3. Go to the diagnostic procedure that corresponds tothe DTC(s) present.
NOTE: If more than one DTC is present, go to thechart corresponding to the lowest number DTCand diagnose that problem to correction unlessdirected to do otherwise.
4. If no DTC(s) are present, proceed to theappropriate symptom diagnostic chart in Group 150of this Section.
5. After any repairs are made, recheck to make sureall DTCs have been eliminated.
NOTE: After using the DST or SERVICE ADVISOR,always replace the dust cap on the diagnosticconnector.
IMPORTANT: Care should be used duringdiagnostic procedures to avoiddamaging the terminals ofconnectors, sensors, and actuators.Probes should not be poked into oraround the terminals or damage willresult. Probes should only betouched against the terminals tomake measurements. It isrecommended that JT07328Connector Adapter Test Kit be usedto make measurements inconnectors, sensors, and actuators.These adapters will ensure thatterminal damage does not occur.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-27 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=187
Trouble Code Diagnostics and Tests
04160
28
RG40854,0000107 –19–15JAN02–1/1
Intermittent Fault Diagnostics
Intermittent faults are problems that periodically “goaway”. A problem such as a loose terminal thatintermittently doesn’t make contact is a likely cause ofan intermittent fault. Other intermittent faults may beset only under certain operating conditions such asheavy load, extended idle, etc. When diagnosingintermittent faults, take special note of the condition ofwiring and connectors since a high percentage ofintermittent problems originate here. Check for loose,dirty, or disconnected connectors. Inspect the wiringrouting looking for possible shorts caused by contactwith external parts (for example, rubbing against sharpsheet metal edges). Inspect the connector vicinitylooking for wires that have pulled out of connectorterminals, damaged connectors, poorly positionedterminals, and corroded or damaged terminals. Lookfor broken wires, damaged splices, and wire-to-wireshorts. Use good judgement if component replacementis thought to be required.
NOTE: The ECU is the component LEAST likely tofail.
Suggestions for diagnosing intermittent faults:
• If diagnostic chart indicates that the problem isintermittent, try to reproduce the operating conditionsthat were present when the DTC set. The DiagnosticScan Tool (DST) or SERVICE ADVISOR can beused to help locate intermittent problems, as it
includes a function called Recording. This functionpermits the recording of data parameter valuesduring a diagnostic session. If a DTC sets during acertain diagnostic session, the parameters can beplayed back and observed to see what eachparameters’ value was when the DTC occurred.
• If a faulty connection or wire is suspected to be thecause of the intermittent problem: clear DTCs, thencheck the connection or wire by wiggling it whilewatching the DST or SERVICE ADVISOR to see ifthe fault resets.
• To check the connection between the harness and asensor or the harness and the ECU, use JT07328Connector Adapter Test Kit. Insert the male end ofthe appropriate test adapter into the female end ofthe ECU or sensor connector terminal. There shouldbe moderate resistance when the test adapter isinserted into the terminal. If the connection is loose,replace the female terminal.
Possible Causes of Intermittent Faults:
• Faulty connection between sensor or actuator andharness.
• Faulty contact between terminals in connector.• Faulty terminal/wire connection.• Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc. can causefaulty signals to be sent to the ECU.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-28 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=188
Trouble Code Diagnostics and Tests
0416029
RG40854,0000108 –19–15JAN02–1/1
Listing of Throttle Codes
NOTE: For each different application, a SPN-FMI mightrefer to a different diagnostic procedure thananother application. To get to the correctprocedure, identify the application and the DTC,and proceed to the page that the table below lists.
Application 2-Digit/Other SPN-FMI Code Go to page that reads:Code
Backhoes F425 91 - 3 - Throttle 1 T3 - Analog Throttle (A) Input HighF420 91 - 4 - Throttle 1 T4 - Analog Throttle (A) Input LowF42A 91 - 14 - Throttle 1 T22 - Analog Throttle (A) Input Voltage Out of Range
Crawlers F425 91 - 3 - Throttle 1 T3 - Analog Throttle (A) Input HighF420 91 - 4 - Throttle 1 T4 - Analog Throttle (A) Input LowF428 91 - 7 - Throttle 1 T19 - Throttle Not Calibrated ProperlyF421 91 - 10 - Throttle 1 T20 - Throttle Input Voltage Below Lower Calibration LimitF423 91 - 13 - Throttle 1 T21 - Throttle Calibration AbortedF42A 91 - 14 - Throttle 1 T22 - Analog Throttle (A) Input Voltage Out of Range
Excavators 13 28 - 3 - Throttle 1 T11 - Excavator Throttle Reference Voltage High14 28 - 4 - Throttle 1 T12 - Excavator Throttle Reference Voltage Low15 29 - 3 - Throttle 1 T13 - Excavator Throttle Ground Voltage High16 29 - 4 - Throttle 1 T14 - Excavator Throttle Ground Voltage Low11 91 - 3 - Throttle 1 T15 - Excavator Throttle Signal Voltage High12 91 - 4 - Throttle 1 T16 - Excavator Throttle Signal Voltage Low
Forwarders 15 29 - 3 - Throttle 2 T5 - Analog Throttle (B) Input High16 29 - 4 - Throttle 2 T6 - Analog Throttle (B) Input Low11 91 - 3 - Throttle 1 T3 - Analog Throttle (A) Input High12 91 - 4 - Throttle 1 T4 - Analog Throttle (A) Input Low
OEM 13 28 - 3 - Throttle 3 T5 - Analog Throttle (B) Input High15 29 - 3 - Throttle 2 T3 - Analog Throttle (A) Input High16 29 - 4 - Throttle 2 T4 - Analog Throttle (A) Input Low11 91 - 3 - Throttle 1 T1 - Multi-state Throttle Input High12 91 - 4 - Throttle 1 T2 - Multi-state Throttle Input Low
Skidders F403 91 - 3 - Throttle 1 T3 - Analog Throttle (A) Input HighF404 91 - 4 - Throttle 1 T4 - Analog Throttle (A) Input LowF405 91 - 14 - Throttle 1 T22 - Analog Throttle (A) Input Voltage Out of RangeF400 29 - 3 - Throttle 2 T1 - Multi-state Throttle Input HighF401 29 - 4 - Throttle 2 T2 - Multi-state Throttle Input LowF402 29 - 14 - Throttle 2 T23 - Multi-state Throttle Input Voltage Out of Range
Tele-handlers 11 91 - 3 - Throttle 1 T3 - Analog Throttle (A) Input High12 91 - 4 - Throttle 1 T4 - Analog Throttle (A) Input Low
CTM331 (09APR02) 04-160-29 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=189
Trouble Code Diagnostics and Tests
04160
30
RG40854,00000A2 –19–07DEC01–1/1
Level 12 ECU - T1 - Multi-state Throttle Input High
Instrument PanelConnector
Idle SwitchConnector
G
C A F
ED
BX
W
V
UT
SR
P
NM
L
K
J
High IdleLow Idle
Idle Switch
Low Idle
High Idle
R High/Low Idle Input C1
R
S Sensor Ground D3
S
JOHN DEEREInstrument Panel
H
A
B
A
B
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
6–1
9–14
DE
C01
Multi-state Throttle Switch
• Multi-state throttle is composed of an idle switch thatallows engine speed to be at high or low idle. Onsome applications, there is a bump up and a bumpdown feature. This allows for high and low idle to becontrolled.
• On certain applications, an additional throttle is usedin addition to the multi-state throttle. If the desiredengine speed of the additional throttle is greater thanthe multi-state throttle, the multi-state throttle will beoverridden. When the desired engine speed of themulti-state throttle is greater than the additionalthrottle, the multi-state throttle will be in total control.
This code will set if:
• The multi-state throttle input voltage exceeds themaximum threshold. The voltage is higher than whatis physically possible for the throttle lever to achieve.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the multi-state throttle, and willuse the input values from another throttle.
• If the multi-state throttle is the only throttle or alladditional throttles are also faulted, the ECU will usea default “limp-home” throttle value that will onlyallow idle engine speed.
CTM331 (09APR02) 04-160-30 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=190
Trouble Code Diagnostics and Tests
RG40854,00000A1 –19–07DEC01–1/1
Level 12 ECU - T1 - Multi-state Throttle Input High - Continued
– – –1/1
Level 12 ECU - T1 - Multi-State Throttle Input High Diagnostic Procedure
0416031
– – –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.
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUTHIGH supporting information.
Perform a preliminary inspection of the ECU connector and the multi-state throttleconnector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUTHIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using the DST or SERVICE ADVISOR
5. Make note of any DTCs, then clear all DTCs.
6. Ignition ON, engine OFF
7. Move the multi-state switch through all the positions.
8. Read DTCs using the DST or SERVICE ADVISOR.
NOTE: Skidder applications use a different SPN for multi-state throttle than otherapplications.
SPN 91 FMI 3 (Skidders:SPN 29 FMI 3) reoccurs:GO TO 3
SPN 91 FMI 3 (Skidders:SPN 29 FMI 3) does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-31 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=191
Trouble Code Diagnostics and Tests
04160
32
– – –1/1
3 Throttle PositionInput Shorted Test
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUTHIGH supporting information.
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel.
3. Install a jumper wire between both terminals of the switch harness connector.
4. Read DTCs using the DST or SERVICE ADVISOR
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine OFF
7. Read DTCs using the DST or SERVICE ADVISOR.
NOTE: Skidder applications use a different SPN for multi-state throttle than otherapplications.
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 throttleswitch connectorORFaulty multi-state throttleswitch
– – –1/1
4 Throttle PositionGround Circuit OpenTest
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUTHIGH supporting information.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure voltage between multi-state switch 5 V input terminaland a good chassis ground.
Between 4.0 V and 6.0V:Open in multi-state switchground circuitORFaulty ECU connectionORFaulty ECU
Below 4.0 V:Open in multi-state switch5 V input circuitORFaulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-32 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=192
Trouble Code Diagnostics and Tests
0416033
CTM331 (09APR02) 04-160-33 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=193
Trouble Code Diagnostics and Tests
04160
34
RG40854,00000A0 –19–07DEC01–1/1
Level 12 ECU - T2 - Multi-state Throttle Input Low
Instrument PanelConnector
Idle SwitchConnector
G
C A F
ED
BX
W
V
UT
SR
P
NM
L
K
J
High IdleLow Idle
Idle Switch
Low Idle
High Idle
R High/Low Idle Input C1
R
S Sensor Ground D3
S
JOHN DEEREInstrument Panel
H
A
B
A
B
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
6–1
9–14
DE
C01
Multi-state Throttle Switch
• Multi-state throttle is composed of an idle switch thatallows engine speed to be at high or low idle. Onsome applications, there is a bump up and a bumpdown feature. This allows for high and low idle to becontrolled.
• On certain applications, an additional throttle is usedin addition to the multi-state throttle. If the desiredengine speed of the additional throttle is greater thanthe multi-state throttle, the multi-state throttle will beoverridden. When the desired engine speed of themulti-state throttle is greater than the additionalthrottle, the multi-state throttle will be in total control.
This code will set if:
• The multi-state throttle input voltage drops below theminimum threshold. The voltage is lower than whatis physically possible for the throttle lever to achieve.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the multi-state throttle, and willuse the input values from another throttle.
• If the multi-state throttle is the only throttle or alladditional throttles are also faulted, the ECU will usea default “limp-home” throttle value that will onlyallow idle engine speed.
CTM331 (09APR02) 04-160-34 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=194
Trouble Code Diagnostics and Tests
RG40854,00000A3 –19–11DEC01–1/1
Level 12 ECU - T2 - Multi-state Throttle Input Low - Continued
– – –1/1
Level 12 ECU - T2 - Multi-State Throttle Input Low Diagnostic Procedure
0416035
– – –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.
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUTLOW supporting information.
Perform a preliminary inspection of the ECU connector and the multi-state throttleconnector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUTLOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using the DST or SERVICE ADVISOR
5. Make note of any DTCs, then clear all DTCs.
6. Ignition ON, engine OFF
7. Move the multi-state switch through all the positions.
8. Read DTCs using DST or SERVICE ADVISOR.
NOTE: Skidder applications use a different SPN for multi-state throttle than otherapplications.
SPN 91 FMI 4 (Skidders:SPN 29 FMI 4) reoccurs:GO TO 3
SPN 91 FMI 4 (Skidders:SPN 29 FMI 4) does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-35 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=195
Trouble Code Diagnostics and Tests
04160
36
– – –1/1
3 Throttle PositionWiring Test
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUTLOW supporting information.
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel.
3. Read DTCs using the DST or SERVICE ADVISOR.
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine OFF
6. Read DTCs using the DST or SERVICE ADVISOR.
NOTE: Skidder applications use a different SPN for multi-state throttle than otherapplications.
SPN 91 FMI 4 (Skidders:SPN 29 FMI 4) reoccurs:Short to ground inmulti-state input circuitOROpen in multi-state inputcircuitORFaulty ECU
SPN 91 FMI 3 (Skidders:SPN 29 FMI 3) occurs:Faulty multi-state throttleswitch connectorORFaulty multi-state throttleswitch.
CTM331 (09APR02) 04-160-36 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=196
Trouble Code Diagnostics and Tests
0416037
CTM331 (09APR02) 04-160-37 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=197
Trouble Code Diagnostics and Tests
04160
38
RG40854,000009E –19–07DEC01–1/1
Level 12 ECU - T3 - Analog Throttle (A) Input High
Analog Throttle (A)Sensor Connector
AnalogThrottle (A)
Sensor
A A
B BC C
Instrument PanelConnector
G
C A F
ED
BX
W
V
U
T
SRP
NM
L
K
JH
C Sensor Return D3
L Sensor Input E1
M Sensor 5V E2
C L M
JOHN DEEREInstrument Panel
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
4–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For non-OEM engine wiringinformation, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Analog Throttle Position Sensor
• The analog throttle position sensor is a variableresistor (potentiometer) used to measure the positionof the throttle. The throttle input voltage normallyvaries between 1.0 and 4.0 volts depending onthrottle position. Analog throttle voltage at low idlewill be approximately 1.0 volt and 4.0 volts at highidle. The ECU has the ability to learn differentvoltages for low and high idle, so the voltage rangemay change per application.
This code will set if:
• The analog throttle (A) input voltage exceeds thesensor’s high voltage specification. The voltage ishigher than what is physically possible for thethrottle lever to achieve.– For OEM applications, the high analog throttle (A)
input voltage specification is 4.7 volts.– For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the high analog throttle (A) inputvoltage specification.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the analog throttle, and will usethe input values from another throttle.
• If the analog throttle is the only throttle or alladditional throttles are also faulted, the ECU will usea default “limp-home” throttle value that will onlyallow idle engine speed.
CTM331 (09APR02) 04-160-38 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=198
Trouble Code Diagnostics and Tests
RG40854,00000A4 –19–11DEC01–1/1
Level 12 ECU - T3 - Analog Throttle (A) Input High - Continued
– – –1/1
Level 12 ECU - T3 - Analog Throttle (A) Input High Diagnostic Procedure
0416039
– – –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.
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUTHIGH supporting information.
Perform a preliminary inspection of the ECU connector, the analog (A) throttleconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection:Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUTHIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Analog Throttle (A) in the idle position.
5. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (A) Input Voltage
NOTE: For OEM applications, the high analog throttle (A) input voltage specificationis 4.7V. For the high voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
4.7 V or greater:GO TO 4
Below 4.7 V:GO TO 3
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-39 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=199
Trouble Code Diagnostics and Tests
04160
40
– – –1/1
3 Throttle TravelVoltage Test
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUTHIGH supporting information.
While slowly operating analog throttle (A) through its full travel, use the DST orSERVICE ADVISOR for the following:
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (A) Input Voltage
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is4.7V. For the high voltage specification on non-OEM applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
Goes above 4.7 V:Faulty analog throttle (A)sensor connectorOROpen in analog throttle(A) sensor ground circuitORFaulty analog throttle (A)sensor
Never goes above 4.7 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group
– – –1/1
4 Throttle PositionInput Shorted Test
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUTHIGH supporting information.
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind instrument panel.
3. Ignition ON, Engine OFF
4. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (A) Input Voltage
NOTE: For OEM applications, the low analog throttle (A) input voltage specificationis 0.3V. For the low voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
0.3 V or less:GO TO 5
Above 0.3 V:Short to voltage in analogthrottle (A) input circuitORFaulty ECU
SERVICE ADVISOR is a trademark of Deere & Company
– – –1/1
5 Throttle PositionGround Circuit OpenTest
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUTHIGH supporting information.
1. Ignition OFF
2. Analog throttle (A) sensor connector still disconnected.
3. Using a test light connected to battery (+), probe the ground terminal in throttle (A)sensor harness connector.
Light ON:Faulty analog throttle (A)sensor connectorORFaulty analog throttle (A)sensor
Light OFF:Open in analog throttle(A) ground circuit
CTM331 (09APR02) 04-160-40 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=200
Trouble Code Diagnostics and Tests
0416041
CTM331 (09APR02) 04-160-41 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=201
Trouble Code Diagnostics and Tests
04160
42
RG40854,000009C –19–07DEC01–1/1
Level 12 ECU - T4 - Analog Throttle (A) Input Low
Analog Throttle (A)Sensor Connector
AnalogThrottle (A)
Sensor
A A
B BC C
Instrument PanelConnector
G
C A F
ED
BX
W
V
U
T
SRP
NM
L
K
JH
C Sensor Return D3
L Sensor Input E1
M Sensor 5V E2
C L M
JOHN DEEREInstrument Panel
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
4–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For non-OEM engine wiringinformation, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Analog Throttle Position Sensor
• The analog throttle position sensor is a variableresistor (potentiometer) used to measure the positionof the throttle. The throttle input voltage normallyvaries between 1.0 and 4.0 volts depending onthrottle position. Analog throttle voltage at low idlewill be approximately 1.0 volt and 4.0 volts at highidle. The ECU has the ability to learn differentvoltages for low and high idle, so the voltage rangemay change per application.
This code will set if:
• The analog throttle (A) input voltage goes below thesensor’s low voltage specification. The voltage islower than what is physically possible for the throttlelever to achieve.– For OEM applications, the low analog throttle (A)
input voltage specification is 0.3 volts.– For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the low analog throttle (A) inputvoltage specification.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the analog throttle, and will usethe input values from another throttle.
• If the analog throttle is the only throttle or alladditional throttles are also faulted, the ECU will usea default “limp-home” throttle value that will onlyallow idle engine speed.
CTM331 (09APR02) 04-160-42 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=202
Trouble Code Diagnostics and Tests
RG40854,00000A5 –19–13DEC01–1/1
Level 12 ECU - T4 - Analog Throttle (A) Input Low - Continued
– – –1/1
Level 12 ECU - T4 - Analog Throttle (A) Input Low Diagnostic Procedure
0416043
– – –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.
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUTLOW supporting information.
Perform a preliminary inspection of the ECU connector, the analog (A) throttleconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection:Repair faulty connection.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUTLOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Throttle (A) in the idle position.
5. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (A) Input Voltage
NOTE: For OEM applications, the low analog throttle (A) input voltage specificationis 0.3V. For the low voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
0.3 V or less:GO TO 4
Above 0.3 V:GO TO 3
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-43 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=203
Trouble Code Diagnostics and Tests
04160
44
– – –1/1
3 Throttle TravelVoltage Test
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUTLOW supporting information.
While slowly operating analog throttle (A) through its full travel, use the DST orSERVICE ADVISOR for the following:
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (A) Input Voltage
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is0.3V. For the low voltage specification on non-OEM applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
Goes below 0.3 V:Faulty analog throttle (A)sensor connectorOROpen in analog throttle(A) sensor ground circuitORFaulty analog throttle (A)sensor
Never goes above 0.3 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group
– – –1/1
4 Throttle PositionWiring Test
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUTLOW supporting information.
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector.
3. Install a jumper wire between the 5 V Supply terminal and the input terminal in theharness side of the sensor connector.
4. Ignition ON, engine OFF
5. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (A) Input Voltage
NOTE: For OEM applications, the high analog throttle (A) input voltage specificationis 4.7V. For the high voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Below 4.7 V:GO TO 5
4.7 V or greater:Faulty analog throttle (A)sensor connectorORFaulty analog throttle (A)sensor
CTM331 (09APR02) 04-160-44 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=204
Trouble Code Diagnostics and Tests
0416045
– – –1/1
5 Throttle Position 5VSupply Test
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUTLOW supporting information.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the analog throttle (A) groundterminal and the 5 V Supply terminal in the sensor harness connector.
Between 4.0 V and 6.0V:Open in analog throttle(A) input circuitORShort to ground in analogthrottle (A) input circuitORFaulty ECU connectorORFaulty ECU
Below 4.0 V:Open in analog throttle(A) 5 V Supply circuitORShort to ground in analogthrottle (A) 5 V SupplycircuitORFaulty ECU connectorORFaulty ECU
CTM331 (09APR02) 04-160-45 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=205
Trouble Code Diagnostics and Tests
04160
46
RG40854,000009A –19–07DEC01–1/1
Level 12 ECU - T5 - Analog Throttle (B) Input High
Sensor Return D3
Analog Throttle (B) Input F2
Sensor 5V E2
Analog Throttle (B)Sensor Connector
Throttle Emulator
AnalogThrottle (B)
Sensor
A
A A
B B
C C
B
C
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
5–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For non-OEM engine wiringinformation, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Analog Throttle Position Sensor
• The analog throttle position sensor is a variableresistor (potentiometer) used to measure the positionof the throttle. The throttle input voltage normallyvaries between 1.0 and 4.0 volts depending onthrottle position. Analog throttle voltage at low idlewill be approximately 1.0 volt and 4.0 volts at highidle. The ECU has the ability to learn differentvoltages for low and high idle, so the voltage rangemay change per application.
This code will set if:
• The analog throttle (B) input voltage exceeds thesensor’s high voltage specification. The voltage ishigher than what is physically possible for thethrottle lever to achieve.– For OEM applications, the high analog throttle (B)
input voltage specification is 4.7 volts.– For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the high analog throttle (B) inputvoltage specification.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the analog throttle, and will usethe input values from another throttle.
• If the analog throttle is the only throttle or alladditional throttles are also faulted, the ECU will usea default “limp-home” throttle value that will onlyallow idle engine speed.
CTM331 (09APR02) 04-160-46 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=206
Trouble Code Diagnostics and Tests
RG40854,00000A6 –19–13DEC01–1/1
Level 12 ECU - T5 - Analog Throttle (B) Input High - Continued
– – –1/1
Level 12 ECU - T5 - Analog Throttle (B) Input High Diagnostic Procedure
0416047
– – –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.
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUTHIGH supporting information.
Perform a preliminary inspection of the ECU connector, the analog (B) throttleconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUTHIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Analog Throttle (B) in the idle position.
5. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the high analog throttle (B) input voltage specificationis 4.7V. For the high voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
4.7 V or greater:GO TO 4
Below 4.7 V:GO TO 3
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-47 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=207
Trouble Code Diagnostics and Tests
04160
48
– – –1/1
3 Throttle TravelVoltage Test
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUTHIGH supporting information.
While slowly operating analog throttle (B) through its full travel, use the DST orSERVICE ADVISOR for the following:
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is4.7V. For the high voltage specification on non-OEM applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
Goes above 4.7 V:Faulty analog throttle (B)sensor connectorOROpen in analog throttle(B) sensor ground circuitORFaulty analog throttle (B)sensor
Never goes above 4.7 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group
– – –1/1
4 Throttle PositionInput Shorted Test
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUTHIGH supporting information.
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector behind instrument panel.
3. Ignition ON, Engine OFF
4. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the low analog throttle (B) input voltage specificationis 0.3V. For the low voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
0.3 V or less:GO TO 5
Above 0.3 V:Short to voltage in analogthrottle (B) input circuitORFaulty ECU
– – –1/1
5 Throttle PositionGround Circuit OpenTest
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUTHIGH supporting information.
1. Ignition OFF
2. Analog throttle (B) sensor connector disconnected.
3. Using a test light connected to battery (+), probe the ground terminal in throttle (B)sensor harness connector.
Light ON:Faulty analog throttle (B)sensor connectorORFaulty analog throttle (B)sensor
Light OFF:Open in analog throttle(B) ground circuit
CTM331 (09APR02) 04-160-48 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=208
Trouble Code Diagnostics and Tests
0416049
CTM331 (09APR02) 04-160-49 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=209
Trouble Code Diagnostics and Tests
04160
50
RG40854,0000098 –19–07DEC01–1/1
Level 12 ECU - T6 - Analog Throttle (B) Input Low
Sensor Return D3
Analog Throttle (B) Input F2
Sensor 5V E2
Analog Throttle (B)Sensor Connector
Throttle Emulator
AnalogThrottle (B)
Sensor
A
A A
B B
C C
B
C
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
5–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For non-OEM engine wiringinformation, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Analog Throttle Position Sensor
• The analog throttle position sensor is a variableresistor (potentiometer) used to measure the positionof the throttle. The throttle input voltage normallyvaries between 1.0 and 4.0 volts depending onthrottle position. Analog throttle voltage at low idlewill be approximately 1.0 volt and 4.0 volts at highidle. The ECU has the ability to learn differentvoltages for low and high idle, so the voltage rangemay change per application.
This code will set if:
• The analog throttle (B) input voltage goes below thesensor’s low voltage specification. The voltage islower than what is physically possible for the throttlelever to achieve.– For OEM applications, the low analog throttle (B)
input voltage specification is 0.3 volts.– For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the low analog throttle (B) inputvoltage specification.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the analog throttle, and will usethe input values from another throttle.
• If the analog throttle is the only throttle or alladditional throttles are also faulted, the ECU will usea default “limp-home” throttle value that will onlyallow idle engine speed.
CTM331 (09APR02) 04-160-50 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=210
Trouble Code Diagnostics and Tests
RG40854,00000A7 –19–13DEC01–1/1
Level 12 ECU - T6 - Analog Throttle (B) Input Low - Continued
– – –1/1
Level 12 ECU - T6 - Analog Throttle (B) Input Low Diagnostic Procedure
0416051
– – –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.
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUTLOW supporting information.
Perform a preliminary inspection of the ECU connector, the analog (B) throttleconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUTLOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Analog Throttle (B) in the idle position.
5. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the low analog throttle (B) input voltage specificationis 0.3V. For the low voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
0.3 V or less:GO TO 4
Above 0.3 V:GO TO 3
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-51 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=211
Trouble Code Diagnostics and Tests
04160
52
– – –1/1
3 Throttle TravelVoltage Test
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUTLOW supporting information.
While slowly operating analog throttle (B) through its full travel, use the DST orSERVICE ADVISOR for the following:
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (B) Input Voltage
Goes below 0.3 V:Faulty analog throttle (B)sensor connectorOROpen in analog throttle(B) sensor ground circuitORFaulty analog throttle (B)sensor
Never goes above 0.3 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group
– – –1/1
4 Throttle PositionWiring Test
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUTLOW supporting information.
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector.
3. Install a jumper wire between the 5 V Supply terminal and the input terminal in theharness side of the sensor connector.
4. Ignition ON, engine OFF
5. Using the DST or SERVICE ADVISOR:
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)• For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the high analog throttle (B) input voltage specificationis 4.7V. For the high voltage specification on non-OEM applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Below 4.7 V:GO TO 5
4.7 V or greater:Faulty analog throttle (B)sensor connectorORFaulty analog throttle (B)sensor
CTM331 (09APR02) 04-160-52 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=212
Trouble Code Diagnostics and Tests
0416053
– – –1/1
5 Throttle Position 5 VSupply Test
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUTLOW supporting information.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the analog throttle (B) groundterminal and the 5 V Supply terminal in the sensor harness connector.
Between 4.0 V and 6.0V:Open in analog throttle(B) input circuitORShort to ground in analogthrottle (B) input circuitORFaulty ECU connectorORFaulty ECU
Below 4.0 V:Open in analog throttle(B) 5 V Supply circuitORShort to ground in analogthrottle (B) 5 V SupplycircuitORFaulty ECU connectorORFaulty ECU
CTM331 (09APR02) 04-160-53 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=213
Trouble Code Diagnostics and Tests
04160
54
RG40854,0000096 –19–07DEC01–1/1
Level 12 ECU - T7 - CAN Throttle Invalid
CAN Low
CAN High
CAN Shield
BA
C
DCEBA
Switched Voltage
CAN Terminator
Static Ground
DiagnosticConnector
DC
BJ
HG
F
E
B A A B
CC
A
F1
G1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
2–1
9–14
DE
C01
CAN (Controller Area Network) Throttle
• CAN (Controller Area Network) throttle is informationsent to the ECU by another controller over CAN ofthe desired throttle position.
This code will set if:
• The ECU either does not receive throttle informationover CAN, or the information received is not valid.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU willignore the input from the CAN throttle, and will usethe input values from another throttle.
• If the CAN throttle is the only throttle or all additionalthrottles are also faulted, the ECU will use a default“limp-home” throttle value that will only allow idleengine speed.
CTM331 (09APR02) 04-160-54 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=214
Trouble Code Diagnostics and Tests
RG40854,00000A8 –19–13DEC01–1/1
Level 12 ECU - T7 - CAN Throttle Invalid - Continued
– – –1/1
Level 12 ECU - T7 - CAN Throttle Invalid Diagnostic Procedure
0416055
– – –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.
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALIDsupporting information.
Perform a preliminary inspection of the ECU connector and any connectors associatedwith the CAN throttle. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALIDsupporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs.
6. Ignition ON, engine running
7. Read DTCs using DST or SERVICE ADVISOR.
SPN 91 FMI 9 reoccurs:GO TO 3
SPN 91 FMI 9 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-55 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=215
Trouble Code Diagnostics and Tests
– – –1/1
3 Application RelatedDTCs Test
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALIDsupporting information.
If application has other machine controllers communicating on the CAN bus, checkthose controllers for CAN related DTCs.
No CAN related DTCsfound on othercontrollers:GO TO 4
Found CAN relatedDTCs found on othercontrollers:Refer to diagnosticprocedure for thatcontroller.
04160
56
– – –1/1
4 Resistance BetweenCAN High and LowTest
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALIDsupporting information.
1. Ignition OFF
2. Using a multimeter, measure resistance between terminals C and D in the harnessend of the diagnostic connector.
Between 45-75 ohms:GO TO 5
Less than 45 or greaterthan 75 ohms:Faulty or missing CANterminator connector(s)OROpen or short in CANwiring harness.
– – –1/1
5 CAN Wiring Shortedto Ground or VoltageTest
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALIDsupporting information.
1. Ignition OFF
2. Using a multimeter, measure voltage between a good chassis ground and:
• Terminal C in the diagnostic connector.• Terminal D in the diagnostic connector.
Both measurementsbetween 1.5 V and 3.5V:Faulty ECU connectorOROther connector in theCAN systemORFaulty ECU.
Either measurementless than 1.5 V orgreater than 3.5 V:CAN wiring shorted toground or voltageORAnother controller in theCAN system is faultyORFaulty ECU
CTM331 (09APR02) 04-160-56 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=216
Trouble Code Diagnostics and Tests
0416057
CTM331 (09APR02) 04-160-57 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=217
Trouble Code Diagnostics and Tests
04160
58
RG40854,0000094 –19–07DEC01–1/1
Level 12 ECU - T11 - Excavator Throttle Reference Voltage High
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Throttle Reference F3
Throttle Input B3
Throttle Ground C1
To Pumpand ValveController
RG
1197
7–1
9–14
DE
C01
Excavator Throttle
• The Excavator uses an analog throttle to measurethrottle position. This throttle is connected to thePump and Valve controller, which sends throttleinput information to the ECU through a dedicatedwire. Since the ECU and Pump and Valve controllerdo not share a common ground, a throttle voltagereference wire and a throttle ground wire accompanythe throttle input wire. The ECU calculates thedifferences in controller grounds in order todetermine the throttle request by the Pump andValve controller.
This code will set if:
• The excavator throttle reference voltage to the ECUexceeds 4.2 volts.
If this code sets, the following will occur:
• The ECU will default excavator reference throttlevoltage to 3.75 volts.
CTM331 (09APR02) 04-160-58 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=218
Trouble Code Diagnostics and Tests
RG40854,00000A9 –19–13DEC01–1/1
Level 12 ECU - T11 - Excavator Throttle Reference Voltage High - Continued
– – –1/1
Level 12 ECU - T11 - Excavator Throttle Reference Voltage High Diagnostic Procedure
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
0416059
– – –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.
NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLEREFERENCE VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLEREFERENCE VOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs using DST or SERVICE ADVISOR.
NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active, follow those DTCs first.
6. Read DTCs using DST or SERVICE ADVISOR.
• Ignition ON, engine OFF• Ignition ON, engine running
SPN 28 FMI 3 reoccurswhen engine is off andrunning:GO TO 3
SPN 28 FMI 3 reoccursonly when engine isrunning:GO TO 4
SPN 28 FMI 3 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-59 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=219
Trouble Code Diagnostics and Tests
– – –1/1
3 Throttle ReferenceWire Test
NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLEREFERENCE VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect ECU connector.
3. Using a multimeter, measure voltage between terminal F3 in the harness end of theECU connector and the ground stud of the Pump and Valve controller.
3.95 V or less:GO TO 4
Greater than 3.95 V:Short to power in throttlereference wireORFaulty Pump and Valvecontroller connectorORFaulty Pump and Valvecontroller
04160
60
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLEREFERENCE VOLTAGE HIGH supporting information.
There is a difference between grounds of the ECU and Pump and Valve controller.Check for loose ground connections at each controller.
CTM331 (09APR02) 04-160-60 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=220
Trouble Code Diagnostics and Tests
0416061
CTM331 (09APR02) 04-160-61 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=221
Trouble Code Diagnostics and Tests
04160
62
RG40854,0000092 –19–07DEC01–1/1
Level 12 ECU - T12 - Excavator Throttle Reference Voltage Low
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Throttle Reference F3
Throttle Input B3
Throttle Ground C1
To Pumpand ValveController
RG
1197
7–1
9–14
DE
C01
Excavator Throttle
• The Excavator uses an analog throttle to measurethrottle position. This throttle is connected to thePump and Valve controller, which sends throttleinput information to the ECU through a dedicatedwire. Since the ECU and Pump and Valve controllerdo not share a common ground, a throttle voltagereference wire and a throttle ground wire accompanythe throttle input wire. The ECU calculates thedifferences in controller grounds in order todetermine the throttle request by the Pump andValve controller.
This code will set if:
• The excavator throttle reference voltage to the ECUgoes below 2.7 volts.
If this code sets, the following will occur:
• The ECU will default excavator reference throttlevoltage to 3.75 volts.
CTM331 (09APR02) 04-160-62 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=222
Trouble Code Diagnostics and Tests
RG40854,0000091 –19–07DEC01–1/1
Level 12 ECU - T12 - Excavator Throttle Reference Voltage Low - Continued
– – –1/1
Level 12 ECU - T12 - Excavator Throttle Reference Voltage Low Diagnostic Procedure
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
0416063
– – –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.
NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLEREFERENCE VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLEREFERENCE VOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs.
NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active, follow those DTCs first.
6. Read DTCs using DST or SERVICE ADVISOR.
• Ignition ON, engine OFF• Ignition ON, engine running
SPN 28 FMI 4 reoccurswhen engine is off andrunning:GO TO 3
SPN 28 FMI 4 reoccursonly when engine isrunning:GO TO 4
SPN 28 FMI 4 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-63 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=223
Trouble Code Diagnostics and Tests
– – –1/1
3 Throttle ReferenceWire Test
NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLEREFERENCE VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure voltage between terminal F3 in the harness end of theECU connector and the ground stud of the Pump and Valve controller.
3.55 V or greater:GO TO 4
Less than 3.55 V:Open in throttle referencewireORFaulty Pump and Valvecontroller connectorORFaulty Pump and Valvecontroller
04160
64
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLEREFERENCE VOLTAGE LOW supporting information.
There is a difference between the grounds of the ECU and Pump and Valve controller.Check for loose ground connections at each controller.
CTM331 (09APR02) 04-160-64 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=224
Trouble Code Diagnostics and Tests
0416065
CTM331 (09APR02) 04-160-65 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=225
Trouble Code Diagnostics and Tests
04160
66
RG40854,0000090 –19–07DEC01–1/1
Level 12 ECU - T13 - Excavator Throttle Ground Voltage High
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Throttle Reference F3
Throttle Input B3
Throttle Ground C1
To Pumpand ValveController
RG
1197
7–1
9–14
DE
C01
Excavator Throttle
• The Excavator uses an analog throttle to measurethrottle position. This throttle is connected to thePump and Valve controller, which sends throttleinput information to the ECU through a dedicatedwire. Since the ECU and Pump and Valve controllerdo not share a common ground, a throttle voltagereference wire and a throttle ground wire accompanythe throttle input wire. The ECU calculates thedifferences in controller grounds in order todetermine the throttle request by the Pump andValve controller.
This code will set if:
• The excavator throttle ground voltage to the ECUexceeds 3.0 volts.
If this code sets, the following will occur:
• The ECU will default excavator throttle groundvoltage to 0 volts.
CTM331 (09APR02) 04-160-66 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=226
Trouble Code Diagnostics and Tests
RG40854,00000AA –19–13DEC01–1/1
Level 12 ECU - T13 - Excavator Throttle Ground Voltage High - Continued
– – –1/1
Level 12 ECU - T13 - Excavator Throttle Ground Voltage High Diagnostic Procedure
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
0416067
– – –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.
NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLEGROUND VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLEGROUND VOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs.
6. Read DTCs using DST or SERVICE ADVISOR.
• Ignition ON, engine OFF• Ignition ON, engine running
SPN 29 FMI 3 reoccurswhen engine is off andrunning:GO TO 3
SPN 29 FMI 3 reoccursonly when engine isrunning:GO TO 4
SPN 29 FMI 3 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-67 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=227
Trouble Code Diagnostics and Tests
04160
68
– – –1/1
3 Throttle Ground WireTest
NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLEGROUND VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Disconnect Pump and Valve controller connector.
4. Using a multimeter, measure resistance between terminal C1 in the harness end ofthe ECU connector and the corresponding ground terminal of the Pump and Valvecontroller connector.
770 ohms or less:GO TO 4
Greater than 770 ohms:Short to power in throttleground wire betweenECU and 750 ohmresistorOROpen in throttle groundwireORFaulty 750 ohm resistorORFaulty ECU connectorORFaulty ECU
– – –1/1
4 Pump and ValveController Test
NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLEGROUND VOLTAGE HIGH supporting information.
1. Ignition OFF
2. ECU connector still disconnected.
3. Using a multimeter, measure resistance between terminal C1 in the harness end ofthe ECU connector and the ground stud of the Pump and Valve controller.
770 ohms or less:GO TO 5
Greater than 770 ohms:Faulty Pump and Valvecontroller connectorORFaulty Pump and Valvecontroller
– – –1/1
5 Ground Test NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLEGROUND VOLTAGE HIGH supporting information.
There is a difference between grounds of the ECU and Pump and Valve controller.Check for loose ground connection at each controller.
CTM331 (09APR02) 04-160-68 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=228
Trouble Code Diagnostics and Tests
0416069
CTM331 (09APR02) 04-160-69 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=229
Trouble Code Diagnostics and Tests
04160
70
RG40854,000008E –19–07DEC01–1/1
Level 12 ECU - T14 - Excavator Throttle Ground Voltage Low
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Throttle Reference F3
Throttle Input B3
Throttle Ground C1
To Pumpand ValveController
RG
1197
7–1
9–14
DE
C01
Excavator Throttle
• The Excavator uses an analog throttle to measurethrottle position. This throttle is connected to thePump and Valve controller, which sends throttleinput information to the ECU through a dedicatedwire. Since the ECU and Pump and Valve controllerdo not share a common ground, a throttle voltagereference wire and a throttle ground wire accompanythe throttle input wire. The ECU calculates thedifferences in controller grounds in order todetermine the throttle request by the Pump andValve controller.
This code will set if:
• The excavator throttle ground voltage to the ECUgoes below 2.0 volts.
If this code sets, the following will occur:
• The ECU will default excavator throttle groundvoltage to 0 volts.
CTM331 (09APR02) 04-160-70 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=230
Trouble Code Diagnostics and Tests
RG40854,00000AB –19–13DEC01–1/1
Level 12 ECU - T14 - Excavator Throttle Ground Voltage Low - Continued
– – –1/1
Level 12 ECU - T14 - Excavator Throttle Ground Voltage Low Diagnostic Procedure
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
0416071
– – –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.
NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLEGROUND VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLEGROUND VOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs.
6. Read DTCs using DST or SERVICE ADVISOR.
• Ignition ON, engine OFF• Ignition ON, engine running
SPN 29 FMI 4 reoccurswhen engine is off andrunning:GO TO 3
SPN 29 FMI 4 reoccursonly when engine isrunning:GO TO 4
SPN 29 FMI 4 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-71 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=231
Trouble Code Diagnostics and Tests
– – –1/1
3 Throttle Ground Test NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLEGROUND VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure resistance between terminal C1 in the harness end ofthe ECU connector and the corresponding ground terminal of the Pump and Valvecontroller connector.
730 ohms or greater:GO TO 4
Less than 730 ohms:Short to ground in throttleground wire betweenECU and resistorORFaulty ECU connectorORFaulty ECU
04160
72
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLEGROUND VOLTAGE LOW supporting information.
There is a difference between grounds of the ECU and Pump and Valve controller.Check for loose ground connection at each controller.
CTM331 (09APR02) 04-160-72 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=232
Trouble Code Diagnostics and Tests
0416073
CTM331 (09APR02) 04-160-73 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=233
Trouble Code Diagnostics and Tests
04160
74
RG40854,0000089 –19–07DEC01–1/1
Level 12 ECU - T15 - Excavator Throttle Input Voltage High
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Throttle Reference F3
Throttle Input B3
Throttle Ground C1
To Pumpand ValveController
RG
1197
7–1
9–14
DE
C01
Excavator Throttle
• The Excavator uses an analog throttle to measurethrottle position. This throttle is connected to thePump and Valve controller, which sends throttleinput information to the ECU through a dedicatedwire. Since the ECU and Pump and Valve controllerdo not share a common ground, a throttle voltagereference wire and a throttle ground wire accompanythe throttle input wire. The ECU calculates thedifferences in controller grounds in order todetermine the throttle request by the Pump andValve controller.
This code will set if:
• The excavator throttle input voltage to the ECUexceeds 4.9 volts.
If this code sets, the following will occur:
• The ECU will use a default “limp-home” throttlevalue that will only allow idle engine speed.
CTM331 (09APR02) 04-160-74 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=234
Trouble Code Diagnostics and Tests
RG40854,00000AC –19–13DEC01–1/1
Level 12 ECU - T15 - Excavator Throttle Input Voltage High - Continued
– – –1/1
Level 12 ECU - T15 - Excavator Throttle Input Voltage High Diagnostic Procedure
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
0416075
– – –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.
NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUTVOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUTVOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read active DTCs and stored DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs.
NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active, follow those DTCs first.
6. Read DTCs using DST or SERVICE ADVISOR.
• Ignition ON, engine OFF• Ignition ON, engine running
SPN 91 FMI 3 reoccurswhen engine is off andrunning:GO TO 3
SPN 91 FMI 3 reoccursonly when engine isrunning:GO TO 4
SPN 91 FMI 3 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-75 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=235
Trouble Code Diagnostics and Tests
– – –1/1
3 Throttle Signal WireTest
NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUTVOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure voltage between terminal B3 in the harness end of theECU connector and the ground pin of the Pump and Valve controller.
4.0 V or less:GO TO 4
Greater than 4.0 V:Short to power in throttlesignal wireORFaulty Pump and Valvecontroller connectorORFaulty Pump and Valvecontroller
04160
76
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUTVOLTAGE HIGH supporting information.
There is a difference between grounds of the ECU and Pump and Valve controller.Check for loose ground connection at each controller.
CTM331 (09APR02) 04-160-76 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=236
Trouble Code Diagnostics and Tests
0416077
CTM331 (09APR02) 04-160-77 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=237
Trouble Code Diagnostics and Tests
04160
78
RG40854,000008B –19–07DEC01–1/1
Level 12 ECU - T16 - Excavator Throttle Input Voltage Low
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Throttle Reference F3
Throttle Input B3
Throttle Ground C1
To Pumpand ValveController
RG
1197
7–1
9–14
DE
C01
Excavator Throttle
• The Excavator uses an analog throttle to measurethrottle position. This throttle is connected to thePump and Valve controller, which sends throttleinput information to the ECU through a dedicatedwire. Since the ECU and Pump and Valve controllerdo not share a common ground, a throttle voltagereference wire and a throttle ground wire accompanythe throttle input wire. The ECU calculates thedifferences in controller grounds in order todetermine the throttle request by the Pump andValve controller.
This code will set if:
• The excavator throttle input voltage to the ECU goesbelow 0.1 volts.
If this code sets, the following will occur:
• The ECU will use a default “limp-home” throttlevalue that will only allow idle engine speed.
CTM331 (09APR02) 04-160-78 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=238
Trouble Code Diagnostics and Tests
RG40854,00000AD –19–13DEC01–1/1
Level 12 ECU - T16 - Excavator Throttle Input Voltage Low - Continued
– – –1/1
Level 12 ECU - T16 - Excavator Throttle Input Voltage Low Diagnostic Procedure
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
0416079
– – –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.
NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUTVOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUTVOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
NOTE: If DTCs SPN 29 FMI 3 or SPN 29 FMI 4 are active, follow those DTCs first.
6. Read DTCs using DST or SERVICE ADVISOR.
• Ignition ON, engine OFF• Ignition ON, engine running
SPN 91 FMI 4 reoccurswhen engine is off andrunning:GO TO 3
SPN 91 FMI 4 reoccursonly when engine isrunning:GO TO 4
SPN 91 FMI 4 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-79 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=239
Trouble Code Diagnostics and Tests
– – –1/1
3 Throttle Signal WireTest
NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUTVOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure voltage between terminal B3 in the harness end of theECU connector and the ground pin of the Pump and Valve controller.
1.0 V or greater:GO TO 4
Less than 1.0 V:Open in throttle signalwireORFaulty Pump and Valvecontroller connectorORFaulty Pump and Valvecontroller
04160
80
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUTVOLTAGE LOW supporting information.
There is a difference between grounds of the ECU and Pump and Valve controller.Check for loose ground connection at each controller.
CTM331 (09APR02) 04-160-80 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=240
Trouble Code Diagnostics and Tests
0416081
RG40854,0000118 –19–28JAN02–1/1
Level 12 ECU - T19 - Throttle Not Calibrated Properly
Throttle Calibration
Throttle calibration is necessary to allow the ECU tolearn the range of the throttle. It is done when a newECU or a new throttle has been installed.
This code will set if:
• The ECU detects an improper throttle calibrationrange.
If this code sets, the following will occur:
• Throttle position will not match percent throttle.
If this code sets:
• Diagnose other DTCs first.• If no other DTCs are found, perform throttle sensor
diagnostics.– For 310G Backhoe Loaders, see THROTTLE
POSITION SENSOR TEST (S.N. XXXXXX— ) inSection 9015, Group 120 of TM1885.
– For 310SG/315SG Backhoe Loaders, seeTHROTTLE POSITION SENSOR TEST (S.N.XXXXXX— ) in Section 9015, Group 120 ofTM1883.
CTM331 (09APR02) 04-160-81 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=241
Trouble Code Diagnostics and Tests
04160
82
RG40854,000011F –19–28JAN02–1/1
Level 12 ECU - T20 - Throttle Input Voltage Below Lower Calibration Limit
Throttle Calibration
Throttle calibration is necessary to allow the ECU tolearn the range of the throttle. It is performed when anew ECU or a new throttle has been installed.
This code will set if:
• The ECU detects a throttle input voltage lower thanthe defined low calibration limit.
If this code sets, the following will occur:
• Throttle position will not match percent throttle.
If this code sets:
• Diagnose other DTCs first.• If no other DTCs are found, perform throttle sensor
diagnostics.– For 310G Backhoe Loaders, see THROTTLE
POSITION SENSOR TEST (S.N. XXXXXX— ) inSection 9015, Group 120 of TM1885.
– For 310SG/315SG Backhoe Loaders, seeTHROTTLE POSITION SENSOR TEST (S.N.XXXXXX— ) in Section 9015, Group 120 ofTM1883.
CTM331 (09APR02) 04-160-82 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=242
Trouble Code Diagnostics and Tests
0416083
RG40854,000011E –19–28JAN02–1/1
Level 12 ECU - T21 - Throttle Calibration Aborted
Throttle Calibration
Throttle calibration is necessary to allow the ECU tolearn the range of the throttle. It is done when a newECU or a new throttle has been installed.
This code will set if:
• Throttle calibration mode was enabled but wasaborted before it was completed.
If this code sets, the following will occur:
• Throttle position will not match percent throttle.
If this code sets:
• Diagnose other DTCs first.• If no other DTCs are found, perform throttle sensor
diagnostics.– For 310G Backhoe Loaders, see THROTTLE
POSITION SENSOR TEST (S.N. XXXXXX— ) inSection 9015, Group 120 of TM1885.
– For 310SG/315SG Backhoe Loaders, seeTHROTTLE POSITION SENSOR TEST (S.N.XXXXXX— ) in Section 9015, Group 120 ofTM1883.
CTM331 (09APR02) 04-160-83 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=243
Trouble Code Diagnostics and Tests
04160
84
RG40854,000011D –19–28JAN02–1/1
Level 12 ECU - T22 - Analog Throttle (A) Input Voltage Out of Range
Analog Throttle Sensor
The analog throttle position sensor is a variableresistor (potentiometer) used to measure the positionof the throttle. The throttle input voltage normallyvaries between 1.0 and 4.0 volts depending on throttleposition. Analog throttle voltage at low idle will beapproximately 1.0 volt and 4.0 volts at high idle. TheECU has the ability to learn different voltages for lowand high idle, so the voltage range may change perapplication.
This code will set if:
• The ECU detects a high or low out of range analogthrottle (A) input voltage.
If this code sets, the following will occur:
• For engines with only one throttle, the ECU will notread the input of the throttle and run the engine atlow idle.
• For engine with multiple throttles, the ECU will notread the input of the faulty throttle, so the ECU runentirely off of the other throttle.
If this code sets:
• Diagnose other DTCs first.• If no other DTCs are found, perform throttle sensor
diagnostics.– For 310G Backhoe Loaders, see THROTTLE
POSITION SENSOR TEST (S.N. XXXXXX— ) inSection 9015, Group 120 of TM1885.
– For 310SG/315SG Backhoe Loaders, seeTHROTTLE POSITION SENSOR TEST (S.N.XXXXXX— ) in Section 9015, Group 120 ofTM1883.
• Check for other throttle DTCs. Diagnose those first.• Return throttle to 0% throttle position• Some applications require key OFF/restart cycle to
clear the code.
CTM331 (09APR02) 04-160-84 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=244
Trouble Code Diagnostics and Tests
0416085
RG40854,000011C –19–28JAN02–1/1
Level 12 ECU - T23 - Multi-state Throttle Input Voltage Out of Range
Multi-state Throttle Switch
• Multi-state throttle is composed of an idle switch thatallows engine speed to be at high or low idle. Onsome applications, there is a bump up and a bumpdown feature. This allows for high and low idle to becontrolled.
• On certain applications, an additional throttle is usedin addition to the multi-state throttle. If the desiredengine speed of the additional throttle is greater thanthe multi-state throttle, the multi-state throttle will beoverridden. When the desired engine speed of themulti-state throttle is greater than the additionalthrottle, the multi-state throttle will be in total control.
This code will set if:
• The ECU detects a high or low out of rangemulti-state throttle input voltage.
If this code sets, the following will occur:
• The engine will not run if this code is active.
If this code sets:
• Check to see if DTC SPN 91 FMI 3 or 4 is active.Diagnose those first.
• Return throttle to 0% throttle position
CTM331 (09APR02) 04-160-85 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=245
Trouble Code Diagnostics and Tests
RG40854,0000002 –19–12MAR02–1/1
Level 12 ECU - DTC SPN 28, 29, 91 FMI 3, 4, 7, 9, 10, 13, 14
Diagnostic Trouble Codes (DTCs) assigned to throttleschanges per application. Because of this, a table isnecessary to give direction to the appropriate
procedure for your application. See LISTING OFTHROTTLE CODES earlier in this Group.
04160
86
CTM331 (09APR02) 04-160-86 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=246
Trouble Code Diagnostics and Tests
0416087
CTM331 (09APR02) 04-160-87 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=247
Trouble Code Diagnostics and Tests
04160
88
RG40854,0000088 –19–07DEC01–1/2
Level 12 ECU - DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Oil PressureSensor Connector
Oil PressureSensor
BC
AA
C
B
B
C
A
D3 F3 E2
B 5V Supply
C Oil Pressure Input
A Sensor Ground
RG
1197
8–1
9–14
DE
C01
Oil PressureSwitch
Oil Pressure Input C1P
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1204
5–1
9–20
DE
C01
NOTE: Wiring schematics show OEM engineapplications for the oil pressure sensor andTelehandler applications for the oil pressureswitch. For wiring on other applications, seeAPPLICATION SPECIFICATIONS in Section06, Group 210 of this manual.
Oil Pressure Sensor or Switch
• The oil pressure sensor is a pressure transducerconnected to the main oil galley. As engine oilpressure increases, the oil pressure sensor inputvoltage increases. The ECU monitors oil pressure inorder to protect the engine in case of a low oilpressure condition. For further oil pressure sensorinformation, see MEASURING PRESSURE inSection 03, Group 140 earlier in this manual.
• The oil pressure switch is used to detect a loss of oilpressure. Oil pressure causes the contacts in theswitch close when oil pressure drops below theminimum oil pressure threshold. The switch is openwhen the engine is not running and engine isrunning with sufficient oil pressure.
DTC SPN 100 FMI 1 will set if:
• For engines with an oil pressure sensor, the ECUsenses an extremely low oil pressure.
• For engines with an oil pressure switch, the ECUsensses the oil pressure switch is open after theengine is above cranking RPM for several seconds.
If DTC SPN 100 FMI 1 sets, the following willoccur:
CTM331 (09APR02) 04-160-88 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=248
Continued on next page
Trouble Code Diagnostics and Tests
RG40854,0000088 –19–07DEC01–2/2
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: The derate feature will go
into effect when the code is set, and the enginewill shut down after 30 seconds.
– With Derate Feature: On OEM applications, theengine derates 60% per minute until the engine isrunning at 40% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
0416089
CTM331 (09APR02) 04-160-89 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=249
Trouble Code Diagnostics and Tests
RG40854,00000B2 –19–13DEC01–1/1
Level 12 ECU - DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low - Continued
– – –1/1
Level 12 ECU - DTC SPN 100 FMI 1 Engine Oil Pressure Extremely Low Diagnostic Procedure
04160
90
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 1ENGINE OIL PRESSURE EXTREMELY LOW supporting information
Perform a preliminary inspection of the ECU connector, the oil pressure sensor, andany connectors in between them. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Oil Pressure Check NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 1ENGINE OIL PRESSURE EXTREMELY LOW supporting information
Under the conditions where DTC SPN 100 FMI 1 occurs, measure engine oil pressure.See CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5 L & 6.8 LDiesel Engines Base Engine Manual (CTM 104).
Oil pressure withinspecification:Verify that oil pressuresensor or switch circuitsis OK.If oil pressure sensor orswitch circuits are OK,replace oil pressuresensor or switch andretest.
Oil pressure belowspecification:Low oil pressure problem.See 4.5L/6.8L - L2 -ENGINE OIL PRESSURELOW in Section 04,Group 150 of 4.5 L and6.8 L Diesel EnginesBase Engine Manual(CTM 104).
CTM331 (09APR02) 04-160-90 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=250
Trouble Code Diagnostics and Tests
0416091
CTM331 (09APR02) 04-160-91 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=251
Trouble Code Diagnostics and Tests
04160
92
RG40854,0000086 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Oil PressureSensor Connector
Oil PressureSensor
BC
AA
C
B
B
C
A
D3 F3 E2
B 5V Supply
C Oil Pressure Input
A Sensor Ground
RG
1197
8–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Oil Pressure Sensor
• The oil pressure sensor is a pressure transducerconnected to the main oil galley. As engine oilpressure increases, the oil pressure sensor inputvoltage increases. The ECU monitors oil pressure inorder to protect the engine in case of a low oilpressure condition. For further oil pressure sensorinformation, see MEASURING PRESSURE inSection 03, Group 140 earlier in this manual.
DTC SPN 100 FMI 3 will set if:
• The oil pressure input voltage exceeds the sensor’shigh voltage specification. The voltage is higher thanwhat is physically possible for oil pressure.– For OEM applications, the high oil pressure input
voltage specification is 4.5 volts.– For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the high oil pressure input voltagespecification.
If DTC SPN 100 FMI 3 sets, the following willoccur:
• ECU uses a default oil pressure of 260 kPa (2.6 bar)(37.5 bar).
• ECU’s low oil pressure engine protection featuredisabled.
CTM331 (09APR02) 04-160-92 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=252
Trouble Code Diagnostics and Tests
RG40854,00000B3 –19–14DEC01–1/1
Level 12 ECU - DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High - Continued
– – –1/1
Level 12 ECU - DTC SPN 100 FMI 3 Engine Oil Pressure Input Voltage High Diagnostic Procedure
0416093
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 3ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information
Perform a preliminary inspection of the ECU connector, the oil pressure sensorconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 3ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine running
7. Read Oil Pressure Input Voltage using the DST or SERVICE ADVISOR.
NOTE: For OEM applications, the high oil pressure input voltage specification is4.5V. For the high voltage specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
4.5 V or greater:GO TO 3
Below 4.5 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-93 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=253
Trouble Code Diagnostics and Tests
– – –1/1
3 Oil Pressure InputShorted Test
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 3ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information
1. Ignition OFF
2. Disconnect oil pressure sensor connector
3. Ignition ON, engine OFF
4. Read Oil Pressure Input Voltage using the DST or SERVICE ADVISOR.
NOTE: For OEM applications, the low oil pressure input voltage specification is0.3V. For the low voltage specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
0.3 V or below:GO TO 4
Above 0.3 V:Short to voltage in oilpressure sensor inputcircuitORFaulty ECU
04160
94
– – –1/1
4 Oil Pressure GroundCircuit Open Test
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 3ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information
Probe oil pressure sensor ground (Terminal A) in sensor harness connector with a testlight connected to battery voltage.
Light ON:Faulty oil pressure sensorORFaulty ECU connectionORFaulty ECU
Light OFF:Open in oil pressuresensor ground circuitORFaulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-94 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=254
Trouble Code Diagnostics and Tests
0416095
CTM331 (09APR02) 04-160-95 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=255
Trouble Code Diagnostics and Tests
04160
96
RG40854,0000084 –19–07DEC01–1/2
Level 12 ECU - DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Oil PressureSensor Connector
Oil PressureSensor
BC
AA
C
B
B
C
A
D3 F3 E2
B 5V Supply
C Oil Pressure Input
A Sensor Ground
RG
1197
8–1
9–14
DE
C01
Oil PressureSwitch
Oil Pressure Input C1P
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1204
5–1
9–20
DE
C01
NOTE: Wiring schematics show OEM engineapplications for the oil pressure sensor andTelehandler applications for the oil pressureswitch. For wiring on other applications, seeAPPLICATION SPECIFICATIONS in Section06, Group 210 of this manual.
Oil Pressure Sensor or Switch
• The oil pressure sensor is a pressure transducerconnected to the main oil galley. As engine oilpressure increases, the oil pressure sensor inputvoltage increases. The ECU monitors oil pressure inorder to protect the engine in case of a low oilpressure condition. For further oil pressure sensorinformation, see MEASURING PRESSURE inSection 03, Group 140 earlier in this manual.
• The oil pressure switch is used to detect a loss of oilpressure. A lack of oil pressure causes the contactsin the switch close when oil pressure drops belowthe minimum oil pressure threshold. The switch isopen when the engine is not running and engine isrunning with sufficient oil pressure.
DTC SPN 100 FMI 4 will set if:
• For oil pressure sensors, the oil pressure inputvoltage drops below the sensor’s low voltagespecification. The voltage is lower than what isphysically possible for oil pressure.– For OEM applications, the low oil pressure input
voltage specification is 0.3 volts.
CTM331 (09APR02) 04-160-96 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=256
Continued on next page
Trouble Code Diagnostics and Tests
RG40854,0000084 –19–07DEC01–2/2
– For other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual for the high oil pressure input voltagespecification.
• For oil pressure switches, the oil pressure switch isclosed when key is on and there is no engine speed.
If DTC SPN 100 FMI 4 sets, the following willoccur:
• ECU uses a default oil pressure of 260 kPa (2.6 bar)(37.5 bar).
• ECU’s low oil pressure engine protection featuredisabled.
0416097
CTM331 (09APR02) 04-160-97 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=257
Trouble Code Diagnostics and Tests
RG40854,00000B4 –19–14DEC01–1/1
Level 12 ECU - DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low - Continued
– – –1/1
Level 12 ECU - DTC SPN 100 FMI 4 Engine Oil Pressure Input Voltage Low Diagnostic Procedure
04160
98
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 4ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information
Perform a preliminary inspection of the ECU connector, the oil pressure sensorconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 4ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine running
7. Read DTCs using the DST or SERVICE ADVISOR.
SPN 100 FMI 4reoccurs:GO TO 3
SPN 100 FMI 4 doesn’treoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-98 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=258
Trouble Code Diagnostics and Tests
– – –1/1
3 Oil Pressure SensorCheck
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 4ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information.
Determine whether an oil pressure sensor or an oil pressure switch is being used.
Oil pressure sensorbeing used:GO TO 4
Oil pressure switchbeing used:GO TO 6
0416099
– – –1/1
4 Oil Pressure SensorWiring Test
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 4ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect oil pressure sensor connector
3. Install a jumper wire between oil pressure 5 V supply and oil pressure input inharness sensor connector
4. Read the Oil Pressure Input Voltage parameter using the DST or SERVICEADVISOR.
NOTE: For OEM applications, the high oil pressure input voltage specification is4.5V. For the high voltage specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
Below 4.5 V:GO TO 5
4.5 V or greater:Faulty oil pressure sensorconnectorORFaulty oil pressure sensor
– – –1/1
5 Oil Pressure Sensor 5V Supply Test
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 4ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Remove jumper wire
3. Ignition ON, engine OFF
4. Using a multimeter, measure voltage between oil pressure 5 V supply terminal anda good chassis ground
Between 4.0 V and 6.0V:Open in oil pressure inputcircuitORShort to ground in oilpressure input circuitORFaulty ECU connectorORFaulty ECU
Below 4.0 V:Open in oil pressure 5 Vsupply circuitORShort to ground in oilpressure 5 V supplycircuitORFaulty ECU connectorORFaulty ECU
CTM331 (09APR02) 04-160-99 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=259
Trouble Code Diagnostics and Tests
– – –1/1
6 Oil Pressure SwitchShort in Wire Check
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 4ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect oil pressure switch connector and ECU connector
3. Using a multimeter, measure the resistance between terminal C1 in the ECU and:
• All other terminals in the ECU connector• A good ground
All measurementsgreater than 2000 ohms:Faulty oil pressure switchORFaulty ECU
Any measurement lessthan 2000 ohms:Short in oil pressure inputcircuit
04160,100
CTM331 (09APR02) 04-160-100 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=260
Trouble Code Diagnostics and Tests
04160,101
CTM331 (09APR02) 04-160-101 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=261
Trouble Code Diagnostics and Tests
04160,102
RG40854,0000082 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Oil PressureSensor Connector
Oil PressureSensor
BC
AA
C
B
B
C
A
D3 F3 E2
B 5V Supply
C Oil Pressure Input
A Sensor Ground
RG
1197
8–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Oil Pressure Sensor
• The oil pressure sensor is a pressure transducerconnected to the main oil galley. As engine oilpressure increases, the oil pressure sensor inputvoltage increases. The ECU monitors oil pressure inorder to protect the engine in case of a low oilpressure condition. For further oil pressure sensorinformation, see MEASURING PRESSURE inSection 03, Group 140 earlier in this manual.
DTC SPN 100 FMI 18 will set if:
• For engines with an oil pressure sensor, the ECUsenses a moderately low oil pressure.
If DTC SPN 100 FMI 18 sets, the following willoccur:
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: No shutdown available
for this code.– With Derate Feature: On OEM applications, the
engine derates 40% per minute until the engine isrunning at 60% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
CTM331 (09APR02) 04-160-102 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=262
Trouble Code Diagnostics and Tests
RG40854,00000B5 –19–14DEC01–1/1
Level 12 ECU - DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low - Continued
– – –1/1
Level 12 ECU - DTC SPN 100 FMI 18 Engine Oil Pressure Moderately Low Diagnostic Procedure
04160,103
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 18ENGINE OIL PRESSURE MODERATELY LOW supporting information
Perform a preliminary inspection of the ECU connector, the oil pressure sensorconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Oil Pressure Check NOTE: For wiring and theory of operation information, see DTC SPN 100 FMI 18ENGINE OIL PRESSURE MODERATELY LOW supporting information
Under the conditions where DTC SPN 100 FMI 18 occurs, measure engine oilpressure. CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5 L & 6.8 LDiesel Engines Base Engine Manual (CTM 104).
Oil pressure withinspecification:Low oil pressure problem.See 4.5L/6.8L - L2 -ENGINE OIL PRESSURELOW in Section 04,Group 150 of 4.5 L and6.8 L Diesel EnginesBase Engine Manual(CTM 104).
Oil pressure belowspecification:Verify that oil pressuresensor 5 V supply, input,and ground circuits areOK.If oil pressure sensorcircuits are OK, replaceoil pressure sensor andretest.
CTM331 (09APR02) 04-160-103 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=263
Trouble Code Diagnostics and Tests
04160,104
RG40854,0000080 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High
D1
A A
BB
D3
MAT SensorConnector
Sensor Ground
MAT Input
MAT Sensor
t
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1197
9–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
MAT (Manifold Air Temperature) Sensor
• The MAT sensor is a thermistor (temperaturesensitive resistor) mounted in the intake manifold.The MAT sensor is used to measure thetemperature of the intake air. The MAT sensor’svariable resistance causes the input voltage to theECU to vary. Higher intake air temperatures result inlower MAT input voltages to the ECU; lowertemperatures result in higher voltages. For furtherMAT sensor information, see MEASURINGTEMPERATURE in Section 03, Group 140.
DTC SPN 105 FMI 3 will set if:
• The manifold air temperture input voltage exceedsthe sensor’s high voltage specification. The voltageis higher than what is physically possible formanifold air.– For OEM applications, the high manifold air
temperature input voltage specification is 4.9volts.
– For other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual for the high manifold air temperaturespecification.
If DTC SPN 105 FMI 3 sets, the following willoccur:
• ECU uses a default MAT value of 60°C (140°F).• ECU’s high manifold air temperature engine
protection feature disabled.
CTM331 (09APR02) 04-160-104 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=264
Trouble Code Diagnostics and Tests
RG40854,00000B6 –19–18DEC01–1/1
Level 12 ECU - DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High -Continued
– – –1/1
Level 12 ECU - DTC SPN 105 FMI 3 Manifold Air Temperature Input Voltage High Diagnostic Procedure
04160,105
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 3MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the manifold air temperaturesensor connector, and any connectors in between them. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 3MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Ignition ON, engine OFF
5. Read the Manifold Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: For OEM applications, the high manifold air temperature input voltagespecification is 4.9V. For the high voltage specification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
4.9 V or greater:GO TO 3
Below 4.9 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-105 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=265
Trouble Code Diagnostics and Tests
04160,106
– – –1/1
3 MAT Sensor andConnector Test
NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 3MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect MAT sensor connector
3. Install a jumper wire between both terminals in the MAT sensor harness connector
4. Ignition ON, engine OFF
5. Read the Manifold Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: For OEM applications, the low manifold air temperature input voltagespecification is 0.1V. For the low voltage specification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Above 0.1 V:GO TO 4
0.1 V or below:Faulty MAT sensorconnectorORFaulty MAT sensor
– – –1/1
4 MAT Sensor OpenGround Circuit Test
NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 3MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire between both terminals.
3. Install jumper wire between MAT sensor harness connector input terminal and agood chassis ground.
4. Ignition ON, engine OFF
5. Read the Manifold Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: For OEM applications, the low manifold air temperature input voltagespecification is 0.1V. For the low voltage specification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Above 0.1 V:Open in MAT sensorinput circuitORFaulty ECU connectionORFaulty ECU
0.1 V or below:Open in MAT sensorground circuitORFaulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-106 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=266
Trouble Code Diagnostics and Tests
04160,107
CTM331 (09APR02) 04-160-107 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=267
Trouble Code Diagnostics and Tests
04160,108
RG40854,000007D –19–07DEC01–1/1
Level 12 ECU - DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low
D1
A A
BB
D3
MAT SensorConnector
Sensor Ground
MAT Input
MAT Sensor
t
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1197
9–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
MAT (Manifold Air Temperature) Sensor
• The MAT sensor is a thermistor (temperaturesensitive resistor) mounted in the intake manifold.The MAT sensor is used to measure thetemperature of the intake air. The MAT sensor’svariable resistance causes the input voltage to theECU to vary. Higher intake air temperatures result inlower MAT input voltages to the ECU; lowertemperatures result in higher voltages. For furtherMAT sensor information, see MEASURINGTEMPERATURE in Section 03, Group 140.
DTC SPN 105 FMI 4 will set if:
• The manifold air temperature input voltage goesbelow the sensor’s low voltage specification. Thevoltage is lower than what is physically possiblemanifold air temperature to achieve.– For OEM engine applications, the low manifold air
temperature input voltage specification is 0.1volts.
– For other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual for the low manifold temperature inputvoltage specification.
If DTC SPN 105 FMI 4 sets, the following willoccur:
• ECU uses a default MAT value of 60°C (140°F) torun engine.
• ECU’s high manifold air temperature engineprotection feature disabled.
CTM331 (09APR02) 04-160-108 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=268
Trouble Code Diagnostics and Tests
RG40854,00000B7 –19–18DEC01–1/1
Level 12 ECU - DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low -Continued
– – –1/1
Level 12 ECU - DTC SPN 105 FMI 4 Manifold Air Temperature Input Voltage Low Diagnostic Procedure
04160,109
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 4MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, the manifold air temperaturesensor connector, and any connectors in between them. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 4MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Ignition ON, engine OFF
5. Read the Manifold Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: For OEM engine applications, the low manifold air temperature input voltagespecification is 0.1V. For the low voltage specification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
0.1 V or below:GO TO 3
Above 0.1 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-109 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=269
Trouble Code Diagnostics and Tests
04160,110
– – –1/1
3 MAT Sensor Test NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 4MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect MAT sensor connector.
3. Ignition ON, engine OFF
4. Read the Manifold Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: For OEM engine applications, the high manifold air temperature inputvoltage specification is 4.9V. For the high voltage specification on otherapplications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of thismanual.
Below 4.9 V:Short to ground in MATsensor input circuitORFaulty ECU connectorORFaulty ECU
4.9 V or greater:Faulty MAT sensorconnectorORFaulty MAT sensor
CTM331 (09APR02) 04-160-110 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=270
Trouble Code Diagnostics and Tests
04160,111
CTM331 (09APR02) 04-160-111 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=271
Trouble Code Diagnostics and Tests
04160,112
RG40854,000007B –19–07DEC01–1/1
Level 12 ECU - DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High
D1
A A
BB
D3
MAT SensorConnector
Sensor Ground
MAT Input
MAT Sensor
t
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1197
9–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
MAT (Manifold Air Temperature) Sensor
• The MAT sensor is a thermistor (temperaturesensitive resistor) mounted in the intake manifold.The MAT sensor is used to measure thetemperature of the intake air. The MAT sensor’svariable resistance causes the input voltage to theECU to vary. Higher intake air temperatures result inlower MAT input voltages to the ECU; lowertemperatures result in higher voltages. For furtherMAT sensor information, see MEASURINGTEMPERATURE in Section 03, Group 140.
DTC SPN 105 FMI 16 will set if:
• The ECU senses MAT on OEM applications above100°C (212°F) for “H engines” and 120°C (248°F)for “T engines”. For MAT specifications on otherapplications, see APPLICATION SPECIFICATIONSin Section 06, Group 210 of this manual.
If DTC SPN 105 FMI 16 sets, the following willoccur:
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: The ECU does not use
shutdown feature with this code.– With Derate Feature: On OEM applications, the
engine derates 2% per minute until the engine isrunning at 80% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
CTM331 (09APR02) 04-160-112 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=272
Trouble Code Diagnostics and Tests
RG40854,00000B8 –19–18DEC01–1/1
Level 12 ECU - DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High -Continued
– – –1/1
Level 12 ECU - DTC SPN 105 FMI 16 Manifold Air Temperature Moderately High Diagnostic Procedure
04160,113
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 16MANIFOLD AIR TEMPERATURE MODERATELY HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the manifold air temperaturesensor connector, and any connectors in between them. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Failures Causing HighMAT Check
NOTE: For wiring and theory of operation information, see DTC SPN 105 FMI 16MANIFOLD AIR TEMPERATURE MODERATELY HIGH supporting information.
Check the following items that can cause high intake air temperatures:
• Excessively high ambient air temperature.• Restricted, dirty, or damaged charge air cooler.• Loose cooling fan belt.• Malfunctioning cooling fan.• Restricted or damaged intake air piping.• Damaged cooling fan shroud.
Cause of high MATlocated:Repair problem andretest.
No cause of high MATlocated:Verify that MAT sensorinput and ground circuitsare OK. If MAT sensorcircuits are OK, replaceMAT sensor and retest.
CTM331 (09APR02) 04-160-113 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=273
Trouble Code Diagnostics and Tests
04160,114
RG40854,0000071 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe
t
ECT SensorConnector
ECT Ground
ECT Input
ECTSensor
B1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
0–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Engine Coolant Temperature (ECT) Sensor
• The ECT sensor is a thermistor (temperaturesensitive resistor) mounted on the thermostathousing or in the rear of the cylinder head. It is usedto measure the coolant temperature. The ECT’svariable resistance causes the input voltage to theECU to vary. Higher coolant temperatures result inlower ECT input voltages to the Engine Control Unit(ECU); lower temperatures result in higher voltages.For further ECT sensor information, seeMEASURING TEMPERATURE in Section 03, Group140 earlier in this manual.
DTC SPN 110 FMI 0 will set if:
• The ECU senses ECT on OEM applications above118°C (244°F). For the most severe ECTspecification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06,Group 210 of this manual.
If DTC SPN 110 FMI 0 sets, the following willoccur:
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: The derate feature will go
into effect when the code is set, and the enginewill shut down after 30 seconds.
– With Derate Feature: On OEM applications, theengine derates 60% per minute until the engine isrunning at 40% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
CTM331 (09APR02) 04-160-114 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=274
Trouble Code Diagnostics and Tests
RG40854,00000B9 –19–18DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe -Continued
– – –1/1
Level 12 ECU - DTC SPN 110 FMI 0 Engine Coolant Temperature High Most Severe Diagnostic Procedure
04160,115
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 0ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE supporting information
Perform a preliminary inspection of the ECU connector, the Engine CoolantTemperature (ECT) connector, and any connectors in between them. Look for dirty,damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 ECT Sensor andCircuit Test
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 0ENGINE COOLANT TEMPERATURE HIGH MOST SEVERE supporting information
Under the conditions where DTC SPN 110 FMI 0 occurs, use a temperature gaugeand verify that engine coolant temperature is above the most severe ECT specification.
NOTE: On OEM applications, the most severe ECT specification is 118°C•(244°F). Forthe most severe ECT specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
ECT 118°C (244°F) orabove:Engine overheatingproblem. See 4.5L/6.8L -C1 - ENGINE COOLANTTEMPERATURE ABOVENORMAL in Section 04,Group 150 of 4.5 L & 6.8L Diesel Engines BaseEngine Manual (CTM104).
ECT significantly lessthan 118°C (244°F):Verify that ECT input andground circuits are OKIf both circuits are OK,replace ECT sensor andretest
CTM331 (09APR02) 04-160-115 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=275
Trouble Code Diagnostics and Tests
04160,116
RG40854,0000072 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High
t
ECT SensorConnector
ECT Ground
ECT Input
ECTSensor
B1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
0–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Engine Coolant Temperature (ECT) Sensor
• The ECT sensor is a thermistor (temperaturesensitive resistor) mounted on the thermostathousing or in the rear of the cylinder head. It is usedto measure the coolant temperature. The ECT’svariable resistance causes the input voltage to theECU to vary. Higher coolant temperatures result inlower ECT input voltages to the Engine Control Unit(ECU); lower temperatures result in higher voltages.For further ECT sensor information, seeMEASURING TEMPERATURE in Section 03, Group140 earlier in this manual.
DTC SPN 110 FMI 3 will set if:
• The ECT input voltage goes above the sensor’s highvoltage specification. This voltage corresponds to atemperature that is lower than what is physicallypossible for engine coolant.– For OEM engine applications, the high ECT input
voltage specification is 4.9 volts.– For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the high ECT input voltagespecification.
If DTC SPN 110 FMI 3 sets, the following willoccur:
• When in start mode, the ECU will default the ECT to-30°C (-22°F).
• When in running mode, the ECU will default the ECTto 90°C (194°F).
• ECU’s high ECT engine protection feature disabled.
CTM331 (09APR02) 04-160-116 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=276
Trouble Code Diagnostics and Tests
RG40854,00000BA –19–19DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High -Continued
– – –1/1
Level 12 ECU - DTC SPN 110 FMI 3 Engine Coolant Temperature Input Voltage High Diagnostic Procedure
04160,117
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 3ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
Perform a preliminary inspection of the ECU connector, the Engine CoolantTemperature (ECT) connector, and any connectors in between them. Look for dirty,damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 3ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Ignition ON, engine running
5. Read the Engine Coolant Temperature Input Voltage parameter using DST orSERVICE ADVISOR.
NOTE: On OEM applications, the high ECT input voltage specification is 4.9V. Forhigh input voltage specifications on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
At or above 4.9 V:GO TO 3
Below 4.9 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-117 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=277
Trouble Code Diagnostics and Tests
04160,118
– – –1/1
3 Engine CoolantTemperature (ECT)Sensor andConnector Test
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 3ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1. Ignition OFF
2. Disconnect ECT sensor connector
3. Install a jumper wire between both terminals in the ECT sensor harness connector
4. Ignition ON, engine OFF
5. Read the Engine Coolant Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: On OEM applications, the low ECT input voltage specification is 0.1 voltsand below. For ECT input voltage specifications on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Above 0.1 V:GO TO 4
At or below 0.1 V:Faulty ECT sensorconnectorORFaulty ECT sensor
– – –1/1
4 Engine CoolantTemperature (ECT)Open Ground Test
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 3ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1. Ignition OFF
2. Remove jumper wire between both terminals
3. Install jumper wire between ECT sensor harness connector input terminal and agood chassis ground
4. Ignition ON, engine OFF
5. Read the Engine Coolant Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
NOTE: On OEM applications, the low ECT input voltage specification is 0.1 voltsand below. For ECT input voltage specifications on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Above 0.1 V:Open in ECT inputsensor circuitORFaulty ECU connectionORFaulty ECU
0.1 V or below:Open in ECT sensorground circuitORFaulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-118 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=278
Trouble Code Diagnostics and Tests
04160,119
CTM331 (09APR02) 04-160-119 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=279
Trouble Code Diagnostics and Tests
04160,120
RG40854,0000074 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low
t
ECT SensorConnector
ECT Ground
ECT Input
ECTSensor
B1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
0–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Engine Coolant Temperature (ECT) Sensor
• The ECT sensor is a thermistor (temperaturesensitive resistor) mounted on the thermostathousing. It is used to measure the coolanttemperature. The ECT’s variable resistance causesthe input voltage to the ECU to vary. Higher coolanttemperatures result in lower ECT input voltages tothe ECU; lower temperatures result in highervoltages. For further ECT sensor information, seeMEASURING TEMPERATURE in Section 03, Group140 earlier in this manual.
DTC SPN 110 FMI 4 will set if:
• The ECT input voltage goes below the sensor’s lowvoltage specification. This voltage corresponds to atemperature that is higher than what is physicallypossible for engine coolant.– For OEM engine applications, the low ECT input
voltage specification is 0.1 volts.– For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 ofthis manual for the high ECT input voltagespecification.
If DTC SPN 110 FMI 4 sets, the following willoccur:
• When in start mode, the ECU will default the ECT to-30°C (-22°F).
• When in running mode, the ECU will default the ECTto 90°C (194°F).
• ECU’s high ECT engine protection feature disabled.
CTM331 (09APR02) 04-160-120 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=280
Trouble Code Diagnostics and Tests
RG40854,00000BB –19–19DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low -Continued
– – –1/1
Level 12 ECU - DTC SPN 110 FMI 4 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure
04160,121
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 4ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
Perform a preliminary inspection of the ECU connector, the Engine CoolantTemperature (ECT) sensor connector, and any connectors in between them. Look fordirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 4ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Ignition ON, engine OFF
5. Read the Engine Coolant Temperature Input Voltage parameter using DST orSERVICE ADVISOR.
NOTE: For OEM engine applications, the low ECT input voltage specification is0.1V. For the low voltage specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
0.1 V or below:GO TO 3
Above 0.1 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-121 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=281
Trouble Code Diagnostics and Tests
04160,122
– – –1/1
3 Engine CoolantTemperature (ECT)Sensor Test
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 4ENGINE 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 orSERVICE ADVISOR.
NOTE: For OEM engine applications, the high ECT input voltage specification is4.9V. For the high voltage specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
Below 4.9 V:Short to ground in ECTsensor input circuitORFaulty ECU
4.9 V or greater:Faulty ECT sensor
CTM331 (09APR02) 04-160-122 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=282
Trouble Code Diagnostics and Tests
04160,123
CTM331 (09APR02) 04-160-123 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=283
Trouble Code Diagnostics and Tests
04160,124
RG40854,0000076 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe
t
ECT SensorConnector
ECT Ground
ECT Input
ECTSensor
B1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
0–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Engine Coolant Temperature (ECT) Sensor
• The ECT sensor is a thermistor (temperaturesensitive resistor) mounted on the thermostathousing or at the rear of the cylinder head. It is usedto measure the coolant temperature. The ECT’svariable resistance causes the input voltage to theECU to vary. Higher coolant temperatures result inlower ECT input voltages to the ECU; lowertemperatures result in higher voltages. For furtherECT sensor information, see MEASURINGTEMPERATURE in Section 03, Group 140 earlier inthis manual.
DTC SPN 110 FMI 15 will set if:
• The ECU senses ECT on OEM applications above108°C (226°F). For the least severe ECTspecification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06,Group 210 of this manual.
If DTC SPN 110 FMI 15 sets, the following willoccur:
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: No shutdown available
for this code.– With Derate Feature: On OEM applications, the
engine derates 2% per minute until the engine isrunning at 95% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
CTM331 (09APR02) 04-160-124 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=284
Trouble Code Diagnostics and Tests
RG40854,00000BC –19–19DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe -Continued
– – –1/1
Level 12 ECU - DTC SPN 110 FMI 15 Engine Coolant Temperature High Least Severe Diagnostic Procedure
04160,125
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 15ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information
Perform a preliminary inspection of the ECU connector, the Engine CoolantTemperature (ECT) sensor connector, and any connectors in between them. Look fordirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Engine CoolantTemperature (ECT)Sensor and CircuitTest
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 15ENGINE 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.
NOTE: On OEM applications, the least servere ECT specification is 108°C (226°F). Forthe least severe ECT specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
ECT above 108°C(226°F):
Engine overheatingproblem. See 4.5L/6.8L -C1 - ENGINE COOLANTTEMPERATURE ABOVENORMAL in Section 04,Group 150 of 4.5 L & 6.8L Diesel Engines BaseEngine Manual (CTM104).
ECT significantly lessthan 108°C (226°F):Verify that ECT sensorinput and ground circuitsare OK.If ECT sensor circuits areOK, replace ECT sensorand retest
CTM331 (09APR02) 04-160-125 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=285
Trouble Code Diagnostics and Tests
04160,126
RG40854,0000079 –19–07DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe
t
ECT SensorConnector
ECT Ground
ECT Input
ECTSensor
B1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
0–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Engine Coolant Temperature (ECT) Sensor
• The ECT sensor is a thermistor (temperaturesensitive resistor) mounted on the thermostathousing or at the rear of the cylinder head. It is usedto measure the coolant temperature. The ECT’svariable resistance causes the input voltage to theECU to vary. Higher coolant temperatures result inlower ECT input voltages to the ECU; lowertemperatures result in higher voltages. For furtherECT sensor information, see MEASURINGTEMPERATURE in Section 03, Group 140 earlier inthis manual.
DTC SPN 110 FMI 16 will set if:
• The ECU senses ECT on OEM applications above113°C (235°F). For the moderately ECT specificationon other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of thismanual.
If DTC SPN 110 FMI 16 sets, the following willoccur:
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: No shutdown available
for this code.– With Derate Feature: On OEM applications, the
engine derates 40% per minute until the engine isrunning at 60% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
CTM331 (09APR02) 04-160-126 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=286
Trouble Code Diagnostics and Tests
RG40854,00000BD –19–19DEC01–1/1
Level 12 ECU - DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe- Continued
– – –1/1
Level 12 ECU - DTC SPN 110 FMI 16 Engine Coolant Temperature High Moderately Severe DiagnosticProcedure
04160,127
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 16ENGINE COOLANT TEMPERATURE HIGH MODERATELY SEVERE supportinginformation
Perform a preliminary inspection of the ECU connector, the Engine CoolantTemperature (ECT) sensor connector, and any connectors in between them. Look fordirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Engine CoolantTemperature (ECT)Sensor and CircuitTest
NOTE: For wiring and theory of operation information, see DTC SPN 110 FMI 16ENGINE COOLANT TEMPERATURE HIGH MODERATELY SEVERE supportinginformation
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).
NOTE: On OEM applications, the moderately high ECT specification is 113°C•(235°F).For the moderately high ECT specification on other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 of this manual.
ECT above 113°C(235°F):
Engine overheatingproblem. See 4.5L/6.8L -C1 - ENGINE COOLANTTEMPERATURE ABOVENORMAL in Section 04,Group 150 of 4.5 L & 6.8L Diesel Engines BaseEngine Manual (CTM104).
ECT significantly lessthan 113°C (235°F):Verify that ECT sensorinput and ground circuitsare OK.If ECT sensor circuits areOK, replace ECT sensorand retest
CTM331 (09APR02) 04-160-127 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=287
Trouble Code Diagnostics and Tests
04160,128
RG40854,000006F –19–06DEC01–1/1
Level 12 ECU - DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High
tSensor Ground
Input
C1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Loss of CoolantTemperature Sensor
Connector
Loss of CoolantTemperature
Sensor
RG
1198
1–1
9–24
JAN
02
Loss of Coolant Temperature Sensor
• The loss of coolant temperature sensor is athermistor (temperature sensitive resistor) mountedin the rear of the cylinder head. It is used tomeasure the coolant temperature to detect whetherthere is a loss of coolant. The sensor’s variableresistance causes the input voltage to the ECU tovary. Higher coolant temperatures result in lowerloss of coolant temperature input voltages to theECU; lower temperatures result in higher voltages.For further loss of coolant temperature sensorinformation, see MEASURING TEMPERATURE inSection 03, Group 140 earlier in this manual.
DTC SPN 111 FMI 0 will set if:
• The ECU senses a coolant temperature above124°C (255°F).
If DTC SPN 111 FMI 0 sets, the following willoccur:
• The engine derates 20% per minute until the engineis running at 60% of full power. If the temperaturegoes below 124°C (255°F), the engine will regainpower at 20% per minute.
CTM331 (09APR02) 04-160-128 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=288
Trouble Code Diagnostics and Tests
RG40854,00000BE –19–19DEC01–1/1
Level 12 ECU - DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High -Continued
– – –1/1
Level 12 ECU - DTC SPN 111 FMI 0 Loss of Coolant Temperature Extremely High Diagnostic Procedure
04160,129
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 0 LOSSOF COOLANT TEMPERATURE EXTREMELY HIGH supporting information
Perform a preliminary inspection of the ECU connector, the loss of coolant temperaturesensor connector, and any connectors in between them. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Loss of CoolantTemperature Sensorand Circuit Test
NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 0 LOSSOF 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 than124°C (255°F):Verify that loss of coolanttemperature sensor inputand ground circuits areOK.If loss of coolanttemperature sensorcircuits are OK, replaceloss of coolanttemperature sensor andretest
Temperature above124°C (255°F):Engine overheatingproblem. See 4.5L/6.8L -C1 - ENGINE COOLANTTEMPERATURE ABOVENORMAL in Section 04,Group 150 of 4.5 L & 6.8L Diesel Engines BaseEngine Manual (CTM104).
CTM331 (09APR02) 04-160-129 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=289
Trouble Code Diagnostics and Tests
04160,130
RG40854,00000C0 –19–19DEC01–1/1
Level 12 ECU - DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High
tSensor Ground
Input
C1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Loss of CoolantTemperature Sensor
Connector
Loss of CoolantTemperature
Sensor
RG
1198
1–1
9–24
JAN
02
Loss of Coolant Temperature Sensor
• The loss of coolant temperature sensor is athermistor (temperature sensitive resistor) mountedin the rear of the cylinder head. It is used tomeasure the coolant temperature to detect whetherthere is a loss of coolant. The sensor’s variableresistance causes the input voltage to the ECU tovary. Higher coolant temperatures result in lowerloss of coolant temperature input voltages to theECU; lower temperatures result in higher voltages.For further loss of coolant temperature sensorinformation, see MEASURING TEMPERATURE inSection 03, Group 140 earlier in this manual.
DTC SPN 111 FMI 3 will set if:
• The loss of coolant temperature input voltageexceeds 4.975 volts. This voltage corresponds to atemperature that is lower than what is physicallypossible for engine coolant.
If DTC SPN 111 FMI 3 sets, the following willoccur:
• ECU’s high loss of coolant temperature engineprotection feature disabled.
CTM331 (09APR02) 04-160-130 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=290
Trouble Code Diagnostics and Tests
RG40854,00000C1 –19–19DEC01–1/1
Level 12 ECU - DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High -Continued
– – –1/1
Level 12 ECU - DTC SPN 111 FMI 3 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure
04160,131
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 3 LOSSOF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
Perform a preliminary inspection of the ECU connector, the loss of coolant temperaturesensor connector, and any connectors in between them. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 3 LOSSOF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine running
7. Read DTCs using the DST or SERVICE ADVISOR.
SPN 111 FMI 3reoccurs:GO TO 3
SPN 111 FMI 3 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-131 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=291
Trouble Code Diagnostics and Tests
– – –1/1
3 Loss of CoolantTemperature Sensorand Connector Test
NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 3 LOSSOF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1. Ignition OFF
2. Disconnect loss of coolant temperature sensor connector
3. Install a jumper wire between both terminals in the loss of coolant temperaturesensor harness connector
4. Ignition ON, engine OFF
5. Read DTCs using the DST or SERVICE ADVISOR.
SPN 111 FMI 3reoccurs:GO TO 4
SPN 111 FMI 4 occurs:Faulty loss of coolanttemperature sensorconnectorORFaulty loss of coolanttemperature sensor
04160,132
– – –1/1
4 Loss of CoolantTemperature OpenGround Test
NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 3 LOSSOF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1. Ignition OFF
2. Remove jumper wire between both terminals
3. Install jumper wire between loss of coolant temperature sensor harness connectorinput terminal and a good chassis ground
4. Ignition ON, engine OFF
5. Using a multimeter, measure voltage between loss of coolant temperature input (5Vsupply) terminal and a good chassis ground.
Between 4.0 V and 6.0V:Open in loss of coolanttemperature input sensorcircuitORFaulty ECU connectionORFaulty ECU
Below 4.0 V:Open in loss of coolanttemperature sensorground circuitORFaulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-132 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=292
Trouble Code Diagnostics and Tests
04160,133
CTM331 (09APR02) 04-160-133 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=293
Trouble Code Diagnostics and Tests
04160,134
RG40854,0000069 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low
tSensor Ground
Input
C1 D3
B
A
B
A
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Loss of CoolantTemperature Sensor
Connector
Loss of CoolantTemperature
Sensor
RG
1198
1–1
9–24
JAN
02
Loss of Coolant Temperature Sensor
• The loss of coolant temperature sensor is athermistor (temperature sensitive resistor) mountedin the rear of the cylinder head. It is used tomeasure the coolant temperature to detect whetherthere is a loss of coolant. The sensor’s variableresistance causes the input voltage to the ECU tovary. Higher coolant temperatures result in lowerloss of coolant temperature input voltages to theECU; lower temperatures result in higher voltages.For further loss of coolant temperature sensorinformation, see MEASURING TEMPERATURE inSection 03, Group 140 earlier in this manual.
DTC SPN 111 FMI 4 will set if:
• The loss of coolant temperature input voltage dropsbelow 0.05 volts. This voltage corresponds to atemperature that is higher than what is physicallypossible for engine coolant.
If DTC SPN 111 FMI 4 sets, the following willoccur:
• ECU’s high loss of coolant temperature engineprotection feature disabled.
CTM331 (09APR02) 04-160-134 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=294
Trouble Code Diagnostics and Tests
RG40854,00000C2 –19–19DEC01–1/1
Level 12 ECU - DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low -Continued
– – –1/1
Level 12 ECU - DTC SPN 111 FMI 4 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure
04160,135
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 4 LOSSOF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
Perform a preliminary inspection of the ECU connector, the loss of coolant temperaturesensor connector, and any connectors in between them. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 111 FMI 4 LOSSOF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine OFF
7. Read DTCs using DST or SERVICE ADVISOR.
SPN 111 FMI 4reoccurs:GO TO 3
SPN 111 FMI 4 does notreoccur:Problem is intermittent. Ifno other codes arepresent, INTERMITTENTFAULT DIAGNOSTICS,earlier in this Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-135 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=295
Trouble Code Diagnostics and Tests
– – –1/1
3 Loss of CoolantTemperature SensorTest
NOTE: For wiring and theory of operation information, DTC SPN 111 FMI 4 LOSS OFCOOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1. Ignition OFF
2. Disconnect loss of coolant temperature sensor connector
3. Ignition ON
4. Read DTCs using DST or SERVICE ADVISOR.
SPN 111 FMI 4reoccurs:Short to ground in loss ofcoolant temperaturesensor input circuitORFaulty ECU
SPN 111 FMI 3 occurs:Faulty loss of coolanttemperature sensor
04160,136
CTM331 (09APR02) 04-160-136 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=296
Trouble Code Diagnostics and Tests
04160,137
CTM331 (09APR02) 04-160-137 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=297
Trouble Code Diagnostics and Tests
04160,138
RG40854,0000066 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 158 FMI 17 ECU Power Down Error
K1 A2
IgnitionSwitch
VSW
VBAT30 A
Battery
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
2–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
DTC SPN 158 FMI 17 will set if:
• ECU detects voltage is on the switched voltage inputwire to the ECU.
If DTC SPN 158 FMI 17 sets, the following willoccur:
• Vehicle battery may be drained because ECU willnot power down.
CTM331 (09APR02) 04-160-138 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=298
Trouble Code Diagnostics and Tests
RG40854,0000109 –19–15JAN02–1/1
Level 12 ECU - DTC SPN 158 FMI 17 ECU Power Down Error - Continued
– – –1/1
Level 12 ECU - DTC SPN 158 FMI 17 ECU Power Down Error Diagnostic Procedure
04160,139
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 158 FMI 17 ECUPOWER DOWN ERROR supporting information.
Perform a preliminary inspection of the ECU connector, ignition power circuit, and anyconnectors in between them. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 158 FMI 17 ECUPOWER DOWN ERROR supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Cycle ignition OFF for 10 seconds, then back ON
7. Read DTCs using the DST or SERVICE ADVISOR.
SPN 158 FMI 17reoccurs:GO TO 3
SPN 158 FMI 17 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-139 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=299
Trouble Code Diagnostics and Tests
04160,140
– – –1/1
3 Wiring Test NOTE: For wiring and theory of operation information, see DTC SPN 158 FMI 17 ECUPOWER DOWN ERROR supporting information.
1. Ignition OFF
2. Disconnect the ECU connector
3. Ignition ON, engine OFF
4. Using a multimeter, measure voltage between terminal A2 the ECU wiring harnessconnector and a good chassis ground.
Measurement above 3.0V:Faulty ignition switchcircuitORECU key-on power supplyshorted to voltageORFaulty ignition switch
Measurement below 3.0V:Faulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-140 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=300
Trouble Code Diagnostics and Tests
04160,141
CTM331 (09APR02) 04-160-141 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=301
Trouble Code Diagnostics and Tests
04160,142
RG40854,0000062 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High
C3
A A
BB
D3
Fuel TempConnector
Fuel TempSensor
Sensor Ground
Fuel Temp Input
t
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
8–1
9–08
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Fuel Temperature Sensor
• The fuel temperature sensor is a thermistor(temperature sensitive resistor) located on theinjection pump fuel outlet housing. The fueltemperature sensor’s variable resistance causes theinput voltage to the ECU to vary. Higher fueltemperatures result in lower fuel temperature inputvoltages to the ECU; lower temperatures result inhigher voltages. The ECU uses the fuel temperaturesensor input to adjust the fuel delivery for thevariations in fuel density caused by varying fueltemperatures. For more fuel temperature sensorinformation, see MEASURING TEMPERATURE inSection 03, Group 140 of this manual.
DTC SPN 174 FMI 3 will set if:
• The fuel temperature input voltage goes above thesensor’s high voltage specification. This voltagecorresponds to a temperature that is lower than whatis physically possible for fuel temperature.– For OEM engine applications, the high fuel
temperature input voltage specification is 4.9volts.
– For other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual for the high fuel temperature inputvoltage specification.
If DTC SPN 174 FMI 3 sets, the following willoccur:
• The ECU will use a "limp-home" fuel temperaturevalue of -20°C (-4°F) during cranking, and 40°C(104°F) during running.
• Engine power will be slightly derated.
CTM331 (09APR02) 04-160-142 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=302
Trouble Code Diagnostics and Tests
RG40854,00000F3 –19–07JAN02–1/1
Level 12 ECU - DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High - Continued
– – –1/1
Level 12 ECU - DTC SPN 174 FMI 3 Fuel Temperature Input Voltage High Diagnostic Procedure
04160,143
– – –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.
NOTE: For wiring, theory of operation, and sensor location information, see DTC SPN174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the fuel temperature sensorconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring, theory of operation, and sensor location information, see DTC SPN174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Ignition ON, engine running
5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICEADVISOR.
NOTE: On OEM applications, the high fuel temperature input voltage specification is4.9 volts and above. For fuel temperature input voltage specifications on otherapplications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of thismanual.
4.9 V or greater:GO TO 3
Below 4.9 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-143 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=303
Trouble Code Diagnostics and Tests
04160,144
– – –1/1
3 Fuel TemperatureSensor andConnector Test
NOTE: For wiring, theory of operation, and sensor location information, see DTC SPN174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect fuel temperature sensor connector
3. Install a jumper wire between both terminals in the fuel temperature sensor harnessconnector
4. Ignition ON, engine OFF
5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICEADVISOR.
NOTE: On OEM applications, the low fuel temperature input voltage specification is0.1 volts and below. For fuel temperature input voltage specifications on otherapplications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of thismanual.
Above 0.1 V:GO TO 4
At or below 0.1 V:Faulty fuel temperaturesensor connectorORFaulty fuel temperaturesensor
– – –1/1
4 Fuel TemperatureOpen Ground Test
NOTE: For wiring, theory of operation, and sensor location information, see DTC SPN174 FMI 3 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire between both terminals
3. Install jumper wire between fuel temperature sensor harness connector inputterminal and a good chassis ground
4. Ignition ON, engine OFF
5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICEADVISOR.
NOTE: On OEM applications, the low fuel temperature input voltage specification is0.1 volts and below. For fuel temperature input voltage specifications on otherapplications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of thismanual.
Above 0.1 V:Open in fuel temperatureinput sensor circuitORFaulty ECU connectionORFaulty ECU
0.1 V or below:Open in fuel temperaturesensor ground circuitORFaulty ECU connectionORFaulty ECU
CTM331 (09APR02) 04-160-144 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=304
Trouble Code Diagnostics and Tests
04160,145
CTM331 (09APR02) 04-160-145 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=305
Trouble Code Diagnostics and Tests
04160,146
RG40854,0000064 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low
C3
A A
BB
D3
Fuel TempConnector
Fuel TempSensor
Sensor Ground
Fuel Temp Input
t
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
8–1
9–08
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Fuel Temperature Sensor
• The fuel temperature sensor is a thermistor(temperature sensitive resistor) located on theinjection pump fuel outlet housing. The fueltemperature sensor’s variable resistance causes theinput voltage to the ECU to vary. Higher fueltemperatures result in lower fuel temperature inputvoltages to the ECU; lower temperatures result inhigher voltages. The ECU uses the fuel temperaturesensor input to adjust the fuel delivery for thevariations in fuel density caused by varying fueltemperatures. For more fuel temperature sensorinformation, see MEASURING TEMPERATURE inSection 03, Group 140 of this manual.
DTC SPN 174 FMI 4 will set if:
• The fuel temperature input voltage goes above thesensor’s low voltage specification. This voltagecorresponds to a temperature that is higher thanwhat is physically possible for fuel temperature.– For OEM engine applications, the low fuel
temperature input voltage specification is 0.1volts.
– For other applications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual for the low fuel temperature inputvoltage specification.
If DTC SPN 174 FMI 4 sets, the following willoccur:
• The ECU will use a "limp-home" fuel temperaturevalue of -20°C (-4°F) during cranking, and 40°C(104°F) during running.
• Engine power will be slightly derated.
CTM331 (09APR02) 04-160-146 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=306
Trouble Code Diagnostics and Tests
RG40854,00000F2 –19–07JAN02–1/1
Level 12 ECU - DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low - Continued
– – –1/1
Level 12 ECU - DTC SPN 174 FMI 4 Fuel Temperature Input Voltage Low Diagnostic Procedure
04160,147
– – –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.
NOTE: For wiring, theory of operation, and sensor location information, see DTC SPN174 FMI 4 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, the fuel temperature sensorconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring, theory of operation, and sensor location information, see DTC SPN174 FMI 4 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Ignition ON, engine OFF
5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICEADVISOR
NOTE: For OEM engine applications, the low fuel temperature input voltagespecification is 0.1V. For the low voltage specification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
0.1 V or below:GO TO 3
Above 0.1 V:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-147 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=307
Trouble Code Diagnostics and Tests
04160,148
– – –1/1
3 Fuel TemperatureSensor Test
NOTE: For wiring, theory of operation, and sensor location information, seeDTC SPN174 FMI 4 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect fuel temperature sensor connector
3. Ignition ON
4. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICEADVISOR.
NOTE: For OEM engine applications, the high fuel temperature input voltagespecification is 4.9V. For the high voltage specification on other applications, seeAPPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Below 4.9 V:Short to ground in fueltemperature sensor inputcircuitORFaulty ECU
4.9 V or greater:Faulty fuel temperaturesensor
CTM331 (09APR02) 04-160-148 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=308
Trouble Code Diagnostics and Tests
04160,149
CTM331 (09APR02) 04-160-149 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=309
Trouble Code Diagnostics and Tests
04160,150
RG40854,0000061 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 174 FMI 16 Fuel Temperature Moderately High
C3
A A
BB
D3
Fuel TempConnector
Fuel TempSensor
Sensor Ground
Fuel Temp Input
t
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
8–1
9–08
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Fuel Temperature Sensor
• The fuel temperature sensor is a thermistor(temperature sensitive resistor) located on theinjection pump fuel outlet housing. The fueltemperature sensor’s variable resistance causes theinput voltage to the ECU to vary. Higher fueltemperatures result in lower fuel temperature inputvoltages to the ECU; lower temperatures result inhigher voltages. The ECU uses the fuel temperaturesensor input to adjust the fuel delivery for thevariations in fuel density caused by varying fueltemperatures. For more fuel temperature sensorinformation, see MEASURING TEMPERATURE inSection 03, Group 140 of this manual.
DTC SPN 174 FMI 16 will set if:
• The ECU senses fuel temperature on OEMapplications above 120°C (248°F). For fueltemperature specifications on other applications, seeAPPLICATION SPECIFICATIONS in Section 06,Group 210 of this manual.
If DTC SPN 174 FMI 16 sets, the following willoccur:
• Engine protection is enabled. See ENGINEPROTECTION in Section 03, Group 140 of thismanual.– With Shutdown Feature: No shutdown available
for this code.– With Derate Feature: On OEM applications, the
engine derates 2% per minute until the engine isrunning at 80% of full power. For non-OEMapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
CTM331 (09APR02) 04-160-150 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=310
Trouble Code Diagnostics and Tests
RG40854,00000F5 –19–08JAN02–1/1
Level 12 ECU - DTC SPN 174 FMI 16 Fuel Temperature Moderately High - Continued
– – –1/1
Level 12 ECU - DTC SPN 174 FMI 16 Fuel Temperature Moderately High Diagnostic Procedure
04160,151
– – –1/1
1 DTC SPN 174 FMI 16Preliminary Check
Before using this diagnostic procedure:
1. Ensure that the fuel level in the fuel tank is not extremely low
2. Ensure that fuel cooler is clean
No problems found:GO TO 2
Problem found:Repair and retest
– – –1/1
2 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.
NOTE: For wiring and theory of operation information, see DTC SPN 174 FMI 16FUEL TEMPERATURE MODERATELY HIGH supporting information
Perform a preliminary inspection of the ECU connector, the fuel temperature sensorconnector, and any connectors in between them. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 3
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
3 Fuel Supply PressureCheck
NOTE: For wiring and theory of operation information, see DTC SPN 174 FMI 16FUEL TEMPERATURE MODERATELY HIGH supporting information
Determine fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in Section04, Group 150 of this manual.
Fuel pressure withinspecification:GO TO 4
Fuel pressure belowspecification:Determine cause of lowfuel supply pressure. SeeF1 - FUEL SUPPLYSYSTEM CHECKDIAGNOSTICPROCEDURE in Section04, Group 150 of thismanual.Repair and retest.
CTM331 (09APR02) 04-160-151 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=311
Trouble Code Diagnostics and Tests
– – –1/1
4 Fuel Return LinesRestriction Check
NOTE: For wiring and theory of operation information, see DTC SPN 174 FMI 16FUEL 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 NOTrestricted:Faulty fuel coolerORFaulty injection pump
Restriction found ineither fuel return line:Determine the cause ofrestrictionRepair and retest
04160,152
CTM331 (09APR02) 04-160-152 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=312
Trouble Code Diagnostics and Tests
04160,153
CTM331 (09APR02) 04-160-153 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=313
Trouble Code Diagnostics and Tests
04160,154
RG40854,0000148 –19–11FEB02–1/1
Level 12 ECU - DTC SPN 190 FMI 0 Engine Overspeed Extreme
Crank Position Input
Crank Position Return
Crank PositionSensor
Crank SensorConnector
A
B
A
B
B2 D2
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
4–1
9–23
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Crank Position Sensor
• The crank position sensor is located on the front ofthe crankshaft, behind the pressed-on crank gear. Itis an inductive type pickup sensor that detects teethon the crank timing wheel. The ECU uses the crankposition input to determine engine speed andprecise piston position in relation to the firing order.The crank timing wheel is composed of 46 evenlyspaced teeth and 2 missing teeth. The missing teethhelp the ECU to determine Top-Dead-Center (TDC).
DTC SPN 190 FMI 0 will set if:
• The ECU detects that engine speed exceeds 3400rpm.
If DTC SPN 190 FMI 0 sets, the following willoccur:
• The ECU shuts fuel off until engine speed is below2800 rpm.
If DTC SPN 190 FMI 0 sets:
• With DTC SPN 190 FMI 0, there may or not be aproblem with the electronic control system. Using theDST or SERVICE ADVISOR, monitor DTCs on theactive code display parameter. To find DTC list, seeLISTING OF DIAGNOSTIC TROUBLE CODES(DTCS) ON ECU earlier in this Group. If there areother codes, go to the appropriate diagnosticprocedure.
• If there are no other stored or active DTCs, clearDTC SPN 190 FMI 0 and monitor codes to see ifDTC SPN 190 FMI 0 reoccurs.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-154 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=314
Trouble Code Diagnostics and Tests
04160,155
RG40854,0000149 –19–11FEB02–1/1
Level 12 ECU - DTC SPN 190 FMI 16 Engine Overspeed Moderate
Crank Position Input
Crank Position Return
Crank PositionSensor
Crank SensorConnector
A
B
A
B
B2 D2
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
4–1
9–23
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Crank Position Sensor
• The crank position sensor is located on the front ofthe crankshaft, behind the pressed-on crank gear. Itis an inductive type pickup sensor that detects teethon the crank timing wheel. The ECU uses the crankposition input to determine engine speed andprecise piston position in relation to the firing order.The crank timing wheel is composed of 46 evenlyspaced teeth and 2 missing teeth. The missing teethhelp the ECU to determine Top-Dead-Center (TDC).
DTC SPN 190 FMI 16 will set if:
• The ECU detects that engine speed is higher than3000 rpm.
If DTC SPN 190 FMI 16 sets, the following willoccur:
• The ECU shuts fuel off until engine speed is below2800 rpm.
If DTC SPN 190 FMI 16 sets:
• With DTC SPN 190 FMI 16, there may or not be aproblem with the electronic control system. Using theDST or SERVICE ADVISOR, monitor DTCs on theactive code display parameter. To find DTC list, seeLISTING OF DIAGNOSTIC TROUBLE CODES(DTCS) ON ECU earlier in this Group. If there areother codes, go to the appropriate diagnosticprocedure.
• If there are no other stored or active DTCs, clearDTC SPN 190 FMI 16 and monitor codes to see ifDTC SPN 190 FMI 16 reoccurs.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-155 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=315
Trouble Code Diagnostics and Tests
04160,156
RG40854,000005C –19–06DEC01–1/1
Level 12 ECU - DTC SPN 620 FMI 3 Sensor Supply Voltage High
OilPressureSensor
AnalogThrottle (A)Sensor
AnalogThrottle (B)Sensor
E2
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1198
3–1
9–24
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Sensor Supply Voltage
• The ECU supplies voltage to a few different sensorsdepending on the application. The ECU monitors thedrop in voltage that the sensor causes andcompares that drop to preprogrammed values in theECU’s memory to determine the value of theparameter the sensor was measuring. In addition,
the ECU monitors the exact voltage on the 5 voltsupply circuit in order to ensure accurate readings.
DTC SPN 620 FMI 3 will set if:
• The ECU detects a voltage that is higher than 5.5volts on the ECU 5 volt sensor supply circuit.
If DTC SPN 620 FMI 3 sets, the following willoccur:
• The ECU will use default values for the sensors thatuse sensor supply input voltage.
CTM331 (09APR02) 04-160-156 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=316
Trouble Code Diagnostics and Tests
RG40854,00000F6 –19–08JAN02–1/1
Level 12 ECU - DTC SPN 620 FMI 3 Sensor Supply Voltage High - Continued
– – –1/1
Level 12 ECU - DTC SPN 620 FMI 3 Sensor Supply Voltage High Diagnostic Procedure
04160,157
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 3SENSOR SUPPLY VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 3SENSOR SUPPLY VOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine OFF
7. Read DTCs using the DST or SERVICE ADVISOR.
SPN 620 FMI 3reoccurs:GO TO 3
SPN 620 FMI 3 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-157 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=317
Trouble Code Diagnostics and Tests
– – –1/1
3 Sensor Supply WireCheck for Short
NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 3SENSOR SUPPLY VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using multimeter, measure resistance between terminal E2 in the harness end ofthe ECU connector and all other terminals in the harness end of the ECUconnector.
Greater than 20,000ohms:Faulty ECU connectorORFaulty ECU
Less than 20,000 ohms:Short to voltage in sensorsupply wire
04160,158
CTM331 (09APR02) 04-160-158 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=318
Trouble Code Diagnostics and Tests
04160,159
CTM331 (09APR02) 04-160-159 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=319
Trouble Code Diagnostics and Tests
04160,160
RG40854,000005E –19–06DEC01–1/1
Level 12 ECU - DTC SPN 620 FMI 4 Sensor Supply Voltage Low
OilPressureSensor
AnalogThrottle (A)Sensor
AnalogThrottle (B)Sensor
E2
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1198
3–1
9–24
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Sensor Supply Voltage
• The ECU supplies voltage to a few different sensorsdepending on the application. The ECU monitors thedrop in voltage that the sensor causes andcompares that drop to preprogrammed values in theECU’s memory to determine the value of the
parameter the sensor was measuring. In addition,the ECU monitors the exact voltage on the 5 voltsupply circuit in order to ensure accurate readings.
DTC 620 FMI 4 will set if:
• The ECU detects a voltage that is lower than 4.44volts on the ECU 5 volt sensor supply circuit.
If DTC 620 FMI 4 sets, the following will occur:
• The ECU will use default values for the sensors thatuse sensor supply input voltage.
CTM331 (09APR02) 04-160-160 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=320
Trouble Code Diagnostics and Tests
RG40854,00000F7 –19–08JAN02–1/1
Level 12 ECU - DTC SPN 620 FMI 4 Sensor Supply Voltage Low - Continued
– – –1/1
Level 12 ECU - DTC SPN 620 FMI 4 Sensor Supply Voltage Low Diagnostic Procedure
04160,161
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Sensor Check NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition OFF
7. Disconnect all sensors that receive their 5V supply from terminal E2 of the ECU
8. Ignition ON, engine running
9. Read DTCs using the DST or SERVICE ADVISOR.
SPN 620 FMI 4reoccurs:GO TO 4
SPN 620 FMI 4 does notreoccur:GO TO 3
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-161 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=321
Trouble Code Diagnostics and Tests
– – –1/1
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Ignition ON, engine OFF
2. While reconnecting each sensor one at a time, monitor DTCs using the DST orSERVICE ADVISOR.
SPN 620 FMI 4reoccurs:Faulty sensorReplace and retest
SPN 620 FMI 4 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
04160,162
– – –1/1
4 Sensor Supply Shortto Ground Check
NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect the ECU connector
3. Using a multimeter, measure resistance between terminal D3 in the harness end ofthe ECU connector and:
• A good chassis ground• Terminal J2 in the harness end of the ECU connector
Greater than 20,000ohms:Faulty ECU connectorORFaulty ECU
Less than 20,000 ohms:Sensor 5 volt supplycircuit shorted to ground
CTM331 (09APR02) 04-160-162 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=322
Trouble Code Diagnostics and Tests
04160,163
CTM331 (09APR02) 04-160-163 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=323
Trouble Code Diagnostics and Tests
04160,164
RG40854,000014B –19–13FEB02–1/1
Level 12 ECU - DTC SPN 627 FMI 4 ECU Unswitched Power Missing
K1 A2
IgnitionSwitch
VSW
VBAT30 A
Battery
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
2–1
9–14
DE
C01
DTC SPN 627 FMI 4 will set if:
• The ECU does not detect battery voltage.
If DTC SPN 627 FMI 4 sets, the following willoccur:
• The engine will not start or run.
CTM331 (09APR02) 04-160-164 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=324
Trouble Code Diagnostics and Tests
RG40854,000014C –19–13FEB02–1/1
Level 12 ECU - DTC SPN 627 FMI 4 ECU Unswitched Power Missing - Continued
– – –1/1
Level 12 ECU - DTC SPN 627 FMI 4 ECU Unswitched Power Missing Diagnostic Procedure
04160,165
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 620 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector. Look for dirty, damaged, orpoorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 627 FMI 4 ECUUNSWITCHED POWER MISSING supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make notes of any DTCs, then clear all DTCs
6. Ignition ON, engine running
7. Read DTCs using the DST or SERVICE ADVISOR.
SPN 627 FMI 4reoccurs:GO TO 3
SPN 627 FMI 4 does notreoccur:Problem is intermittent. Ifno other codes arepresent,seeINTERMITTENTFAULT DIAGNOSTICS,earlier in this Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-165 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=325
Trouble Code Diagnostics and Tests
– – –1/1
3 ECU and ECUConnector Test
NOTE: For wiring and theory of operation information, see DTC SPN 627 FMI 4 ECUUNSWITCHED POWER MISSING supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure voltage between a good chassis ground and terminalK1
Voltage is substantiallyless than batteryvoltage:GO TO 4
Voltages are at or nearbattery voltage on bothterminals:Faulty ECU connectionORFaulty ECU
04160,166
– – –1/1
4 Battery VoltageCheck
NOTE: For wiring and theory of operation information, see DTC SPN 627 FMI 4 ECUUNSWITCHED POWER MISSING supporting information.
Using a multimeter, measure battery voltage at the battery terminals.
Voltage withinspecification forbattery:Faulty ECU power supplyfuseORFaulty ECU connectionOROpen or short in ECUpower circuit
Voltage substantiallyless than batteryvoltage:Faulty battery or chargingsystem
CTM331 (09APR02) 04-160-166 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=326
Trouble Code Diagnostics and Tests
04160,167
CTM331 (09APR02) 04-160-167 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=327
Trouble Code Diagnostics and Tests
RG40854,000003C –19–06DEC01–1/1
Level 12 ECU - DTC SPN 629 FMI 13 ECU Error
DTC SPN 629 FMI 13 will set if:
• The ECU detects an internal problem.
If DTC SPN 629 FMI 13 sets, the following willoccur:
• The engine will not start or run.
04160,168
– – –1/1
Level 12 ECU - DTC SPN 629 FMI 13 ECU Error Diagnostic Procedure
– – –1/1
1 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 629 FMI 13 ECUERROR supporting information.
1. Verify that controllers on vehicle are in correct location and connected to the correctwiring harness
2. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
3. Ignition ON, engine OFF
4. Start the ECU communication software
5. Read DTCs using DST or SERVICE ADVISOR.
6. Make note of any DTCs, then clear all DTCs
7. Ignition ON, engine running or cranking for 15 seconds
8. Read DTCs using DST or SERVICE ADVISOR.
SPN 629 FMI 13reoccurs:Faulty ECU
SPN 629 FMI 13 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-168 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=328
Trouble Code Diagnostics and Tests
04160,169
CTM331 (09APR02) 04-160-169 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=329
Trouble Code Diagnostics and Tests
04160,170
RG40854,0000038 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 637 FMI 2 Crank Position Input Noise
Crank Position Input
Crank Position Return
Crank PositionSensor
Crank SensorConnector
A
B
A
B
B2 D2
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
4–1
9–23
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Crank Position Sensor
• The crank position sensor is located on the front ofthe crankshaft, behind the pressed-on crank gear. Itis an inductive type pickup sensor that detects teethon the crank timing wheel. The ECU uses the crankposition input to determine engine speed andprecise piston position in relation to the firing order.
The crank timing wheel is composed of 46 evenlyspaced teeth and 2 missing teeth. The missing teethhelp the ECU to determine Top-Dead-Center (TDC).
DTC SPN 637 FMI 2 will set if:
• The ECU detects excessive noise (extra pulses) onthe crank position input.
If DTC SPN 637 FMI 2 sets, the following willoccur:
• Engine probably will not run
CTM331 (09APR02) 04-160-170 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=330
Trouble Code Diagnostics and Tests
RG40854,00000F8 –19–08JAN02–1/1
Level 12 ECU - DTC SPN 637 FMI 2 Crank Position Input Noise - Continued
– – –1/1
Level 12 ECU - DTC SPN 637 FMI 2 Crank Position Input Noise Diagnostic Procedure
04160,171
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 2CRANK POSITION INPUT NOISE supporting information.
Perform a preliminary inspection of the ECU connector, the crank position sensorconnector, and any other connector. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 2CRANK POSITION INPUT NOISE supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of all DTCs, then clear all DTCs
6. Warm engine
7. Ignition ON, engine running
8. Read DTCs using DST or SERVICE ADVISOR.
SPN 637 FMI 2reoccurs:GO TO 3
SPN 637 FMI 2 does notreoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-171 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=331
Trouble Code Diagnostics and Tests
04160,172
– – –1/1
3 Crank Signal NoiseTest
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 2CRANK POSITION INPUT NOISE supporting information.
1. SPN 637 FMI 2 is most likely caused by radiated or conducted electrical "noise"from some part of the machine. This problem may be caused by loose electricalground or power connections anywhere on the machine. Things to check:
• All harness connectors• Alternator connections• Chassis ground connections, battery ground connection• Corrosion, dirt, or paint can cause intermittent and "noisy" connections• Check the wiring for intermittent open and short circuits; particularly the crank
sensor wiring• Check wiring for proper pin location in the crank sensor and ECU connectors
2. 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
CTM331 (09APR02) 04-160-172 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=332
Trouble Code Diagnostics and Tests
04160,173
CTM331 (09APR02) 04-160-173 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=333
Trouble Code Diagnostics and Tests
04160,174
RG40854,000003A –19–06DEC01–1/1
Level 12 ECU - DTC SPN 637 FMI 10 Crank Position Input Pattern Error
Crank Position Input
Crank Position Return
Crank PositionSensor
Crank SensorConnector
A
B
A
B
B2 D2
A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR RG
1198
4–1
9–23
JAN
02
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Crank Position Sensor
• The crank position sensor is located on the front ofthe crankshaft, behind the pressed-on crank gear. Itis an inductive type pickup sensor that detects teethon the crank timing wheel. The ECU uses the crankposition input to determine engine speed andprecise piston position in relation to the firing order.
The crank timing wheel is composed of 46 evenlyspaced teeth and 2 missing teeth. The missing teethhelp the ECU to determine Top-Dead-Center (TDC).
DTC SPN 637 FMI 10 will set if:
• The ECU detects an improper pattern on the crankposition input.
If DTC SPN 637 FMI 10 sets, the following willoccur:
• Engine probably will not run.
CTM331 (09APR02) 04-160-174 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=334
Trouble Code Diagnostics and Tests
RG40854,000010A –19–15JAN02–1/1
Level 12 ECU - DTC SPN 637 FMI 10 Crank Position Input Pattern Error - Continued
– – –1/1
Level 12 ECU - DTC SPN 637 FMI 10 Crank Position Input Pattern Error Diagnostic Procedure
04160,175
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
Perform a preliminary inspection of the ECU connector, the crank position sensorconnector, and any other connector. Look for dirty, damaged, or poorly positionedterminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of any DTCs, then clear all DTCs
6. Ignition ON, engine running
7. Read DTCs using DST or SERVICE ADVISOR.
SPN 637 FMI 10reoccurs:GO TO 3
SPN 637 FMI 10 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-175 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=335
Trouble Code Diagnostics and Tests
– – –1/1
3 Crank PositionSensor Test
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Ignition OFF
2. Disconnect crank position sensor connector
3. Using a multimeter, measure resistance between both terminals of the crankposition sensor.
Between 2500 and 3500ohms:GO TO 4
Below 2500 ohms orabove 3500 ohms:Faulty crank positionsensor
04160,176
– – –1/1
4 Open in Crank SensorInput and ReturnCheck
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Ignition OFF
2. Disconnect crank position sensor connector
3. Disconnect ECU connector
4. Using a multimeter, measure resistance between:
• Terminal A of the crank position sensor harness connector and terminal B2 in theharness end of the ECU connector
• Terminal B of the crank position sensor harness connector and terminal D2 in theharness end of the ECU connector
Both measurements 5ohms or less:GO TO 5
Either measurementgreater than 5 ohms:Open in crank positionsensor input wireOROpen in crank positionsensor return wireORTerminals A and B in thecrank position sensorharness connectorpossibly inverted
– – –1/1
5 Crank Sensor InputWiring Check
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Ignition OFF
2. Crank position sensor connector and ECU connector still disconnected
3. Using a multimeter measure resistance between terminal B2 in the harness end ofthe ECU connector and the following:
• A good ground• All other terminals in both ECU connectors
All measurementsgreater than 2000 ohms:GO TO 6
Any measurement lessthan 2000 ohms:Faulty crank positionsensor input wiringharness
CTM331 (09APR02) 04-160-176 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=336
Trouble Code Diagnostics and Tests
– – –1/1
6 Crank Sensor ReturnWiring Check
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Ignition OFF
2. Crank position sensor connector and ECU connector still disconnected
3. Using a multimeter measure resistance between terminal D2 in the harness end ofthe ECU connector and the following:
• A good ground• All other terminals in both ECU connectors
All measurementsgreater than 2000 ohms:GO TO 7
Any measurement lessthan 2000 ohms:Faulty crank positionsensor return wiringharness
04160,177
– – –1/1
7 Crank Sensor andTiming Wheel Check
NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Remove crank position sensor from injection pump
2. Remove crank position sensor
3. Inspect sensor for cracks, corrosion, or any foreign material on the end of thesensor
4. Inspect the crank timing wheel notches for burrs or chips
All components OK:GO TO 8
Fault found in acomponent:Repair or replacecomponent as needed
– – –1/1
8 Gear Timing Check NOTE: For wiring and theory of operation information, see DTC SPN 637 FMI 10CRANK POSITION INPUT PATTERN ERROR supporting information.
1. Ignition OFF
2. Remove timing cover
3. Check timing between camshaft, crankshaft, and injection pump gears. SeeINSTALL CAMSHAFT in Group 050 of 4.5 & 6.8 L Diesel Engines Base EngineManual (CTM 104).
All gears in time:Faulty crank positionsensor connectorORFaulty ECU connectorORFaulty ECU
One or more gears outof time:Make necessaryadjustments to ensurecorrect timing. SeeINSTALL CAMSHAFT inSection 02, Group 050 of4.5 L & 6.8 L DieselEngines Base EngineManual (CTM 104).
CTM331 (09APR02) 04-160-177 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=337
Trouble Code Diagnostics and Tests
04160,178
RG40854,0000036 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 639 FMI 13 CAN Error
CAN Low
CAN High
CAN Shield
BA
C
DCEBA
Switched Voltage
CAN Terminator
Static Ground
DiagnosticConnector
DC
BJ
HG
F
E
B A A B
CC
A
F1
G1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1197
2–1
9–14
DE
C01
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Controller Area Network (CAN)
• CAN is the network in which the individualcontrollers on a machine communicate with eachother. The number of controllers communicating onCAN depends on the application. On someapplications, the ECU is the only controller on CAN;
on other applications, there are many controllers onCAN.
DTC SPN 639 FMI 13 will set if:
• The ECU detects a problem communicating on CAN.
If DTC SPN 639 FMI 13 sets, the following willoccur:
• Depending on the application, engine operation mayor may not be affected.
CTM331 (09APR02) 04-160-178 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=338
Trouble Code Diagnostics and Tests
RG40854,000010F –19–16JAN02–1/1
Level 12 ECU - DTC SPN 639 FMI 13 CAN Error - Continued
– – –1/1
Level 12 ECU - DTC SPN 639 FMI 13 CAN Error Diagnostic Procedure
04160,179
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 639 FMI 13 CANERROR supporting information
Perform a preliminary inspection of the ECU connector, the CAN connections, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 639 FMI 13 CANERROR supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start ECU communication software
4. Read DTCs using DST or SERVICE ADVISOR.
5. Make note of all DTCs, then clear all DTCs
6. Ignition ON
7. Read DTCs using the DST or SERVICE ADVISOR.
DTC SPN 639 FMI 13reoccurs:GO TO 3
DTC SPN 639 FMI 13does not reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-179 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=339
Trouble Code Diagnostics and Tests
– – –1/1
3 Check OtherControllers For CANRelated DTCs
NOTE: For wiring and theory of operation information, see DTC SPN 639 FMI 13 CANERROR supporting information
If application has other machine controllers communicating on the CAN bus, checkthose controllers for CAN related DTCs
No CAN related DTCsfound on othercontrollers:GO TO 4
Found CAN relatedDTCs on othercontrollers:Refer to machine manualto diagnose and repairthe cause of DTC, thendetermine if DTC SPN639 FMI 13 reoccurs
04160,180
– – –1/1
4 CAN Resistance Test NOTE: For wiring and theory of operation information, see DTC SPN 639 FMI 13 CANERROR supporting information
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure resistance between•terminals F1 and G1 in theharness end of the ECU connector
Between 55 ohms and65 ohms:Faulty ECU connectorORFaulty ECU
Less than 55 ohms orgreater than 65 ohms:Open or short in CANcommunication circuit
CTM331 (09APR02) 04-160-180 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=340
Trouble Code Diagnostics and Tests
04160,181
RG40854,0000114 –19–22JAN02–1/1
Level 12 ECU - DTC SPN 898 FMI 9 VehicleSpeed or Torque Message Invalid
CAN (Controller Area Network) Vehicle Speed orTorque Message
• The CAN (Controller Area Network) transmits thevehicle’s desired engine speed or torque to the ECUfrom another controller.
DTC SPN 898 FMI 9 will set if:
• The ECU does not receive the engine speed or torquemessage over CAN or it is not valid.
If DTC SPN 898 FMI 9 sets, the following will occur:
• The ECU will default engine speed to low idle.
If DTC SPN 898 FMI 9 sets:
• Connect the DST or SERVICE ADVISOR. Forinstructions on connecting to the DST or SERVICEADVISOR, see CONNECTING TO DIAGNOSTICSCAN TOOL (DST) OR SERVICE ADVISOR earlier inthis Group.
• With ignition ON and engine OFF, start the ECUcommunication software
• Read active DTCs and stored DTCs using DST orSERVICE ADVISOR. If DTC SPN 639 FMI 13 alsooccurs, see DTC SPN 639 FMI 13 CAN ERRORDIAGNOSTIC PROCEDURE earlier in this Group.
• If no other stored or active CAN or vehicle related DTCsare found, replace the ECU and retest.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-181 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=341
Trouble Code Diagnostics and Tests
04160,182
RG40854,000003E –19–06DEC01–1/1
Level 12 ECU - DTC SPN 970 FMI 31 Auxiliary Engine Shutdown Switch Active
To ExternalShutdown
Switch Switch Input A1
D3
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Sensor Ground
RG
1204
7–1
9–24
JAN
02
IMPORTANT: Do not force probes into connectorterminals or damage will result. UseJT07328 Connector Adapter Test Kitto make measurements inconnectors. This will ensure thatterminal damage does not occur.
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
Auxiliary Engine Shutdown Switch
• On OEM applications, the engine shutdown switch isa normally open switch. When the property being
measured exceeds a certain value, the switch willclose. When the switch is closed, the voltage isgrounded, which will cause the ECU to shutdown theengine.
DTC SPN 970 FMI 31 will set if:
• The ECU does not read an input voltage on theauxiliary engine shutdown input wire.
If DTC SPN 970 FMI 31 sets, the following willoccur:
• The ECU will shut the engine down immediately.
CTM331 (09APR02) 04-160-182 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=342
Trouble Code Diagnostics and Tests
04160,183
RG40854,000003F –19–06DEC01–1/1
Level 12 ECU - DTC SPN 971 FMI 31 External Engine Derate Switch Active
To ExternalDerateSwitch Input C2
D3
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
Sensor Ground
RG
1204
6–1
9–23
JAN
02
IMPORTANT: Do not force probes into connectorterminals or damage will result. UseJT07328 Connector Adapter Test Kitto make measurements inconnectors. This will ensure thatterminal damage does not occur.
NOTE: Wiring schematic shows OEM engineapplications only. For wiring on otherapplications, see APPLICATIONSPECIFICATIONS in Section 06, Group 210 ofthis manual.
External Fuel Derate Switch
• On OEM applications, the external derate switch is anormally open switch. When property being
measured exceeds a certain value, the switch willclose. When the switch is closed, the voltage isgrounded, which will cause the ECU to derate theengine.
DTC SPN 971 FMI 31 will set if:
• The ECU does not read an input voltage.
If DTC SPN 971 FMI 31 sets, the following willoccur:
• On OEM applications, the ECU will derate theengine 2% per minute until the engine is running at80% of full power. For derates on other applications,see APPLICATION SPECIFICATIONS in Section 06,Group 210 of this manual.
CTM331 (09APR02) 04-160-183 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=343
Trouble Code Diagnostics and Tests
04160,184
RG40854,0000040 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an fuelcontrol solenoid that is controlled by the EngineControl Unit (ECU). The ECU switches current onand off in order to charge the solenoid. When thecurrent to the solenoid is increased, it moves apump control valve into a position that allows forinjection pressure to be developed. When thecurrent to the solenoid is decreased, the pumpcontrol valve will return to a position that endsinjection pressure. By controlling current to thesolenoid, the ECU has the ability to manage thequantity and timing of fuel delivery to the engine. For
more operation information, see FUEL INJECTIONPUMP OPERATION in Section 03, Group 130 of thismanual.
DTC SPN 1076 FMI 0 will set if:
• The ECU determines that the pump control valvetakes too long to close.
If DTC SPN 1076 FMI 0 sets, the following willoccur:
• Engine performance may be erratic.
CTM331 (09APR02) 04-160-184 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=344
Trouble Code Diagnostics and Tests
RG40854,0000124 –19–29JAN02–1/1
Level 12 ECU - DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long - Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 0 Pump Control Valve Closure Too Long Diagnostic Procedure
04160,185
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 0PUMP CONTROL VALVE CLOSURE TOO LONG supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 0PUMP CONTROL VALVE CLOSURE TOO LONG supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 0reoccurs:GO TO 3
SPN 1076 FMI 0 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-185 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=345
Trouble Code Diagnostics and Tests
– – –1/1
3 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 0PUMP CONTROL VALVE CLOSURE TOO LONG supporting information.
1. Remove and install new injection pump. See REMOVE INJECTION PUMP andINSTALL INJECTION PUMP in Section 02, Group 090 of this manual.
2. Ignition ON, engine running.
3. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 0reoccurs:Faulty ECU
SPN 1076 FMI 0 doesnot reoccur:Problem repaired
04160,186
CTM331 (09APR02) 04-160-186 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=346
Trouble Code Diagnostics and Tests
04160,187
CTM331 (09APR02) 04-160-187 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=347
Trouble Code Diagnostics and Tests
04160,188
RG40854,0000044 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an fuelcontrol solenoid that is controlled by the EngineControl Unit (ECU). The ECU switches current onand off in order to charge the solenoid. When thecurrent to the solenoid is increased, it moves apump control valve into a position that allows forinjection pressure to be developed. When thecurrent to the solenoid is decreased, the pumpcontrol valve will return to a position that endsinjection pressure. By controlling current to thesolenoid, the ECU has the ability to manage thequantity and timing of fuel delivery to the engine. For
more operation information, see FUEL INJECTIONPUMP OPERATION in Section 03, Group 130 of thismanual.
DTC SPN 1076 FMI 1 will set if:
• The ECU determines that the control valve closestoo quickly.
If DTC SPN 1076 FMI 1 sets, the following willoccur:
• Engine performance may be erratic.
CTM331 (09APR02) 04-160-188 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=348
Trouble Code Diagnostics and Tests
RG40854,0000125 –19–29JAN02–1/1
Level 12 ECU - DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short - Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 1 Pump Control Valve Closure Too Short Diagnostic Procedure
04160,189
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 1PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 1PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 1reoccurs:GO TO 3
SPN 1076 FMI 1 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-189 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=349
Trouble Code Diagnostics and Tests
– – –1/1
3 Checking BatteryVoltage
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 1PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information.
1. Ignition ON, engine OFF
2. Read the Battery Voltage parameter using the DST or SERVICE ADVISOR.
At or near batteryvoltage:GO TO 4
Significantly above orbelow battery voltage:Faulty power supply
04160,190
– – –1/1
4 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 1PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information.
1. Remove and install new injection pump. See REMOVE INJECTION PUMP andINSTALL INJECTION PUMP in Section 02, Group 090 of this manual.
2. Ignition ON, engine running.
3. Read DTCs using the DST or SERVICE ADVISOR.
SPN 1076 FMI 1reoccurs:Faulty ECU
SPN 1076 FMI 1 doesnot reoccur:Problem repaired
CTM331 (09APR02) 04-160-190 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=350
Trouble Code Diagnostics and Tests
04160,191
CTM331 (09APR02) 04-160-191 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=351
Trouble Code Diagnostics and Tests
04160,192
RG40854,0000046 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 3 Pump Solenoid Current High
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an internalsolenoid that is controlled by the Engine Control Unit(ECU). The ECU switches current on and off inorder to charge the solenoid. When the current tothe solenoid is increased, it moves a pump controlvalve into a position that allows for injection pressureto be developed. When the current to the solenoid isdecreased, the pump control valve will return to aposition that ends injection pressure. By controllingcurrent to the solenoid, the ECU has the ability tomanage the quantity and timing of fuel delivery to
the engine. For more operation information, seeFUEL INJECTION PUMP OPERATION in Section03, Group 130 of this manual.
DTC SPN 1076 FMI 3 will set if:
• The ECU determines that pump solenoid current ishigher than normal.
If DTC SPN 1076 FMI 3 sets, the following willoccur:
• Engine performance may be erratic.
CTM331 (09APR02) 04-160-192 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=352
Trouble Code Diagnostics and Tests
RG40854,0000126 –19–29JAN02–1/1
Level 12 ECU - DTC SPN 1076 FMI 3 Pump Solenoid Current High - Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 3 Pump Solenoid Current High Diagnostic Procedure
04160,193
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 3PUMP SOLENOID CURRENT HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 3PUMP SOLENOID CURRENT HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 3reoccurs:GO TO 3
SPN 1076 FMI 3 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-193 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=353
Trouble Code Diagnostics and Tests
– – –1/1
3 Pump SolenoidReturn Wire Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 3PUMP SOLENOID CURRENT HIGH supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, measure resistance between Terminal A3 and all otherterminals in the ECU connector
Measurement greaterthan 20,000 ohms:GO TO 4
Measurement less than20,000 ohms:Short to power in pumpsolenoid return wire
04160,194
– – –1/1
4 Pump SolenoidSupply Wire Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 3PUMP SOLENOID CURRENT HIGH supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, measure resistance between Terminal K2 and all otherterminals in the ECU connector
Measurement greaterthan 20,000 ohms:GO TO 5
Measurement less than20,000 ohms:Short to power in pumpsolenoid supply wire
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 3PUMP SOLENOID CURRENT HIGH supporting information.
1. Remove and install new injection pump. See REMOVE INJECTION PUMP andINSTALL INJECTION PUMP in Section 02, Group 090 of this manual.
2. Ignition ON, engine running.
3. Read DTCs using the DST or SERVICE ADVISOR.
SPN 1076 FMI 3reoccurs:Faulty ECU
SPN 1076 FMI 3 doesnot reoccur:Problem repaired
CTM331 (09APR02) 04-160-194 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=354
Trouble Code Diagnostics and Tests
04160,195
CTM331 (09APR02) 04-160-195 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=355
Trouble Code Diagnostics and Tests
04160,196
RG40854,0000049 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an internalsolenoid that is controlled by the Engine Control Unit(ECU). The ECU switches current on and off inorder to charge the solenoid. When the current tothe solenoid is increased, it moves a pump controlvalve into a position that allows for injection pressureto be developed. When the current to the solenoid isdecreased, the pump control valve will return to aposition that ends injection pressure. By controllingcurrent to the solenoid, the ECU has the ability tomanage the quantity and timing of fuel delivery to
the engine. For more operation information, seeFUEL INJECTION PUMP OPERATION in Section03, Group 130 of this manual.
DTC SPN 1076 FMI 5 will set if:
• The ECU determines that pump solenoid circuit isopen.
If DTC SPN 1076 FMI 5 sets, the following willoccur:
• Engine will not run.
CTM331 (09APR02) 04-160-196 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=356
Trouble Code Diagnostics and Tests
RG40854,000004C –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open - Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 5 Pump Solenoid Circuit Open Diagnostic Procedure
04160,197
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 5PUMP SOLENOID CIRCUIT OPEN supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 5PUMP SOLENOID CIRCUIT OPEN supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 5reoccurs:GO TO 3
SPN 1076 FMI 5 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-197 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=357
Trouble Code Diagnostics and Tests
– – –1/1
3 ECU Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 5PUMP SOLENOID CIRCUIT OPEN supporting information.
1. Ignition OFF, engine OFF
2. Disconnect ECU connector
3. Using a multimeter, measure resistance between terminal K2 and terminal A3 of theharness side of the ECU connector.
Measurement less than5 ohms:GO TO 4
Measurment 5 ohms orgreater:Faulty ECU connectorORFaulty ECU
04160,198
– – –1/1
4 Injection PumpWiring Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 5PUMP SOLENOID CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, 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 measurementsless than 5 ohms:Faulty pump connectorORFaulty injection pump
Either measurementgreater than 5 ohms:Faulty pump connectorORFaulty ECU connectorOROpen in pump solenoidsupply wireOROpen in pump solenoidreturn wire
CTM331 (09APR02) 04-160-198 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=358
Trouble Code Diagnostics and Tests
04160,199
CTM331 (09APR02) 04-160-199 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=359
Trouble Code Diagnostics and Tests
04160,200
RG40854,000004D –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an internalsolenoid that is controlled by the Engine Control Unit(ECU). The ECU switches current on and off inorder to charge the solenoid. When the current tothe solenoid is increased, it moves a pump controlvalve into a position that allows for injection pressureto be developed. When the current to the solenoid isdecreased, the pump control valve will return to aposition that ends injection pressure. By controllingcurrent to the solenoid, the ECU has the ability tomanage the quantity and timing of fuel delivery to
the engine. For more operation information, seeFUEL INJECTION PUMP OPERATION in Section03, Group 130 of this manual.
DTC SPN 1076 FMI 6 will set if:
• The ECU determines that pump solenoid circuit isshorted.
If DTC SPN 1076 FMI 6 sets, the following willoccur:
• ECU will shut engine down immediately.
CTM331 (09APR02) 04-160-200 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=360
Trouble Code Diagnostics and Tests
RG40854,0000127 –19–29JAN02–1/1
Level 12 ECU - DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted - Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 6 Pump Solenoid Circuit Severely Shorted Diagnostic Procedure
04160,201
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 6PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 6PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISORearlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 6reoccurs:GO TO 3
SPN 1076 FMI 6 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-201 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=361
Trouble Code Diagnostics and Tests
– – –1/1
3 Pump SolenoidSupply Circuit Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 6PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, measure resistance between terminal K2 of the harness side ofthe ECU connector and:
• A good ground• All other terminals in the ECU connector
Measurement greaterthan 20,000 ohms:GO TO 4
Measurement less than20,000 ohms:Pump solenoid supplywire shorted
04160,202
– – –1/1
4 Pump SolenoidReturn Circuit Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 6PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, measure resistance between terminal A3 of the harness side ofthe ECU connector and:
• A good ground• All other terminals in the ECU connector
Measurement greaterthan 20,000 ohms:GO TO 5
Measurement less than20,000 ohms:Pump solenoid returnwire shorted
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 6PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.
1. Remove and install new injection pump. See REMOVE INJECTION PUMP andINSTALL INJECTION PUMP in Section 02, Group 090 of this manual.
2. Ignition ON, engine running.
3. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 6reoccurs:Faulty ECU
SPN 1076 FMI 6 doesnot reoccur:Problem repaired
CTM331 (09APR02) 04-160-202 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=362
Trouble Code Diagnostics and Tests
04160,203
CTM331 (09APR02) 04-160-203 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=363
Trouble Code Diagnostics and Tests
04160,204
RG40854,000004F –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an internalsolenoid that is controlled by the Engine Control Unit(ECU). The ECU switches current on and off inorder to charge the solenoid. When the current tothe solenoid is increased, it moves a pump controlvalve into a position that allows for injection pressureto be developed. When the current to the solenoid isdecreased, the pump control valve will return to aposition that ends injection pressure. By controllingcurrent to the solenoid, the ECU has the ability tomanage the quantity and timing of fuel delivery to
the engine. For more operation information, seeFUEL INJECTION PUMP OPERATION in Section03, Group 130 of this manual.
DTC SPN 1076 FMI 7 will set if:
• The ECU determines that it can not detect theclosure of the pump control valve.
If DTC SPN 1076 FMI 7 sets, the following willoccur:
• Engine performance may be erratic.
CTM331 (09APR02) 04-160-204 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=364
Trouble Code Diagnostics and Tests
RG40854,0000050 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected -Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 7 Pump Control Valve Closure Not Detected Diagnostic Procedure
04160,205
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 7PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 7PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using the DST or SERVICE ADVISOR.
SPN 1076 FMI 7reoccurs:GO TO 3
SPN 1076 FMI 7 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-205 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=365
Trouble Code Diagnostics and Tests
– – –1/1
3 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 7PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information.
1. Remove and install new injection pump. See REMOVE INJECTION PUMP andINSTALL INJECTION PUMP in Section 02, Group 090 of this manual.
2. Ignition ON, engine running.
3. Read DTCs using the DST or SERVICE ADVISOR.
SPN 1076 FMI 7reoccurs:Faulty ECU
SPN 1076 FMI 7 doesnot reoccur:Problem repaired
04160,206
CTM331 (09APR02) 04-160-206 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=366
Trouble Code Diagnostics and Tests
04160,207
CTM331 (09APR02) 04-160-207 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=367
Trouble Code Diagnostics and Tests
04160,208
RG40854,0000051 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an internalsolenoid that is controlled by the Engine Control Unit(ECU). The ECU switches current on and off inorder to charge the solenoid. When the current tothe solenoid is increased, it moves a pump controlvalve into a position that allows for injection pressureto be developed. When the current to the solenoid isdecreased, the pump control valve will return to aposition that ends injection pressure. By controllingcurrent to the solenoid, the ECU has the ability tomanage the quantity and timing of fuel delivery tothe engine. For more operation information, see
FUEL INJECTION PUMP OPERATION in Section03, Group 130 of this manual.
DTC SPN 1076 FMI 10 will set if:
• Pump solenoid circuit is moderately shorted topower.
If DTC SPN 1076 FMI 10 sets, the following willoccur:
• ECU will derate engine to 50% of full powerimmediately.
CTM331 (09APR02) 04-160-208 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=368
Trouble Code Diagnostics and Tests
RG40854,0000050 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted -Continued
– – –1/1
Level 12 ECU - DTC SPN 1076 FMI 10 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure
04160,209
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 10PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and anyother connector. Look for dirty, damaged, or poorly positioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 10PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine cranking or running
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1076 FMI 10reoccurs:GO TO 3
SPN 1076 FMI 10 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-209 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=369
Trouble Code Diagnostics and Tests
– – –1/1
3 Pump SolenoidSupply Circuit Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 10PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, measure resistance between terminal K2 of the harness side ofthe ECU connector and:
• A good ground• All other terminals in the ECU connector
Measurement greaterthan 20,000 ohms:GO TO 4
Measurement less than20,000 ohms:Pump solenoid supplywire shorted
04160,210
– – –1/1
4 Pump SolenoidReturn Circuit Check
NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 10PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information.
1. Ignition OFF
2. Disconnect pump solenoid connector and ECU connector
3. Using a multimeter, measure resistance between terminal A3 of the harness side ofthe ECU connector and:
• A good ground• All other terminals in the ECU connector
Measurement greaterthan 20,000 ohms:GO TO 5
Measurement less than20,000 ohms:Pump solenoid returnwire shorted
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC SPN 1076 FMI 10PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information.
1. Remove and install new injection pump. See REMOVE INJECTION PUMP andINSTALL INJECTION PUMP in Section 02, Group 090 of this manual.
2. Ignition ON, engine running.
3. Read DTCs using the DST or SERVICE ADVISOR.
SPN 1076 FMI 10reoccurs:Faulty ECU
SPN 1076 FMI 10 doesnot reoccur:Problem repaired
CTM331 (09APR02) 04-160-210 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=370
Trouble Code Diagnostics and Tests
04160,211
CTM331 (09APR02) 04-160-211 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=371
Trouble Code Diagnostics and Tests
04160,212
RG40854,0000052 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1079 FMI 3 Sensor Supply Voltage High
Analog Throttle (A)Sensor Connector
AnalogThrottle (A)
Sensor
A A
B BC C
Sensor Return D3
Analog Throttle (A) Input B3
Sensor 5V E2
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1204
4–1
9–23
JAN
02
Sensor Supply Voltage
• The ECU supplies voltage to a few different sensorsdepending on the application. The ECU monitors thedrop in voltage that the sensor causes andcompares that drop to preprogrammed values in theECU’s memory to determine the value of theparameter the sensor was measuring. In addition,the ECU monitors the exact voltage on the 5 voltsupply circuit in order to ensure accurate readings.
DTC 1079 FMI 3 will set if:
• The ECU detects a voltage that is higher than 5.5volts on the ECU 5 volt sensor supply circuit.
If DTC 1079 FMI 3 sets, the following will occur:
• The ECU will use default values for the sensors thatuse sensor supply input voltage.
CTM331 (09APR02) 04-160-212 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=372
Trouble Code Diagnostics and Tests
RG40854,000010E –19–16JAN02–1/1
Level 12 ECU - DTC SPN 1079 FMI 3 Sensor Supply Voltage High - Continued
– – –1/1
Level 12 ECU - DTC SPN 1079 FMI 3 Sensor Supply Voltage High Diagnostic Procedure
04160,213
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1079 FMI 3SENSOR SUPPLY VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the analog throttle (A)connector, and any connectors in between. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1079 FMI 3SENSOR SUPPLY VOLTAGE HIGH supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make notes of any DTCs, then clear all DTCs
5. Ignition ON, engine OFF
6. Read DTCs using DST or SERVICE ADVISOR.
SPN 1079 FMI 3reoccur:GO TO 3
SPN 1079 FMI 3 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-213 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=373
Trouble Code Diagnostics and Tests
– – –1/1
3 Sensor Supply WireCheck for Short
NOTE: For wiring and theory of operation information, DTC SPN 1079 FMI 3 SENSORSUPPLY VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure resistance between terminal E2 the harness end ofthe ECU connector and all other terminals in the harness end of the ECU connector
Greater than 20,000ohms:Faulty ECU connectorORFaulty ECU
Less than 20,000 ohms:Short to voltage in sensorsupply wire
04160,214
CTM331 (09APR02) 04-160-214 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=374
Trouble Code Diagnostics and Tests
04160,215
CTM331 (09APR02) 04-160-215 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=375
Trouble Code Diagnostics and Tests
04160,216
RG40854,0000054 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1079 FMI 4 Sensor Supply Voltage Low
Analog Throttle (A)Sensor Connector
AnalogThrottle (A)
Sensor
A A
B BC C
Sensor Return D3
Analog Throttle (A) Input B3
Sensor 5V E2
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
ECU
HARNESS
CONNECTOR
RG
1204
4–1
9–23
JAN
02
Sensor Supply Voltage
• The ECU supplies voltage to a few different sensorsdepending on the application. The ECU monitors thedrop in voltage that the sensor causes andcompares that drop to preprogrammed values in theECU’s memory to determine the value of theparameter the sensor was measuring. In addition,the ECU monitors the exact voltage on the 5 voltsupply circuit in order to ensure accurate readings.
DTC 1079 FMI 4 will set if:
• The ECU detects a voltage that is lower than 4.44volts on the ECU 5 volt sensor supply circuit.
If DTC 1079 FMI 4 sets, the following will occur:
• The ECU will use default values for the sensors thatuse sensor supply input voltage.
CTM331 (09APR02) 04-160-216 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=376
Trouble Code Diagnostics and Tests
RG40854,000010D –19–16JAN02–1/1
Level 12 ECU - DTC SPN 1079 FMI 4 Sensor Supply Voltage Low - Continued
– – –1/1
Level 12 ECU - DTC SPN 1079 FMI 4 Sensor Supply Voltage Low Diagnostic Procedure
04160,217
– – –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.
NOTE: For wiring and theory of operation information, see DTC SPN 1079 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, the analog throttle (A)connector, and any connectors in between. Look for dirty, damaged, or poorlypositioned terminals.
No faulty connection(s):GO TO 2
Faulty connection(s):Repair faultyconnection(s)
– – –1/1
2 Sensor Check NOTE: For wiring and theory of operation information, see DTC SPN 1079 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to theDST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs
5. Ignition OFF
6. Disconnect all of the sensors that receive their 5 V supply from terminal E2 in theECU connector.
7. Ignition ON, engine running
8. Read DTCs using DST or SERVICE ADVISOR.
SPN 1079 FMI 4reoccurs:GO TO 4
SPN 1079 FMI 4 doesnot reoccur:GO TO 3
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 04-160-217 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=377
Trouble Code Diagnostics and Tests
– – –1/1
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC SPN 1079 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Ignition ON
2. While reconnecting each of the sensors one at a time, read DTCs using the DST orSERVICE ADVISOR.
SPN 1079 FMI 4reoccurs:Sensor that reset theDTC is faultyReplace and retest
SPN 1079 FMI 4 doesnot reoccur:Problem is intermittent. Ifno other codes arepresent, seeINTERMITTENT FAULTDIAGNOSTICS, earlier inthis Group.
04160,218
– – –1/1
4 Sensor Supply Shortto Ground Check
NOTE: For wiring and theory of operation information, see DTC SPN 1079 FMI 4SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect ECU connector
3. Using a multimeter, measure resistance individually between terminal E2 in theharness 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 20,000ohms:Faulty ECU connectorORFaulty ECU
Less than 20,000 ohms:Sensor 5 volt supplycircuit shorted to aground
CTM331 (09APR02) 04-160-218 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=378
Trouble Code Diagnostics and Tests
04160,219
CTM331 (09APR02) 04-160-219 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=379
Trouble Code Diagnostics and Tests
04160,220
RG40854,0000056 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1109 FMI 31 Engine Protection Shutdown Warning
Engine Shutdown Warning:
• This code informs the operator that the ECU willshut the engine down because it has detected acondition such as low oil pressure, high enginecoolant temperature, high loss of coolanttemperature, low coolant level, high fueltemperature, or a faulty injection pump. If the ECU isprogrammed with engine protection with shutdown,the ECU has shut the engine down within 30seconds. Prior to shutdown, the engine will bederated.
DTC SPN 1109 FMI 31 will set if:
• The ECU detects low oil pressure.• The ECU detects a high engine coolant temperature.• The ECU detects a high loss of coolant temperature.• The ECU detects a high fuel temperature.
If DTC SPN 1109 FMI 31 sets, the following willoccur:
• If the ECU has engine protection with shutdown, itwill derate (according to relating DTC) the engine for30 seconds and will shut the engine down.
If DTC 1109 FMI 31 sets:
• If DTC SPN 100 FMI 1 is active, see DTC SPN 100FMI 1 ENGINE OIL PRESSURE EXTREMELY LOWDIAGNOSTIC PROCEDURE earlier in this Group ofthe manual.
• If DTC SPN 110 FMI 0 is active, see DTC SPN 110FMI 0 ENGINE COOLANT TEMPERATURE HIGHMOST SEVERE DIAGNOSTIC PROCEDURE earlierin this Group of the manual.
• If DTC SPN 111 FMI 0 is active, see DTC SPN 111FMI 0 LOSS OF COOLANT TEMPERATUREEXTREMELY HIGH DIAGNOSTIC PROCEDUREearlier in this Group of the manual.
• If DTC SPN 174 FMI 16 is active, see DTC SPN174 FMI 16 FUEL TEMPERATURE MODERATELYHIGH DIAGNOSTIC PROCEDURE earlier in thisGroup of the manual.
CTM331 (09APR02) 04-160-220 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=380
Trouble Code Diagnostics and Tests
04160,221
RG40854,0000057 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1110 FMI 31 Engine Protection Shutdown
Engine Protection Shutdown:
• This code informs the operator that the ECU shutthe engine down because it has detected a conditionsuch low oil pressure, high engine coolanttemperature, high loss of coolant temperature, or lowcoolant level. If the ECU is programmed with engineprotection with shutdown, the ECU has shut theengine down.
DTC SPN 1110 FMI 31 will set if:
• The ECU detects low oil pressure.• The ECU detects a high engine coolant temperature.• The ECU detects a high loss of coolant temperature.• The ECU detects a high fuel temperature.
If DTC SPN 1110 FMI 31 sets, the following willoccur:
• The ECU will have shut the engine down.
If DTC 1110 FMI 31 sets:
• If DTC SPN 100 FMI 1 is active, see DTC SPN 100FMI 1 ENGINE OIL PRESSURE EXTREMELY LOWDIAGNOSTIC PROCEDURE earlier in this Group ofthe manual.
• If DTC SPN 110 FMI 0 is active, see DTC SPN 110FMI 0 ENGINE COOLANT TEMPERATURE HIGHMOST SEVERE DIAGNOSTIC PROCEDURE earlierin this Group of the manual.
• If DTC SPN 111 FMI 0 is active, see DTC SPN 111FMI 0 LOSS OF COOLANT TEMPERATUREEXTREMELY HIGH DIAGNOSTIC PROCEDUREearlier in this Group of the manual.
• If DTC SPN 174 FMI 16 is active, see DTC SPN174 FMI 16 FUEL TEMPERATURE MODERATELYHIGH DIAGNOSTIC PROCEDURE earlier in thisGroup of the manual.
CTM331 (09APR02) 04-160-221 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=381
Trouble Code Diagnostics and Tests
04160,222
RG40854,0000058 –19–06DEC01–1/1
Level 12 ECU - DTC SPN 1569 FMI 31 Fuel Derate
Fuel Derate
• The fuel derate trouble code is set to indicate thatthe ECU has detected a condition such as low oilpressure, high manifold air temperature, high coolanttemperature, high loss of coolant temperature, orhigh fuel temperature. If the ECU detects one ofthese conditions, it will begin to derate the amount offuel delivered to the engine.
DTC SPN 1569 FMI 31 will set if:
• The ECU detects low oil pressure.• The ECU detects high manifold air temperature.• The ECU detects a high engine coolant temperature.• The ECU detects a high loss of coolant temperature.• The ECU detects a high fuel temperature.
If DTC SPN 1569 FMI 31 sets, the following willoccur:
• The ECU will limit the amount of fuel available to theengine in an attempt to protect the engine.
If DTC SPN 1569 FMI 31 sets:
• If DTC SPN 100 FMI 1 or DTC SPN 100 FMI 18 isactive, see one of the following procedures earlier inthis Group of the manual:– DTC SPN 100 FMI 1 ENGINE OIL PRESSURE
EXTREMELY LOW DIAGNOSTIC PROCEDURE
– DTC SPN 100 FMI 18 ENGINE OIL PRESSUREMODERATELY LOW DIAGNOSTICPROCEDURE
• If DTC SPN 105 FMI 16 is active, see DTC SPN105 FMI 16 MANIFOLD AIR TEMPERATUREMODERATELY HIGH DIAGNOSTIC PROCEDUREearlier in this Group of the manual.
• If DTC SPN 110 FMI 0, DTC SPN 110 FMI 15, orDTC SPN 110 FMI 16 is active, see one of thefollowing procedures earlier in this Group of themanual:– DTC SPN 110 FMI 0 ENGINE COOLANT
TEMPERATURE HIGH MOST SEVEREDIAGNOSTIC PROCEDURE
– DTC SPN 110 FMI 15 ENGINE COOLANTTEMPERATURE HIGH LEAST SEVEREDIAGNOSTIC PROCEDURE
– DTC SPN 110 FMI 16 ENGINE COOLANTTEMPERATURE HIGH MODERATELY SEVEREDIAGNOSTIC PROCEDURE
• If DTC SPN 111 FMI 0 is active, see DTC SPN 111FMI 0 LOSS OF COOLANT TEMPERATUREEXTREMELY HIGH DIAGNOSTIC PROCEDUREearlier in this Group of the manual.
• If DTC SPN 174 FMI 16 is active, see DTC SPN174 FMI 16 FUEL TEMPERATURE MODERATELYHIGH DIAGNOSTIC PROCEDURE earlier in thisGroup of the manual.
CTM331 (09APR02) 04-160-222 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=382
Trouble Code Diagnostics and Tests
04160,223
RG40854,000005A –19–06DEC01–1/1
Level 12 ECU - DTC SPN 2000 FMI 6 Internal ECU Failure
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Pump Solenoid Return
Pump Solenoid Supply
PumpSolenoid Pump
Solenoid Connector
A3
K2
CONNECTOR
ECU
HARNESS
B
A
B
A
RG
1198
5–1
9–20
DE
C01
Stanadyne DE10 Injection Pump
• The Stanadyne DE10 injection pump has an internalsolenoid that is controlled by the Engine Control Unit(ECU). The ECU switches current on and off inorder to charge the solenoid. When the current tothe solenoid is increased, it moves a pump controlvalve into a position that allows for injection pressureto be developed. When the current to the solenoid isdecreased, the pump control valve will return to aposition that ends injection pressure. By controllingcurrent to the solenoid, the ECU has the ability tomanage the quantity and timing of fuel delivery tothe engine. For more operation information, seeFUEL INJECTION PUMP OPERATION in Section03, Group 130 of this manual.
DTC SPN 2000 FMI 6 will set if:
• ECU has detected a short in the ECU that causesan extremely high current at the injection pump.
If DTC SPN 2000 FMI 6 sets, the following willoccur:
• Engine shuts down immediately
If DTC SPN 2000 FMI 6 sets:
• Replace the ECU and retest.
CTM331 (09APR02) 04-160-223 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=383
Trouble Code Diagnostics and Tests
04160,224
RG40854,000005B –19–06DEC01–1/1
Level 12 ECU - DTC SPN 2000 FMI 13 Security Violation
Security Violation
• When the ignition is first turned on, all of thecontrollers on the machine communicate with eachother to make sure that all controllers are correct forthe particular machine.
DTC SPN 2000 FMI 13 will set if:
• The ECU determines that it, OR another controlleron the machine is not the right controller for theparticular machine.
If DTC SPN 2000 FMI 13 sets, the following willoccur:
• The ECU will allow the engine to start, but will onlyallow low idle engine speed.
If DTC SPN 2000 FMI 13 sets:
• If one of the controllers on the machine has justbeen replaced, make sure the correct controller wasinstalled.
• If all controllers on the machine are the correct partnumbers, check to see if any of the controllers haveactive or stored CAN related DTCs. If they do, go tothe appropriate diagnostic procedure.
CTM331 (09APR02) 04-160-224 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=384
Section 05Tools and Other Materials
Contents
Page
Group 170—Electronic Fuel/Control System RepairTools and Other Materials
Fuel System Repair and AdjustmentEssential Tools . . . . . . . . . . . . . . . . . . . . . .05-170-1
Fuel System Repair and AdjustmentService Equipment and Tools . . . . . . . . . . .05-170-3
Fuel System Repair and Adjustment OtherMaterials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-4
Control System Repair and AdjustmentEssential Tools . . . . . . . . . . . . . . . . . . . . . .05-170-5
Control System Repair and Adjustment OtherMaterials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-9
05Group 180—Diagnostic Service ToolsElectronic Fuel System Diagnostic Tools. . . . .05-180-1
CTM331 (09APR02) 05-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=1
Contents
05
CTM331 (09APR02) 05-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Group 170Electronic Fuel/Control System Repair Tools and Other Materials
OUO1080,000020F –19–27NOV01–1/10
Fuel System Repair and AdjustmentEssential Tools
NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
051701
OUO1080,000020F –19–27NOV01–2/10
RG12017 –UN–16NOV01
JDG1560
Injection Pump Drive Gear Puller . . . . . . . . . . JDG1560
Remove drive gear from tapered shaft of injection pump.
OUO1080,000020F –19–27NOV01–3/10
RG12020 –UN–19NOV01
JDG1559
DE10 Injection Pump Timing Pin . . . . . . . . . . JDG1559
Used for static lock pin timing during installation ofinjection pump.
OUO1080,000020F –19–27NOV01–4/10
RG
1203
1–U
N–2
0DE
C01
JDG1571
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDG1571
Used to lock flywheel at No. 1 TDC for injection pumptiming. This timing pin MUST be used on engineapplications using the tapered-nose crankshaft due to thehigher torque specification for damper retaining capscrew.
CTM331 (09APR02) 05-170-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=387
Continued on next page
Electronic Fuel/Control System Repair Tools and Other Materials
OUO1080,000020F –19–27NOV01–5/10
RG11741 –UN–24MAY01
JDG1515-1
Injection Nozzle Puller . . . . . . . . . . . . . . . . JDG1515-1
Use with slide hammer to remove injection nozzles.
05170
2
OUO1080,000020F –19–27NOV01–6/10
RG5084 –UN–23AUG88
JDE39
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . . JDE39
Clean injection nozzle bore in cylinder head.
OUO1080,000020F –19–27NOV01–7/10
RG11742 –UN–24MAY01
JDG1521
Spring Chamber Cap Wrench . . . . . . . . . . . . JDG1521
Used to remove the spring chamber cap on RSN nozzles.
OUO1080,000020F –19–27NOV01–8/10
RG12023 –UN–27NOV01
JDG1522
Pressure Adjusting Screw Tool . . . . . . . . . . . JDG1522
Used to adjust opening pressure on RSN nozzles.
Continued on next page
CTM331 (09APR02) 05-170-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=388
Electronic Fuel/Control System Repair Tools and Other Materials
OUO1080,000020F –19–27NOV01–9/10
JDG15152 –UN–13JUN01
Pressure Adjusting Screw Lock NutWrench . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1515-2
Used to loosen or tighten lock nut of pressure adjustingscrews.
051703
OUO1080,000020F –19–27NOV01–10/10
RG
6254
–UN
–22J
UL9
2
JD258 (JD-258)
Nozzle Carbon Stop Seal Installer . . . . . JD258 (JD-258)
Used to install carbon stop seal in injection nozzle groove.
OUO1080,0000210 –19–27NOV01–1/3
Fuel System Repair and Adjustment ServiceEquipment and Tools
NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC). Sometools may be available from a local supplier.
SERVICEGARD is a trademark of Deere & Company Continued on next page
CTM331 (09APR02) 05-170-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=389
Electronic Fuel/Control System Repair Tools and Other Materials
OUO1080,0000210 –19–27NOV01–2/3
CD
3030
7–U
N–0
7MA
R95
JT25510
Injection Nozzle Tester (R. BOSCH) . . . . . . . . . JT25510
Check nozzle opening pressure.
05170
4
OUO1080,0000210 –19–27NOV01–3/3
CD30308 –UN–08MAR95
KJD10109
Fuel Pressure Line . . . . . . . . . . . . . . . . . . .KJD10109
To connect injection nozzle to BOSCH tester.
OUO1080,0000211 –19–27NOV01–1/1
Fuel System Repair and Adjustment OtherMaterials
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to fuel supply pump mountingTY9473 (Canadian) Strength) screws and fuel line fittings.242 (LOCTITE)
LOCTITE is a registered trademark of Loctite Corp.
CTM331 (09APR02) 05-170-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=390
Electronic Fuel/Control System Repair Tools and Other Materials
RG40854,0000003 –19–12MAR02–1/17
Control System Repair and AdjustmentEssential Tools
NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
051705
RG40854,0000003 –19–12MAR02–2/17
RW25539 –UN–28AUG96
Terminal Extraction Tool . . . . . . . . . . . . . . . . .JDG364
Used to extract WEATHER PACK terminals fromelectrical connectors.
WEATHER PACK is a trademark of Packard Electric
RG40854,0000003 –19–12MAR02–3/17
RW
2554
2A–U
N–0
7MA
R02
WEATHER PACK Crimping Tool . . . . . . . . . . JDG783
Used to crimp WEATHER PACK male and femaleterminals on 14-20 gauge wires. This tool crimps both thewire and the seal retainer at the same time.
WEATHER PACK is a trademark of Packard Electric
RG40854,0000003 –19–12MAR02–4/17
RW
2554
2A–U
N–0
7MA
R02
METRI-PACK Crimping Tool . . . . . . . . . . . . . JDG865
Used to crimp METRI-PACK male and female terminalson 14-20 gauge wires.
METRI-PACK is a trademark of Packard Electric Inc.
CTM331 (09APR02) 05-170-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=391
Continued on next page
Electronic Fuel/Control System Repair Tools and Other Materials
RG40854,0000003 –19–12MAR02–5/17
RG
1167
9–U
N–0
5FE
B01
Packard Crimper . . . . . . . . . . . . . . . . . . . . . . JDG707
Used to crimp WEATHER PACK, METRIPACK,SUMITOMO, and YAZAKI male and female terminals on12-20 gauge wires. This tool crimps the wire and the sealretainer separately.
05170
6
RG40854,0000003 –19–12MAR02–6/17
RW
2555
8–U
N–2
9AU
G96
Technician’s Electrical Repair Kit . . . . . . . . . . . JDG155
This kit is assembled with the most commonly usedterminal extraction tools used to repair wiring harnesseson John Deere applications. This kit includes thefollowing: JDG107 - Holding Plate, JDG139 - Sure-Sealterminal insertion tool, JDG140 - CPC and Metrimateterminal extraction tool, JDG141 - CPC Blade Typeterminal extraction tool, JDG142 - Mate-N-Lock terminalextraction tool, JDG143 - Mate-N-Lock terminal extractiontool, JDG144 - Universal Crimping Pliers, JDG145 -Electrician’s Pliers, JDG146 - Carrying Case, and JDG785- Deutsch 6-8 gauge terminal extraction/insertion tool.
RG40854,0000003 –19–12MAR02–7/17
RG
1168
6–U
N–1
3FE
B01
Electrician’s Pliers . . . . . . . . . . . . . . . . . . . . . JDG145
Used to cut, strip, and splice wires.
Continued on next page
CTM331 (09APR02) 05-170-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=392
Electronic Fuel/Control System Repair Tools and Other Materials
RG40854,0000003 –19–12MAR02–8/17
RW
2555
8–U
N–2
9AU
G96
Technician’s Electrical Repair Kit . . . . . . . . . . JT07195B
This kit is assembled with the most commonly usedterminal extraction tools used to repair wiring harnesseson John Deere applications. This kit includes thefollowing: JDG140 - CPC and Metrimate terminalextraction tool, JDG141 - CPC Blade Type terminalextraction tool, JDG361 - Deutsch 12-14 gauge terminalextraction/insertion tool, JDG362 - Deutsch 16-18 gaugeterminal extraction/insertion tool, JDG364 -WEATHERPACK terminal extraction tool, JDG776 -Metripack terminal extraction tool - Wide, JDG777 -METRI-PACK terminal extraction tool - Narrow, andJDG785 - Deutsch 6-8 gauge terminal extraction/insertiontool.
051707
RG40854,0000003 –19–12MAR02–9/17
RW25541 –UN–20AUG96
METRI-PACK Extractor (Wide) . . . . . . . . . . . JDG776
Used to remove terminals from 56-Series, 280-Series, and630-Series METRI-PACK connectors.
METRI-PACK is a trademark of Packard Electric Inc.
RG40854,0000003 –19–12MAR02–10/17
RW25541 –UN–20AUG96
METRI-PACK Extractor (Narrow) . . . . . . . . . . JDG777
Used to remove terminals from 150-SeriesMETRI-PACK, SUMITOMO, and YAZAKI connectors.
METRI-PACK is a trademark of Packard Electric Inc. Continued on next page
CTM331 (09APR02) 05-170-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=393
Electronic Fuel/Control System Repair Tools and Other Materials
RG40854,0000003 –19–12MAR02–11/17
RW
2554
0–U
N–0
6SE
P96
JDG359
DEUTSCH Electrical Repair Tool Kit . . . . . . . .JDG359
Repair DEUTSCH electrical connector bodies.
DEUTSCH is a trademark of Deutsch Company
05170
8
RG40854,0000003 –19–12MAR02–12/17
12—14 Gauge Extractor (Set of Two) . . . . . . . . JDG361
Extracts wire.
RG40854,0000003 –19–12MAR02–13/17
16—18 Gauge Extractor (Set of Two) . . . . . . . . JDG362
Extracts wire.
RG40854,0000003 –19–12MAR02–14/17
20—24 Gauge Extractor (Set of Two). . . . . . . . JDG363
Extracts wire.
RG40854,0000003 –19–12MAR02–15/17
Crimping Tool. . . . . . . . . . . . . . . . . . . . . . . . JDG360
Install DEUTSCH contacts
DEUTSCH is a trademark of Deutsch Co.
RG40854,0000003 –19–12MAR02–16/17
RG10740 –UN–31MAY00
FKM10457
Terminal Extraction Tool . . . . . . . . . . . . . . . FKM10457
Used to extract terminals from ECU connector.
CTM331 (09APR02) 05-170-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=394
Continued on next page
Electronic Fuel/Control System Repair Tools and Other Materials
RG40854,0000003 –19–12MAR02–17/17
RG10739 –UN–26MAY00
JDG144
Crimping Pliers . . . . . . . . . . . . . . . . . . . . . . .JDG144
Used to crimp wire terminal ends for ECU connector.
051709
OUO1080,0000215 –19–27NOV01–1/1
Control System Repair and Adjustment OtherMaterials
Number Name Use
JDT405 (U.S.) High Temperature Grease Sensor O-rings.
TY9375 (U.S.) Pipe Sealant Apply to threads of oil pressureTY9480 (Canadian) sensor.592 (LOCTITE)
AT66865 (U.S.) Lubricant Insulate electrical connectors
LOCTITE is a registered trademark of Loctite Corp.
CTM331 (09APR02) 05-170-9 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=395
Electronic Fuel/Control System Repair Tools and Other Materials
05170
10
CTM331 (09APR02) 05-170-10 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=396
Group 180Diagnostic Service Tools
RG40854,0000002 –19–09APR02–1/9
Electronic Fuel System Diagnostic Tools
NOTE: Order tools according to information given inthe U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC)unless otherwise noted.
SERVICEGARD is a trademark of Deere & Company.
051801
RG40854,0000002 –19–09APR02–2/9
RG
8518
–UN
–20M
AY
98
JDG998
Fuel System Cap Plug Kit . . . . . . . . . . . . . . . . JDG998
Used to protect the fuel system from dirt and debris whendisconnecting fuel system components during fuel transferpump pressure check.
RG40854,0000002 –19–09APR02–3/9
RG5162 –UN–23AUG88
JT05412
Universal Pressure Test Kit . . . . . . . . . . . . . . . JT05412
Used for testing engine oil pressure, intake manifoldpressure (turbo boost), and fuel supply pump pressure.
Continued on next page
CTM331 (09APR02) 05-180-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=397
Diagnostic Service Tools
RG40854,0000002 –19–09APR02–4/9
RG
8554
–UN
–26N
OV
97
JDIS122
ECU Communication Software Kit. . . . . . . . . . . JDIS122
Please refer to your John Deere Dealer website forinformation on obtaining the latest version of software.
05180
2
RG40854,0000002 –19–09APR02–5/9
NOTE: Available from John Deere Distribution ServiceCenter (DSC). United States and CanadianAgricultural dealers DO NOT ORDER withoutfirst contacting your Branch or TAM.
RG40854,0000002 –19–09APR02–6/9
RG
1174
7–U
N–0
9JU
L01
ECU Communication Hardware Kit . . . . . . . . . . JDIS121
Used with JDIS122 - ECU Communication Software Kit.Together, the kits enable a Windows (’95 or ’98) or NTcompatible computer to read information from the EngineControl Unit (ECU). The computer must be at least a486/66 with 8 MB of RAM and an IEEE 1284 compliantparallel port.
RG40854,0000002 –19–09APR02–7/9
NOTE: Available from John Deere Distribution ServiceCenter (DSC). United States and CanadianAgricultural dealers DO NOT ORDER withoutfirst contacting your Branch or TAM.
Continued on next page
CTM331 (09APR02) 05-180-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=398
Diagnostic Service Tools
RG40854,0000002 –19–09APR02–8/9
RG
1112
6–U
N–1
9JU
N00
Digital Multimeter . . . . . . . . . . . . . . . . . . . . JT07306
Test electrical components for voltage, resistance, currentflow, or temperature. It is especially good for measuringlow voltage or high resistance circuits.
051803
RG40854,0000002 –19–09APR02–9/9
RG
8803
–UN
–26N
OV
97
JT07328
Connector Adapter Test Kit . . . . . . . . . . . . . . . JT07328
Used with JT05791 Digital Multimeter to make voltage andresistance measurements in control system wiring harnessconnectors. Can also be used to test terminals for properfit.
CTM331 (09APR02) 05-180-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=399
Diagnostic Service Tools
05180
4
CTM331 (09APR02) 05-180-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=400
Section 06Specifications
Contents
Page Page
Group 200—Repair Specifications Skidders - Governor Mode Selection. . . . . . .06-210-31Unified Inch Bolt and Cap Screw Torque Skidders - ECU Terminal Identification . . . . .06-210-32
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1 Telehandlers - Sensor Specifications . . . . . .06-210-34Metric Bolt and Cap Screw Torque Values . . .06-200-2 Telehandlers - Torque Curve Selection . . . . .06-210-35General OEM Engine Specifications . . . . . . . .06-200-3 Telehandlers - Governor Mode Selection . . .06-210-35Electronic Fuel System Repair and Telehandlers - ECU Terminal
Adjustment Specifications . . . . . . . . . . . . . .06-200-4 Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-36Electronic Engine Control Repair and
Adjustment Specifications . . . . . . . . . . . . . .06-200-5
Group 210—Diagnostic SpecificationsGroup 150/160 Electronic Fuel System
Diagnostic Specifications . . . . . . . . . . . . . . .06-210-1Application Specifications . . . . . . . . . . . . . . . .06-210-3Backhoes - Sensor Specifications . . . . . . . . . .06-210-4Backhoes - Torque Curve Selection . . . . . . . .06-210-4Backhoes - Governor Mode Selection . . . . . . .06-210-5Backhoes - ECU Terminal Identification . . . . .06-210-5 06Crawlers - Sensor Specifications. . . . . . . . . . .06-210-6Crawlers - Torque Curve Selection . . . . . . . . .06-210-7Crawlers - Governor Mode Selection. . . . . . . .06-210-7Crawlers - ECU Terminal Identification . . . . . .06-210-8Excavators - Sensor Specifications . . . . . . . .06-210-10Excavators - Torque Curve Selection . . . . . .06-210-11Excavators - Governor Mode Selection . . . . .06-210-11Excavators - ECU Terminal Identification . . .06-210-12Forwarders - Sensor Specifications . . . . . . . .06-210-14Forwarders - Torque Curve Selection . . . . . .06-210-16Forwarders - Governor Mode Selection. . . . .06-210-16Forwarders - ECU Terminal Identification . . .06-210-17Harvesters - Sensor Specifications . . . . . . . .06-210-18Harvesters - Torque Curve Selection . . . . . .06-210-19Harvesters - Governor Mode Selection . . . . .06-210-19Harvesters - ECU Terminal Identification. . . .06-210-20OEM Engines - Sensor Specifications . . . . . .06-210-22OEM Engines - Torque Curve Selection . . . .06-210-24OEM Engines - Governor Mode Selection. . .06-210-24OEM Engines - ECU Terminal
Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-25OEM Engines - Electronic Control System
Wiring Diagram . . . . . . . . . . . . . . . . . . . . .06-210-26OEM Engines - 4.5L & 6.8L Instrument
Panel/Engine Start Components Electrical WiringDiagram. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-28
Skidders - Sensor Specifications . . . . . . . . . .06-210-30Skidders - Torque Curve Selection . . . . . . . .06-210-31
CTM331 (09APR02) 06-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=1
Contents
06
CTM331 (09APR02) 06-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Group 200Repair Specifications
062001
DX,TORQ1 –19–20JUL94–1/1
Unified Inch Bolt and Cap Screw Torque Values
TS
1656
–19–
02A
PR
97
CTM331 (09APR02) 06-200-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=403
Repair Specifications
06200
2
DX,TORQ2 –19–20JUL94–1/1
Metric Bolt and Cap Screw Torque Values
TS
1657
–19–
02A
PR
97
CTM331 (09APR02) 06-200-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=404
Repair Specifications
062003
DPSG,OUO1004,102 –19–19NOV01–1/1
General OEM Engine Specifications
ITEM
4045TF275 4045HF275 6068TF275 6068HF275
Number of Cylinders 4 4 6 6
Bore 106 mm (4.19 in.) 106 mm (4.19 in.) 106 mm (4.19 in.) 106 mm (4.19 in.)
Stroke 127 mm (5.0 in.) 127 mm (5.0 in.) 127 mm (5.0 in.) 127 mm (5.0 in.)
Displacement 4.5 L 4.5 L 6.8 L 6.8 L(276 cu in.) (276 cu in.) (414 cu in.) (414 cu in.)
Compression Ratio 17.0:1 17.0:1 17.0:1 17.0:1
Max. Crank Pressure 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa(2 H2O) (2 H2O) (2 H2O) (2 H2O)
Governor Regulation (Industrial) 7—10 % 7—10 % 7—10 % 7—10 %
Governor Regulation (Generator) 5 % 5% 5% 5 %
Oil Pressure At Rated Speed, Full 345 kPa (50 psi) 345 kPa (50 psi) 345 kPa (50 psi) 345 kPa (50 psi)Load (± 15 psi)
Oil Pressure At Low Idle (Minimum) 105 kPa (15 psi) 105 kPa (15 psi) 105 kPa (15 psi) 105 kPa (15 psi)
Length 860 mm (33.9 in.) 860 mm (33.9 in.) 1119 mm (43.9 in.) 1123 mm (44.2 in.)
Width 612 mm (24.1 in.) 612 mm (24.1 in.) 623 mm (24.5 in.) 623 mm (24.5 in.)
Height 994 mm (39.1 in.) 994 mm (39.1 in.) 1012 mm (39.9 in.) 1015 mm (40.0 in.)
Weight 451 kg (993 lb) 451 kg (993 lb) 587 kg (1290 lb) 587 kg (1290 lb)
CTM331 (09APR02) 06-200-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=405
Repair Specifications
06200
4
OUO1080,0000212 –19–27NOV01–1/2
Electronic Fuel System Repair andAdjustment Specifications
Item Measurement Specification
Final Fuel Filter Bracket-to-Cylinder Torque 73 N•m (54 lb-ft)Head
Final Fuel Filter Mounting Torque 73 N•m (54 lb-ft)Base-to-Bracket
Primary Fuel Filter Torque 73 N•m (54 lb-ft)Bracket-to-Cylinder Head andAlternator
Primary Fuel Filter/Water Bowl Torque 50 N•m (36 lb-ft)Mounting Base-to-Bracket
Fuel Supply Pump Pressure 28—41 kPa (0.28—0.41 bar)(4—6 psi)
Fuel Supply Pump Cap Screws Torque 30 N•m (22 lb-ft)
Injection Pump Mounting Stud Nuts Torque 25 N•m (19 lb-ft)
Injection Pump Gear Mounting Nut Torque 195 N•m (145 lb-ft)
Injection Pump Fuel Delivery Torque 27 N•m (20 lb-ft)(Pressure) Lines
Injection Pump Timing Pin Plug Torque 9.5 N•m (7.5 lb-ft)
Fuel Injection Nozzle
Nozzle Return Leakage at 1 to 14 drops (maximum) within 3010 300 kPa (103 bar) (1500 psi) seconds
Fuel Injection Nozzle
Rate Shaping Nozzle Opening Pressure for Setting 24 400—24 900 kPa(New or Reconditioned) (244—249 bar) (3540—3620 psi)Opening Pressure for Checking 24 100 kPa (241 bar) (3500 psi) Min(New or Reconditioned)Opening Pressure for Setting (Used) 23 000—23 600 kPa
(230—236 bar) (3340—3420 psi)Opening Pressure for Checking 21 800 kPa (218 bar) (3170 psi) Min(Used)
CTM331 (09APR02) 06-200-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=406
Continued on next page
Repair Specifications
06OUO1080,0000212 –19–27NOV01–2/2
Item Measurement Specification
Rate Shaping Nozzle Opening pressure difference 700 kPa (7 bar) (100 psi) Maxbetween cylinders
Fuel Injection Nozzle
Pressure Adjusting Screw Lock Torque 10 N•m (7 lb-ft)Nut
Lift Adjusting Screw Lock Nut Torque 5 N•m (3.5 lb-ft)
Fuel Injection Nozzle Hold-Down Torque 40 N•m (30 lb-ft)Clamp Cap Screws
Fuel Leak-Off Line Hex Nut Torque 5 N•m (3.7 lb-ft)(44 lb-in.)
Fuel Injection Pump Return Line Torque 27 N•m (20 lb-ft)
Fuel Injection Nozzle Delivery Lines Torque 27 N•m (20 lb-ft)
2005
OUO1080,0000216 –19–27NOV01–1/1
Electronic Engine Control Repair andAdjustment Specifications
Item Measurement Specification
Coolant Temperature Sensor in Torque 15 N•m (11 lb-ft)Thermostat Housing
Coolant Temperature Sensor in Torque 35 N•m (26 lb-ft)Cylinder Head
Crankshaft Position Sensor Torque 14 N•m (10 lb-ft)
Oil Pressure Sensor Torque 15 N•m (11 lb-ft)
Manifold Air Temperature Sensor Torque 10 N•m (7 lb-ft)
Fuel Temperature Sensor Torque 13—18 N•m (10—13 lb-ft)
Fuel Heater Torque 9 N•m (7 lb-ft)
CTM331 (09APR02) 06-200-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=407
Repair Specifications
06200
6
CTM331 (09APR02) 06-200-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=408
Group 210Diagnostic Specifications
DPSG,OUO1004,2762 –19–17MAY00–1/1
Group 150/160 Electronic Fuel System Diagnostic Specifications
Item Measurement 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 15 kPa (0.15 bar) (2.0 psi)Engine Speed
Fuel Supply Pump Minimum Positive Pressure at 2400 21—34 kPa (0.21—0.34 bar) (3—5rpm Engine Speed psi)
Fuel Supply Pump Minimum Flow at 2400 rpm Engine 1.5 L/min (0.42 gpm)Speed
062101
CTM331 (09APR02) 06-210-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=409
Diagnostic Specifications
06210
2
CTM331 (09APR02) 06-210-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=410
Diagnostic Specifications
062103
RG40854,0000128 –19–29JAN02–1/1
Application Specifications
Below is an overview of the specfications listed forapplications in the next few pages.
• Backhoes– Sensor Specifications– Torque Curve Selection– Governor Mode Selection– ECU Terminal Identification– Vehicle Wiring - See Vehicle manual.
• Crawlers– Sensor Specifications– Torque Curve Selection– Governor Mode Selection– ECU Terminal Identification– Vehicle Wiring - See Vehicle manual.
• Excavators– Sensor Specifications– Torque Curve Selection– Governor Mode Selection– ECU Terminal Identification– Vehicle Wiring - See Vehicle manual.
• Forwarders– Sensor Specifications– Torque Curve Selection– Governor Mode Selection– ECU Terminal Identification– Vehicle Wiring - See Vehicle manual.
• Harvesters– 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– 4.5L & 6.8L OEM Application Instrument
Panel/Engine Start Components Electrical WiringDiagram
• Skidders– Sensor Specifications– Torque Curve Selection– Governor Mode Selection– ECU Terminal Identification– Vehicle Wiring - See Vehicle manual.
• Telehandlers– Sensor Specifications– Torque Curve Selection– Governor Mode Selection– ECU Terminal Identification– Vehicle Wiring - See Vehicle manual.
CTM331 (09APR02) 06-210-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=411
Diagnostic Specifications
06210
4
RG40854,000013A –19–30JAN02–1/1
Backhoes - Sensor Specifications
The specifications shown below are voltage, pressure,and temperature parameters that the Engine Control Unit(ECU) uses to determine whether a Diagnostic TroubleCode (DTC) is set for a given sensor.
Sensor Specifications for Backhoes
Sensor Measured Sensor Parameter Out of Range Value Derate
Analog Throttle (A) High Input Voltage Above 4.7 Volts If no other throttle is available,engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.1 Volts High MAT engine protection isdisabled.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.1 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 113°C (235°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
RG40854,000013B –19–30JAN02–1/1
Backhoes - Torque Curve Selection
Torque Curve Selection for Backhoes
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal operation
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=412
Diagnostic Specifications
RG40854,000013E –19–30JAN02–1/1
Backhoes - Governor Mode Selection
Desired Speed Governor Selection for Backhoes
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Backhoes
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
062105
SERVICE ADVISOR is a trademark of Deere & Company
RG40854,000013F –19–30JAN02–1/1
Backhoes - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 N/Aa
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Analog Throttle (A) Input B3 B
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 AaN/A = Not Applicable
CTM331 (09APR02) 06-210-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=413
Diagnostic Specifications
06210
6
RG40854,0000132 –19–30JAN02–1/1
Crawlers - Sensor Specifications
The specifications shown below are voltage, pressure,and temperature parameters that the Engine Control Unit(ECU) uses to determine whether a Diagnostic TroubleCode (DTC) is set for a given sensor.
Sensor Specifications for Crawlers
Sensor Measured Sensor Parameter Out of Range Value Derate
Analog Throttle (A) High Input Voltage Above 4.75 Volts If no other throttle is available,engine will run at idle speed.
Low Input Voltage Below 0.25 Volts If no other throttle is available,engine will run at idle speed.
Oil Pressure High Input Voltage Above 4.5 Volts Low oil pressure engineprotection is disabled.
Low Input Voltage Below 0.25 Volts Low oil pressure engineprotection is disabled.
Extremely Low Pressure Below an extremely low engine ECU derates engine 20% peroil pressure. This pressure minute until engine runs at 60%increases with engine speed. of full power.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.05 Volts High MAT engine protection isdisabled.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.05 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 113°C (235°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Loss of Coolant Temperature High Input Voltage Exceeds 4.9 Volts High loss of coolant temperatureengine protection is disabled.
Low Input Voltage Below 0.05 Volts High loss of coolant temperatureengine protection is disabled.
Extremely High Temperature Exceeds 124°C (255°F) ECU derates engine 20% perminute until engine runs at 60%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.05 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
CTM331 (09APR02) 06-210-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=414
Diagnostic Specifications
RG40854,0000135 –19–30JAN02–1/1
Crawlers - Torque Curve Selection
Torque Curve Selection for Crawlers
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal operation
SERVICE ADVISOR is a trademark of Deere & Company
062107
RG40854,0000134 –19–30JAN02–1/1
Crawlers - Governor Mode Selection
Desired Speed Governor Selection for Crawlers
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Excavators
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-7 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=415
Diagnostic Specifications
06210
8
RG40854,0000137 –19–30JAN02–1/1
Crawlers - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 N/Aa
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Analog Throttle (A) Input B3 B
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 A
Oil Pressure Input F3 B
Loss of Coolant Temperature C1 AaN/A = Not Applicable
CTM331 (09APR02) 06-210-8 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=416
Diagnostic Specifications
062109
CTM331 (09APR02) 06-210-9 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=417
Diagnostic Specifications
06210
10
RG40854,000012E –19–30JAN02–1/1
Excavators - Sensor Specifications
The specifications shown below are voltage, pressure,and temperature parameters that the Engine Control Unit(ECU) uses to determine whether a Diagnostic TroubleCode (DTC) is set for a given sensor.
Sensor Specifications for Excavators
Sensor Measured Sensor Parameter Out of Range Value Derate
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.1 Volts High MAT engine protection isdisabled.
Moderately High Temperature Exceeds 88°C (190°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.1 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 115°C (239°F) ECU derates engine 20% perminute until engine runs at 75%of full power.
Moderately Severe Temperature Exceeds 113°C (235°F) ECU derates engine 4% perminute until engine runs at 90%of full power.
Least Severe Temperature Exceeds 110°C (230°F) ECU derates engine 2% perminute until engine runs at 95%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
CTM331 (09APR02) 06-210-10 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=418
Diagnostic Specifications
RG40854,000012F –19–30JAN02–1/1
Excavators - Torque Curve Selection
Torque Curve Selection for Excavators
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal operation
2 Altitude Derate
0621011
SERVICE ADVISOR is a trademark of Deere & Company
RG40854,0000131 –19–30JAN02–1/1
Excavators - Governor Mode Selection
Desired Speed Governor Selection for Excavators
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Excavators
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-11 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=419
Diagnostic Specifications
06210
12
RG40854,0000130 –19–30JAN02–1/1
Excavators - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 NA
Sensor Ground D3 Changes with each sensor
Throttle Reference F3 N/Aa
Throttle Input B3 N/Aa
Throttle Ground C1 N/Aa
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 AaN/A = Not Applicable
CTM331 (09APR02) 06-210-12 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=420
Diagnostic Specifications
0621013
CTM331 (09APR02) 06-210-13 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=421
Diagnostic Specifications
RG40854,0000158 –19–21FEB02–1/2
Forwarders - Sensor Specifications
The specifications shown below are voltage, pressure,and temperature parameters that the Engine Control Unit(ECU) uses to determine whether a Diagnostic TroubleCode (DTC) is set for a given sensor.
Continued on next page
06210
14
CTM331 (09APR02) 06-210-14 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=422
Diagnostic Specifications
0621015
RG40854,0000158 –19–21FEB02–2/2
Sensor Specifications for Forwarders
Sensor Measured Sensor Parameter Out of Range Value Derate
Analog Throttle (A) (1010 High Input Voltage Above 4.7 Volts If no other throttle is available,Forwarders ONLY) engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Analog Throttle (B) (1010 High Input Voltage Above 4.7 Volts If no other throttle is available,Forwarders ONLY) engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Oil Pressure High Input Voltage Above 4.5 Volts Low oil pressure engineprotection is disabled.
Low Input Voltage Below 0.3 Volts Low oil pressure engineprotection is disabled.
Extremely Low Pressure Pressure goes below an engine ECU derates engine 20% perspeed dependent value. minute until engine runs at 60%
of full power.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.1 Volts High MAT engine protection isdisabled.
Moderately High Temperature Exceeds 88°C (190°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.1 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 115°C (239°F) ECU derates engine 20% perminute until engine runs at 60%of full power.
Moderately Severe Temperature Exceeds 110°C (230°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
CTM331 (09APR02) 06-210-15 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=423
Diagnostic Specifications
RG40854,0000159 –19–21FEB02–1/1
Forwarders - Torque Curve Selection
Torque Curve Selection for Forwarders
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal Operation
SERVICE ADVISOR is a trademark of Deere & Company
06210
16
RG40854,000015A –19–21FEB02–1/1
Forwarders - Governor Mode Selection
Desired Speed Governor Selection for Forwarders
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Forwarders
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-16 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=424
Diagnostic Specifications
0621017
RG40854,000015B –19–21FEB02–1/1
Forwarders - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 NA
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Analog Throttle (A) Input (1010 Forwarders ONLY) E1 B
Analog Throttle (B) Input (1010 Forwarders ONLY) F2 B
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 A
Oil Pressure Input F3 BaN/A = Not Applicable
CTM331 (09APR02) 06-210-17 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=425
Diagnostic Specifications
06210
18
RG40854,0000167 –19–21FEB02–1/1
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 TroubleCode (DTC) is set for a given sensor.
Sensor Specifications for Harvesters
Sensor Measured Sensor Parameter Out of Range Value Derate
Oil Pressure High Input Voltage Above 4.5 Volts Low oil pressure engineprotection is disabled.
Low Input Voltage Below 0.3 Volts Low oil pressure engineprotection is disabled.
Extremely Low Pressure Pressure goes below an engine ECU derates engine 20% perspeed dependent value. minute until engine runs at 60%
of full power.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.1 Volts High MAT engine protection isdisabled.
Moderately High Temperature Exceeds 88°C (190°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.1 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 115°C (239°F) ECU derates engine 20% perminute until engine runs at 60%of full power.
Moderately Severe Temperature Exceeds 110°C (230°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
CTM331 (09APR02) 06-210-18 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=426
Diagnostic Specifications
RG40854,0000166 –19–21FEB02–1/1
Harvesters - Torque Curve Selection
Torque Curve Selection for Harvesters
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal operation
SERVICE ADVISOR is a trademark of Deere & Company
0621019
RG40854,0000165 –19–21FEB02–1/1
Harvesters - Governor Mode Selection
Desired Speed Governor Selection for Harvesters
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Harvesters
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-19 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=427
Diagnostic Specifications
06210
20
RG40854,0000164 –19–21FEB02–1/1
Harvesters - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 NA
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 A
Oil Pressure Input F3 BaN/A = Not Applicable
CTM331 (09APR02) 06-210-20 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=428
Diagnostic Specifications
0621021
CTM331 (09APR02) 06-210-21 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=429
Diagnostic Specifications
RG40854,0000129 –19–29JAN02–1/3
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 TroubleCode (DTC) is set for a given sensor.
Continued on next page
06210
22
CTM331 (09APR02) 06-210-22 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=430
Diagnostic Specifications
0621023
RG40854,0000129 –19–29JAN02–2/3
Sensor Specifications for OEM Engines
Sensor Measured Sensor Parameter Out of Range Value Derate
Analog Throttle (A) High Input Voltage Above 4.7 Volts If no other throttle is available,engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Analog Throttle (B) High Input Voltage Above 4.7 Volts If no other throttle is available,engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Oil Pressure High Input Voltage Above 4.5 Volts Low oil pressure engineprotection is disabled.
Low Input Voltage Below 0.3 Volts Low oil pressure engineprotection is disabled.
Extremely Low Pressure Below an extremely low engine ECU derates engine 60% peroil pressure. This pressure minute until engine runs at 40%increases with engine speed. of full power.
Moderately Low Pressure Below a moderately low engine ECU derates engine 40% peroil pressure. This pressure minute until engine runs at 60%increases with engine speed. of full power.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.1 Volts High MAT engine protection isdisabled.
Moderately High Temperature H engines: ECU derates engine 2% perExceeds 100°C (212°F) minute until engine runs at 80%T engines: of full power.Exceeds 120°C (248°F)
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.05 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 118°C (244°F) ECU derates engine 60% perminute until engine runs at 40%of full power.
Moderately Severe Temperature Exceeds 113°C (235°F) ECU derates engine 40% perminute until engine runs at 60%of full power.
Least Severe Temperature Exceeds 108°C (226°F) ECU derates engine 2% perminute until engine runs at 95%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
CTM331 (09APR02) 06-210-23 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=431
Continued on next page
Diagnostic Specifications
RG40854,0000129 –19–29JAN02–3/3
Sensor Specifications for OEM Engines
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
06 RG40854,000012A –19–29JAN02–1/1
OEM Engines - Torque Curve Selection
Torque Curve Selection for OEM Engines
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal Curve
21024
SERVICE ADVISOR is a trademark of Deere & Company
RG40854,000012B –19–29JAN02–1/1
OEM Engines - Governor Mode Selection
Desired Speed Governor Selection for OEM Engines
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal Droop
10 Isochronous Droop
Max. Speed Governor Selection for OEM Engines
Mode Selected on DST orSERVICE ADVISOR Conditions:
0 Normal Droop
9 Gen Sets ONLY: Above 93% throttle at1800 RPM
10 Isochronous Droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-24 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=432
Diagnostic Specifications
0621025
RG40854,000012C –19–29JAN02–1/1
OEM Engines - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 NA
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Analog Throttle (A) Input E1 B
Analog Throttle (B) Input F2 B
Multi-state Throttle Input C1 B
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 A
Oil Pressure Input F3 B
Auxiliary Engine Shutdown Switch Input A1 May change by application
External Engine Derate Switch Input C2 May change by applicationaN/A = Not Applicable
CTM331 (09APR02) 06-210-25 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=433
Diagnostic Specifications
RG40854,0000121 –19–28JAN02–1/1
OEM Engines - Electronic Control System Wiring Diagram
SE3- Focus 12 (ECU)
B5
t
B3
914
461
448
447
Twisted ShieldedPair
X10
X11
SAE J1939/11 3-WayDeutsch Term
SAE J1939/11 3-Way
905
904
C
B
A
012 IGN +12V OR +24V
012
01
2
020
905
904
905 CAN L
904 CAN H
020 CAN Shield
012
01
2
020
D3B1 D2 B2
J2
A2
F1 G1
B
C
A
B
B
A
SE2
Instrument PanelConnector
Hig
h/Lo
w Id
leC1
947
IncreasePressure
B1
A
B
C
F3
020
020
905
905
904
904
Ove
rrid
e S
hut D
N/B
link
Cod
esB3
918
911 Sensor Excitation (+5V)
012 IGN +12V OR +24V
905 CAN L
904 CAN H
020 CAN Shield
911 Sensor Excitation (+5V)
012 IGN +12V OR +24V
905 CAN L
904 CAN H
020 CAN Shield
911 Sensor Excitation (+5V)
SE2
463
MAT
D1
A
B
B4
FGHJ
Diagnostic Connector X7 050
020
905
904
904
905
020
N R
A
BCD AE
911
91
1 91
1
Sen
sor
Ret
urn
914 Sensor Return
CAN L CAN HK1
050
022
SE2
Uns
witc
hed
Bat
tery
022
Sys
tem
Gro
und
050
TempCoolant
467
SensorEngine Crank
ReturnSensor
Engine Control Unit (ECU)John Deere Level 12 (12V or 24V)
Options On 12V ECUs AndIncluded On All 24V ECUs
BatterySwitched
Located Near ECUDeutsch Connector
ECU Connector
Inje
ct L
o 49
3
A3
491
K2
Inje
ct H
i
A
B
Y1
A1A
SolenoidControlFuel
911
E2
911
Voltage (+5V)Excitation
428
t
TempFuel
A
B
B2
C3
A B C D E F G H J K L M N O
911
012
01
2 01
2 01
2
914
91
4 91
4 91
4
Res
ume
Coa
st
F2
Sec
onda
ry A
nalo
g T
hrot
tle91
3
J3
Cru
ise
On/
ISO
C. G
OV.
954
C2
Cru
ise
CA
NC
. RE
S./E
xter
nal D
erat
e98
1
Set
Acc
el
Cru
se B
rake
Air
Hea
ted
Wai
t Lam
p
G2
474
SE2
A
Ana
log
Thr
ottle
E1
915
SE2
L
SE2 SE2 SE2
Bum
p E
nabl
e
H1H3 H2
955
936
B
ump
DN
Bum
p U
p
923
T W X
936 Resume Coast/Bump DN
955 Set Accel/Bump Up
923 Cruse Brake/Bump Enable
050050050 050 050
050
PairTwisted
911
911
Clean SideSensorPressureOil
914
85 87 87A
86 30
K1
050
062
050
RelaySupplyPumpFuel
F0210A
A
B
SE2
Uns
witc
hed
Bat
tery
002
X9Fuel Heater
A
050
B
072
SE4- Fuel Heater Option
X6
Auxillary Connector
012
01
2
Faul
t Lam
p
G3
473
H X3P Q R S T U V W X
A1
Ext
erna
l Shu
tdow
n94
1
Tach
omet
er
E3
439
K
K3
Air
Hea
ter
429
J1
Spa
re -
Sou
rcin
g D
river
241
7
UT
417
UT
429
=
RG11986 –19–19DEC01
CTM331 (09APR02) 06-210-26 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=434
Diagnostic Specifications
0621027
CTM331 (09APR02) 06-210-27 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=435
Diagnostic Specifications
RG40854,0000122 –19–28JAN02–1/1
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical WiringDiagram
B
A
Air
Hea
ter W
ait L
amp
012
B
F110A
SinglePointGround
+12V
050
050
050
002 BAT
422 Starter Relay Solenoid
412 ACC
012 IGN +12V OR +24V
002
905 CAN L
904 CAN H
020 CAN Shield
022
022
A
X4
BA
C B A
TwistedShielded Pair
050 SPG
ABC
SAE J1939/11 3-WayDeutsch Term
SAE J1939/11 3-WayDeutsch Conn
050 SPG
24V Regulator
A B C
A B C
12V Back Light Option
High
Low(CW)
A B
Back LightDimmer
FBG
020
904
C
Bac
k Li
ghtin
g
41
1
411
SP
G
050
DA B C
24V
GN
D
12V
24V Back Light Option
032
050
442
904
905
020
442
442
442
+12V
OR
+24
V
E
925
D
ata
-
H
929
D
ata
+
AC
Bac
k Li
ghtin
g
41
1
SP
G
050
B
442
+12V
OR
+24
V
A
925
D
ata
-
D
929
D
ata
+
FC
Bac
k Li
ghtin
g
41
1
SP
G
050
B
442
+12V
OR
+24
V
A
925
D
ata
-
D
929
D
ata
+
FC
Bac
k Li
ghtin
g
41
1
SP
G
050
B
442
+1
2V O
R +
24V
A
925
D
ata
-
D
929
D
ata
+
FC
Bac
k Li
ghtin
g
41
1
SP
G
050
B
442
+12V
OR
+24
V
A
925
D
ata
-
D
929
D
ata
+
FC B A D F
929
D
ata
+
925
D
ata
-
442
+12V
OR
+24
V
SP
G
050
Bac
k Li
ghtin
g
41
1
SE2-Control Panel
411
050
442
925
929
411
050
442
925
929
411
050
442
925
929
411
050
442
925
929
411
050
442
925
929
Back Light No Dimmer
Back Light Options
BA
Dimmer Option
020
905
020
905
904
A
B
5A
Ignition Switch
AccessoryOffRunStart
Run
BAT
ST
IGN
GND
422
S2Speed SelectMomentary
Bump UpOffBump DownOffAB
C
SE3
Bum
p D
own
SE3
Bum
p U
p
S3Bump EnableMomentary
Bump EnableOffBump EnableOFF
A
B
SE3
S4Idle Switch
All A
C
Hig
h Id
le
Low IdleHigh Idle
Low
Idle
390 Ohm
SE394
7
012
012
012
012
012
936
955
1300 Ohm
947
947
Bum
p E
nabl
e92
3
B
B A
S5Override Shutdown Momentary
Off
A
B
Override Shutdown
Off
SE3
918
918
918
911 Sensor Excitation (+5V)
911
911
B
E
V U F
ACC
SE3
UT
X3
X03 PC
D
G
J
412
412
S1
X3
X3
P
X3
P1 P2 P3 P4 P5 P6
BA
BA
X5Remote On/OffPlug
N1(12V OR 24V)
G1 M1
KST
ALT12V
StartMotor12V
StarterRelay12V OR 24V
002
SIG
N
050
SP
G
SE1-Engine Start Components
TVP
002
002
050
050
412
409
A
Wiri
ng S
uppl
ied
With
JD A
ltern
ator
X1
Out Coil
2 Coil
S
OU
TP
UT
BATA
B
A X02
422
42
2
UT
022
022
032
032022
002
002
SE4
002
Idle
Full
(CW)
AnalogThrottle
ThrottlePOT
B
C
A
914 Sensor Return
002 BAT
012 IGN +12V OR +24V
905 CAN L
904 CAN H
020 CAN Shield
911 Sensor Excitation (+5V)
914 Sensor Return
002 BAT
012 IGN +12V OR +24V
905 CAN L
904 CAN H
020 CAN Shield
911 Sensor Excitation (+5V)
914 Sensor Return
002 BAT
012 IGN +12V OR +24V
905 CAN L
904 CAN H
020 CAN Shield
911 Sensor Excitation (+5V)
914 Sensor Return
SE3
911
911
911
915
915
915
914
M C
SE3
474
474
474
012
050 SPG
S
Instrument PanelConnector
Instrument PanelConnector
Instrument PanelConnector
Instrument PanelConnector
RG11987 –19–19DEC01
CTM331 (09APR02) 06-210-28 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=436
Diagnostic Specifications
0621029
CTM331 (09APR02) 06-210-29 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=437
Diagnostic Specifications
06210
30
RG40854,000016C –19–21FEB02–1/1
Skidders - Sensor Specifications
The specifications shown below are voltage, pressure,and temperature parameters that the Engine Control Unit(ECU) uses to determine whether a Diagnostic TroubleCode (DTC) is set for a given sensor.
Sensor Specifications for Skidders
Sensor Measured Sensor Parameter Out of Range Value Derate
Analog Throttle (A) High Input Voltage Above 4.7 Volts If no other throttle is available,engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Oil Pressure High Input Voltage Above 4.5 Volts Low oil pressure engineprotection is disabled.
Low Input Voltage Below 0.3 Volts Low oil pressure engineprotection is disabled.
Extremely Low Pressure Pressure goes below an engine ECU derates engine 20% perspeed dependent value. minute until engine runs at 60%
of full power.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.3 Volts High MAT engine protection isdisabled.
Moderately High Temperature Exceeds 88°C (190°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.3 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 115°C (239°F) ECU derates engine 20% perminute until engine runs at 60%of full power.
Moderately Severe Temperature Exceeds 110°C (230°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
CTM331 (09APR02) 06-210-30 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=438
Diagnostic Specifications
RG40854,000016D –19–21FEB02–1/1
Skidders - Torque Curve Selection
Torque Curve Selection for Skidders
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal operation
SERVICE ADVISOR is a trademark of Deere & Company
0621031
RG40854,000016F –19–21FEB02–1/1
Skidders - Governor Mode Selection
Desired Speed Governor Selection for Skidders
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Skidders
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-31 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=439
Diagnostic Specifications
06210
32
RG40854,0000170 –19–21FEB02–1/1
Skidders - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 NA
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Analog Throttle (A) Input E1 B
Multi-state Throttle Input C1 B
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 A
Oil Pressure Input F3 BaN/A = Not Applicable
CTM331 (09APR02) 06-210-32 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=440
Diagnostic Specifications
0621033
CTM331 (09APR02) 06-210-33 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=441
Diagnostic Specifications
06210
34
RG40854,0000140 –19–30JAN02–1/1
Telehandlers - Sensor Specifications
The specifications shown below are voltage, pressure,and temperature parameters that the Engine Control Unit(ECU) uses to determine whether a Diagnostic TroubleCode (DTC) is set for a given sensor.
Sensor Specifications for Telehandlers
Sensor Measured Sensor Parameter Out of Range Value Derate
Analog Throttle (A) High Input Voltage Above 4.7 Volts If no other throttle is available,engine will run at idle speed.
Low Input Voltage Below 0.3 Volts If no other throttle is available,engine will run at idle speed.
Oil Pressure Switch Low Input Voltage Input circuit is grounded at key No derate.ON with no engine speed.
Extremely Low Pressure Input circuit is grounded when No derateengine is running at a minimumengine speed.
Manifold Air Temperature (MAT) High Input Voltage Above 4.9 Volts High MAT engine protection isdisabled.
Low Input Voltage Below 0.1 Volts High MAT engine protection isdisabled.
Engine Coolant Temperature High Input Voltage Exceeds 4.9 Volts High ECT engine protection is(ECT) disabled.
Low Input Voltage Below 0.1 Volts High ECT engine protection isdisabled.
Most Severe Temperature Exceeds 118°C (244°F) ECU derates engine 20% perminute until engine runs at 40%of full power.
Moderately Severe Temperature Exceeds 113°C (235°F) ECU derates engine 20% perminute until engine runs at 60%of full power.
Least Severe Temperature Exceeds 108°C (226°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
Fuel Temperature High Input Voltage Exceeds 4.9 Volts High fuel temperature engineprotection is disabled.
Low Input Voltage Below 0.1 Volts High fuel temperature engineprotection is disabled.
Moderately High Temperature Exceeds 120°C (248°F) ECU derates engine 2% perminute until engine runs at 80%of full power.
CTM331 (09APR02) 06-210-34 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=442
Diagnostic Specifications
RG40854,0000141 –19–30JAN02–1/1
Telehandlers - Torque Curve Selection
Torque Curve Selection for Telehandlers
Torque Curve # on DST orSERVICE ADVISOR Conditions for Torque Curve
1 Normal Operation
SERVICE ADVISOR is a trademark of Deere & Company
0621035
RG40854,0000142 –19–30JAN02–1/1
Telehandlers - Governor Mode Selection
Desired Speed Governor Selection for Telehandlers
Mode Selected on DST orSERVICE ADVISOR Conditions
0 Normal Droop
Max. Speed Governor Selection for Telehandlers
Mode Selected on DST orSERVICE ADVISOR Conditions:
9 Normal droop
SERVICE ADVISOR is a trademark of Deere & Company
CTM331 (09APR02) 06-210-35 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=443
Diagnostic Specifications
06210
36
RG40854,0000143 –19–30JAN02–1/1
Telehandlers - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery A2 N/Aa
Unswitched Battery K1 N/Aa
System Ground J2 N/Aa
CAN High G1 N/Aa
CAN Low F1 NA
5V Sensor Supply E2 Changes with each sensor
Sensor Ground D3 Changes with each sensor
Analog Throttle (A) Input E1 B
Crank Position Input B2 A
Crank Position Return D2 B
Pump Solenoid Return A3 B
Pump Solenoid Supply K2 A
Fuel Temperature Input C3 A
Engine Coolant Temperature Input B1 A
Manifold Air Temperature Input D1 A
Oil Pressure Input C1 Refer to vehicle manual for this.aN/A = Not Applicable
CTM331 (09APR02) 06-210-36 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=444
IndexPage Page
A Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3Cruise control operation . . . . . . . . . . . . . . .03-140-12Cylinder misfire test . . . . . . . . . . . . . . . . . .04-150-56Air heater, intake
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-42Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Air in fuel test . . . . . . . . . . . . . . . . . . . . . . .04-150-49DAir temperature sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Data parameter description . . . . . . . . . . . .04-160-16
Derate programsApplication specificationsBackhoes . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Application specifications . . . . . . . . . . . . .06-210-3
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-13Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3Forwarders . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Diagnostic Gauge
Clearing stored codes . . . . . . . . . . . . . . .04-160-13Harvesters . . . . . . . . . . . . . . . . . . . . . . . .06-210-3OEM engines . . . . . . . . . . . . . . . . . . . . . .06-210-3 Diagnostics
ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-36Skidders . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3Telehandlers . . . . . . . . . . . . . . . . . . . . . . .06-210-3 ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-36
ACP-Err/No Addr . . . . . . . . . . . . . . . . .04-150-36Does not communicate with ECU . . . .04-150-36EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-36B
Engine configuration parameters. . . . . . .04-160-10Viewing active codes . . . . . . . . . . . . . . .04-160-12
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2Viewing stored codes . . . . . . . . . . . . . . .04-160-12
Bleed fuel system. . . . . . . . . . .02-090-26, 04-150-53Diagnostic Scan Tool (DST)
Data parameter description . . . . . . . . . . .04-160-16Diagnostics
ECU does not communicate withCDST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32
TestsCANdefinition of . . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Excavator torque curve change . . . . . .04-160-19Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-11 Diagnostic Trouble Codes (DTCs)
IndxCheck Active engine codes . . . . . . . . . . . . . . . .04-160-121Fuel supply pressure. . . . . . . . . . . . . . . .04-150-50 Active vs. inactive . . . . . . . . . . . . . . . . . .03-140-15
Fuel supply quality . . . . . . . . . . . . . . . . .04-150-47 Blinking Codes . . . . . . . . . . . . . . . . . . . .04-160-15Clearing engine codes . . . . . . . . . . . . . .04-160-13Circuit malfunctions
Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-4 Clearing stored codes . . . . . . . . . . . . . . .03-140-15Diagnosing intermittent faults . . . . . . . . .04-160-28Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5
Connectors, electrical Diagnostic procedure . . . . . . . . . . . . . . .04-160-27Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20
DEUTSCH, repair . . . . . . . . . . . . . . . . . .02-110-17 SPN/FMI codes . . . . . . . . . . . . . . . . . .04-160-222-digit codes . . . . . . . . . . . . . . . . . . . .04-160-24General information. . . . . . . . . . . . . . . . . .02-110-6
METRI-PACK, pull type. . . . . . . . . . . . . .02-110-12 OtherF4A0 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24METRI-PACK, push type . . . . . . . . . . . .02-110-14
Remove blade terminals from connector F4A5 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24F4A7 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24body . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11
Controller Area Network (CAN), F4EA . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24F4ED. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24operation. . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 F4E0 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24F4E3 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Coolant temperature sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 F400 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24F401 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Remove and install . . . . . . . . . . . . . . . . . .02-110-2
Crank sensor F402 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24F403 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-9
CTM331 (09APR02) Index-1 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=1
Index
Page Page
F404 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0091 FMI 09 . . . . . . . . . . . . . . . .04-160-86SPN 0091 FMI 10 . . . . . . . . . . . . . . . .04-160-86F405 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F411 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0091 FMI 13 . . . . . . . . . . . . . . . .04-160-86SPN 0091 FMI 14 . . . . . . . . . . . . . . . .04-160-86F413 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F414 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0100 FMI 01 . . . . . . . . . . . . . . . .04-160-88SPN 0100 FMI 03 . . . . . . . . . . . . . . . .04-160-92F415 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F416 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0100 FMI 04 . . . . . . . . . . . . . . . .04-160-96SPN 0100 FMI 18 . . . . . . . . . . . . . . .04-160-102F417 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F418 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0105 FMI 03 . . . . . . . . . . . . . . .04-160-104SPN 0105 FMI 04 . . . . . . . . . . . . . . .04-160-108F419 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F420 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0105 FMI 16 . . . . . . . . . . . . . . .04-160-112SPN 0110 FMI 00 . . . . . . . . . . . . . . .04-160-114F421 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F422 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0110 FMI 03 . . . . . . . . . . . . . . .04-160-116SPN 0110 FMI 04 . . . . . . . . . . . . . . .04-160-120F423 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F424 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0110 FMI 15 . . . . . . . . . . . . . . .04-160-124SPN 0110 FMI 16 . . . . . . . . . . . . . . .04-160-126F425 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F426 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0111 FMI 00 . . . . . . . . . . . . . . .04-160-128SPN 0111 FMI 03 . . . . . . . . . . . . . . .04-160-130F428 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F429 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0111 FMI 04 . . . . . . . . . . . . . . .04-160-134SPN 0158 FMI 17 . . . . . . . . . . . . . . .04-160-138F430 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F432 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0174 FMI 03 . . . . . . . . . . . . . . .04-160-142SPN 0174 FMI 04 . . . . . . . . . . . . . . .04-160-146F436 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F439 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0174 FMI 16 . . . . . . . . . . . . . . .04-160-150SPN 0190 FMI 00 . . . . . . . . . . . . . . .04-160-154F440 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F445 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0190 FMI 16 . . . . . . . . . . . . . . .04-160-155SPN 0620 FMI 03 . . . . . . . . . . . . . . .04-160-156F446 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F459 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0620 FMI 04 . . . . . . . . . . . . . . .04-160-160SPN 0627 FMI 04 . . . . . . . . . . . . . . .04-160-164F460 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F461 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0629 FMI 13 . . . . . . . . . . . . . . .04-160-168SPN 0637 FMI 02 . . . . . . . . . . . . . . .04-160-170F463 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F464 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0637 FMI 10 . . . . . . . . . . . . . . .04-160-174SPN 0639 FMI 13 . . . . . . . . . . . . . . .04-160-178F465 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F470 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0898 FMI 09 . . . . . . . . . . . . . . .04-160-181
Indx2
F474 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 0970 FMI 31 . . . . . . . . . . . . . . .04-160-182SPN 0971 FMI 31 . . . . . . . . . . . . . . .04-160-183F475 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F476 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 1076 FMI 00 . . . . . . . . . . . . . . .04-160-184SPN 1076 FMI 01 . . . . . . . . . . . . . . .04-160-188F477 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F48B . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 1076 FMI 03 . . . . . . . . . . . . . . .04-160-192SPN 1076 FMI 05 . . . . . . . . . . . . . . .04-160-196F49A . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F490 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 1076 FMI 06 . . . . . . . . . . . . . . .04-160-200SPN 1076 FMI 07 . . . . . . . . . . . . . . .04-160-204F491 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F492 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 1079 FMI 03 . . . . . . . . . . . . . . .04-160-212SPN 1079 FMI 04 . . . . . . . . . . . . . . .04-160-216F493 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
F494 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN 1109 FMI 31 . . . . . . . . . . . . . . .04-160-220SPN 1110 FMI 31 . . . . . . . . . . . . . . .04-160-221SPN/FMI
SPN 0028 FMI 03 . . . . . . . . . . . . . . . .04-160-86 SPN 1569 FMI 31 . . . . . . . . . . . . . . .04-160-222SPN 2000 FMI 06 . . . . . . . . . . . . . . .04-160-223SPN 0028 FMI 04 . . . . . . . . . . . . . . . .04-160-86
SPN 0029 FMI 03 . . . . . . . . . . . . . . . .04-160-86 SPN 2000 FMI 13 . . . . . . . . . . . . . . .04-160-224Stored engine codes . . . . . . . . . . . . . . . .04-160-12SPN 0029 FMI 04 . . . . . . . . . . . . . . . .04-160-86
SPN 0029 FMI 14 . . . . . . . . . . . . . . . .04-160-86 Warning light. . . . . . . . . . . . . . . . . . . . . .03-140-152-Digit codesSPN 0091 FMI 03 . . . . . . . . . . . . . . . .04-160-86
SPN 0091 FMI 04 . . . . . . . . . . . . . . . .04-160-86 DTC 11 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24DTC 12 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24SPN 0091 FMI 07 . . . . . . . . . . . . . . . .04-160-86
CTM331 (09APR02) Index-2 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=2
Index
Page Page
ECU does not communicate with ServiceDTC 13 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-32DTC 14 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Engine cranks/won’t start. . . . . . . . . . . .04-150-2DTC 15 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Engine does not develop full power . . .04-150-11DTC 16 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Engine emits excessive black or gray exhaustDTC 18 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-19DTC 19 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Engine emits excessive white exhaustDTC 21 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-16DTC 22 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Engine idles poorly . . . . . . . . . . . . . . .04-150-22DTC 23 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Engine misfires/runs irregularly . . . . . . .04-150-7DTC 24 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Engine will not crank . . . . . . . . . . . . . .04-150-22DTC 25 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
OEM wiring diagram . . . . . . . . . . . . . . . .06-210-26DTC 26 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1DTC 32 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Digital multimeter, how to use . . . . . . . . . . .04-160-2DTC 37 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24DSTDTC 38 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-14DTC 39 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2DTC 42 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
DTCDTC 54 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2DTC 55 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
DTC 62 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24DTC 63 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24DTC 64 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 EDTC 65 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24DTC 68 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
ECUDTC 69 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2DTC 71 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-10DTC 72 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24Repair and adjustment . . . . . . . . . . . . . . .02-110-1DTC 73 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Electrical circuitDTC 74 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2DTC 75 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-2DTC 76 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 IndxTroubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 3DTC 77 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-1DTC 79 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 Electrical connectorsDTC 81 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20DTC 82 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DEUTSCH . . . . . . . . . . . . . . . . . . . . . . .02-110-17DTC 83 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 General information. . . . . . . . . . . . . . . . . .02-110-6DTC 84 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 METRI-PACK . . . . . . . . . . . .02-110-12, 02-110-14DTC 88 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 WEATHERPACK . . . . . . . . . . . . . . . . . . .02-110-8
Diagnostics Electrical insulating compound . . . . . . . . . . .02-110-6Air heater check . . . . . . . . . . . . . . . . . . .04-150-42 Electronic control systemFuel system Air heater operation . . . . . . . . . . . . . . . .03-140-12
Excessive fuel consumption. . . . . . . . .04-150-29 Analog throttle operation . . . . . . . . . . . . . .03-140-8Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-29 CAN throttle operation. . . . . . . . . . . . . . . .03-140-8Supply system check. . . . . . . . . . . . . .04-150-26 Cruise control operation . . . . . . . . . . . . .03-140-12
Observable Derating . . . . . . . . . . . . . . . . . . . . . . . . .03-140-13Abnormal engine noise . . . . . . . . . . . .04-150-23 Engine protection . . . . . . . . . . . . . . . . . .03-140-13Analog Throttle (B) does not Excavator throttle operation . . . . . . . . . . .03-140-8
respond . . . . . . . . . . . . . . . . . . . . . .04-150-25 Governor modes . . . . . . . . . . . . . . . . . . .03-140-14ECU does not communicate with Diagnostic Measuring engine speed. . . . . . . . . . . . . .03-140-9
Gauge . . . . . . . . . . . . . . . . . . . . . . .04-150-36 Measuring pressure . . . . . . . . . . . . . . . . .03-140-7ECU does not communicate with Measuring temperature . . . . . . . . . . . . . . .03-140-5
Monitoring engine parameters. . . . . . . . . .03-140-3DST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32
CTM331 (09APR02) Index-3 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=3
Index
Page Page
Multi-state throttle operation . . . . . . . . . . .03-140-8 Seal installation. . . . . . . . . . . . . . . . . . . .02-090-24Spray pattern test . . . . . . . . . . . . . . . . . .02-090-20Operation, theory of . . . . . . . . . . . . . . . . .03-140-3
Overview. . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-19Valve seat checking . . . . . . . . . . . . . . . .02-090-20Pump solenoid . . . . . . . . . . . . . . . . . . . . .03-140-9
Engine Valve stem and guide wear checking . . .02-090-20Fuel injection pumpApplication charts . . . . . . . . . . . . . . . . . . .01-001-4
Model designation. . . . . . . . . . . . . . . . . . .01-001-1 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13Serial number plate. . . . . . . . . . . . . . . . . .01-001-2
Engine configuration parameters . . . . . . . .04-160-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11Engine Control Unit (ECU)
Operation, theory of . . . . . . . . . . . . . . . .03-140-10 Static timing . . . . . . . . . . . . . . . . . . . . . .02-090-10Fuel supply pumpRepair and adjustment . . . . . . . . . . . . . . .02-110-1
Self-diagnosis . . . . . . . . . . . . . . . . . . . . .03-140-15 Bench test. . . . . . . . . . . . . . . . . . . . . . . .04-150-51Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10Engine cranks/won’t start . . . . . . . . . . . . . . .04-150-2
Engine does not develop full power . . . . . .04-150-11 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9Engine emits excessive black or gray exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19 Fuel systemAir in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-49Engine emits excessive white exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-16 Bleed . . . . . . . . . . . . . . . . . .02-090-26, 04-150-53Cylinder misfire test . . . . . . . . . . . . . . . .04-150-56Engine idles poorly . . . . . . . . . . . . . . . . . . .04-150-22
Engine misfires/runs irregularly. . . . . . . . . . .04-150-7 DiagnosticsExcessive fuel consumption. . . . . . . . .04-150-29Engine noise, abnormal . . . . . . . . . . . . . . .04-150-23
Engine Protection . . . . . . . . . . . . . . . . . . . .03-140-13 Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-29Supply system check. . . . . . . . . . . . . .04-150-26Engine will not crank . . . . . . . . . . . . . . . . .04-150-22
Fuel drain back test . . . . . . . . . . . . . . . .04-150-48Fuel supply pressure check . . . . . . . . . .04-150-50Fuel supply quality check . . . . . . . . . . . .04-150-47
F General information. . . . . . . . . . . . . . . . . .02-090-1Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2Relieve pressure . . . . . . . . . . . . . . . . . . . .02-090-1FMI, definition of. . . . . . . . . . . . . . . . . . . . . .03-140-2
Fuel Supply pressure specifications . . . . . . . . .06-210-1Fuel temperature sensorBio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Indx4
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4Fuel drain back test . . . . . . . . . . . . . . . . . .04-150-48Fuel filter
Exploded view (final). . . . . . . . . . . . . . . . .02-090-6 GExploded view (primary) . . . . . . . . . . . . . .02-090-5Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Glossary of termsRemove and install . . . . . . . . . . . . . . . . . .02-090-2
Electronic control system . . . . . . . . . . . . .03-140-2Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7
Governor modeFuel heater
Application specifications . . . . . . . . . . . . .06-210-3Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14Fuel injection nozzles
Adjustment . . . . . . . . . . . . . . . . . . . . . . .02-090-23Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-18Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 HDiagnose malfunctions . . . . . . . . . . . . . .04-150-30Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-22 Heater, air intake
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-42Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25Opening pressure test. . . . . . . . . . . . . . .02-090-21 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
High pressure washer, using with electricalOperation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 components . . . . . . . . . . . . . . . . . . . . . . .02-110-7
CTM331 (09APR02) Index-4 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=4
Index
Page Page
I S
Sensor, operationInch torque values . . . . . . . . . . . . . . . . . . . .06-200-1Coolant temperature . . . . . . . . . . . . . . . . .03-140-5Injection nozzlesCrank position. . . . . . . . . . . . . . . . . . . . . .03-140-9Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-18Fuel temperature. . . . . . . . . . . . . . . . . . . .03-140-7Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18Loss of coolant temperature . . . . . . . . . . .03-140-6Diagnose malfunctions . . . . . . . . . . . . . .04-150-30Manifold air temperature . . . . . . . . . . . . . .03-140-6Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-22Oil pressure . . . . . . . . . . . . . . . . . . . . . . .03-140-8Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25
Sensor, replaceRemove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16Coolant temperature . . . . . . . . . . . . . . . . .02-110-2Injection pumpCrank position. . . . . . . . . . . . . . . . . . . . . .02-110-3Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6Fuel temperature. . . . . . . . . . . . . . . . . . . .02-110-4Solenoid operation . . . . . . . . . . . . . . . . . .03-140-9Loss of coolant temperature . . . . . . . . . . .02-110-2Instrument panel (OEM)Manifold air temperature . . . . . . . . . . . . . .02-110-4Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-15Oil pressure . . . . . . . . . . . . . . . . . . . . . . .02-110-3Clearing stored codes . . . . . . . . . . . . . . .04-160-13
Serial number plate . . . . . . . . . . . . . . . . . . .01-001-2Diagnostic gauge diagnostics . . . . . . . . .04-150-36Service ADVISORViewing active codes . . . . . . . . . . . . . . .04-160-12
Conecting to . . . . . . . . . . . . . . . . . . . . . .04-160-14Viewing stored codes . . . . . . . . . . . . . . .04-160-12Data parameter description . . . . . . . . . . .04-160-16Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-28DiagnosticsIntake air heater
ECU does not communicate with SeviceDiagnostic check. . . . . . . . . . . . . . . . . . .04-150-42ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-32Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
TestsIntermittent fault, diagnosing. . . . . . . . . . . .04-160-28Excavator torque curve change . . . . . .04-160-19
SpecificationsBackhoes
L ECU terminal identification. . . . . . . . . . .06-210-5Governor mode selection. . . . . . . . . . . .06-210-5
Loss of coolant temperature sensor Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-4Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Torque curve selection . . . . . . . . . . . . .06-210-4
IndxRemove and install . . . . . . . . . . . . . . . . . .02-110-2 Crawlers 5Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 ECU terminal identification. . . . . . . . . . .06-210-8Governor mode selection. . . . . . . . . . . .06-210-7Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-6Torque curve selection . . . . . . . . . . . . .06-210-7M
ExcavatorsECU terminal identification. . . . . . . . . .06-210-12Manifold air temperature sensorGovernor mode selection. . . . . . . . . . .06-210-11Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-10Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4Torque curve selection . . . . . . . . . . . .06-210-11MAT, definition of . . . . . . . . . . . . . . . . . . . . .03-140-2
ForwardersMetric torque values . . . . . . . . . . . . . . . . . . .06-200-2ECU terminal identification. . . . . . . . . .06-210-17Misfire test, cylinderGovernor mode selection. . . . . . . . . . .06-210-16Cylinder misfire . . . . . . . . . . . . . . . . . . . .04-150-56Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-14Multimeter, how to use . . . . . . . . . . . . . . . . .04-160-2Torque curve selection . . . . . . . . . . . .06-210-16
Fuel supply pressure. . . . . . . . . . . . . . . . .06-210-1General OEM engine specifications . . . . .06-200-3
O HarvestersECU terminal identification. . . . . . . . . .06-210-20Governor mode selection. . . . . . . . . . .06-210-19Oil pressure sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-18Torque curve selection . . . . . . . . . . . .06-210-19Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
CTM331 (09APR02) Index-5 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=5
Index
Page Page
OEM engines T15 - Excavator throttle input voltagehigh . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-74ECU terminal identification. . . . . . . . . .06-210-25
Governor mode selection. . . . . . . . . . .06-210-24 T16 - Excavator throttle input voltagelow . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-78Instrument panel wiring diagram . . . . .06-210-28
Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-22 T19 - Throttle not calibrated properly . . .04-160-81T20 - Throttle input voltage below lower calibrationStart components wiring diagram. . . . .06-210-28
Torque curve selection . . . . . . . . . . . .06-210-24 limit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-82T21 - Throttle calibration aborted . . . . . .04-160-83Wiring diagram . . . . . . . . . . . . . . . . . .06-210-26
Skidders T22 - Analog throttle (A) input voltage out ofrange. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-84ECU terminal identification. . . . . . . . . .06-210-32
Governor mode selection. . . . . . . . . . .06-210-31 T23 - Multi-state throttle input voltage out ofrange. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-85Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-30
Torque curve selection . . . . . . . . . . . .06-210-31 Throttle, operationAnalog . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8Telehandlers
ECU terminal identification. . . . . . . . . .06-210-36 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8Excavator . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8Governor mode selection. . . . . . . . . . .06-210-35
Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-34 Multi-state . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8ToolsTorque curve selection . . . . . . . . . . . .06-210-35
Speed governing . . . . . . . . . . . . . . . . . . . .03-140-14 Electronic Fuel System Diagnostic . . . . . .05-180-1Torque curve selectionSPN, definition of . . . . . . . . . . . . . . . . . . . . .03-140-2
Start components Application specifications . . . . . . . . . . . . .06-210-3Excavator change test. . . . . . . . . . . . . . .04-160-19Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-28Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
Torque valuesInch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
T Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2Trouble codes
Diagnostic procedure . . . . . . . . . . . . . . .04-160-27TestAir heater check . . . . . . . . . . . . . . . . . . .04-150-42 Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22Air in fuel . . . . . . . . . . . . . . . . . . . . . . . .04-150-49Cylinder misfire . . . . . . . . . . . . . . . . . . . .04-150-56Excavator torque curve change. . . . . . . .04-160-19 WFuel drain back . . . . . . . . . . . . . . . . . . . .04-150-48
Indx6
Fuel supply pressure. . . . . . . . . . . . . . . .04-150-50Wiring diagram
Fuel supply quality check . . . . . . . . . . . .04-150-47Instrument panel (OEM) . . . . . . . . . . . . .06-210-28
Fuel supply system check . . . . . . . . . . . .04-150-26OEM engines . . . . . . . . . . . . . . . . . . . . .06-210-26
Throttle DTCsListing of . . . . . . . . . . . . . . . .04-160-29, 04-160-86T01 - Multi-state throttle input high . . . . .04-160-30T02 - Multi-state throttle input low . . . . . .04-160-34T03 - Analog throttle (A) input high . . . . .04-160-38T04 - Analog throttle (A) input low . . . . .04-160-42T05 - Analog throttle (B) input high . . . . .04-160-46T06 - Analog throttle (B) input low . . . . .04-160-50T07 - CAN throttle invalid . . . . . . . . . . . .04-160-54T11 - Excavator throttle reference voltage
high . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-58T12 - Excavator throttle reference voltage
low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-62T13 - Excavator throttle ground voltage
high . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-66T14 - Excavator throttle ground voltage
low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-70
CTM331 (09APR02) Index-6 4.5 L & 6.8 L Level 12 Electronic Fuel System040902
PN=6