Service Manual 6068 May 03

COMPONENT TECHNICAL MANUAL
PowerTech 4.5 & 6.8 L Diesel Engines Level 4 Electronic Fuel System CTM170 14MAY03 (English)
POWERTECH 4.5L & 6.8L Diesel Engines Level 4 Electronic Fuel Systems With Bosch VP44 Pump
TECHNICAL MANUAL POWERTECH 4.5 & 6.8 L Diesel Engines Level 4 Electronic Fuel System
14MAY03 (ENGLISH)
For complete service information also see: POWERTECH 4.5 L and 6.8 L Diesel Engines Base Engine. . . . . . . . . . . . . . . . . CTM104 POWERTECH 4.5 L and 6.8 L Diesel Engines Mechanical Fuel Systems . . . . . . CTM207 Alternators and Starter Motors . . . . . . . . . . . CTM77 OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems

LITHO IN U.S.A.
Introduction
Forward
This manual (CTM 170) is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. This manual covers only Level 4 Electronic Fuel Systems with the Bosch VP44 injection pump. It is one of five volumes on 4.5 L and 6.8 L engines. The following four companion manuals cover the base engine and mechanical fuel system repair, operation and diagnostics: CTM104Base Engine CTM207Mechanical Fuel Systems CTM220Level 11 Electronic Fuel System with Denso High Pressure Common Rail CTM331Level 12 electronic Fuel System with DE10 Pump Other manuals will be added in the future to provide additional information on electronic fuel systems as needed. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components. Information is organized in sections and groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Before beginning repair on an engine, clean the engine. This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized. Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures. Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual.
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
DPSG,OUO1004,2760 1917JUL011/1
CTM170 (14MAY03)
4.5 L & 6.8 L Level 4 Electronic Fuel System

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Contents
01
SECTION 01General Group 000Safety Group 001Engine Identification Group 002Fuels SECTION 02Repair and Adjustments Group 090Electronic Fuel System Repair and Adjustments Group 110Electrical Engine Control Repair and Adjustment SECTION 03Theory of Operation Group 130Electronic Fuel System Operation Group 140Electronic Control System Operation SECTION 04Diagnostics Group 150Observable Diagnostics and Tests Group 160Trouble Code Diagnostics and Tests SECTION 05Tools and Other Materials Group 170Electronic Fuel/Control System Repair Tools and Other Materials Group 180Diagnostic Service Tools SECTION 06Specifications Group 200Repair Specifications Group 210Diagnostic Specifications
04 02
03
05
06
INDX
All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT 2000 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual
CTM170 (14MAY03)

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Contents
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02
03
04
05
06
INDX
CTM170 (14MAY03)
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01
Section 01
General
Contents
Page
Group 000Safety . . . . . . . . . . . . . . . . . . . .01-000-1 Group 001Engine Identification Engine Model Designation. . . . . . . . . . . . . . . .01-001-1 Engine Serial Number Plate Information . . . . .01-001-2 OEM Engine Option Code Label . . . . . . . . . . .01-001-3 Engine Application Chart . . . . . . . . . . . . . . . . .01-001-4 Tier 1 vs. Tier 2. . . . . . . . . . . . . . . . . . . . . . . .01-001-5 Group 002Fuels Lubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1 Diesel Fuel - Tier 1 . . . . . . . . . . . . . . . . . . . . .01-002-1 Diesel Fuel - Tier 2 . . . . . . . . . . . . . . . . . . . . .01-002-2 Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-4 Dieselscan Fuel Analysis. . . . . . . . . . . . . . . . .01-002-4 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-5
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Group 000
Safety
Handle Fluids SafelyAvoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
Avoid Fires
01 000 1
DX,FLAME 1929SEP981/1
Handle Starting Fluid Safely

Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables. To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location. Do not incinerate or puncture a starting fluid container.
UN18MAR92
DX,FIRE3 1916APR921/1
Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
DX,RCAP 1904JUN901/1
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TS281
UN23AUG88
TS1356
TS227
UN23AUG88
Safety
01 000 2
Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F).
DX,SPARKS 1903MAR931/1
Prepare for Emergencies

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.
UN23AUG88
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
DX,FIRE2 1903MAR931/1
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TS291
TS204
UN23AUG88
Safety
Handling Batteries Safely

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 1530 minutes. Get medical attention immediately. If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
UN23AUG88
01 000 3
DPSG,OUO1004,2758 1911MAY001/1
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TS203
UN23AUG88
TS204
Safety
01 000 4
Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.
UN23AUG88
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
High-Pressure Fluids
DX,FLUID 1903MAR931/1
Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.
Protective Clothing
DX,WEAR 1910SEP901/1
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X9811
Safety
Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
UN23AUG88
01 000 5
Moving Parts
DX,LOOSE 1904JUN901/1
Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area
UN23AUG88
Engine Exhaust Fumes
DX,AIR 1917FEB991/1
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TS220
TS228
Safety
01 000 6
Work in Clean Area

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.
Clean Work Area
DX,CLEAN 1904JUN901/1
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: Remove paint a minimum of 76 mm (3 in.) from area to be 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 with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Do all work in an area that is ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.
UN23AUG88
DX,PAINT 1922OCT991/1
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TS220
T6642EJ
UN18OCT88
Safety
Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
01 000 7
Flammable Spray
DX,TORCH 1903MAR931/1
Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Illuminate Work Area Safely
DX,LIGHT 1904JUN901/1
Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.
DX,LIFT 1904JUN901/1
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TS226
UN23AUG88
TS223
UN23AUG88
TS953
UN15MAY90
Safety
01 000 8
Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials and good workmanship. Do not weld tools unless you have the proper equipment and experience to perform the job.
UN01JUL97
Construct Dealer-Made Tools Safely
DPSG,OUO1004,899 1919MAY991/1
Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.
Keep Area Clean
DX,SERV 1917FEB991/1
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TS218
UN23AUG88
LX1016749
Safety
Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use Proper Tools
01 000 9
Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
Dispose of Waste Properly

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earths atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.
UN26NOV90
Recycle Waste
DX,DRAIN 1903MAR931/1
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TS1133
TS779
UN08NOV89
Safety
01 000 10
Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
1907OCT88
Safety Systems
DX,LIVE 1925SEP921/1
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TS231
Group 001
Engine Identification
Engine Model Designation
John Deere Engine Model4045 and 6068 Engines John Deere engine model designation includes number of cylinders, displacement in liters, aspiration, user code, and applicable code. For example:
4045TF150 Engine 4 ............................. 4.5 .......................... T ............................ F ............................ 1 ............................. 50 ........................... Aspiration Code D ............................ T ............................ A ............................ H ............................ User Factory Code AP .......................... CQ ......................... DW ......................... E ............................ F ............................ FF .......................... FG .......................... FM ......................... H ............................ KV .......................... L ............................. LA .......................... LV .......................... N ............................ P ............................ RW ......................... T ............................ T8 .......................... YC .......................... Z ............................ Model Designation 1 or 2 ..................... Application Code 50 or above ........... Number of cylinders Liter displacement Aspiration code User code Internal engine configuration type POWERTECH application code Naturally aspirated Turbocharged (No aftercooling) Turbocharged and Air-to-Coolant Aftercooled Turbocharged and Air-to-Air Aftercooled Saltillo (Mexico) S.L.C. Horizontina (Brazil) John Deere Davenport Works John Deere Ottumwa Works OEM (Outside Equipment Manufacturers) Kernersville Deere-Hitachi (North Carolina) Goldoni (Italy) Marine Engines John Deere Harvester Works John Deere Knoxville (Tennessee) John Deere Werke Mannheim (Germany) John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump) John Deere Augusta, Georgia John Deere Des Moines Works Saltillo/Monterrey (Mexico) John Deere Waterloo Tractor Works John Deere Dubuque Works Cameco (Deere) (Louisiana) John Deere Jialian Harvester Co. Limited (China) John Deere WERKE Zweibrucken (Germany) Indicates different internal engine components POWERTECH code for specific application 01 001 1
POWERTECH is a registered trademark of Deere & Company
RG,01,DT7028 1909MAY011/1
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01 001 2
Engine Serial Number Plate Information

IMPORTANT: The engine serial number plate (A) can be easily destroyed. Before hot tank cleaning the block, remove the plate. Engine Serial Number (B) Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example:
Engine Serial Number Plate
T04045T000000 T0 ........................... Factory producing engine 4045T ..................... Engine model designation 000000 ................... Sequential serial number Factory Code (Engine Manufacturer) T0 ........................... Dubuque, Iowa CD .......................... Saran, France PE .......................... Torreon, Mexico Engine Model Designation 4045T ..................... Definition explained previously. (See ENGINE MODEL DESIGNATION earlier in this group. Sequential Number 000000 ................... 6-digit sequential serial number
UN04JUN01 RG11736A
Engine Application Data (C)

Dubuque Engine Serial Number Plate
The second line of information on the serial number plate identifies the engine/machine or OEM relationship. See ENGINE APPLICATION CHART later in this group. Coefficient of Absorption (D) (Saran-Built Engines Only) The second line of information on Saran serial number plate also contains the coefficient of absorption value for smoke emissions.
AEngine Serial Number Plate BEngine Serial Number CEngine Application Data DCoefficient of Absorption (Saran Engines Only)
UN16MAR98
Saran Engine Serial Number Plate
Torreon Engine Serial Number Plate
RG,01,DT7029 1909MAY011/1
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RG9062
UN16MAR98
RG9061
RG9060
UN16MAR98
OEM Engine Option Code Label

An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition. Always provide option code information and engine base code when ordering repair parts. A listing of option codes is given in Parts Catalogs and Operators Manuals.
UN10MAY95
01 001 3
NOTE: Before hot tank cleaning, ensure that option codes are recorded elsewhere. It is recommended to record this information in the spaces provided in the Operation and Maintenance Manual.
DPSG,OUO1004,482 1913AUG011/1
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CD30433
01 001 4
Engine Application Chart

Machine Model Waterloo - TRACTORS 7320 Tractor 7420 Tractor 7520 Tractor MANNHEIM - TRACTORS 6310 Tractor 6410 Tractor 6510 Tractor 6610 Tractor 6810 Tractor 6910 Tractor 6910S Tractor, Boost) 6320 (North America) Tractor 6320 Tractor 6420 (North America) Tractor 6420 Tractor 6420S Boost Tractor 6620 Tractor 6820 Tractor 6920 Tractor 6920S Boost Tractor JOHN DEERE AGRICULTURAL EQUIPMENT Emission Level Engine Model Tier 1 Tier 1 Tier 1 CD6068HRW01 CD6068HRW01 CD6068HRW01
Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier Tier
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
CD4045TLA50 CD4045TLA51 CD6068TLA50 CD6068TLA51 CD6068TLA52 CD6068TLA53 CD4045HLA71 CD4045HLA70 CD4045HLA72 CD4045HLA72 CD4045HLA73 CD6068HLA70 CD6068HLA71 CD6068HLA72 CD6068HLA73
ZWEIBRUCKEN - COMBINES/TELESCOPIC HANDLERS 9540 Combine Tier 2 9540 HM Combine Tier 2 3800 Telescopic Handler Tier 1 HORIZONTINA - COMBINES 1450 CWS Combine 1550 CWS Combine
CD6068HZ060 CD6068HZ060 CD4045HZ050
Tier 2 Tier 2
CD6068HCQ60 CD6068HCQ61
Machine Model DEERE-HITACHI - KERNERSVILLE 200 LC Excavator 230 LC Excavator HITACHI - JAPAN 270 LC Excavator
JOHN DEERE CONSTRUCTION EQUIPMENT Emission Level Engine Model Tier 2 Tier 2 PE6068HT053 PE6068HT054
Tier 2
PE6068HT055
Machine Model OEM OEM Marine Marine Marine
JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS) Emission Level Engine Model Tier Tier Tier Tier 2 2 2 2 PE6068HF275 T06068SFM50 PE6068SFM50 CD6068SFM50
RG41221,0000134 1917OCT021/1
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Tier 1 vs. Tier 2

The fuel transfer pump is located on the final fuel filter header on Tier 1 applications and primary fuel filter on Tier 2 applications. Some Tier 2 applications use a remote mounted fuel transfer pump. For more information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. The transfer pump is electrically controlled by the Electronic Control Unit (ECU). All Tier 1 engines are equipped with a fuel pressure sensor on the final fuel filter. Some Tier 2 engines use a fuel pressure sensor and some do not. Tier 1 engines may be equipped with a primary fuel filter/water separator. All Tier 2 engines will have both a primary and final fuel filter.
UN20JUN01
01 001 5
Tier 1 - Final Fuel Filter
Tier 1 engines may be equipped with either a 30 micron or 150 micron primary filter. All Tier 2 engines have a 30 micron primary filter. All engines are equipped with a round final fuel filter. All engines use 9.5 mm pencil-type nozzles. Fuel system options include fuel heater and water separator bowl. IMPORTANT: The Bosch VP44 Injection Pump is electronically controlled. All connectors on the pump and the engine control unit (ECU) must be disconnected before any welding is accomplished on the engine, or damage to the electrical system is likely to occur.
Tier 2 - Final Fuel filter
Tier 2 - Primary Fuel Filter
RG41221,0000204 1922MAY011/1
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UN22JUN01
RG11720
RG11745
UN22JUN01
PN=21
01 001 6
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Group 002
Fuels
Lubricants and Coolant
NOTE: For information on lubricants and coolants, refer to Section 01, Group 002 of CTM104 Base Engine Manual for information on lubricants and coolants.
01 002 1
DPSG,OUO1004,2761 1916MAY001/1
Diesel Fuel - Tier 1

NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual.
Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are recommended. In all cases, the fuel shall meet the following properties: Cetane Number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below 20C (4F) or elevations above 1500 m (5000 ft). Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5C (9F) below the expected low temperature. Fuel Lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. Sulfur Content Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred. If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval for engine oil and filter by 50%. DO NOT use diesel fuel with sulfur content greater than 1.0%. Bio-diesel fuels with properties meeting DIN 51606 or equivalent specification may be used. DO NOT mix used engine oil or any other type of lubricant with diesel fuel.
RG,02,DT7324 1917OCT021/1
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Fuels
01 002 2
Diesel Fuel - Tier 2

Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are recommended. Required fuel properties In all cases, the fuel must meet the following properties: Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20C (-4F) or elevations above 1500 m (5000 ft). Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5C (9F) below the expected low temperature. Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or, maximum scar diameter of 0.45 mm as measured by ASTM D6079. Sulfur content: Diesel fuel quality and fuel sulfur content must comply with all existing regulations for the area in which the engine operates. Sulfur content less than 0.05% (500 ppm) is preferred. If diesel fuel with sulfur content greater than 0.05% (500 ppm) is used, crankcase oil service intervals may be affected. (See recommendation for Diesel Engine Oil.) DO NOT use diesel fuel with sulfur content greater than 1.0%. IMPORTANT: DO NOT mix used engine oil or any other type of lubricating oil with diesel fuel.
RG41221,0000085 1923OCT021/1
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Fuels
01 002 3
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Fuels
01 002 4
Bio-Diesel Fuel
Consult your local fuel distributor for properties of the bio-diesel fuel available in your area. Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM PS121, DIN 51606 or equivalent specification. It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend in petroleum diesel fuel. When using a blend of bio-diesel fuel, the engine oil level must be checked daily when the air temperature is -10C (14F) or lower. If the oil becomes diluted with fuel, shorten oil change intervals accordingly. IMPORTANT: Raw pressed vegetable oils are NOT acceptable for use for fuel in any concentration in John Deere engines. These oils do not burn completely, and will cause engine failure by leaving deposits on injectors and in the combustion chamber. A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas of concern include: Quality of new fuel Water content of the fuel Problems due to aging of the fuel Potential problems resulting from deficiencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms: Power loss and deterioration of performance Fuel leakage Corrosion of fuel injection equipment Coked and/or blocked injector nozzles, resulting in engine misfire Filter plugging Lacquering and/or seizure of internal components Sludge and sediments Reduced service life of engine components
RG41183,0000046 1915NOV011/1
Dieselscan Fuel Analysis

DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
DX,FUEL6 1906DEC001/1
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Fuels
Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components. Diesel fuels for highway use in the United States, Canada, and the European Union require sulfur content less than 0.05%. Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks. Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke. Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test. If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.
01 002 5
DX,FUEL5 1917FEB991/1
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Fuels
01 002 6
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Section 02
Repair and Adjustments

Contents
Page Page 02
Group 090Electronic Fuel System Repair and Adjustments Fuel SystemGeneral Information . . . . . . . . .02-090-1 Relieve Fuel System Pressure . . . . . . . . . . . .02-090-2 Remove and Install Primary Fuel Filter/Water Separator Base - Tier 2 . . . . . .02-090-3 Remove and Install Final Fuel Filter/Water Separator Base - Tier 1 . . . . . . . . . . . . . . . .02-090-5 Remove and Install Final Fuel Filter/Water Separator Base - Tier 2 . . . . . . . . . . . . . . . .02-090-7 Final Fuel Filter Assembly - Tier 1. . . . . . . . . .02-090-8 Final Fuel Filter Assembly - Tier 2. . . . . . . . . .02-090-9 Replace Final Fuel Filter Element . . . . . . . . .02-090-10 Remove and Install Electronic Fuel Transfer Pump - Filter Mount . . . . . . . . . . .02-090-11 Remove and Install Electronic Fuel Transfer Pump - Remote Mount. . . . . . . . .02-090-12 Service Injection Pump Overflow Valve . . . . .02-090-13 Bosch VP44 Injection Pump Static Timing. . .02-090-14 Remove Bosch VP44 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Repair Bosch VP44 Fuel Injection Pump. . . .02-090-18 Install Bosch VP44 Fuel Injection Pump . . . .02-090-19 Remove Fuel Injection Nozzles . . . . . . . . . . .02-090-22 Clean Fuel Injection Nozzle Bore . . . . . . . . .02-090-24 Clean Fuel Injection Nozzles . . . . . . . . . . . . .02-090-24 Test Fuel Injection Nozzles . . . . . . . . . . . . . .02-090-25 Disassemble Fuel Injection Nozzles . . . . . . .02-090-30 Inspect and Clean Fuel Injection Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-33 Inspect and Clean Valve and Valve Seat . . .02-090-34 Inspect Valve Adjusting Mechanism . . . . . . .02-090-36 Assemble Fuel Injection Nozzles. . . . . . . . . .02-090-37 Adjust Fuel Injection Nozzles . . . . . . . . . . . .02-090-38 Install Seals on Fuel Injection Nozzle . . . . . .02-090-41 Install Fuel Injection Nozzles . . . . . . . . . . . . .02-090-42 Group 110Electrical Engine Control Repair and Adjustment Engine Control Unit (ECU) . . . . . . . . . . . . . . .02-110-1 Remove and Install Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . .02-110-2 Replace Fuel Pressure Sensor . . . . . . . . . . . .02-110-3 Replace Pump Position Sensor . . . . . . . . . . . .02-110-4 Replace Crankshaft Position Sensor . . . . . . . .02-110-4 Remove and Install Oil Pressure Sensor . . . . .02-110-5 CTM170 (14MAY03)
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-6 Use Electrical Insulating Compound . . . . . . . .02-110-6 Using High-Pressure Washer . . . . . . . . . . . . .02-110-6 Repair WEATHERPACK Connector . . . . . . .02-110-7 Remove Blade Terminals from Connector Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-10 Repair (Pull Type) METRI-PACK Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-11 Repair (Push Type) METRI-PACK Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-13 Repair DEUTSCH Connectors . . . . . . . . . .02-110-16 Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-19
02-1

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Contents
02
CTM170 (14MAY03)
02-2

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Group 090
Electronic Fuel System Repair and Adjustments

Fuel SystemGeneral Information
For static lock-pin timing of the Bosch VP44 Injection Pump, see BOSCH VP44 INJECTION PUMP STATIC TIMING in this Group. The fuel transfer pump is located on the final fuel filter header on Tier 1 applications and primary fuel filter, or remote mounted on Tier 2 applications. For more information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. The transfer pump is electrically controlled by the Electronic Control Unit (ECU). Tier 1 engines may be equipped with a primary fuel filter/water separator. All Tier 2 engines will have both a primary and final fuel filter. All engines are equipped with a round final fuel filter. All engines use 9.5 mm pencil-type nozzles. Fuel system options include fuel heater and water separator bowl. IMPORTANT: The Bosch VP44 Injection Pump is electronically controlled. All connectors on the pump and the engine control unit (ECU) must be disconnected before any welding is accomplished on the engine, or damage to the electrical system is likely to occur.
02 090 1
DPSG,OUO1004,2639 1909MAY011/1
CTM170 (14MAY03)
02-090-1

051403
PN=31
Relieve Fuel System Pressure

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious injury. Before disconnecting lines, be sure to relieve pressure. Before applying pressure to the system, be sure ALL connections are tight and lines, pipes and hoses are not damaged. Keep hands and body away from pinholes and nozzles which eject fluid under pressure. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG,35,JW7625 1920NOV971/1
CTM170 (14MAY03)
02-090-2

051403
PN=32
X9811
UN23AUG88
02 090 2
Remove and Install Primary Fuel Filter/Water Separator Base - Tier 2

The primary fuel filter may be equipped with a water separator bowl. The electronic fuel transfer pump is mounted on top of the filter head.
Primary Fuel Filter - Tier 2
1. Thoroughly clean primary fuel filter/water separator assembly and surrounding area to keep from getting dirt and debris into fuel system. 2. Connect a fuel line to filter drain (if equipped) on bottom of filter and drain all fuel from the system. 3. Remove primary fuel filter element.
AFilter Bracket to Engine Mounting Cap Screws BFilter Base to Bracket Mounting Cap Screws CFuel Inlet Line (From Fuel Tank) DFuel Outlet (To Final Fuel Filter) EPrimary Fuel Filter FFuel Transfer Pump Connector
NOTE: Fuel lines may be connected to different inlet and outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (C) and fuel outlet (D). 5. Disconnect fuel transfer pump connector (F). 6. Remove filter base cap screws (B) and primary fuel filter base.
NOTE: Mounting bracket does not need to be removed.

7. Replace parts as necessary. 8. If removed, install mounting bracket on engine. Install filter base on mounting bracket. Tighten cap screws to specification.
Specification Primary Fuel Filter Mounting Bracket-to-Cylinder Head Cap ScrewsTorque ........................................................... 74 Nm (54.5 lb-ft) Primary Fuel Filter Base-to-Bracket Cap Screws Torque ............................................................................. 60 Nm (44 lb-ft)
Continued on next page
RG41221,00000FB 1917OCT021/2
CTM170 (14MAY03)
02-090-3

051403
RG11725A
UN12JUL01
02 090 3
PN=33

9. Install water separator and primary fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT later in this Group.
02 090 4
10. Connect fuel lines to fuel inlet (C) and fuel outlet (D) and tighten to specification.
Specification Primary Fuel Filter Inlet Line Torque ............................................................................. 30 Nm (22 lb-ft) Primary Fuel Filter Outlet Line Torque ............................................................................. 30 Nm (22 lb-ft)
11. Reconnect fuel transfer pump electrical connector. 12. Bleed the fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,00000FB 1917OCT022/2
CTM170 (14MAY03)
02-090-4

051403
PN=34
Remove and Install Final Fuel Filter/Water Separator Base - Tier 1

UN04MAY00
02 090 5
Final fuel filter may be equipped with a water separator bowl. The electronic fuel transfer pump is mounted on top of the filter header. 1. Thoroughly clean fuel filter/water separator assembly and surrounding area to keep from getting dirt and debris into fuel system. 2. Connect a fuel line to filter drain on bottom of filter and drain all fuel from system. 3. Remove final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT, later in this Group.
Final Fuel Filter - Tier 1

AFilter Base Mounting Cap Screws BFuel Inlet Line (From Prefilter) CFuel Pressure Sensor Connector DFinal Fuel Filter EFuel Overflow Line (To Injection Pump Overflow Valve) FFuel Outlet Line (To Injection Pump Inlet) GFuel Transfer Pump Connector
NOTE: Fuel lines may be connected to different filter inlet and outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (B), overflow valve (E), and fuel outlet (F). 5. Disconnect fuel transfer pump connector (G) and fuel pressure sensor connector (C) (both shown disconnected). 6. Remove cap screws (A) and final fuel filter base.
NOTE: Mounting bracket does not need to be removed.

7. Replace parts as necessary. 8. If removed, install filter mounting bracket on engine. Install filter base on mounting bracket. Tighten cap screws to specifications.
Specification Final Fuel Filter Mounting Bracket-to-Exhaust Manifold Torque ............................................................................. 70 Nm (52 lb-ft) Final Fuel Filter Base-to-Bracket Cap ScrewsTorque ...................................................... 70 Nm (52 lb-ft)
RG41221,0000105 1917OCT021/2
CTM170 (14MAY03)
02-090-5

051403
PN=35
RG10721A

9. Install water separator and fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT later in this Group.
02 090 6
10. Connect fuel lines to fuel inlet (B), overflow valve (E), and fuel outlet (F) and tighten to specification.
Specification Final Fuel Filter Inlet Line Torque ............................................................................. 30 Nm (22 lb-ft) Final Fuel Filter Outlet Line Torque ............................................................................. 30 Nm (22 lb-ft)
11. Reconnect fuel transfer pump and fuel pressure sensor electrical connectors. 12. Bleed the fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,0000105 1917OCT022/2
CTM170 (14MAY03)
02-090-6

051403
PN=36
Remove and Install Final Fuel Filter/Water Separator Base - Tier 2

Final fuel filter may be equipped with a water separator bowl. 1. Thoroughly clean fuel filter/water separator assembly and surrounding area to keep from getting dirt and debris into fuel system. 2. Connect a fuel line to filter drain and drain all fuel from system. 3. Remove final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT later in this Group.

AFilter Base Mounting Cap Screws BFuel Inlet Line (From Prefilter) CFuel Pressure Sensor Connector DFinal Fuel Filter EFuel Overflow Line (To Injection Pump Overflow Valve) FFuel Outlet Line (To Injection Pump Inlet)
NOTE: Fuel lines may be connected to different filter inlet and outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (B), overflow valve (E), and fuel outlet (F). 5. Disconnect fuel pressure sensor connector (C). 6. Remove cap screws (A) and final fuel filter base. Remove final filter. 7. Replace parts as necessary. 8. Install filter base on engine cylinder head. Tighten cap screws to specifications.
Specification Final Fuel Filter Base-to-Cylinder HeadTorque ................................................................. 70 Nm (52 lb-ft)
9. Install water separator and fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT later in this Group. 10. Connect fuel lines to fuel inlet (B), overflow valve (E), and fuel outlet (F) and tighten to specification.
RG41221,00000FC 1917OCT021/2
CTM170 (14MAY03)
02-090-7

051403
RG11720B
UN20JUN01
02 090 7
PN=37

Specification Final Fuel Filter Inlet Line Torque ............................................................................. 30 Nm (22 lb-ft) Final Fuel Filter Outlet Line Torque ............................................................................. 30 Nm (22 lb-ft) 02 090 8
11. Reconnect the fuel pressure electrical connector. 12. Bleed the fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,00000FC 1917OCT022/2
Final Fuel Filter Assembly - Tier 1

1Fuel Transfer Pump 2O-Ring 3O-Ring 4O-Ring 5Fitting 6Fitting 7Fuel Pressure Sensor 8Air Bleed Spring and Ball (Non-Serviceable) 9O-Ring 10Dust Seal 11Copper Washer 12Banjo Bolt 13Banjo Fitting 14Hose Clamp 15Retaining Ring 16Filter 17O-Ring 18Gasket 19O-Ring 20Drain Adapter 21Screw 22O-Ring 23Water Separator Bowl 24Adapter 25O-Ring 26O-Ring 27Fitting 28Plug1 29O-Ring 30Filter Base
An optional fuel heater is available for installation in this bore.

RG41221,0000106 1909MAY011/1
CTM170 (14MAY03)
02-090-8

051403
PN=38
RG10723
UN02MAY00
Final Fuel Filter Assembly - Tier 2

1Filter Base 2Final Fuel Filter Cover 3O-Ring 4O-Ring 5Fitting 6Fitting 7Fuel Pressure Sensor 8Air Bleed Spring and Ball (Non-Serviceable) 9O-Ring 10Dust Seal 11Copper Washer 12Banjo Bolt 13Banjo Fitting 14Hose Clamp 15Retaining Ring 16Filter 17O-Ring 18Gasket 19O-Ring 20Drain Adapter 21Screw 22O-Ring 23Water Separator Bowl 24Adapter 25O-Ring 26O-Ring 27Fitting 28Plug1 29O-Ring
02 090 9
An optional fuel heater is available for installation in this bore.

RG41221,00000FE 1908MAY011/1
CTM170 (14MAY03)
02-090-9

051403
PN=39
RG11708
UN04JUN01
Replace Final Fuel Filter Element

NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: Refer to operators manual for proper servicing and (hourly) replacement intervals.
1. Thoroughly clean fuel filter/water separator assembly and surrounding area, if not previously done. 2. Connect a fuel line to filter drain adapter and drain all fuel from filter/water separator.
Final Fuel Filter Element - Tier 1
UN04MAY00
02 090 10
NOTE: Lifting up on retaining ring (A) as it is rotated helps to get it past raised locators.
UN20JUN01
3. Firmly grasp the retaining ring (A) and loosen it 1/4 turn. Remove retaining ring with filter element (B) and water separator (D) (if equipped). 4. Inspect filter mounting base for cleanliness. Clean as required. 5. Remove water separator bowl (D), if equipped. Drain and clean separator bowl. Dry with compressed air. 6. Install water separator bowl, if equipped, onto new filter element. Tighten adapter (C) securely. 7. Thoroughly inspect filter base seal ring. Replace as needed.
Final Fuel Filter Element - Tier 2
ARetaining Ring BFilter Element CAdapter DWater Separator Bowl
NOTE: The fuel filter must be indexed properly and the key on canister must be oriented in slot of mounting base for correct installation.
8. Install new filter element onto mounting base and position element using a slight rocking motion. Be sure element is properly indexed on mounting base. 9. Install retaining ring onto mounting base and tighten about 1/3 turn until ring snaps into the detent. DO NOT overtighten the retaining ring. 10. Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,0000107 1909MAY011/1
CTM170 (14MAY03)
02-090-10

051403
RG11720A
PN=40
RG10721B
Remove and Install Electronic Fuel Transfer Pump - Filter Mount

NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: On Tier 1 applications the fuel transfer pump is located on the final fuel filter. Tier 2 applications have the fuel transfer pump on the primary fuel filter.
1. Disconnect fuel transfer pump connector (D). 2. Remove heat shield above fuel transfer pump (Tier 1 applications only). 3. Unscrew the holding ring (C). If necessary, loosen cap screws (B) holding fuel filter base. 4. Remove electronic fuel transfer pump assembly (A) from filter base. Discard O-rings. 5. Replace complete fuel transfer pump as necessary. 6. Install transfer pump using new O-rings (E) and (F), observing orientation shown. Do not rotate pump after installation. 7. Hand tighten holding ring keeping correct transfer pump orientation.
UN04MAY00
Electronic Fuel Transfer Pump - Tier 1
Electronic Fuel Transfer Pump - Tier 2
8. When needed, tighten fuel filter base cap screws to specifications.

Specification Final Fuel Filter Base Mounting Cap ScrewsTorque ...................................................... 70 Nm (52 lb-ft) Primary Fuel Filter Base-to-Bracket Cap Screws Torque ............................................................................. 60 Nm (44 lb-ft)
RG11721A
UN20JUN01
Electrical Fuel Transfer Pump Details

AFuel Transfer Pump BFilter Base Cap Screw (2 used) CHolding Ring DFuel Transfer Pump Connector EO-Ring FO-Ring
9. Reconnect electrical connection. 10. Install heat shield above fuel transfer pump (Tier 1 applications only). 11. Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,0000108 1913AUG011/1
CTM170 (14MAY03)
02-090-11

051403
PN=41
RG10727A
RG10726A
UN04MAY00
02 090 11
Remove and Install Electronic Fuel Transfer Pump - Remote Mount

NOTE: On 24 volt applications the fuel transfer pump is mounted to the engine or remote mounted on the frame of the vehicle.
1. Disconnect ring terminals from the fuel transfer pump power (A) and ground (B) studs. 2. Remove fuel lines from fuel inlet (D) and outlet (C) on transfer pump.
Remote Mount Transfer Pump Wiring
3. Remove fuel transfer pump. 4. Replace complete fuel transfer pump as necessary. 5. Install fuel transfer pump. 6. Connect fuel inlet and outlet lines.
UN20JUL01
7. Reconnect electrical connections. Tighten retaining nuts to specification.

Specification Fuel Transfer Pump Wiring Retaining Nut (+)Torque ............................................ 1.2 Nm (0.9 lb-ft) Fuel Transfer Pump Wiring Retaining Nut (-)Torque ............................................. 1.6 Nm (1.2 lb-ft)
Remote Mount Transfer Pump

APower Stud BGround Stud CFuel Outlet DFuel Inlet
8. Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,0000214 1909JUL011/1
CTM170 (14MAY03)
02-090-12

051403
RG11756A
NOTE: Do not overtighten retaining nuts on power and ground stud. Studs can break off requiring the replacement of the pump.
RG11757A
UN20JUL01
02 090 12
PN=42
Service Injection Pump Overflow Valve

The overflow valve (A) cannot be adjusted or serviced. Replace valve as required. Tighten to specifications.
Fuel Injection Pump Overflow Valve (VP44)Torque ................................................. 25 Nm (18.5 lb-ft)
UN20OCT99
Specification
02 090 13
Overflow Valve on VP44 Pump
DPSG,CD03523,103 1917OCT021/1
CTM170 (14MAY03)
02-090-13

051403
PN=43
CD30792
AOverflow Valve
Bosch VP44 Injection Pump Static Timing

Static lock-pin timing is accomplished during installation of the injection pump with engine locked at No. 1 TDC.
UN12JUL01
02 090 14
1. Remove plug from block. 2. Rotate engine using JDE820 Flywheel Turning Tool (A) (in normal running direction) until No. 1 piston is at TDC of its compression stroke. At this point, JDE81-4 Timing Pin (B) should enter the hole in the flywheel. 3. Remove injection pump driver gear cover and O-ring. 4. Install KJD10233 Timing Pin (E) through drive hub until it bottoms. IMPORTANT: The normal backlash of gears is enough to throw the pump timing off by several degrees, resulting in poor engine performance. It is important that pump timing be rechecked after pump has been installed.
Flywheel Turning Tool and Timing Pin
NOTE: Normal engine rotation is counterclockwise, viewed from flywheel end.

5. To check alignment of injection pump and eliminate backlash of timing gear train, remove both timing pins and rotate the flywheel opposite the direction of normal rotation. Install JDE81-4 Timing Pin and rotate flywheel in the direction of normal rotation until timing pin engages in timing pin hole. IMPORTANT: Do not loosen the central nut (G) which must be removed only by a specialized diesel workshop. 6. If KJD10233 Timing Pin will not install through drive hub and bottom out, loosen drive gear cap screws (F) and rotate hub until timing pin can be installed and locked in place.
Timing Injection Pump

AJDE820 Flywheel Turning Tool BJDE81-4 Timing Pin EKJD10233 Timing Pin FDrive Gear Screws GNut
DPSG,OUO1004,2640 1917OCT021/2
CTM170 (14MAY03)
02-090-14

051403
RG12805A
UN16JAN03
RG11752A
PN=44
Electronic Fuel System Repair and Adjustments NOTE: When tightening pump drive gear cap screws (F), apply light force (clockwise) to gear to eliminate any backlash with camshaft gear.
7. Tighten pump drive gear cap screws to specifications.
Specification Bosch VP44 Injection Pump Drive Gear Cap ScrewsTorque ............................................. 50 Nm (37 lb-ft) 02 090 15
8. Install injection pump drive gear cover and O-ring. Tighten cap screws to specification.
Specification Injection Pump Drive Gear Cover Cap ScrewsTorque ....................................................... 6 Nm (4.4 lb-ft)
9. Remove timing pin and flywheel turning tool from block.
DPSG,OUO1004,2640 1917OCT022/2
CTM170 (14MAY03)
02-090-15

051403
PN=45
Remove Bosch VP44 Fuel Injection Pump

IMPORTANT: Do not bend high pressure fuel lines. Bending can cause failures in the line when high pressure fuel is routed through lines. IMPORTANT: Do not use a high-pressure cleaner. Never steam clean or pour cold water on a fuel injection pump when engine is running or while pump is warm. 1. Clean fuel injection pump, lines and area around pump with cleaning solvent or a steam cleaner. 2. Rotate engine using JDE820 Flywheel Turning Tool (in normal running direction) until No. 1 piston is at TDC of its compression stroke. At this point, JDE81-4 Timing Pin (B) should enter the hole in the flywheel to lock engine at No. 1 TDC compression stroke. 3. Pull connector locking mechanism outward and disconnect electrical connector (A). IMPORTANT: Always use a backup wrench when loosening or tightening fuel injection lines at injection pump to prevent rotation of the discharge fitting. 4. Disconnect fuel injection lines (B) at both pump and nozzle ends, to prevent cross-threading of lines when reconnecting. 5. Disconnect supply line (C) and return line (D). 6. Plug all open connections on pump and fuel lines. Do not use fibrous material. 7. Remove injection pump drive gear cover and O-ring. 8. Install KJD10233 VP44 Timing Pin (E) through injection pump drive gear into injection pump hub until it bottoms. Do not leave pin in injection pump if pump is sent out for repair.
Remove Bosch VP44 Injection Pump

AElectrical Connector BInjection Lines CFuel Supply Line DFuel Return Line EKJD10233 Timing Pin FDrive Gear Screws GNut
RG41221,00001F7 1917OCT021/3
CTM170 (14MAY03)
02-090-16

051403
RG12805A
UN16JAN03
PN=46
CD30782
UN19OCT99
02 090 16

IMPORTANT: Do not loosen the central nut (G) which must be removed only by a specialized diesel service shop. 9. Remove the four drive gear screws (F).
02 090 17
RG41221,00001F7 1917OCT022/3
10. Remove the four nuts (H) which secure the pump to the front plate. 11. Carefully remove injection pump from mounting studs and place it on a clean flat surface. 12. Disconnect the pump position sensors electrical connector. 13. Remove spacer (J) from engine front plate.
HPump-to-Front Plate Nuts JSpacer
UN19OCT99
Remove Bosch VP44 Injection Pump (3)
Remove Bosch VP44 Injection Pump (4)
RG41221,00001F7 1917OCT023/3
CTM170 (14MAY03)
02-090-17

051403
PN=47
CD30785
UN19OCT99
CD30784
Repair Bosch VP44 Fuel Injection Pump

IMPORTANT: Do not disassemble fuel injection pump further than necessary for installing available service parts, not even for cleaning. Be sure that all identification numbers are legible so that pump is set to the correct specifications for its intended use. The Bosch VP44 fuel injection pump is only repairable by an authorized Bosch service shop. When diagnostics show evidence of injection pump failure, contact your local Bosch service shop. Unauthorized repairs made to the injection pump will void its warranty.
Repair Bosch VP44 Injection Pump
AKJD10233 Timing Pin
NOTE: Remove KJD10233 Timing Pin (A) before sending injection pump out for repair.
RG41221,00001F8 1917MAY011/1
CTM170 (14MAY03)
02-090-18

051403
RG12806A
UN16JAN03
02 090 18
PN=48
Install Bosch VP44 Fuel Injection Pump

1. Ensure that No. 1 cylinder is at TDC compression stroke.
UN16JAN03
2. If removed, install KJD10233 Timing Pin (A) into drive hub until it bottoms. 3. Install a new O-ring (B) into the pilot groove. Lightly lubricate O-ring with AR54749 Soap Lubricant. 4. Slide spacer (C) with new O-rings (D) and (E) over studs. 5. Install injection pump over studs, inserting pump shaft and timing pin in drive gear. 6. If removed, install pump position sensor on spacer (C). See REPLACE PUMP POSITION SENSOR in Group 110.
AKJD10233 Timing Pin BO-Ring CSpacer DO-Ring EO-Ring
02 090 19
Install Bosch VP44 Injection Pump (1)
RG12807A
RG41221,00001F9 1917OCT021/3
CTM170 (14MAY03)
02-090-19

051403
PN=49
CD30788
UN19OCT99

7. Tighten four nuts (F) on studs to specifications.
Specification Bosch VP44 Injection Pump Mounting NutsTorque .................................................. 70 Nm (52 lb-ft)
IMPORTANT: Do not bend high pressure fuel lines. Bending can cause failures in the line when high pressure fuel is routed through lines. 8. Connect injection lines (G). Begin with outlet (H) and continue around the pump head in counterclockwise direction, attaching lines in same order as engine firing (1-5-3-6-2-4 on 6-cylinder engines and 1-3-4-2 on 4-cylinder engines). Tighten lines to specifications.
Specification Bosch VP44 Injection Pump Delivery LinesTorque ................................................... 27 Nm (20 lb-ft)
IMPORTANT: Always use a backup wrench when loosening or tightening fuel injection lines at injection pump to prevent rotation of the high pressure discharge fitting.
9. Connect injection lines to nozzles. Tighten to specification.

Specification Bosch VP44 Injection Pump Delivery LinesTorque ................................................... 27 Nm (20 lb-ft)
FNuts GInjection Lines HOutlet Port JSupply Line KReturn Line LElectrical Connector
10. Install NEW copper sealing washer and connect fuel supply line (J). Tighten to specifications.
Specification Bosch VP44 Injection Pump Supply LineTorque ....................................................... 27 Nm (20 lb-ft)
11. Install NEW copper sealing washer and connect fuel return line (K). Tighten to specifications.
Specification Bosch VP44 Injection Pump Return LineTorque ....................................................... 27 Nm (20 lb-ft)
12. Install electrical connector (L). Make sure connector locking mechanism is completely latched in detents.
RG41221,00001F9 1917OCT022/3
CTM170 (14MAY03)
02-090-20

051403
PN=50
CD30790
UN19OCT99
CD30789
UN19OCT99
02 090 20
Electronic Fuel System Repair and Adjustments NOTE: The injection pump needs to be properly timed during installation of pump to ensure that gear backlash is removed. See BOSCH VP44 INJECTION PUMP STATIC TIMING earlier in this Group for proper injection pump timing and elimination of backlash with camshaft gear.
13. Install drive gear-to-pump hub screws (M) and tighten to specifications.
Specification Bosch VP44 Injection Pump Drive Gear-to-Pump Hub Screws Torque ............................................................................. 48 Nm (35 lb-ft)

MGear-to-Pump Hub Screws NKJD10233 Timing Pin
14. Remove KJD10233 Timing Pin (N), then install cover with a new O-ring. Tighten cover cap screws to specifications.
Specification Bosch VP44 Injection Pump Drive Gear CoverTorque ........................................................ 6 Nm (4.4 lb-ft)
15. Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
RG41221,00001F9 1917OCT023/3
CTM170 (14MAY03)
02-090-21

051403
RG12805B
UN16JAN03
02 090 21
PN=51
Remove Fuel Injection Nozzles

General Nozzle Service Precautions
02 090 22
Before removal, thoroughly clean and remove all dirt from the cylinder head around fuel injection nozzles. Clean with compressed air to prevent dirt from entering the cylinders. Plug the bore in the cylinder head after each nozzle has been removed. Cap fuel line openings as soon as they are disconnected. Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage and getting debris in fuel system. Do not bend the fuel delivery lines, as this may affect their durability. When loosening the fuel pressure lines, hold male union of nozzle line stationary with a backup wrench.
RG41221,00001FA 1917MAY011/2
CTM170 (14MAY03)
02-090-22

051403
PN=52
Electronic Fuel System Repair and Adjustments NOTE: When all fuel injection nozzles have to be removed, disconnect leak-off line and remove as a complete assembly. For individual nozzle removal, remove only the section of leak-off line necessary for nozzle removal.
1. Loosen tube nuts at each nozzle to remove leak-off lines and T-fittings as an assembly. 2. Disconnect fuel injection line from nozzle using a backup wrench on nozzle connection as shown. 3. Remove fuel line clamps to allow fuel lines to move enough for the removal of the injectors without bending or damaging lines. If lines still cannot be moved enough, disconnect fuel lines from the fuel injection pump. 4. Remove cap screw securing nozzle in cylinder head nozzle bore. 5. Pull injection nozzle out of cylinder head using JDE38B Injection Nozzle Puller Set (A) or JDG716 Adapter and slide handle from JDE38 or JDE38A Puller Set. IMPORTANT: Do not use screwdrivers, pry bars, or similar tools to remove injectors, as they can easily damage the injection nozzle beyond repair.
ANozzle Puller
UN23NOV97
02 090 23
Fuel Leak-Off Lines
Fuel Injection Line at Nozzle
Injection Nozzle Puller Set

RG41221,00001FA 1917MAY012/2
CTM170 (14MAY03)
02-090-23

051403
RG7726
UN07NOV97
RG7725
UN08JAN97
RG7724
PN=53
Clean Fuel Injection Nozzle Bore

IMPORTANT: Always turn tool clockwise in bore to prevent dulling of cutting edges, even when removing tool from bore. Clean injection nozzle bore using JDE39 Nozzle Bore Cleaning Tool (A). Blow debris from bore using compressed air, and plug the bore to prevent entry of foreign material.
ANozzle Bore Cleaning Tool
UN07NOV97
02 090 24
Clean Injection Nozzle Bore
RG,35,JW7596 1920NOV971/1
Clean Fuel Injection Nozzles

1. Remove carbon dam seal (A) from groove in nozzle body using razor blade or sharp knife and remove upper sealing washer (B). Discard seal and washer. 2. Place nozzle in solvent or clean diesel fuel, so carbon stop seal groove is submerged, and soak for a while. IMPORTANT: Do not scrape or disturb the TEFLON coating on the nozzle body above the carbon stop seal groove. This coating will become discolored during normal operation, but this is not harmful. Do not use a motor-driven brush to clean nozzle body. 3. After soaking, clean nozzle tip with brass wire brush. Never use a steel wire brush or scraper.
UN11NOV97
Clean Fuel Injection Nozzle

ACarbon Dam Seal BUpper Sealing Washer
TEFLON is a registered trademark of the DuPont Co.
RG,35,JW7595 1920NOV971/1
CTM170 (14MAY03)
02-090-24

051403
RG7798
RG7743
PN=54
Test Fuel Injection Nozzles

CAUTION: The nozzle tip should always be directed away from the operator. Fuel from the spray orifices can penetrate clothing and skin causing serious personal injury. Enclosing the nozzle in a clear glass beaker is recommended. Before applying pressure to the nozzle tester, be sure that all connections are tight, and that the fittings are not damaged. Fluid escaping from a very small hole can be almost invisible. To search for suspected leaks, use a piece of cardboard or wood, rather than hands. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. 1. Connect injection nozzle to nozzle tester.
High Pressure Fluid
RG41221,00001FB 1914AUG011/5
CTM170 (14MAY03)
02-090-25

051403
PN=55
X9811
UN23AUG88
02 090 25
Electronic Fuel System Repair and Adjustments NOTE: When using the Bosch Tester (JT25510), use the KJD10109 Fuel Line and connect line to tester and nozzle.
02 090 26
3. Position tip of nozzle below top of beaker (D) and back out 30 from vertical. This is necessary to contain all spray in beaker, as nozzle spray pattern is at an angle to the nozzle centerline. Leave connections slightly loose.
Injection Nozzle Tester

ANozzle Tester BFuel Line CAdapters DBeaker
NOTE: Rapid operation of pump handle will result in inaccurate cracking pressure readings and cause undue wear on gauge.
4. Pump handle several strokes to flush air from lines and to determine the pumping rate required for proper fuel atomization. Tighten all connections securely after all air has been expelled from nozzle and line. IMPORTANT: Make sure that nozzle tester is in good condition and that gauge works properly. Service nozzle tester as recommended in the operating instructions provided with tester. Opening Pressure Test
NOTE: Actual nozzle opening pressure is less important than equal opening pressure of all nozzles. For maximum variation between nozzles see specifications below.
1. Actuate the nozzle tester rapidly several times to allow the valve to seat rapidly. 2. Open gauge valve, actuate the tester and raise the pressure to a point where the gauge needle falls rapidly. This is the nozzle opening pressure, and should be as specified for a new or used nozzle.
RG41221,00001FB 1914AUG012/5
CTM170 (14MAY03)
02-090-26

051403
RG7799
UN11NOV97
2. Use Y900-3 and Y900-5 Adapters (C) and Y900-2 Fuel Line (B) from D01110AA Adapter Set to connect nozzles to D01109AA Nozzle Tester (A).
PN=56

3. Compare readings to the following specifications:
Fuel Injection Nozzles (RE48786)Specification New or Reconditioned Nozzle with New Internal PartsOpening Pressure for Setting .................................................. 25,51126,062 kPa (255260 bar) (37003780 psi) Opening Pressure for Checking (Minimum) ................................................................. 24,683 kPa (246 bar) (3580 psi) Used NozzleOpening Pressure for Checking (Minimum) ........................................... 23,511 kPa (235 bar) (3410 psi) Opening Pressure Difference between CylindersPressure Difference (Maximum) .................................... 700 kPa (7 bar) (101.5 psi)
02 090 27
IMPORTANT: If any of the nozzle opening pressures are not within specified range, reset pressure and valve lift BEFORE checking chatter and spray pattern. Otherwise, these characteristics may be affected. See ADJUST FUEL INJECTION NOZZLES later in this Group. Chatter Test 1. Close gauge shut-off valve and operate nozzle tester at a pumping rate that will cause the nozzle to chatter. Nozzle should chatter softly, and spray pattern should be broad and finely atomized. If nozzle fails to chatter, the nozzle valve may be bent or tight in its guide due to accumulated lacquer deposits. To disassemble nozzle and correct as detailed, see DISASSEMBLE FUEL INJECTION NOZZLES later in this Group.
NOTE: Until the chattering range is reached, fuel will emerge in non-atomized streams.
2. Using the pumping rate for proper atomization, operate tester for ten strokes. The nozzle must atomize on at least eight of the ten strokes without consecutive misses.
RG41221,00001FB 1914AUG013/5
CTM170 (14MAY03)
02-090-27

051403
PN=57

If the nozzle fails to meet this requirement, repeat procedure. Nozzles which do not meet the requirement after second test should be considered unacceptable and should be either repaired or replaced.
02 090 28
Spray Pattern Test 1. Close gauge shut-off valve and operate nozzle tester at a pumping rate that will cause the nozzle to chatter.
NOTE: Partially clogged, chipped, or eroded orifices will cause the spray to deviate from the correct angle. Spray will be streaky, rather than finely atomized.
2. Observe spray pattern and check for plugged orifices. If nozzle fails to chatter or spray properly, disassemble, clean and recondition, see DISASSEMBLE FUEL INJECTION NOZZLES later in this Group.
Specification Fuel Injection Nozzle TipSpray Angle ................................................................................................... 144
Leakage Test 1. Check nozzle for fuel leakage past valve seat by positioning nozzle on nozzle tester with nozzle tip down. 2. Operate pump handle rapidly to firmly seat valve. Wipe the nozzle tip dry with a clean, lint-free cloth 3. Slowly raise pressure at nozzle to about 28003500 kPa (2835 bar) (400500 psi) under specified opening pressure and hold at that pressure. Watch for an accumulation of fuel around the nozzle tip orifices. If fuel drips from nozzle within 5 seconds, nozzle must be lapped.
Specification Nozzle Valve/Seat Tightness Condition at Pressure Test of 28003500 kPa (2835 bar) (400500 psi)Leakage ......................... Nozzle tip dry after 5 seconds. (Slight dampness permissible on used nozzles.)
RG41221,00001FB 1914AUG014/5
CTM170 (14MAY03)
02-090-28

051403
PN=58

Valve Stem and Guide Wear Test 1. Position nozzle with tip slightly above the horizontal plane. CAUTION: Completely enclose spray zone in a glass beaker to avoid possible personal injury from spray. 2. Slowly raise pressure to 10,300 kPa (103 bar) (1500 psi) on test gauge
02 090 29
NOTE: Leakage rate based on use of No. 2 diesel fuel or an equivalent viscosity of test oil at 1824C (6575F) ambient temperature.
3. Look for leakage from the return end of nozzle. After one drop, leakage should be within specifications.
Specification Fuel Injection Nozzle Return Leakage at Pressure Test of 10,300 kPa (103 bar) (1494 psi)Leakage..................................................... 310 Drops/30 Seconds
If nozzle leakage is not within specified range, nozzle must be reconditioned. See DISASSEMBLE FUEL INJECTION NOZZLES later in this Group.
RG41221,00001FB 1914AUG015/5
CTM170 (14MAY03)
02-090-29

051403
PN=59
Disassemble Fuel Injection Nozzles
02 090 30
Fuel Injection Nozzles

ANozzle Tip BCarbon Dam Seal CNozzle Body DNozzle Valve EPlastic Sealing Washer FEdge-Type Filter GFuel Inlet HUpper Guide IUpper Seal JSpring Seat KSpring Screw LSpring Washer MLift Adjusting Screw NPressure Adjusting Screw Lock Nut OPressure Adjusting Screw PLift Adjusting Screw Lock Nut
General Nozzle Repair Notes
Cover the work bench with clean paper before beginning disassembly of injection nozzles. As parts are disassembled, place them in a pan of clean diesel fuel and leave there until needed. Do not permit these parts to strike each other. Use a separate pan of clean fuel for washing parts before assembly.
NOTE: Disassembly of nozzles is not recommended unless servicing is indicated by nozzle operation and testing.
Since dirt and water are the worst contaminants in the fuel injection system, the working area, tools and cleaning materials must be kept clean. Whenever possible, work in an isolated, dust-free area.
RG,35,JW7591 1917OCT021/3
CTM170 (14MAY03)
02-090-30

051403
RG7800A
UN13NOV97
PN=60

To Disassemble Fuel Injection Nozzle 1. Place nozzle in a vice using the indexing clamp (J)1 to secure in place. 2. Remove leak-off fitting (D) from top of injector if not already removed with leak-off line assembly. 3. Remove lift adjusting screw lock nut (K). 4. Remove pressure adjusting screw lock nut (L). 5. Remove nozzle from vise or holding fixture.
UN20JUN01
02 090 31
6. Remove tube nut (B) and Packing (C). 7. Remove hold down clamps (I) and Indexing clamp (J). 8. Using JDG949 Injection Nozzle Wrench, remove pressure adjusting screw (N) and lift adjusting screw (M) as an assembly.
Nozzle Disassembly
NOTE: If JDG949 does not mate with pressure adjusting screw, turn lift adjusting screw in until wrench mates with pressure adjusting screw.
9. Invert nozzle and allow pressure adjusting spring seat and lift adjusting assembly to fall into your hand. Do not bend stem during removal.
ANozzle Assembly BTube Nut CPacking DLeak-Off Fitting ECap Screw FCarbon Dam Seal GPlastic Sealing Washer HSpacer IHold Down Clamps JIndexing Clamp KLift Adjusting Screw Lock Nut LPressure Adjusting Lock Nut MLift Adjusting Screw NPressure Adjusting Screw
Injection Nozzle in Holding Fixture
Injection Nozzle Adjustment Components
If available, ROS17787 Holding Fixture (obsolete) can be used.

Continued on next page RG,35,JW7591 1917OCT022/3
CTM170 (14MAY03)
02-090-31

051403
RG7810C
UN20JUN01
RG7802A
UN23MAY01
PN=61
RG9086A

10. If valve does not slide freely from body (R), use No. 16481 Valve Retractor1 (Q) to remove valve.
RValve Body QValve Retractor
UN23MAY01
02 090 32
Injection Nozzle Body and Valve
No. 16481 Valve Retractor is a Stanadyne tool.

RG,35,JW7591 1917OCT023/3
CTM170 (14MAY03)
02-090-32

051403
RG7803A
PN=62
Inspect and Clean Fuel Injection Nozzle Body

NOTE: Unless otherwise indicated, all tools required for nozzle cleaning can be found in the JDF13B Nozzle Cleaning Kit.
Clean carbon stop seal groove and nozzle tip with a nozzle cleaning wire inserted in holder (A). Inspect tip for cracks and spray orifices for chipping and erosion using an inspection magnifier (B).1 To Clean Carbon from Nozzle Orifices
Clean Injection Nozzle Body
AHolder BInspection Magnifier
UN11NOV97
02 090 33
NOTE: Stoning the wire to provide a flat surface on one side will help in reaming carbon from a clogged hole.
1. Begin with a cleaning wire 0.070.10 mm (0.003 0.004 in.) smaller than the nominal orifice size given in specifications below.
Specification Fuel Injection Nozzle Tip OrificeNumber of Orifices per Nozzle ....................................................................................................... 4 Fuel Injection Nozzle Tip OrificeID ................................................................ 0.29 mm (0.0114 in.)
2. Clamp the wire in pin vise from nozzle cleaning kit. Wire should not protrude from the vise more than 0.8 mm (1/32 in). 3. Insert wire in orifice and rotate. 4. Use scraper from cleaning kit to clean deposits from valve seating area.
If available, ROS16487 Inspection Magnifier (obsolete) can be used.

Continued on next page RG41221,00001FC 1914AUG011/2
CTM170 (14MAY03)
02-090-33

051403
RG7804
PN=63

5. Grasp sac hole drill (A) with valve retractor (B). 6. For final cleaning, use a cleaning wire 0.03 mm (0.001 in.) smaller than the nominal orifice size and repeat steps 2 and 3.
ASac Hole Drill BValve Retractor
UN11NOV97
02 090 34
Injection Nozzle Orifices
RG41221,00001FC 1914AUG012/2
Inspect and Clean Valve and Valve Seat

IMPORTANT: NEVER use a steel wire brush on nozzle parts.
UN11NOV97
Use brass wire brush (B) to remove deposits from seating area on tip of nozzle valve (A). Use a felt pad to remove varnish deposits. Inspect guide area for valve scratches which could cause sticking. This area will generally be polished on one side during operation. Visible vertical marks are normal.
Injection Nozzle Valve and Valve Seat
ANozzle Valve BBrass Wire Brush
RG41221,00001FD 1917MAY011/2
CTM170 (14MAY03)
02-090-34

051403
RG7806
RG7805
PN=64

Inconsistent Chatter or No Chatter A nozzle which during test had spotty chatter or showed definite signs of sticking accompanied by low return leakage, may be corrected by polishing the valve guide area as follows: 1. Place a small amount of nozzle lapping compound on the nozzle valve in guide area only. DO NOT use any other compound for this purpose. 2. Slide valve into body (A).
Nozzle Valve in Nozzle Body
IMPORTANT: Never attempt to rotate the valve in a motor driven chuck for this purpose. 3. Grip top of the valve with retractor (B) and rotate valve in the guide by turning retractor. The amount of lapping required can be accomplished in 1020 turns by hand. The valve should be raised and lowered in the guide every 34 revolutions and direction of rotation changed for best results. 4. Wash nozzle body and valve thoroughly in clean fuel before reassembly. Seat Leakage Seat leakage may be caused by dirt, carbon or fuel deposits in valve area. Inspect valve seat and clean as follows: 1. Apply a small amount of lapping compound to valve tip and insert valve in nozzle body (A). 2. Gripping valve with retractor (B), rotate valve 35 turns to clean up seat. 3. Wash valve and nozzle body thoroughly in clean fuel.
ANozzle Body BRetractor
RG41221,00001FD 1917MAY012/2
CTM170 (14MAY03)
02-090-35

051403
RG7803
UN11NOV97
02 090 35
PN=65
Inspect Valve Adjusting Mechanism

1. Inspect lift adjusting screw (D). Replace if bent or otherwise damaged.
UN13SEP02
02 090 36
2. Inspect pressure adjusting screw (C). Replace if worn or damaged. 3. Inspect pressure adjusting spring (B). Replace if broken or distorted. 4. Inspect spring seat (A) for wear. Replace as necessary. 5. Replace nozzle clamp if bent.
ASpring Seat BPressure Adjusting Spring CPressure Adjusting Screw DLift Adjusting Screw
Inspect Nozzle Valve Adjust Mechanism
Inspect Nozzle Valve Adjust Mechanism

RG41221,00001FE 1917MAY011/1
CTM170 (14MAY03)
02-090-36

051403
RG7808
UN11NOV97
RG7810A
PN=66
Assemble Fuel Injection Nozzles
02 090 37
UN14NOV97
Fuel Injection Nozzles

ANozzle Body BSpacer CIndexing Clamp DNozzle Valve ESpring Seat FPressure Adjusting Spring GWasher HLift Adjusting Screw Lock Nut IPressure Adjusting Screw Lock Nut JLift Adjusting Screw KPressure Adjusting Screw LHold-Down Clamps
IMPORTANT: Wear rubber gloves when assembling nozzles. 1. Install nozzle spacer (B) onto upper nozzle body (A). Position nozzle indexing clamp (C) over upper nozzle body with flanges pointing downward. Install three remaining clamps (L) onto nozzle body. 2. Dip nozzle valve (D) in clean fuel and insert into nozzle body. 3. Thread lift adjusting screw (J) into pressure adjusting screw (K) until top just enters screw. 4. Invert adjusting screw assembly and assemble washer (G), spring (F), and spring seat (E) to adjusting screw.
5. Tilt body, DO NOT allow valve to fall out, and install spring and adjusting screws to body. Be careful not to dislodge spring or seat during initial assembly. 6. Turn pressure adjusting screw (K) down as far as possible by hand, usually about ten full turns. 7. Thread pressure adjusting screw lock nut (I) to pressure adjusting screw finger tight. 8. Thread lift adjusting screw lock nut (H) on lift adjusting screw (J) finger tight. 9. Adjust fuel injection nozzles. See ADJUST FUEL INJECTION NOZZLES later in this Group.
RG41221,00001FF 1917MAY011/1
CTM170 (14MAY03)
02-090-37

051403
RG8042
PN=67
Adjust Fuel Injection Nozzles

CAUTION: Nozzle tip should always be directed away from operator. Fuel from spray orifices can penetrate clothing and skin causing serious personal injury. Enclosing nozzle in a glass beaker is recommended. Before applying pressure to nozzle tester, be sure all connections are tight, and fittings are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. Connect nozzle to nozzle tester. See TEST FUEL INJECTION NOZZLES earlier in this Group.
High Pressure Fluids
RG41221,0000200 1914AUG011/5
Nozzle Opening Pressure Check 1. Close pressure gauge valve and flush nozzle by operating pump rapidly. 2. Raise pressure on pump until nozzle opens (gauge drops sharply). 3. Refer to nozzle opening pressure specifications below.
Fuel Injection Nozzles (RE48786)Specification New or Reconditioned Nozzle with New Internal PartsOpening Pressure for Setting .................................................. 25,51126,062 kPa (255260 bar) (37003780 psi) Opening Pressure for Checking (Minimum) ................................................................. 24,683 kPa (247 bar) (3580 psi) Used NozzleOpening Pressure for Checking (Minimum) ........................................... 23,511 kPa (235 bar) (3410 psi) Opening Pressure Difference between CylindersPressure Difference (Maximum) .................................... 700 kPa (7 bar) (101.5 psi)
Injection Nozzle Tester
RG41221,0000200 1914AUG012/5
CTM170 (14MAY03)
02-090-38

051403
RG7809
UN15JAN98
PN=68
X9811
UN23AUG88
02 090 38

If opening pressure is incorrect: 1. Remove nozzle from tester and install in holding fixture.
UN11NOV97
2. Remove lift adjusting lock nut (D). 3. Loosen pressure adjusting screw lock nut (A). 4. Reconnect nozzle to tester with tip pointing downward. 5. Back out lift adjusting screw (B) far enough (two or three turns) to prevent bottoming when pressure adjusting screw (C) is turned. 6. Turn pressure adjusting screw in (clockwise) to increase opening pressure, or out (counterclockwise) to decrease opening pressure using JDG949 Nozzle Wrench.
02 090 39
Adjust Nozzle Pressure
NOTE: It is desirable to set opening pressure to the high limit of specification. If required, repeat procedure to obtain proper result.
7. Adjust nozzle opening pressure. See ADJUST FUEL INJECTION NOZZLES earlier in this Group. If pressure is still out of specification, repeat steps 5 7 until pressure is set to specification. 8. Remove nozzle from tester and secure in holding fixture. While holding pressure adjusting screw, tighten pressure adjusting screw lock nut to specifications using a crowsfoot wrench or torque wrench adapter, if available.1
Specification Injection Nozzle Pressure Adjusting Screw Lock Nut Torque ............................................................................ 10 Nm (7.4 lb-ft)
Nozzle Pressure Adjusting Screw and Lock Nut

APressure Adjusting Screw Lock Nut BLift Adjusting Screw CPressure Adjusting Screw DLift Adjusting Lock Nut
If available, ROS18958 (English) or No. 24374 (Stanadyne, Metric) Torque Wrench Adapter (obsolete) can be used.
Continued on next page RG41221,0000200 1914AUG013/5
CTM170 (14MAY03)
02-090-39

051403
RG7811
UN15JAN98
RG7810B
PN=69

Adjust Nozzle Valve Lift 1. Reconnect nozzle to tester. While pumping fuel through nozzle, hold pressure adjusting screw and slowly turn lift adjusting screw in (clockwise) until valve ceases to open. IMPORTANT: DO NOT manually bottom the valve with excessive force as bending of the valve may result. 2. Check for valve bottoming by raising opening pressure to 26,06328,133 kPa (260280 bar) (37804080 psi). Although some fuel may collect at nozzle tip, a rapid dribble should not occur. 3. Remove nozzle from tester and install in holding fixture. 4. Carefully turn lift adjusting screw out specified amount. A tolerance of 1/8 turn is permissible.
Specification Fuel Injection Nozzle Valve Needle LiftNeedle Lift (Based on Zero Lift) ..................................................... 3/4 Turn Counterclockwise
02 090 40
Injection Nozzle Valve Lift Adjustment
5. Hold lift adjusting screw stationary and tighten lift adjusting screw lock nut to specifications. Use a crowsfoot wrench or torque wrench adapter, if available.1
Specification Fuel Injection Nozzle Lift Adjusting Screw Lock Nut Torque .............................................................. 5 Nm (3.7 lb-ft) (44 lb-in.)
Nozzle Pressure Adjusting Screw and Lock Nut
1 If available, ROS18958 (English) or No. 24374 (Stanadyne, Metric) Torque Wrench Adapter (obsolete) can be used.
RG41221,0000200 1914AUG014/5
CTM170 (14MAY03)
02-090-40

051403
RG7811
UN15JAN98
PN=70
RG9103
UN31MAR98

6. Recheck nozzle opening pressure.
Fuel Injection Nozzles (RE48786)Specification New or Reconditioned Nozzle with New Internal PartsOpening Pressure for Setting .................................................. 25,51126,062 kPa (255260 bar) (37003780 psi) Opening Pressure for Checking (Minimum) ................................................................. 24,683 kPa (246 bar) (3580 psi) Used NozzleOpening Pressure for Checking (Minimum) ........................................... 23,511 kPa (235 bar) (3410 psi) Opening Pressure Difference between CylindersPressure Difference (Maximum) ....................................... 700 kPa (7 bar) (100 psi)
02 090 41
If nozzle chatter is incorrect after servicing, valve parts may be misaligned. To correct, turn lift adjusting screw through its range of adjustment several times and reset valve lift. Recheck nozzle for chatter. 7. Clean nozzle with brass wire brush.
RG41221,0000200 1914AUG015/5
Install Seals on Fuel Injection Nozzle

IMPORTANT: Each time an injection nozzle is removed from the cylinder head, replace carbon stop seal (B) with a new one. 1. Position JD258 (JD-258) Nozzle Carbon Stop Seal Installer (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 on nozzle body.
Fuel Injection Nozzle Seals
ACarbon Stop Seal Installer BCarbon Stop Seal CSeal Washer
NOTE: If nozzle is not going to be installed at this time, install a No. 16189 Nozzle Protector Cap over nozzle tip. Plug all other openings in nozzle to prevent contamination.
RG41221,0000201 1917MAY011/1
CTM170 (14MAY03)
02-090-41

051403
PN=71
RG9096
UN27MAR98
Install Fuel Injection Nozzles

IMPORTANT: Before installing injection nozzles, make sure nozzles are clean and free from oil or grease.
1. Remove plug (if installed previously) from nozzle bore in cylinder head and blow out bore with compressed air.
Injection Nozzle in Cylinder Head
NOTE: Make sure that the sealing surface of the cylinder head (on which the seal washer will be resting) is smooth and free of damage or dirt. This could prevent proper sealing. Dirt and roughness could also cause nozzle to be distorted when the attaching screw is tightened, making the valve stick. NOTE: Never lubricate the nozzle tip. Oil on the tip will create sooting of the injector tip. The teflon carbon dam seal will lubricate the nozzle bore as it is being installed.
2. Install nozzle with spacer and clamps in cylinder head using a slight twisting motion as nozzle is seated in bore. Illustration shows relationship of parts required for proper installation. 3. Align nozzle clamps and loosely install cap screw. Do not tighten cap screw at this stage. 4. Connect fuel pressure line to nozzle. Leave connection slightly loose until air is bled from system. 5. Tighten nozzle hold-down clamp cap screws to specifications.
Specification Fuel Injection Nozzle Hold-Down Clamp Cap ScrewsTorque........................................... 40 Nm (30 lb-ft)
RG41221,0000202 1917OCT021/2
CTM170 (14MAY03)
02-090-42

051403
RG7744
NOTE: If nozzle bore in cylinder head must be cleaned, use JDE39 Nozzle Bore Cleaning Tool See REMOVE FUEL INJECTION NOZZLES earlier in this Group.
UN23NOV97
02 090 42
PN=72

IMPORTANT: Do NOT over tighten fuel leak-off hex nut. 6. Install leak-off line assembly.
Specification Fuel Leak-Off Hex NutTorque ...................................... 5 Nm (3.7 lb-ft) (44 lb-in.) 02 090 43
7. Bleed air from loose injection line connection. See BLEED THE FUEL SYSTEM in Group 150 later in this manual. Tighten connection using two wrenches to the following specifications.
Specification Fuel Injection Nozzle Delivery LineTorque ................................................................... 27 Nm (20 lb-ft)
Nozzle Fuel Pressure Line
RG41221,0000202 1917OCT022/2
CTM170 (14MAY03)
02-090-43

051403
RG7725
UN08JAN97
PN=73
02 090 44
CTM170 (14MAY03)
02-090-44

051403
PN=74
Group 110
Electrical Engine Control Repair and Adjustment

Engine Control Unit (ECU)
IMPORTANT: DO NOT pressure wash the Engine Control Unit (ECU).
UN17MAY00
Before welding on engines with ECU, protect the ECU from high-current damage as follows: 1. Disconnect ECU-to-vehicle frame ground connection. 2. Disconnect all other connectors from ECU. Also disconnect module connector at injector pump. 3. Connect welder ground close to welding point and make sure ECU and other electrical components are not in the ground path.
02 110 1
NOTE: For diagnosis and testing of the electronic engine control and sensors, refer to Section 04, Group 150 and 160 as required.
IMPORTANT: DO NOT OPEN ENGINE CONTROL UNIT.
NOTE: The sealed ECU assembly is the system component LEAST likely to fail. Ensure that it is isolated and identified as the defective component before replacing. See operation and test manual for 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 serial number when ordering a new ECU. IMPORTANT: If an ECU is not programmed identically with the original (failed) ECU, misleading diagnostic messages, poor performance, or engine damage can occur. The wiring connector for the ECU is repairable. See REPAIR AMP CONNECTORS later in this Group.
DPSG,OUO1004,1177 1917OCT021/1
CTM170 (14MAY03)
02-110-1

051403
PN=75
RG10735
Remove and Install Engine Coolant Temperature Sensor

NOTE: On OEM applications, the ECU uses the ECT sensor in the thermostat housing. Other applications may use the sensor located in the rear of the head.
1. Disconnect engine coolant temperature sensor wiring connector and remove sensor. 2. Remove engine coolant temperature sensor. 3. Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in thermostat housing or in the rear of the cylinder head. Tighten to specifications.
Specification Coolant Temperature Sensor (In Thermostat Cover)Torque............................................ 15 Nm (11 lb-ft) Coolant Temperature Sensor (In Cylinder Head)Torque.................................................. 35 Nm (26 lb-ft)
Engine Coolant Temperature Sensor in Thermostat Housing
Engine Coolant Temperature Sensor in Cylinder Head
RG,RG34710,269 1921MAY011/1
CTM170 (14MAY03)
02-110-2

051403
RG10766A
4. Install sensor wiring connector.
UN12JUN01
PN=76
RG10552
UN02DEC99
02 110 2
Replace Fuel Pressure Sensor

1. Disconnect electrical connector (B) (shown disconnected). 2. Remove fuel pressure sensor (A).
UN04MAY00
02 110 3
NOTE: Plug bore with clean cap plug after removal of sensor.
3. Replace part as necessary. 4. Install pressure sensor then tighten to specifications.
Specification Fuel Pressure Sensor (VP44 Pump)Torque ................................................................... 8 Nm (6 lb-ft)
Replace Fuel Pressure Sensor - Tier 1
5. Install sensor wiring connector. 6. Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150 later in this manual.
APressure Sensor BElectrical Connector
UN20JUN01
Replace Fuel Pressure Sensor - Tier 2
RG41221,000010A 1909MAY011/1
CTM170 (14MAY03)
02-110-3

051403
RG11720C
PN=77
RG10721C
Replace Pump Position Sensor

NOTE: Pump Position sensor (A) can be removed with injection pump installed on engine.
UN19OCT99
02 110 4
1. Disconnect wiring harness from electrical connector (B) (shown disconnected). 2. Remove pump position sensor (A). Discard O-ring. 3. Replace part as necessary. 4. Install pump position sensor with a new O-ring and tighten to specifications.
Specification Injection Pump Position Sensor (VP44 Pump)Torque .................................................... 14 Nm (10 lb-ft)
Replace Pump Position Sensor

APump Position Sensor BElectrical Connector
DPSG,OUO1004,2644 1910APR001/1
Replace Crankshaft Position Sensor

NOTE: Timing wheel sensor is only used on engines with Bosch VP44 injection pumps.
UN19OCT99
1. Disconnect wiring harness connector (shown disconnected). 2. Using a deep well socket, remove crankshaft position sensor (A). 3. Replace sensor and o-ring in timing gear cover. Tighten sensor to specifications.
Specification Crankshaft Position Sensor Torque ............................................................................. 14 Nm (10 lb-ft)
Timing Wheel Sensor (Engines with Bosch VP44 Pumps)

ATiming Wheel Sensor
DPSG,OUO1004,1127 1926OCT991/1
CTM170 (14MAY03)
02-110-4

051403
PN=78
CD30780
CD30786
Remove and Install Oil Pressure Sensor

1. Disconnect oil pressure sensor wiring connector and remove sensor from oil cooler housing.
UN02DEC99
2. Coat threads of sensor with LOCTITE 592 Pipe Sealant with TEFLON. Install sensor in oil cooler housing and tighten to specifications.
Specification Oil Pressure SensorTorque ......................................... 15 Nm (11 lb-ft)
02 110 5
Oil Pressure Sensor
LOCTITE is a registered trademark of Loctite Corp. TEFLON is a registered trademark of Du Pont Co.
DPSG,OUO1004,1178 1929NOV991/1
CTM170 (14MAY03)
02-110-5

051403
PN=79
RG10550
Connectors
Connectors are devices that provide for assembly and disassembly of systems. Connectors should always be serviced using tools designed for that type of connector. A good crimp is important to mechanical and electrical soundness. Repaired connectors should be physically tested by pulling to be sure the contact is firmly attached to the conductor. IMPORTANT: If for some reason the connectors are not connected, such as when the fuel injection pump is removed, it is important to protect the connectors from debris. Refer to the procedures which follow for repair of various types of connectors.
02 110 6
RG,RG34710,1328 1923OCT971/1
Use Electrical Insulating Compound

Apply AT66865 Compound directly to the terminals between the wire seal and connector body. This provides a moisture barrier, especially in wet and humid conditions.
RG,RG34710,1335 1923OCT971/1
Using High-Pressure Washer

IMPORTANT: Reduce pressure when directing pressurized water at electronic or electrical components and connectors as this may cause the components to malfunction. Always reduce pressure, and spray at a 45 to 90 degree angle.
RG,RG34710,1329 1923OCT971/1
CTM170 (14MAY03)
02-110-6

051403
PN=80
T6642EJ
UN18OCT88
Repair WEATHERPACK Connector

1. Disconnect WEATHERPACK connector. Remove the tie 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 cavity location. 4. Insert JDG364 Extraction Tool1 over terminal contact in connector body. Extraction tool needs to be fully seated to unlock terminal tangs from the connector body. When tool is seated, gently pull the wire from the back of the connector. If the wire(s) or terminal(s) are being repaired, go to step 5. If the wires and terminals are OK and only the connector is being replaced, go to step 9. 5. Using JDG145 Universal Electrical Pliers2, cut off wire directly behind the terminal seal crimp. If any part of the 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.
UN23AUG88
02 110 7
WEATHERPACK is a trademark of Packard Electric

1
Included in JT07195B Electrical Repair Kit
Included in JDG155 Electrical Repair Tool Kit

Continued on next page AG,OUOD008,296 1906MAR021/4
CTM170 (14MAY03)
02-110-7

051403
PN=81
TS0128

7. Select correct size of seal. Slide the seal over the wire insulation with the smaller diameter side facing the end of the wire. Small diameter side of seal should line up with the outer edge of the insulation.
UN23AUG88
02 110 8
IMPORTANT: The seal must fit snug over the cable insulation without a gap between the cable seal and the insulation.
Green - 1820 Gauge Wire Gray - 1416 Gauge Wire Blue - 1012 Gauge Wire
AG,OUOD008,296 1906MAR022/4
8. Select correct size terminal on wire and crimp in position with a W-type crimp using a JDG783 WEATHER PACK Crimping Tool.
NOTE: Terminals have numbered identification for two sizes of wire:

#15 - 1416 Gauge Wire #19 - 1820 Gauge Wire
UN02NOV94
WEATHER PACK is a trademark of Packard Electric
AG,OUOD008,296 1906MAR023/4
CTM170 (14MAY03)
02-110-8

051403
PN=82
TS1623
TS0136
NOTE: Cable seals are color coded for three sizes of wire:

9. Insert terminal into connector. Terminal should click when it is fully seated. Make sure the wire is inserted into the correct connector cavity. IMPORTANT: Terminal tangs must be carefully spread to ensure good seating on connector body. If terminal is being reused in a new connector, make sure tangs are spread.
02 110 9
NOTE: Connector bodies are keyed for correct terminals. 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 is locked in position. 11. Repair or transfer remaining wires. 12. Close the secondary lock on the back of the connector. 13. Retape wires and add the required tie bands to the harness.
ASleeve BPin
AG,OUOD008,296 1906MAR024/4
CTM170 (14MAY03)
02-110-9

051403
PN=83
TS0139
UN02DEC88
TS0130
UN23AUG88
Remove Blade Terminals from Connector Body

NOTE: Use JDG776 Extraction Tool with 56, 280, and 630 Series METRI-PACK terminals. Use JDG777 Extraction Tool with 150 Series METRI-PACK terminals.
1. Insert JDG776 or JDG777 Terminal Extraction Tool1 into connector body pushing the terminal locking tang inward. 2. Gently pull wire and remove terminal from connector. 3. Adjust the locking tang on the terminal to its original position before installing into a connector.
ALocking Tang BOriginal Position
Included in JT07195B Electrical Repair Kit

AG,OUOD008,297 1906MAR021/1
CTM170 (14MAY03)
02-110-10

051403
PN=84
RW4218
UN23AUG88
02 110 10
Repair (Pull Type) METRI-PACK Connectors

1. Disconnect the METRI-PACK connector (A) from the ECU.
UN13MAR02
2. Remove tie bands and tape from the wiring harness behind the connector. 3. Identify wire color/number to the connector cavity. Make sure each wire goes back to the correct cavity location. 4. Using JDG776 Terminal Extraction Tool (C)1, carefully remove the connector seal (B) from the back of the connector. IMPORTANT: Make sure no damage to the seal occurs or water and contaminants will corrode terminals.
02 110 11
NOTE: Extraction tool must be used from the back of the connector.
5. Using JDG776 Terminal Extraction Tool (C), angle the tip so it slides along the top edge of the connector. Make sure the extraction tool is centered in the connector cavity and push the tool in until resistance is felt. 6. With extraction tool inserted into the connector, gently rotate tool clockwise and counter-clockwise (no more than 1/8 turn each direction) to depress the terminal locking tang (D). 7. Remove extraction tool from back of connector. 8. Push wire until terminal has extracted from the front of the connector. If terminal does not extract, repeat steps 4-6.
AConnector BConnector Seal CJDG777 Terminal Extraction Tool DTerminal Locking Tang ETerminal
RG12232A
UN13MAR02
RG12231A
METRI-PACK is a trademark of Delphi Packard Electric Systems

1
Included JT07195B Electrical Repair Kit

CTM170 (14MAY03)
02-110-11

051403
PN=85
RW16935A
UN05AUG98

9. Using JDG145 Universal Electrical Pliers1, cut off wire directly behind the terminal. IMPORTANT: Save as much wire as possible. If only a couple of wires are shorter than the rest, all of the strain will be placed on them. Damage to the harness may occur. 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, make sure the wire is fed through the connector (F) and in the correct cavity. 12. Using either JDG783 (G) or JDG707 (H) Crimping Pliers, crimp a new terminal on the wire. 13. Make sure terminal locking tang (D) on new terminal is in outward position. Pull wire back into connector cavity until terminal locks.
UN13MAR02 RG12233A
NOTE: Terminal will seat only one way. If terminal does not pull into the connector body socket, check for correct terminal alignment (E).
14. Push on the wire to make sure terminal is locked into the connector. 15. Slide the connector seal back into the connector. Make sure seal is in its original position. 16. Retape the wires and add the required tie bands to the harness.
RG12234A
UN13MAR02
02 110 12
DTerminal Locking Tang ECorrect Terminal Orientation FWire GJDG783 Terminal Crimping Tool HJDG707 Terminal Crimping Tool
Included in JDG155 Electrical Repair Tool Kit

AG,OUOD008,298 1906MAR022/2
CTM170 (14MAY03)
02-110-12

051403
PN=86
RW16935A
UN05AUG98
Repair (Push Type) METRI-PACK Connectors

1. Disconnect the METRI-PACK connector. Remove the tie 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 cavity location. 4. Insert JDG776 or JDG777 Terminal Extraction Tool1 (B) into connector cavity (C) pushing the terminal locking tab inward.
UN08DEC98
02 110 13
6. Using JDG145 Universal Electrical Pliers2, cut off wire directly 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 wire insulation with the smaller diameter side facing the end of the wire. Small diameter side of seal should line up with the outer edge of the insulation.
AConnector Secondary Lock BExtraction Tool CConnector Body Socket DTerminal
METRI-PACK is a trademark of Delphi Packard Electric Systems

1
Included in JT07195B Electrical Repair Kit Included in JDG155 Electrical Repair Tool Kit
CTM170 (14MAY03)
02-110-13

051403
PN=87
TS0136
5. Remove extraction tool and pull wire from the back of the connector.
UN23AUG88
NOTE: Use JDG776 Extraction Tool with 56, 280, and 630 Series METRI-PACK terminals. Use JDG777 Extraction Tool with 150 Series METRI-PACK terminals.
RW77137

IMPORTANT: The seal must fit snug over the cable insulation, without a gap between the cable seal and the insulation.
02 110 14
NOTE: Cable seals are color coded for three sizes of wire:
Green - 1820 Gauge Wire Gray - 1416 Gauge Wire Blue - 1012 Gauge Wire 9. Select correct size contact for wire.
AG,OUOD008,299 1906MAR022/3
CTM170 (14MAY03)
02-110-14

051403
PN=88

10. Crimp contact (A) on wire with a W type crimp using JDG865 Crimping Tool (B). 11. Crimp cable seal (C) on contact using JDG865 Crimping Tool (B). 12. Make sure locking tang (D) on the new terminal is in the outward position. 13. Push terminal into the correct connector cavity until terminal locks. 14. Gently pull on wire to verify terminal is locked into the connector. 15. Place the secondary lock back on the connector. 16. Retape the wires and add the required tie bands to the harness.
AContact BTool CCable Seal DTerminal Locking Tang
UN07DEC98
02 110 15
AG,OUOD008,299 1906MAR023/3
CTM170 (14MAY03)
02-110-15

051403
PN=89
RW77140A
UN15MAR02
RW77138A
UN15MAR02
RW77139
Repair DEUTSCH Connectors

1. Disconnect the Deutsch connector. Remove the tie bands and tape.
UN07DEC98
02 110 16
2. Identify wire color/number to the connector cavity. Make sure each wire goes back to the correct cavity location. 3. Select correct size extractor tool for size of wire to be removed: JDG361 JDG362 JDG363 JDG785 Extractor Extractor Extractor Extractor Tool Tool Tool Tool 1214 Gauge Wire1 1618 Gauge Wire1 20 Gauge Wire2 6-8 Gauge Wire3
AHandle
4. Start inserting the wire into the handle end (A) of the correct size extraction tool. 5. Slide extraction tool rearward along wire until tool tip snaps onto wire. IMPORTANT: DO NOT twist tool when inserting in connector. 6. Slide extraction tool along wire into connector body until tool is positioned over terminal contact. 7. Pull wire from connector body using extraction tool. 8. Using JDG145 Universal Electrical Pliers4 cut off wire directly 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

1 Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCH Electrical Repair Kit 2
Included in JDG359 DEUTSCH Electrical Repair Kit Included in JT07195B Electrical Repair Tool Kit Included in JDG155 Electrical Repair Tool Kit
AG,OUOD008,304 1926MAR021/4
CTM170 (14MAY03)
02-110-16

051403
PN=90
RW77142

10. Adjust selector (A) on JDG360 Crimping Tool1 for correct wire size . 11. Loosen lock nut (B) and turn adjusting screw (C) in until screw stops.
ASelector BLock Nut CAdjusting Screw
UN23AUG88
02 110 17
Included in JDG359 Electrical Repair Kit

AG,OUOD008,304 1926MAR022/4
12. Insert terminal (A) and turn adjusting screw (D) until terminal is flush with cover (B). IMPORTANT: Select correct size terminal to fit connector body. 13. Tighten lock nut (C).
ATerminal BCover CLock Nut DAdjusting Screw
UN23AUG88
AG,OUOD008,304 1926MAR023/4
CTM170 (14MAY03)
02-110-17

051403
PN=91
TS0134
TS117

14. Insert wire in terminal and crimp until handle contacts stop. IMPORTANT: Terminal must remain centered between indenters while crimping. 15. Release handle and remove terminal. 16. Inspect terminals to ensure all wires are in crimped barrel. IMPORTANT: If all wire strands are not crimped into terminal, cut off wire at terminal and repeat terminal installation procedures.
UN23AUG88
02 110 18
NOTE: Readjust crimping tool for each crimping procedure.

UN23AUG88
17. Push terminal straight into correct connector cavity until positive stop is felt. IMPORTANT: Install terminal in correct connector cavity using correct size grommet. 18. Gently pull on wire to verify terminal is locked into the connector. 19. Transfer remaining wires to correct cavity in new connector.
AG,OUOD008,304 1926MAR024/4
CTM170 (14MAY03)
02-110-18

051403
PN=92
RW77141
UN07DEC98
20. Retape the wires and add the required tie bands to the harness.
TS0135
TS118
Repair AMP Connector
02 110 19
ALocator Assembly BLocator
CWire DCrimping Slot
ECrimping Slot FTerminal
GInsulation Barrel HWire Barrel
1. Disconnect AMP connector. Remove the tie bands and tape. 2. Identify wire color/number to the connector cavity. Make sure the each wire goes back into the correct cavity location. 3. Press JDG1369 Terminal Extraction Tool into face of connector and remove wire and terminal from back of connector.
6. Holding the terminal (F) by the mating end, insert the insulation barrel (G) first, through the front of the tool and into the appropriate crimp slot (D or E). IMPORTANT: Make sure that both sides of the insulation barrel (G) are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned terminal. 7. Position the terminal so that the open U of the wire and insulation barrels (H and G) face the top of the tool. Place the terminal up into the nest so that the movable locator (B) drops into the slot in the terminal as shown. Butt the front end of the wire barrel (H) against the movable locator. 8. Hold the terminal (F) in position and squeeze the tool handles together until ratchet engages sufficiently to hold the terminal in position. DO NOT deform insulation barrel or wire barrel. 9. Insert stripped wire (C) into terminal insulation and wire barrels until it is butted against the wire stop.
NOTE: Verify wire stripping length and crimp height before using AMP crimping tool. See instructions provided with tool.
4. Strip new wire to length indicated in tool instructions. Do not nick or cut wire strands. 5. Hold JDG708 AMP Crimping Tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them to open fully.
NOTE: See instructions provided with tool to determine which crimping slot (D or E) to use.
DPSG,OUO1004,2867 1906MAR021/2
CTM170 (14MAY03)
02-110-19

051403
PN=93
RG10742
UN31MAY00

10. Hold the wire and terminal (A) in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped terminal.
02 110 20
NOTE: The crimped terminal may stick in the crimping area. It can be easily removed by pushing downward on the top of the locator (B).
11. Install wire in correct connector cavity. 12. Retape the wires and add the required tie bands to the harness.
AWire and Terminal BLocator
DPSG,OUO1004,2867 1906MAR022/2
CTM170 (14MAY03)
02-110-20

051403
PN=94
T112335E
UN15MAR02
Section 03
Theory of Operation
Contents
Page
Group 130Electronic Fuel System Operation About this Group . . . . . . . . . . . . . . . . . . . . . . .03-130-1 Fuel System Operation - Tier 1 . . . . . . . . . . . .03-130-2 Fuel System Operation - Tier 2 . . . . . . . . . . . .03-130-4 Primary Fuel Filter Operation - Tier 1 . . . . . . .03-130-5 Primary Fuel Filter Operation - Tier 2 . . . . . . .03-130-5 Final Fuel Filter Operation - Tier 1 . . . . . . . . .03-130-6 Final Fuel Filter Operation - Tier 2 . . . . . . . . .03-130-7 Fuel Injection Pump Operation . . . . . . . . . . . .03-130-8 Fuel Injection Nozzle Operation. . . . . . . . . . .03-130-10 Group 140Electronic Control System Operation About This Group . . . . . . . . . . . . . . . . . . . . . .03-140-1 Electronic Control System Terminology . . . . . .03-140-2 Electronic Control System Operation . . . . . . . .03-140-3 Monitoring Engine Parameters . . . . . . . . . . . .03-140-4 Electronic Control System Overview - Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Electronic Control System Overview - Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Measuring Temperature . . . . . . . . . . . . . . . . .03-140-7 Measuring Pressure . . . . . . . . . . . . . . . . . . .03-140-10 Measuring Throttle Position . . . . . . . . . . . . . .03-140-12 Measuring Engine Speed . . . . . . . . . . . . . . .03-140-16 Electronic Fuel Transfer Pump . . . . . . . . . . .03-140-18 Water in Fuel (WIF) Sensor. . . . . . . . . . . . . .03-140-19 Pump Control Unit. . . . . . . . . . . . . . . . . . . . .03-140-20 Engine Control Unit (ECU) . . . . . . . . . . . . . .03-140-21 Controlled Area Network (CAN). . . . . . . . . . .03-140-22 Intake Air Heater Operation. . . . . . . . . . . . . .03-140-23 Cruise Control Operation. . . . . . . . . . . . . . . .03-140-23 Engine Protection . . . . . . . . . . . . . . . . . . . . .03-140-24 Derate Programs. . . . . . . . . . . . . . . . . . . . . .03-140-24 Multiple Torque Curve Selection . . . . . . . . . .03-140-25 Governor Droop Mode Selection . . . . . . . . . .03-140-25 Engine Control Unit (ECU) Self-Diagnosis. . .03-140-26
03
CTM170 (14MAY03)
03-1

051403
PN=1
Contents
03
CTM170 (14MAY03)
03-2

051403
PN=2
Group 130
Electronic Fuel System Operation

About this Group
In this group, the fuel system information is described in the following categories: Fuel System Operation - Tier 1 Fuel System Operation - Tier 2 Primary Fuel Filter Operation - Tier 1 Primary Fuel Filter Operation - Tier 2 Final Fuel Filter Operation - Tier 1 Final Fuel Filter Operation - Tier 2 Fuel Injection Pump Operation Fuel Injection Nozzle Information
03 130 1
DPSG,RG40854,663 1925MAY001/1
CTM170 (14MAY03)
03-130-1

051403
PN=97
Fuel System Operation - Tier 1
03 130 2
APrimary Filter BFuel Transfer Pump CFinal Filter/Water Separator DAir Bleed-off Valve EFuel Injection Pump
F Injection Pump Overflow Valve GReturn to Tank Fuel Line HFuel Injection Nozzle IFuel Return Leak-off Line
JReturn Pressure Fuel KTransfer Pump Pressure Fuel LInjection Pump Pressure Fuel
MInlet From Fuel Tank AAPrimary Filter/Water Separator CCFinal Filter
RG41221,000010D 1917OCT021/2
CTM170 (14MAY03)
03-130-2

051403
PN=98
RG10772A
UN17MAY01
Electronic Fuel System Operation NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual.
The fuel transfer pump (B) draws fuel from the tank (M) through the primary fuel filter (A) by pressurizing the fuel. Once the fuel is pressurized in the transfer pump, it travels through the final filter with a water separator (C) to the fuel injection pump (E). Air and excess fuel are bled out of the system at the final filter through an air bleed-off valve (D). Fuel is then routed through a fuel return line that is connected to the overflow valve (F) on the injection pump. This fuel returns to the fuel tank (G) after going through a fuel cooler. On some applications, the fuel transfer pump (B) draws fuel from the tank (M) through the primary fuel filter with a water separator (AA). The fuel travels through the final filter (CC) to the injection pump (E). The transfer pump, primary filter, and final filter are located on the side opposite of the injection pump. An air bleed-off valve (D) is located at the final filter. On these applications, air and excess fuel is routed directly to the fuel tank (G). The fuel injection pump raises the required fuel pressure for injection. This high pressure fuel is routed through the delivery (pressure) lines to the fuel injection nozzles (H). If there is excess fuel in the injection pump, it is released through an overflow valve and returned to tank. On all applications, this fuel is routed through a fuel cooler before returning to the fuel tank. Once fuel enters the injection nozzle (H), it overcomes the nozzle valve, and fuel is forced out a small orifice in the nozzle tip. This allows for fuel to atomize as it enters the combustion chamber. Excess fuel from the nozzles is first routed through the fuel return leak-off line (I) and then through the return to tank fuel line (G).
03 130 3
RG41221,000010D 1917OCT022/2
CTM170 (14MAY03)
03-130-3

051403
PN=99
Fuel System Operation - Tier 2
03 130 4
APrimary Filter BFuel Transfer Pump CFinal Filter/Water Separator DAir Bleed-off Valve
EFuel Injection Pump F Injection Pump Overflow Valve GReturn to Tank Fuel Line
HFuel Injection Nozzle IFuel Return Leak-off Line JReturn Pressure Fuel KTransfer Pump Pressure Fuel
LInjection Pump Pressure Fuel MInlet From Fuel Tank
The fuel transfer pump (B) draws fuel from the tank (M) through the primary fuel filter (A) by pressurizing the fuel. Once the fuel is pressurized in the transfer pump, it travels through the final filter with a water separator (C) to the fuel injection pump (E). Air and excess fuel are bled out of the system at the final filter through an air bleed-off valve (D). Fuel is then routed through a fuel return line that is connected to the overflow valve (F) on the injection pump. This fuel returns to the fuel tank (G) after going through a fuel cooler. The fuel injection pump raises the required fuel pressure for injection. This high pressure fuel is routed
through the delivery (pressure) lines to the fuel injection nozzles (H). If there is excess fuel in the injection pump, it is released through an overflow valve and returned to tank. On most applications, this fuel is routed through a fuel cooler before returning to the fuel tank. Some applications use a fuel cooler on the supply side of the fuel tank. Once fuel enters the injection nozzle (H), it overcomes spring pressure in the nozzle valve and is forced out of small orifices in the nozzle tip. This process atomizes the fuel as it enters the combustion chamber. Excess fuel from the nozzles is routed through the fuel return leak-off line (I) and out the return to tank fuel line (G).
RG41221,0000101 1917OCT021/1
CTM170 (14MAY03)
03-130-4

051403
PN=100
RG11709A
UN24OCT02
Primary Fuel Filter Operation - Tier 1

The primary filter (A) is a 150 micron filter, which screens particles out of the fuel system before they reach the transfer pump. The filtered fuel is routed through the final fuel filter and then to the injection pump.
APrimary Filter
UN12JUN01 RG11053A
03 130 5
RG41221,000010F 1917OCT021/1
Primary Fuel Filter Operation - Tier 2

NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: Some Tier 2 applications use a remote mounted fuel filter.
The primary filter is a 30 micron filter, which screens particles out of the fuel system. This filter can either be mounted on the engine or on the frame of the machine. The fuel transfer pump (C) draws fuel from the fuel tank, into the primary fuel filter inlet (A), through the filter element (D), and out the filter outlet (B). The filtered fuel is routed through the final fuel filter and then to the injection pump. A filter drain (E) is located on the bottom of the filter element. This is used to drain excess fuel and water from the filter. A Water in Fuel (WIF) Sensor is located on the filter header with the probe next to the filter drain on Marine engines only. For more WIF sensor information, see WATER IN FUEL (WIF) SENSOR in Section 03, Group 140 later in this manual.
APrimary Fuel Filter Inlet BPrimary Fuel Filter Outlet CFuel transfer pump DFilter element EFilter drain
RG41221,0000102 1917OCT021/1
CTM170 (14MAY03)
03-130-5

051403
RG11710A
UN12JUN01
PN=101
Final Fuel Filter Operation - Tier 1

The final fuel filter is a 5 micron filter. The transfer pump (F) draws fuel from the fuel tank through the primary filter. Fuel enters the final filter at inlet (C), then flows through the center filter element (D) and exits through outlet (reverse side, not shown) to the fuel injection pump. Air or excess fuel is expelled through the bleed-off valve (A). Depending on the application, it runs through a fuel line that either connects with the return to tank fuel line from the overflow of the injection pump or it runs directly to the fuel tank. The filter element is housed in a sediment bowl attached to the base with a threaded retaining ring. Since water and contaminants settle at the bottom of the sediment bowl, a drain plug (E) is provided. Depending on application, a water separator bowl for drainage may be attached to either the final or primary filter. The final filter base houses the fuel pressure sensor (B). For more information on the fuel pressure sensor, see MEASURING PRESSURE in Group 140, later in this manual.
UN12JUN01
03 130 6
ABleed Valve BFuel Pressure Sensor CFuel Inlet DFilter Element EDrain Plug FTransfer Pump
RG41221,000010E 1917OCT021/1
CTM170 (14MAY03)
03-130-6

051403
RG11054A
PN=102
Final Fuel Filter Operation - Tier 2

The final fuel filter is a 5 micron filter. The transfer pump draws fuel from the fuel tank through the primary filter. Fuel enters the final filter at inlet (C), then flows through the center filter element (D) and exits through outlet (reverse side, not shown) to the fuel injection pump. Air or excess fuel is expelled through the bleed-off valve (A) routing the fuel back to the fuel tank. Depending on the application, the fuel may route through a fuel cooler prior to the tank. The filter element is housed in a sediment bowl attached to the base with a threaded retaining ring. Since water and contaminants settle at the bottom of the sediment bowl, a drain plug (E) is provided. Depending on application, a water separator bowl for drainage may be attached to either the final or primary filter. The final filter base houses the fuel pressure sensor (B). For more information on the fuel pressure sensor, see MEASURING PRESSURE in Group 140, later in this manual.
ABleed Valve BFuel Pressure Sensor CFuel Inlet DFilter Element EDrain Plug
UN12JUN01
03 130 7
RG41221,0000103 1917OCT021/1
CTM170 (14MAY03)
03-130-7

051403
RG11711A
PN=103
Fuel Injection Pump Operation
03 130 8
ADriveshaft BSupply Pump CRadial Piston High-Pressure Pump
DDistributor Shaft EHigh Pressure Solenoid Valve
FPump Control Unit GTiming Device
HTiming Solenoid Valve IAngle of Rotation Sensor
NOTE: The above illustration has been reprinted with permission from Robert Bosch Corporation.
The main components of the Bosch VP44 fuel injection pump are the driveshaft (A), the supply pump (B), radial plunger pump (C), distributor shaft (D),
advanced piston timing device (G), and pump control unit (F). The crankshaft drives the driveshaft using gears between the two components. The rotation of the driveshaft moves the supply pump, radial plunger pump, and distributor shaft since all of these components are engaged.
DPSG,RG34710,118 1917OCT021/2
CTM170 (14MAY03)
03-130-8

051403
PN=104
RG11052
UN15AUG01

The vane-type fuel supply pump draws fuel from the final filter and with each revolution delivers a constant quantity of fuel to the radial plunger pump. Since the supply pump pressure is a function of pump speed, it is necessary to prevent excessive pressure in the housing at high speeds. A pressure control valve is used to regulate the fuel pressure in the pump housing. If the fuel pressure exceeds the threshold, the valve opens to relieve the excess supply pressure. This fuel is then routed back to the fuel inlet side of the pump. The radial piston high-pressure pump generates injection pressure for each cylinder. This pump includes a cam ring, plungers, and high pressure solenoid valve (E) to help create the requested high pressure. Fuel at supply pressure enters the radial plunger pump. The amount of fuel entering the radial plunger pump chamber is controlled by the position of the high pressure solenoid valve. Excess fuel is released out of the overflow valve. The plungers are located inside the rotating distributor shaft and move inward and outward by the lobes on the cam ring. When the plungers are forced inward by their rotation within the cam lobes, the fuel reaches injection pressure. The fuel at injection pressure is released when the slot in the distributor shaft is aligned with the high pressure outlet. The fuel travels from the outlet, through the high pressure fitting, to the fuel injection nozzles. The advanced piston timing device (G) controls when injection pressure is created. The main components associated with the timing device are the timing device piston, control plunger, cam ring, and the timing solenoid valve (H). The cam ring has a small ball pivot at its base that rides within a slot inside the timing device piston. This allows the axial movement of the timing piston to be converted into rotational movement of the cam ring. The cam lobes and the timing of the injection pressure are either advanced or retarded by the rotation of the cam ring a few degrees in either direction. A control plunger moves the timing piston through the use of supply pressure fuel, which is controlled by the timing solenoid valve. When the timing solenoid valve is closed, the timing device advances the timing by allowing the supply pressure fuel to buildup and force the control plunger to move in an axial direction. When the timing solenoid valve is open, the timing device retards timing by relieving the pressure behind the control plunger and allowing the same supply pressure fuel to move the control plunger in the opposite direction. The position of the timing solenoid valve is determined by the pump control unit. The pump control unit (PSG) (F) is located on top of the injection pump. The PSG and the ECU (engine control unit) communicate over a controlled area network (CAN). For more information on CAN, see CONTROLLED AREA NETWORK (CAN) later in this Group. The ECU supplies the desired fuel quantity for injection, the start of injection, and engine speed messages to the PSG. The PSG in return sends the ECU the duration of triggering of the high-pressure solenoid valve, injection pump speed, injection pump fuel temperature, and any injection pump generated fault codes. This information in generated by the following components internal to the PSG: angle of rotation sensor (I), timing device (G), fuel temperature sensor, and the high pressure solenoid valve (E). This communication keeps the pump and engine in time with each other and protects the engine and pump from failures. The pump also has the ability to derate the engine by limiting the amount of fuel supply to the engine if there is a pump related problem.
03 130 9
DPSG,RG34710,118 1917OCT022/2
CTM170 (14MAY03)
03-130-9

051403
PN=105
Fuel Injection Nozzle Operation
03 130 10
ANozzle Tip BCarbon Dam Seal CNozzle Body DNozzle Valve
EPlastic Seal Washer FEdge-Type Filter GFuel Inlet HUpper Guide
IUpper Seal JSpring Seat KValve Spring LSpring Washer
MLift Adjusting Screw NLock Nut OPressure Adjusting Screw PLock Nut
The injection nozzles are secured by a locating clamp in the engine cylinder head. The injectors are spring and valve type, hydraulically operated by fuel delivered from the injection pump. The nozzle is sealed at the top end by a plastic seal washer (E). A carbon dam seal (B), located on the lower end of the nozzle body (C), prevents carbon build up from collecting around the nozzle and combustion gases from blowing by the nozzle body in the cylinder head. The nozzle tip (A) is pressed into the nozzle body and cannot be separated. Enclosed in the nozzle body are the valve (D), valve spring (K), and spring seat (J). The nozzle operating pressure is controlled by the pressure adjusting screw (O) in the upper end of the nozzle body. Valve lift is adjusted by the lift adjusting screw (M) located in the pressure adjusting screw. A leak-off line tee is attached to the upper end of the injection nozzle, secured by a hex nut.
Metered fuel under high pressure, is delivered by the injection pump through the nozzle inlet (G) on the valve body into the area surrounding the valve. When fuel pressure reaches nozzle opening pressure, the valve is forced from its seat against the pressure of the spring, permitting a measured amount of fuel to enter the combustion chamber through four small holes in the nozzle tip. After fuel has been injected, the spring closes the valve. In actual operation, the valve opens and closes very rapidly, providing a distinct chatter. A small amount of fuel leaks past the valve into the spring area. This cools and lubricates the nozzles working parts. This excess fuel is then removed from the nozzle at the top by means of a leak-off line routed back to the fuel tank.
DPSG,RG34710,119 1909MAY011/1
CTM170 (14MAY03)
03-130-10

051403
RG7800A
UN13NOV97
PN=106
Group 140
Electronic Control System Operation

About This Group
In this group, the electronic control system is described in the following categories: Electronic Control System Terminology Electronic Control System Operation Monitoring Engine Parameters Electronic Control System Overview - Tier 1 Electronic Control System Overview - Tier 2 Measuring Temperature Engine Coolant Temperature (ECT) Sensor Manifold Air Temperature (MAT) Sensor Measuring Pressure Fuel Pressure Sensor Oil Pressure Sensor Measuring Throttle Position Analog Throttle CAN Throttle Dual State Throttle Excavator Throttle Multi-state Throttle Pulse-Width Modulated (PWM) Throttle Ramp Throttle Tri-state Throttle Measuring Engine Speed Crankshaft Position Sensor Pump Position Sensor Electronic Transfer Pump Water in Fuel (WIF) Sensor Pump Control Unit Engine Control Unit (ECU) Controlled Area Network (CAN) Intake Air Heater Operation Cruise Control Operation Engine Protection Derate Programs Multiple Torque Curves Selection Governor Droop Mode Selection Engine Control Unit (ECU) Self Diagnosis
03 140 1
RG41221,0000110 1909MAY011/1
CTM170 (14MAY03)
03-140-1

051403
PN=107
Electronic Control System Terminology

Actuator Analog Boost CAN A device controlled by the (ECU) to perform a certain function. Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt signals. Air charge pressure in the intake manifold. Controller Area Network. The electronic pathway network on vehicles that allows communication between controllers. Diagnostic Trouble Code. A code which is stored in the ECUs memory when the ECU detects a problem in the electronic control system. Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run special tests. The DST consists of an Windows (95, 98, 2000) or NT compatible computer and a hardware kit available from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The software is available to download from your John Deere home page. A signal which consists of only two-volt levels usually 0 volts and +5 volts. Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant. See MEASURING TEMPERATURE later in this Group for details. Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine. See ENGINE CONTROL UNIT (ECU) later in this Group for details. Failure Mode Identifier. The second part of a two-part code that identifies control system trouble codes according to the SAE J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect Parameter Number (SPN). The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty vehicles. J1587 is the software standard. J1708 is the hardware standard. Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING TEMPERATURE later in this Group for details. Parallel Data Module. Device used as part of the DST that allows communication with the ECU. Programmable, Read-Only Memory. The computer chip which contains the calibration information for the engine control system. See ENGINE CONTROL UNIT (ECU) later in this Group for details. Pump Control Unit. The controller for the Bosch VP44 rotary injection pump. This is located on top of the injection pump. The acronym PSG derives from the German word Pumpensteuergerat. 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. Random Access Memory. The portion of computer memory within the ECU which changes as the engine is running and is stored while the engine is off. See ENGINE CONTROL UNIT (ECU) later in this Group for details. Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance and energy resource conservation. Device used by the ECU to monitor various engine parameters.
DTC 03 140 2
DST
Digital ECT
ECU
FMI
J1587/J1708
MAT
PDM PROM
PSG
PWM
RAM
SAE
Sensor
RG,RG34710,1528 1917OCT021/2
CTM170 (14MAY03)
03-140-2

051403
PN=108

SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to the SAE J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code is the Failure Mode Identifier (FMI). Battery voltage or unswitched voltage. Switched voltage
VBAT VSW
RG,RG34710,1528 1917OCT022/2
03 140 3

Engine Starting Mode When the key is turned to the ON position, a switched power voltage is sent to the Electronic Control Unit (ECU). This energizes the ECU and allows it to boot-up and ready itself for engine start. the Engine Coolant Temperature (ECT) sensor. At this point, the engine will start and the ECU will go into the running mode. Engine Running Mode In the running mode, both the pump and crankshaft position sensors allow the ECU to precisely determine piston position in relation to top-dead-center so that the ECU can inform the pump control unit (PSG) of the operating conditions of the engine. Given the information from the ECU and the sensors internal to the pump, the PSG controls fuel delivery by energizing and de-energizing the high pressure solenoid valve. When the PSG energizes the high pressure solenoid valve, the valve needle closes and injection begins. When the correct amount of fuel has been injected, the PSG de-energizes the high pressure solenoid valve, causing the valve needle to open, and fuel injection to stop.
NOTE: If a wiring problem prevents the key ON signal from getting to the ECU, the engine will not start.
As soon as the ECU receives an input from the crankshaft position sensor that the engine is cranking, it will determine using the pump position sensor input when cylinder number 1 is coming to top-dead-center (TDC) at the end of the compression stroke. It will then start injecting fuel when the next cylinder in the firing order (cylinder number 5) is at the correct position before TDC at the end of its compression stroke. To provide cold temperature enrichment, the amount of fuel injected is based on the temperature measured by
RG,RG34710,1530 1917OCT021/1
CTM170 (14MAY03)
03-140-3

051403
PN=109
Monitoring Engine Parameters

In order for the electronic control system to deliver fuel according to a given set of operating conditions, the following parameters are monitored by the ECU: Engine Coolant Temperature (ECT) Manifold Air Temperature (MAT) Fuel Pressure Oil Pressure Throttle Position Crankshaft Position Sensor Pump Position Sensor Transfer Pump Pump Control Unit
03 140 4
RG,RG34710,1531 1909MAY011/1
CTM170 (14MAY03)
03-140-4

051403
PN=110
Electronic Control System Overview - Tier 1
03 140 5
AECT Sensor (Rear of Cylinder Head) BOil Pressure Sensor
CFuel Pressure Sensor DElectronic Transfer Pump Connector
EPump Position Sensor FCrankshaft Position Sensor GPSG Connector
HECT Sensor (Thermostat Housing) IMAT Sensor
NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: Some of the components shown are optional and not used on all applications.
The electronic control system sends the PSG (pump control unit) fuel delivery quantity information. In order
to achieve this, the engine control system encompasses the following performance functions: Constantly monitors engine operating conditions Precisely determines piston position Informs the PSG of desired fuel quantity Provides multiple control modes Performs self-diagnosis
RG41221,0000111 1917OCT021/1
CTM170 (14MAY03)
03-140-5

051403
RG10765
UN26MAY00
PN=111
Electronic Control System Overview - Tier 2
03 140 6
AECT Sensor (Rear of Cylinder Head) BOil Pressure Sensor
CFuel Pressure Sensor DElectronic Transfer Pump Connector
EPump Position Sensor FCrankshaft Position Sensor GPSG Connector
HECT Sensor (Thermostat Housing) IMAT Sensor
NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: Some of the components shown are optional and not used on all applications.
The electronic control system sends the PSG (pump control unit) fuel delivery quantity information. In order
to achieve this, the engine control system encompasses the following performance functions: Constantly monitors engine operating conditions Precisely determines piston position Informs the PSG of desired fuel quantity Provides multiple control modes Performs self-diagnosis
RG41221,0000112 1917OCT021/1
CTM170 (14MAY03)
03-140-6

051403
RG11712
UN20JUN01
PN=112
Measuring Temperature
The Engine Coolant Temperature (ECT) sensor and the Manifold Air Temperature (MAT) sensor are thermistors (temperature sensitive variable resistors). The sensors resistance goes down as the temperature that it is exposed to goes up (negative temperature coefficient). Higher temperatures result in lower voltages and lower temperatures result in higher voltages. The Engine Control Unit (ECU) sends 5 volts to the sensor, monitors the voltage drop across the sensor, and compares the voltage drop to preprogrammed values in the ECUs memory in order to determine temperature. In addition to temperature sensors, some applications use temperature switches. The loss of coolant temperature switch is an example. Temperature switches close when a specific temperature is reached.
RG11819
UN17AUG01
Temperature Sensor Schematic
03 140 7
RG41221,0000113 1917OCT021/3
CTM170 (14MAY03)
03-140-7

051403
PN=113

Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor is located in the rear of the cylinder head (A) or in the thermostat housing (H) depending on the application using this engine.
03 140 8
The ECU monitors coolant temperature for: Engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group. Starting fuel quantity determination The ECU will adjust the amount of fuel delivered during start-up based on initial ECT readings. Idle speed determination In order to speed engine warm-up, the ECU will increase idle speed after start-up if a low coolant temperature is measured.
AECT Sensor (Rear of Cylinder Head) HECT Sensor (Thermostat Housing)
ECT Sensor (Rear of Cylinder Head)
ECT Sensor (Thermostat Housing)
RG41221,0000113 1917OCT022/3
CTM170 (14MAY03)
03-140-8

051403
RG11096
UN15JAN03
RG10766
NOTE: On OEM applications, the ECU uses the ECT sensor in the thermostat housing. Other applications may use the sensor located in the rear of the head.
UN26MAY00
PN=114

Manifold Air Temperature (MAT) Sensor The Manifold Air Temperature (MAT) sensor is located in the intake manifold (I) or in the cross over tube (I). The MAT sensor measures intake air temperature to help the ECU calculate the correct fueling. The ECU also monitors manifold air temperature for engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group. This sensor is optional and is not included on all applications.
IMAT Sensor Intake Manifold IMAT Sensor Crossover Tube
RG10769
UN15JAN03
MAT Sensor - Tier 1
03 140 9
MAT Sensor - Tier 2

RG41221,0000113 1917OCT023/3
CTM170 (14MAY03)
03-140-9

051403
RG11738A
UN15JAN03
PN=115
Measuring Pressure
The systems pressure sensors are 3 wire variable resistors. As the pressure changes, sensor resistance changes. The ECU sends a 5 volt reference voltage to the sensor, monitors the voltage returning on the sensor signal wire, and compares the voltage drop to preprogrammed values in the ECUs memory to determine pressure. In addition to pressure sensors, some applications use pressure switches. Pressure switches close when a specific pressure is reached.
Pressure Sensor Schematic
03 140 10
RG,RG34710,1533 1917OCT021/3
Fuel Pressure Sensor The fuel pressure sensor (C) is an optional sensor located in the final fuel filter housing. This sensor measures the fuel pressure on the clean side of the filter. The ECU uses the input from the sensor to control the electronic fuel transfer pump and to provide engine protection. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group.
Fuel Pressure Sensor
RG,RG34710,1533 1917OCT022/3
CTM170 (14MAY03)
03-140-10

051403
RG10768
UN15JAN03
RG12827
UN30JAN03
PN=116

Oil Pressure Sensor The oil pressure sensor is an optional sensor located in the main engine galley (B). The ECU monitors oil pressure for engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group.
RG10767
UN15JAN03
Oil Pressure Sensor
03 140 11
RG,RG34710,1533 1917OCT023/3
CTM170 (14MAY03)
03-140-11

051403
PN=117
Measuring Throttle Position

The 4.5L & 6.8L engines have the option of operating with a pulse-width-modulated (PWM) throttle signal, an analog throttle position sensor output signal, multi-state throttle, or a CAN throttle. On some applications, multiple throttles are used.
03 140 12
RG41221,0000029 1923APR031/9
Analog Throttle An analog throttle uses a variable resistor (potentiometer) sensor to measure the position of the throttle. The ECU sends a 5 volt reference voltage to the sensor, monitors the voltage drop across the resistor, and compares the voltage drop to preprogrammed values in the ECUs memory. The analog throttle input voltage normally varies between 1.0 volts and 4.0 depending on throttle position. Analog throttle voltage at low idle is approximately 1.0 volt and 4.0 volts at high idle. The ECU has the ability to learn different voltages for low and high idle, so the voltages above may change depending on application.
Position Sensor
RG41221,0000029 1923APR032/9
CAN Throttle CAN throttle is information sent to the ECU by another controller over the CAN bus of the desired throttle position.
1906MAY02
CAN Throttle Schematic
RG41221,0000029 1923APR033/9
CTM170 (14MAY03)
03-140-12

051403
RG12349
RG11820
UN15JAN03
PN=118

Dual State Throttle The dual state throttle is used on applications that use a few fixed engine speeds. There are two available positions, Low Idle and High Idle. The switch uses two different resistors to change the voltage returned to the ECU. The ECU uses an internal conversion table to convert the voltage to a specific engine speed. When the switch is in the low idle position, the current is routed through a 390 ohm resistor. High idle position uses a 1300 ohm resistor. These speeds can be adjusted and saved depending on the needs of the application.
Dual State Throttle
RG12284
1926APR02
03 140 13
RG41221,0000029 1923APR034/9
Excavator Throttle The Excavator uses an analog throttle to measure throttle position. This throttle is connected to the Pump and Valve controller, which sends throttle input information to the ECU through a dedicated wire. Since the ECU uses and Pump and Valve controller do not share a common ground, a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire. The ECU calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller.
Excavator Throttle
RG41221,0000029 1923APR035/9
CTM170 (14MAY03)
03-140-13

051403
RG12287
1926APR02
PN=119

Multi-state Throttle The multi-state throttle is used when a few fixed engine speeds are desired. There are three types of multi-state throttles; Dual-state, Tri-state, and Ramp. All of these throttles are wired exactly the same. The only difference is the actual switch that is used to control the engine speed. For information on each of these throttles, see DUAL STATE THROTTLE, TRI-STATE THROTTLE, or RAMP THROTTLE later in this Measuring Throttle Position section.
Multi-state Throttle Schematic
03 140 14
RG41221,0000029 1923APR036/9
Pulse-Width-Modulated (PWM) Throttle The PWM throttle signal is sent to the ECU by another controller. The PWM signal is a square wave signal with a constant frequency. The pulse width of the signal varies to indicate the desired throttle opening.
PWM Throttle Schematic
RG41221,0000029 1923APR037/9
CTM170 (14MAY03)
03-140-14

051403
RG12347
1906MAY02
RG12348
1906MAY02
PN=120

Ramp Throttle The ramp throttle allows the operator slowly increase or decrease the engine speed through a three position momentary (spring back to center position) switch. If the switch is held in the upward position, the engine speed will increase in small increments. If the switch is held in the downward position, the engine speed will decrease. Once the desired speed is selected, release the switch into the center position. The switch uses three different resistors to change the voltage returned to the ECU. When the switch is in the desired position (center), the current is routed through a 1300 ohm resistor. When changing engine speed, a 390 ohm resistor to reduce the engine speed and a 3000 ohm resistor to ramp up the engine speed. Speed will remain the same until key cycle or operator change.
RG12286
1926APR02
Ramp Throttle
03 140 15
RG41221,0000029 1923APR038/9
Tri-State Throttle The tri-state throttle works very similar to the dual state throttle. This throttle uses a three position switch, Low Idle, Adjustable High Idle, and Non-Adjustable High Idle. The switch uses three different resistors to change the voltage returned to the ECU. The ECU uses an internal conversion table to convert the voltage to a specific engine speed. When the switch is in the low idle position, the current is routed through a 390 ohm resistor, adjustable high idle position uses a 1300 ohm resistor, and non-adjustable high idle position uses a 3000 ohm resistor. These adjustable speeds can be saved depending on the needs of the applications. The non-adjustable high idle is set at the factory to the engines high idle speed and can not be changed. This position will always set the engine speed to the factory high idle value. The other two positions are adjustable and work exactly like the dual state throttle.
Tri-State Throttle
RG41221,0000029 1923APR039/9
CTM170 (14MAY03)
03-140-15

051403
RG12285
1926APR02
PN=121
Measuring Engine Speed

Both the crank position sensor and the pump position sensor operate by detecting notches on their corresponding gear/timing wheel. When a notch on the gear/timing wheel is directly under the sensor, a voltage is induced. The sensors use an internal magnet to create this voltage signal from the teeth on their respective gear/timing wheel. The magnet is pulled towards the gear/timing wheel as the teeth pass directly under the sensor. As the root diameter (area between teeth) pass the sensor, the magnet returns inside the sensor. This creates the voltage signal that the ECU monitors for timing and speed. When a notch (one or more missing teeth) passes under the sensor, the pattern of the signal changes. By monitoring these changes in the signal, the ECU calculates the speed and the cylinder number that is ready for injection. The ECU monitors both of these sensors to verify that they are in time with each other. Crankshaft Position Sensor The crankshaft position sensor (F) is located on the front of the crank, behind the pressed-on crank gear. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The ECU uses the crankshaft position input to determine engine speed and precise piston position in relation to the firing order. The crank timing wheel is composed of 48 evenly spaced teeth and 2 gaps between the teeth missing. The missing gaps help the ECU to determine Top-Dead-Center (TDC).
03 140 16
Speed Sensors
EPump Position Sensor FCrankshaft Position Sensor
RG,RG34710,1536 1917OCT021/2
CTM170 (14MAY03)
03-140-16

051403
RG10770
UN15JAN03
PN=122

Pump Position Sensor The pump position sensor (E) is located behind the injection pump. It is an inductive type pickup sensor that detects notches in the injection pump gear. The ECU uses the pump position input to determine cylinder identification. The ECU uses this sensor to determine engine speed and to determine when each cylinder is at TDC at the end of the compression stroke. The ECU needs this information in order to deliver the correct amount of fuel to the correct cylinder, at the correct time. The ECU monitors the voltage that is created by the pump position sensor when the slots of the injection pump gear passes. The injection pump gear is composed of 12 evenly spaced slots with one additional notch offset to tell the ECU that cylinder #1 is approaching Top-Dead-Center.
03 140 17
RG,RG34710,1536 1917OCT022/2
CTM170 (14MAY03)
03-140-17

051403
PN=123
Electronic Fuel Transfer Pump

NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: On Tier 1 applications the fuel transfer pump is located on the final fuel filter. Tier 2 applications have the fuel transfer pump on the primary fuel filter or remote mounted inside the engine compartment.
Electronic Transfer Pump - Closed Loop Closed loop pumps can be either mounted on the primary fuel filter (Tier 2), on the final fuel filter (Tier 1), or remote mounted (Tier 2). All closed loop pumps use a fuel pressure sensor at the outlet of the final fuel filter to communicate the pressure to the ECU. The ECU maintains a constant fuel pressure for a given speed by controlling the duty cycle of the Pulse Width Modulated (PWM) signal between the ECU and transfer pump. When fuel pressure increases, the ECU decreases the duty cycle. When fuel pressure decreases, the ECU increases the duty cycle. Transfer pump duty cycle and fuel pressure can be monitored on the Diagnostic Scan Tool (DST) or SERVICE ADVISOR. In addition to helping to maintain a constant fuel pressure, the transfer pump is also used to aid in bleeding air out of the fuel system through the air bleed-off valve in the final fuel filter housing. When the key is ON, the transfer pump works to purge air, and the ECU will let the pump run for up to 40 seconds. Electronic Transfer Pump - Open Loop All open loop pumps are remote mounted on Tier 2 engines only. The ECU uses a Pulse Width Modulated (PWM) signal during priming and cranking. When the engine is running, the ECU sends a constant voltage to the pump. There is a mechanical regulator in the filter header to regulate the fuel pressure prior to the final fuel filter.
Electronic Transfer Pump - Tier 1
UN15JAN03
03 140 18
Electronic Transfer Pump - Tier 2

DElectronic Transfer Pump Connector
SERVICE ADVISOR is a trademark of Deere & Company
RG41221,0000115 1917OCT021/2
CTM170 (14MAY03)
03-140-18

051403
RG11713
UN15JAN03
RG10771
PN=124

The transfer pump is also used to aid in bleeding air out of the fuel system through the air bleed-off valve in the final fuel filter housing. When the key is ON, the transfer pump works to purge air, and the ECU will let the pump run for up to 40 seconds.
RG41221,0000115 1917OCT022/2
03 140 19
Water in Fuel (WIF) Sensor

The WIF sensor (J) is located inside the water separating bowl of the primary fuel filter. The ECU compares the resistance of the sensor probe to the water separator bowl housing and the resistance of the sensor ground to the fuel filter header. When water is present, the resistance between the sensor probe and the water separator bowl increases. This shorts the sensor input to ground to let the ECU know that water has been detected. The ECU monitors this for engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group.
WIF Sensor
JWater in Fuel Sensor
RG41221,00000AC 1902JAN031/1
CTM170 (14MAY03)
03-140-19

051403
RG12804
UN17JAN03
PN=125
Pump Control Unit

Located on top of the injection pump, the pump control unit monitors a few different sensors inside the injection pump and acquires information from the ECU. This helps the pump control unit to determine how to control the high pressure solenoid valve and the timing solenoid valve, which help to provide for accurate quantity and timing of fuel delivery to the engine.
03 140 20
The pump control unit (PSG) is mounted to the top of the fuel injection pump. The PSG is cooled by fuel which runs through a passage under the PSG housing. The PSG contains a nine pin connector that houses all necessary wiring for the ECU (engine control unit) to communication with the pump. The PSG and the ECU (engine control unit) communicate over a controlled area network (CAN). For more information on CAN, see CONTROLLED AREA NETWORK (CAN) later in this Group. The ECU supplies inputs for desired fuel quantity for injection, the start of injection, and engine speed messages to the PSG. The PSG in return sends the ECU the duration of triggering of the high-pressure solenoid valve, injection pump speed, injection pump temperature, and any injection pump generated fault codes. This information in generated by the following components internal to the PSG: angle of rotation sensor, timing device, fuel temperature sensor, and the high pressure solenoid valve. This communication keeps the pump and engine in time with each other and protects the engine and pump from failures. The PSG is an intelligent injection pump. It can adjust fuel quantity by triggering a timing device so that the correct state of delivery is met.
Pump Control Unit

GPump Control Unit Connector
DPSG,RG40854,665 1917OCT021/1
CTM170 (14MAY03)
03-140-20

051403
RG11098
UN15JAN03
PN=126
03 140 21
John Deere Level 4 ECU
The Engine Control Unit (ECU) is the brains of the Electronic Control System. The ECU is a self-contained unit containing electronic circuitry and computer software which together perform the following functions: Converts the electrical signals from the various sensors into digital signals Makes decisions of optimum fuel quantity and injection timing based on information from various sensors Limits maximum fuel for operation on multiple power curves Informs pump control unit (PSG) of desired fuel delivery
Provides all-speed governing Performs self diagnosis on the control system Stores trouble codes in memory The ECU connects to the wiring harness through a 68-way ECU connector. This connector is marked by terminal numbers. The ECU is composed of the following subsystems: Analog/Digital Converters This portion of the ECU converts the analog voltage signals from the various sensors into digital signals that the central processing unit can understand.
RG,RG34710,1537 1930SEP971/2
CTM170 (14MAY03)
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051403
RG10764
UN22MAY00
PN=127

Central Processing Unit (CPU) The central processing unit performs the mathematical computations and logical functions that are necessary in controlling injection fuel quantity and injection timing. The CPU communicates its desired fuel quantity and timing to the pump control unit (PSG), and it controls the self diagnostic system. Memory
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Information in RAM is lost when battery voltage to the ECU 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 is removed. Electrical Erasable Programmable Read Only Memory - EEPROM The EEPROM contains information programmed in at the factory including engine specific data, and application data. Information in the EEPROM is retained when battery voltage is removed.
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 of various calculations are temporarily stored in RAM.
RG,RG34710,1537 1930SEP972/2
Controlled Area Network (CAN)

Controlled Area Network (CAN) is used to allow communication between other controllers on the engine or vehicle and for connecting to diagnostic software. All of the controllers that are required to communicate over CAN are connected together using wires forming a bus. J1939 is an SAE standard that utilizes CAN. Just about any type of information can be communicated over the CAN Bus. Depending on the application, information like part numbers, serial numbers, engine speed, throttle position, application requested derates and shutdowns, ect. The Level 4 control system uses the bus for communication between the Pump Control Unit (PSG) and the Engine Control Unit (ECU). The ECU supplies inputs for desired fuel quantity for injection, the start of injection, and engine speed messages to the PSG. The PSG in return sends the ECU the duration of triggering of the high-pressure solenoid valve, injection pump speed, injection pump temperature, and any injection pump generated fault codes. The engine also uses CAN to talk to other vehicle controllers. Depending on the application, information like throttle position, application requested derates and or engine protection, displaying diagnostic fault codes on vehicle displays, ect. CAN also allows diagnostic software like the Diagnostic Scan Tool (DST) and SERVICE ADVISOR to communicate with our engine controller. All of the information viewed through the diagnostic software and diagnostic gauge is transferred via the CAN Bus.
RG41221,0000248 1917OCT021/1
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PN=128
Intake Air Heater Operation

An optional function not included in all ECUs, the intake air heater is used to increase intake manifold air temperature to improve cold starting. When the operator turns the key from OFF to ON, the ECU uses the fuel temperature sensor to determine engine temperature and ambient air temperature, turns on the Air Heater Indicator light on the dash, and energizes the air heater relay. The air heater relay will in turn energize the air heater coils located in the intake manifold. The ECU will keep the air heater relay energized for an amount of time that 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 light and de-energize the air heater relay. If the operator turns 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 to turn off, the ECU will de-energize the air heater relay and a key-off/key-on cycle is required before preheating is allowed again. Anytime the engine cranks but does not start, a key-off/key-on cycle will be required before preheating is allowed again.
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DPSG,RG34710,8 1903DEC981/1
Cruise Control Operation

The ECU is available with and without the cruise control function. It is an off-road cruise control that maintains constant engine speed under varying load conditions. This function is especially intended for field applications where an operator faces the need to turn the vehicle around at the end of each row. This cruise control allows the driver to use the throttle and/or brake to turn the vehicle around. When ready to resume field operations, the operator brings the engine speed above 1300 rpm and activates the Cancel/Resume function again to resume cruise speed. An internal timer gives the operator one minute to 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 from two different locations. The primary location would normally be in the cab of the vehicle and is used to set a constant engine speed while the vehicle is being driven. The secondary cruise control is normally used in a location that provides PTO speed control and is used with the engine in neutral or out of gear. Both locations have the normal cruise control functions.
DPSG,RG40854,457 1914OCT991/1
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PN=129
Engine Protection
Engine protection is necessary to prevent damage to an engine. There are three different engine protection programs available in Engine Control Units (ECUs): No Protection The ECU does not have the software to derate or shut the engine down. It is the responsibility of the operator to react to warning light(s) on their application. Derating or shutting the engine down may be necessary depending on the Diagnostic Trouble Code (DTC) that is set. Refer to the operators manual to identify this information for a given application. Engine Protection WITHOUT Shutdown The ECU has the capability to derate an engine. It is the responsibility of the operator to react to warning light(s) on their application to identify if it is necessary to shut the engine down. Refer to the operators manual to retrieve this information for a given application. Engine Protection with Shutdown The ECU will derate the engine for given DTCs. If a DTC that requires shutdown is set, the ECU will severely derate the engine and shut the engine down in 30 seconds. If the problem is corrected within the 30 second delay period, the power will increase at a particular rate until full power is reached. There are two levels of engine protection: SHUTDOWN OVERRIDE
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NOTE: Holding the shutdown override switch continuously ON will not reset the 30 second timer.
The engine protection shutdowns can be overridden for 30 seconds at a time. This can be used to move a vehicle to a safe location. Each time the switch is pushed, the shutdown timer is reset to 30 seconds, and the engine will run in a derated power mode.
RG41221,0000116 1917OCT021/1
Derate Programs
The Electronic Control Unit (ECU) will derate the amount of fuel that is delivered to the engine when sensor inputs exceed normal operating ranges. A Diagnostic Trouble Code (DTC) always accompanies a fuel derate. See APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for derate specifications per application.
RG41221,0000117 1917OCT021/1
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PN=130
Multiple Torque Curve Selection

The ECU has the ability to limit the maximum fuel quantity through the pump control unit (PSG) such that multiple torque curves can be individually selected while the engine is running. The selection of multiple torque curves is determined by either switch inputs into the ECUs torque curve select terminal, or by messages from other controllers on the machines Controller Area Network (CAN). In most applications, one torque curve is used for normal operation. Several other derated torque curves will be used to protect vehicle axles, hitches, and transmissions, etc. under certain operating conditions. For example: a machine can choose multiple torque curves using simple switching arrangement. A simple on/off toggle switch and resistor can be used to switch between torque curve 1 (maximum power), and any of the other torque curves. When the switch is open, the ECU will command torque curve 1. When the switch is closed, the ECU will command one of the other curves depending on the resistance in the line. See APPLICATION SPECIFICATIONS in Section 6, Group 210 of this manual for torque curve selection specifications.
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Torque Curves
DPSG,RG40854,460 1923APR031/1
Governor Droop Mode Selection

The electronic control system provides all-speed governing. The Engine Control Unit (ECU) controls the engine speed based on the analog throttle input. The ECU also has the ability to provide normal and isochronous (0%) droop. The normal droop gives a drop in engine speed with an increase in load or an increase in engine speed with a decrease in load. When in isochronous, the droop is set at 0%, and there is a no change in engine speed with changing loads until engines torque limit is reached. The factory low 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 6, Group 210 of this manual for governor droop mode specifications.
DPSG,RG40854,461 1923APR031/1
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RG8552
1918SEP98
PN=131
Engine Control Unit (ECU) Self-Diagnosis

The Engine Control Unit (ECU) has the ability to detect problems internally and in the electronic control system. This includes determining if any sensor input voltages are too high or too low. If the ECU detects a problem with the electronic control system, a Diagnostic Trouble Code (DTC) specific to the failed system will be stored in the ECUs memory.
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coolant temperature circuit. The second part of the code is called the Failure Mode Identifier (FMI) code. The FMI contains 2 digits. The FMI identifies the type of failure that has occurred; for example FMI 3 indicates value above normal. In order to determine the exact failure, both the SPN and FMI are required. Combining SPN 110 with FMI 3 yields engine coolant temperature input voltage high. On all applications with the Level 4 Engine Control Unit (ECU), the ECU transmits SPN/FMI codes over the Controller Area Network (CAN). This allows for service tools such as the DST, SERVICE ADVISOR, and the Diagnostic Gauge to display active and stored DTCs. When using DST or SERVICE ADVISOR the codes will be displayed in a 000000.00 format. For example, SPN 110 FMI 3 will be displayed as 000110.03. 2-DIGIT CODES Some John Deere applications display DTCs as 2-digit codes read from an on-board display. WARNING LAMP On some applications, there is a warning lamp (also referred to as the Air Heater Indicator light) that is used when a code becomes active. When a code is active, this lamp will either blink or stay on solid. A solid light indicates that the ECU is taking extreme measures to protect the engine. A blinking light indicates that the ECU has detected a fault and engine performance may be affected. CLEARING STORED DTCS Stored DTCs can be cleared through the Diagnostic Scan Tool (DST) or SERVICE ADVISOR. Refer to the vehicle machine manual or see CLEARING STORED DTCS ON DIAGNOSTIC GAUGE in Group 160 later in this manual to determine how to clear the code reader.
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 the past, but is not currently occurring. This type of DTC can be caused by an intermittent failure. These could be problems such as a bad connection or a wire intermittently shorting to ground. There are several different methods for displaying both stored and active DTCs from the ECU.
NOTE: If the Diagnostic Scan Tool (DST) or SERVICE ADVISOR is used to read a sensor voltage and calculated value, and there is an active DTC for that sensor, the calculated value for that sensor will be the limp home value and the voltage will be the actual sensor voltage. Use the voltage during diagnostics unless otherwise directed by a diagnostic chart.
SPN/FMI CODES SPN/FMI codes are written from the SAE J1939 standard as a two part code. The first part is called the Suspect Parameter Number (SPN). Typically, it contains between 2 and 4 digits. The SPN identifies the system or the component that has the failure; for example SPN 110 indicates a failure in the engine
SERVICE ADVISOR is a trademark of Deere & Company SERVICE ADVISOR
RG,RG34710,1540 1930SEP971/1
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Section 04
Diagnostics
Contents
Page Page
Group 150Observable Diagnostics and Tests About This Group of the Manual . . . . . . . . . . .04-150-1 E1 - Engine Cranks/Wont Start. . . . . . . . . . . .04-150-2 E1 - Engine Cranks/Wont Start Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-2 E2 - Engine Misfires/Runs Irregularly . . . . . . .04-150-7 E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure. . . . . . . . . . . . . . . . . .04-150-7 E3 - Engine Does Not Develop Full Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-12 E3 - Engine Does Not Develop Full Power Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-12 E4 - Engine Emits Excessive White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-18 E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure . . . .04-150-18 E5 - Engine Emits Excessive Black Or Gray Smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-22 E5 - Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure . . . . . .04-150-22 E6 - Engine Will Not Crank . . . . . . . . . . . . . .04-150-25 E7 - Engine Idles Poorly . . . . . . . . . . . . . . . .04-150-25 E8 - Abnormal Engine Noise . . . . . . . . . . . . .04-150-26 E10 - Analog Throttle (B) Does Not Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-28 F1 - Fuel Supply System Check - Tier 1 . . . .04-150-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32 F1 - Fuel Supply System Check - Tier 1 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-32 F2 - Excessive Fuel Consumption . . . . . . . . .04-150-37 F3 - Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . .04-150-37 F4 - Fuel Supply System Check - Tier 2 . . . .04-150-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-40 F4 - Fuel Supply System Check - Tier 2 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-40 F5 - Fuel Injection Nozzle Check . . . . . . . . .04-150-46 D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR . . . . . . . . . .04-150-50 D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-51 D2 - Diagnostic Gauge Does Not Communicate With ECU . . . . . . . . . . . . . .04-150-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-57 D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-57 CTM170 (14MAY03)
A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-60 A1 - Intake Air Heater Check Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-61 Check Fuel Supply Quality - Tier 1 . . . . . . . .04-150-65 Check Fuel Supply Quality - Tier 2 . . . . . . . .04-150-67 Test for Fuel Drain Back . . . . . . . . . . . . . . . .04-150-68 Test for Air in Fuel - Tier 1 . . . . . . . . . . . . . .04-150-69 Test for Air in Fuel - Tier 2 . . . . . . . . . . . . . .04-150-71 Check Fuel Supply Pressure . . . . . . . . . . . . .04-150-72 Bleed the Fuel System . . . . . . . . . . . . . . . . .04-150-73 Test for Cylinder Misfire (Engine Running) . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-76 Group 160Trouble Code Diagnostics and Tests About this Group of the Manual. . . . . . . . . . . .04-160-1 Electrical Concepts . . . . . . . . . . . . . . . . . . . . .04-160-1 Using a Digital Multimeter . . . . . . . . . . . . . . . .04-160-2 Electrical Circuit Malfunctions . . . . . . . . . . . . .04-160-2 Troubleshooting Circuit Malfunctions . . . . . . . .04-160-5 Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR . . . . . . . . . . . . . . . . .04-160-9 Engine Configuration Data Parameters on Diagnostic Gauge . . . . . . . . . . . . . . . . . . .04-160-11 Viewing Active DTCs on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Viewing Stored DTCs on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Clearing Stored DTCs on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-14 Blinking DTCs Using Diagnostic Blink Code Connector . . . . . . . . . . . . . . . . . . . . . . . . .04-160-15 Data Parameter Description . . . . . . . . . . . . .04-160-18 Engine Test InstructionsCylinder Misfire Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22 Engine Test InstructionsCompression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 Engine Test Instructions Cylinder Cutout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-25 Engine Test Instructions - Excavator Torque Curve Change Test . . . . . . . . . . . .04-160-26 Engine Test Instructions - Tractor Torque Curve Change Test . . . . . . . . . . . . . . . . . .04-160-27 Reprogramming Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-28
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Downloading Payload File For DST. . . . . . . .04-160-29 Reprogramming Engine Control Unit (ECU) With DST . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-34 Downloading Payload File For SERVICE ADVISOR . . . . . . . . . . . . . . . . . . . . . . . .04-160-39 Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR . . . . . .04-160-47 Diagnostic Trouble Codes (DTCs) . . . . . . . . .04-160-51 Listing of Diagnostic Trouble Codes (DTCs) on ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-52 Diagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-56 Intermittent Fault Diagnostics . . . . . . . . . . . .04-160-57 T1 - Multi-state Throttle Input High . . . . . . . .04-160-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-60 T1 - Multi-State Throttle Input High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-60 T2 - Multi-state Throttle Input Low. . . . . . . . .04-160-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-64 T2 - Multi-State Throttle Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-64 T3 - Analog Throttle (A) Input High . . . . . . . .04-160-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-67 T3 - Analog Throttle (A) Input High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-67 T4 - Analog Throttle (A) Input Low . . . . . . . .04-160-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-71 T4 - Analog Throttle (A) Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-71 T5 - Analog Throttle (B) Input High . . . . . . . .04-160-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-75 T5 - Analog Throttle (B) Input High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-75 T6 - Analog Throttle (B) Input Low . . . . . . . .04-160-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-79 T6 - Analog Throttle (B) Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-79 T7 - CAN Throttle Invalid. . . . . . . . . . . . . . . .04-160-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-83 T7 - CAN Throttle Invalid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-83 T11 - Excavator Throttle Reference Voltage High . . . . . . . . . . . . . . . . . . . . . . .04-160-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-87 T11 - Excavator Throttle Reference Voltage High Diagnostic Procedure . . . . . .04-160-87 T12 - Excavator Throttle Reference Voltage Low. . . . . . . . . . . . . . . . . . . . . . . .04-160-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91 T12 - Excavator Throttle Reference Voltage Low Diagnostic Procedure . . . . . .04-160-91 T13 - Excavator Throttle Ground Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-95 CTM170 (14MAY03)
T13 - Excavator Throttle Ground Voltage High Diagnostic Procedure . . . . . . . . . . . .04-160-95 T14 - Excavator Throttle Ground Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-99 T14 - Excavator Throttle Ground Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-99 T15 - Excavator Throttle Input Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102 T15 - Excavator Throttle Input Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-103 T16 - Excavator Throttle Input Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-107 T16 - Excavator Throttle Input Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-107 T17 - Analog Throttle (C) Input High . . . . . .04-160-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-111 T17 - Analog Throttle (C) Input High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-111 T18 - Analog Throttle (C) Input Low . . . . . .04-160-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-115 T18 - Analog Throttle (C) Input Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-115 000028.03 Throttle Voltage High . . . . . .04-160-118 000028.04 Throttle Voltage Low . . . . . . .04-160-118 000029.03 Throttle Voltage High . . . . . .04-160-119 000029.04 Throttle Voltage Low . . . . . . .04-160-119 000084.02 Vehicle Speed Mismatch. . . .04-160-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-121 000084.02 Vehicle Speed Mismatch Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-121 000091.03 Throttle Voltage High . . . . . .04-160-124 000091.04 Throttle Voltage Low . . . . . . .04-160-125 000091.09 Throttle Invalid . . . . . . . . . . .04-160-125 000094.01 Fuel Supply Pressure Extremely Low . . . . . . . . . . . . . . . . . . . . .04-160-126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-127 000094.01 Fuel Supply Pressure Extremely Low Diagnostic Procedure. . . .04-160-127 000094.03 Fuel Supply Pressure Input Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-129 000094.03 Fuel Supply Pressure Input Voltage High Diagnostic Procedure . . . . .04-160-129 000094.04 Fuel Supply Pressure Input Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-133 000094.04 Fuel Supply Pressure Input Voltage Low Diagnostic Procedure . . . . .04-160-133
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000094.18 Fuel Supply Pressure Moderately Low . . . . . . . . . . . . . . . . . . . .04-160-136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-137 000094.18 Fuel Supply Pressure Moderately Low Diagnostic Procedure . . .04-160-137 000097.00 Water in Fuel Continuously Detected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-139 000097.00 Water in Fuel Continuously Detected Diagnostic Procedure . . . . . . . .04-160-139 000097.16 Water in Fuel Detected . . . . .04-160-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-143 000097.16 Water in Fuel Detected Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-143 000100.01 Engine Oil Pressure Extremely Low . . . . . . . . . . . . . . . . . . . . .04-160-146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-148 000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure . . . . . . . . . . . .04-160-148 000100.03 Engine Oil Pressure Input Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-151 000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure . . . . .04-160-151 000100.04 Engine Oil Pressure Input Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-156 000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure . . . . .04-160-156 000100.18 Engine Oil Pressure Moderately Low . . . . . . . . . . . . . . . . . . . .04-160-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-161 000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure . . .04-160-161 000105.00 Manifold Air Temperature Extremely High . . . . . . . . . . . . . . . . . . . .04-160-162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-163 000105.00 Manifold Air Temperature Extremely High Diagnostic Procedure . . .04-160-163 000105.03 Manifold Air Temperature Input Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-165 000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure . . . . .04-160-165 000105.04 Manifold Air Temperature Input Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-169 000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure . . . . .04-160-169 000105.16 Manifold Air Temperature Moderately High. . . . . . . . . . . . . . . . . . . .04-160-172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-173 CTM170 (14MAY03)
000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-173 000107.00 Air Filter Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-175 000107.00 Air Filter Differential Pressure Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-175 000110.00 Engine Coolant Temperature Extremely High . . . . . . . . . . . . . . . . . . . .04-160-178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-179 000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure . . .04-160-179 000110.03 Engine Coolant Temperature Input Voltage High . . . . . . .04-160-180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-181 000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-181 000110.04 Engine Coolant Temperature Input Voltage Low . . . . . . . .04-160-184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-185 000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-185 000110.15 Engine Coolant Temperature High Least Severe . . . . . . .04-160-188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-189 000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-189 000110.16 Engine Coolant Temperature Moderately High. . . . . . . . . . . . . . . . . . . .04-160-190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-191 000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-191 000111.01 Engine Coolant Level Low. . .04-160-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-193 000111.01 Engine Coolant Level Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-193 000158.17 ECU Power Down Error . . . .04-160-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-197 000158.17 ECU Power Down Error Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-197 000174.00 Fuel Temperature High Most Severe . . . . . . . . . . . . . . . . . . . . . .04-160-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-202 000174.00 Fuel Temperature High Most Severe Diagnostic Procedure. . . . . . . . . .04-160-202
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04
000174.15 Fuel Temperature High Least Severe . . . . . . . . . . . . . . . . . . . . . .04-160-204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-205 000174.15 Fuel Temperature High Least Severe Diagnostic Procedure. . . . . . . . . .04-160-205 000174.16 Fuel Temperature High Moderately Severe. . . . . . . . . . . . . . . . . .04-160-208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-209 000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-209 000174.31 Fuel Temperature Sensor Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-213 000174.31 Fuel Temperature Sensor Faulty Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-213 000189.00 Engine Speed Derate . . . . . .04-160-214 000189.31 Engine Speed Derate . . . . . .04-160-215 000190.00 Engine Overspeed Extreme . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-216 000190.16 Engine Overspeed Moderate . . . . . . . . . . . . . . . . . . . . . . . . .04-160-217 000620.03 Sensor Supply Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-219 000620.03 Sensor Supply Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-219 000620.04 Sensor Supply Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-223 000620.04 Sensor Supply Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-223 000627.04 ECU Unswitched Power Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-227 000627.04 ECU Unswitched Power Missing Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-227 000629.13 ECU Error . . . . . . . . . . . . . . .04-160-230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-231 000629.13 ECU Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-231 000629.19 ECU to Pump Communication Error . . . . . . . . . . . . . . . .04-160-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-233 000629.19 ECU to Pump Communication Error Diagnostic Procedure . . . . . . . . . . .04-160-233 000632.02 Fuel Shutoff Error . . . . . . . . . . .04-160-236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-237 000632.02 Fuel Shutoff Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-237 000632.05 Fuel Shutoff Non-Functional . . . . . . . . . . . . . . . . . . . .04-160-240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-241 CTM170 (14MAY03)
000632.05 Fuel Shutoff Non-Functional Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-241 000636.02 Pump Position Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-245 000636.02 Pump Position Input Noise Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-245 000636.08 Pump Position Input Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-249 000636.08 Pump Position Input Missing Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-249 000636.10 Pump Position Input Pattern Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-253 000636.10 Pump Position Input Pattern Error Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-253 000637.02 Crankshaft Position Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-258 000637.02 Crankshaft Position Input Noise Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-258 000637.08 Crankshaft Position Input Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-262 000637.08 Crankshaft Position Input Missing Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-262 000637.10 Crankshaft Position Input Pattern Error . . . . . . . . . . . . . . . . . . . . . .04-160-266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-268 000637.10 Crankshaft Position Input Pattern Error Diagnostic Procedure . . . . .04-160-268 000729.03 Inlet Air Heater Signal High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-273 000729.03 Inlet Air Heater Signal Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-273 000729.05 Inlet Air Heater Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-277 000729.05 Inlet Air Heater Signal Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-277 000810.02 Calculated Vehicle Speed Input Signal Noise . . . . . . . . . . . . . . . . . . . . . .04-160-280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-281 000810.02 Calculated Vehicle Speed Input Signal Noise Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-281 000898.09 Vehicle Speed Invalid/Missing . . . . . . . . . . . . . . . . . . . . .04-160-284 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-285
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000898.09 Vehicle Speed Invalid/Missing Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-285 000970.02 Auxiliary Engine Shutdown Switch Signal Invalid . . . . . . . . . . . . . . . .04-160-288 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-289 000970.02 Auxiliary Engine Shutdown Switch Signal Invalid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-289 000970.31 Auxiliary Engine Shutdown Switch Active . . . . . . . . . . . . . . . . . . . . . .04-160-292 000971.31 External Engine Derate Switch Active . . . . . . . . . . . . . . . . . . . . . .04-160-293 001069.02 Tire Size Error. . . . . . . . . . . .04-160-294 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-295 001069.02 Tire Size Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-295 001076.02 Pump Detected Defect . . . . .04-160-296 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-298 001076.02 Pump Detected Defect Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-298 001077.07 Attempting to Fuel Without Command . . . . . . . . . . . . . . . . . . . . . . . .04-160-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-301 001077.07 Attempting to Fuel Without Command Diagnostic Procedure . . . . . . .04-160-301 001077.11 Pump Supply Voltage Out Of Range . . . . . . . . . . . . . . . . . . . . . . . . .04-160-302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-303 001077.11 Pump Supply Voltage Out Of Range Diagnostic Procedure . . . . . . . . . .04-160-303 001077.12 Pump Self-Test Error . . . . . .04-160-306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-307 001077.12 Pump Self-Test Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-307 001077.19 Pump Detected Communication Error . . . . . . . . . . . . . . . .04-160-308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-309 001077.19 Pump Detected Communication Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-309 001077.31 Pump Initiated Engine Protection . . . . . . . . . . . . . . . . . . . . . . . .04-160-312 001078.07 ECU/Pump Timing Moderately Out of Sync . . . . . . . . . . . . . .04-160-314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-316 001078.07 ECU/Pump Timing Moderately Out of Sync Diagnostic Procedure . . . . . .04-160-316 001078.11 ECU/Pump Engine Speed Out of Sync . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-319 001078.11 ECU/Pump Engine Speed Out of Sync Diagnostic Procedure . . . . . . . . .04-160-319 CTM170 (14MAY03)
001078.31 ECU/Pump Timing Extremely Out of Sync . . . . . . . . . . . . . . .04-160-322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-324 001078.31 ECU/Pump Timing Extremely Out of Sync Diagnostic Procedure . . . . . .04-160-324 001079.03 Sensor Supply 1 Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-329 001079.03 Sensor Supply 1 Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-329 001079.04 Sensor Supply 1 Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-333 001079.04 Sensor Supply 1 Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-333 001080.03 Sensor Supply 2 Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-337 001080.03 Sensor Supply 2 Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-337 001080.04 Sensor Supply 2 Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-341 001080.04 Sensor Supply 2 Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-341 001109.31 Engine Protection Shutdown Warning . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-344 001110.31 Engine Protection Shutdown . . . . . . . . . . . . . . . . . . . . . . . .04-160-345 001485.02 Pump Power Relay Fault . . .04-160-346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-347 001485.02 Pump Power Relay Fault Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-347 001569.31 Fuel Derate . . . . . . . . . . . . . .04-160-352 002000.13 Security Violation . . . . . . . . .04-160-354
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Group 150
Observable Diagnostics and Tests

About This Group of the Manual
This section of the manual contains necessary information for observable diagnostics and fuel-related test procedures. Use this information in conjunction with the 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Group 150 is divided into two areas: diagnosing malfunctions and test procedures. The diagnosing malfunctions area is further divided into the following headings, containing the following observable symptoms: F2 - Excessive Fuel Consumption F3 - Fuel In Oil F4 - Fuel Supply System Check - Tier 2 F5 - Fuel Injection 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 Check Procedures for diagnosing some of the above symptoms are formatted such that a test or repair is recommended, then based on the results another test or repair is recommended. Other symptoms are formatted in a symptom - problem - solution format. In these symptoms, the problems are arranged in the most likely or easiest to check first. Symptoms arranged in both formats refer to testing procedures in the second part of this section. The second part of this section manual contains the following testing procedures: Fuel System Testing Procedures: Check Fuel Supply Quality - Tier 1 Check Fuel Supply Quality - Tier 2 Test for Fuel Drain Back Test for Air in Fuel - Tier 1 Test for Air in Fuel - Tier 2 Check Fuel Supply Pressure Bleed the Fuel System Test For Cylinder Misfire (Engine Running)
NOTE: Follow the diagnostic procedure of an active or stored DTC before pursuing any observable diagnostic procedure. NOTE: To diagnose observable symptoms on engines with a mechanical fuel system, see 4.5 L & 6.8 L Diesel Engines Mechanical Fuel Systems Manual (CTM 207).
(E) Diagnosing General Engine Malfunctions: E1 - Engine Cranks/Wont 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 E10 - Analog Throttle (B) Does Not Respond (F) Diagnosing Fuel System Malfunctions: F1 - Fuel Supply System Check - Tier 1
04 150 1
DPSG,RG40854,512 1917OCT021/1
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E1 - Engine Cranks/Wont Start
RG41221,0000118 1917OCT021/1
E1 - Engine Cranks/Wont Start Diagnostic Procedure
NOTE: This procedure applies to engines with John Deere Engine Control Units (ECUs). This procedure should be used if engine cranking speed is OK, but engine will not start, or only starts after prolonged cranking. If engine will not crank, determine problem in the starting/charging system.
04 150 2
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1 E1 - Preliminary Check
Before using this diagnostic procedure, ensure that: 1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY - TIER 1 or CHECK FUEL SUPPLY QUALITY - TIER 2 later in this Group. 2. Ensure that engine cranking speed is OK. See TEST ENGINE CRANKING SPEED in 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. See A1 - INTAKE AIR HEATER CHECK later in this Group.
No problems found: GO TO 2 Problem found: Repair and retest
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2 Active DTC Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic 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 active DTCs first. If any of the DTCs have a SPN of 636 or 637 go to those first. Cant communicate with ECU: See diagnostic chart D1 ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR later in this Group.
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3 Pump Position and Crankshaft Position Indicators Test 1. Start cranking engine 2. While cranking observe pump position noise, crank noise, and crank status. See Pump Position/Crankshaft Position parameters. For an explanation of these parameters, see DATA PARAMETER DESCRIPTION in Group 160. No pump position or crankshaft position noise and crank status reaches 15: GO TO 5 Pump position or crank noise or crank status does not reach 15: GO TO 4
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4 Vehicle Wiring Inspection Check
Inspect the vehicle for possible failures that can cause either of the following: 1. Bad electrical connections 2. Damaged engine speed sensors 3. EMI from improperly install radio equipment, or other electronic devices 4. Once problem is found, repair and retest. 04 150 3
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5 Air Heater Check
Verify that the air heater is functioning properly. See A1 - INTAKE AIR HEATER CHECK later in this Group.
Air heater functions correctly: GO TO 6 Air heater does not functions correctly: Repair air heater and retest.
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6 Fuel Present at Injection Nozzles Check Perform following procedure to check for fuel at injection nozzle: Consistent squirts of fuel observed: GO TO 8 Dont observe consistent squirts of fuel: GO TO 7
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes and nozzles which could inject fluids under high pressure. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere and Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 1. Using two open-end wrenches, loosen fuel line connection at one of the injection nozzles. 2. Crank engine while monitoring loosened connection for consistent squirts of fuel. 3. Retighten connection at nozzle to specification. 04 150 4 Specification Fuel Injection Nozzle Delivery Lines Torque .................................................................................................... 27 Nm (20 lb-ft)
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7 Fuel Supply System Check
Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 - FUEL SUPPLY SYSTEM CHECK - TIER 2 later in this Group. Repair problem and retest
Fuel supply system is OK: GO TO 8 Fuel supply system problem found: Repair fuel supply system problem and retest.
1/1
8 Intake and Exhaust Restrictions Test
Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
All components operating correctly: GO TO 9 Restrictions are found: Repair faulty component and retest.
1/1
CTM170 (14MAY03)
04-150-4

051403
PN=138

9 Compression Test 1. Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in Group 160 of this manual. 2. Make note of the results. All cylinders scored within 10% of each other: GO TO 10 One or more cylinders scored 10% or lower than the rest: GO TO 11
1/1
10 Fuel Injection Nozzles Check
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group.
Injection nozzles test good: 04 Faulty injection pump. 150 Have injection pump 5 repaired by an authorized diesel repair station or replace pump. Faulty injection nozzle(s) found: Repair or replace injection nozzles. See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
1/1
11 Piston Ring Check
NOTE: DO NOT use too much oil. DO NOT get oil on the valves.
1. Apply oil to the ring area of the piston through injection nozzle bore. See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 of this manual. 2. Retest the compression pressure.
Compression pressure is within specification: GO TO 14 Compression pressure is not within specification: GO TO 12
1/1
CTM170 (14MAY03)
04-150-5

051403
PN=139

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 within specification: GO TO 13 Valve lash on one or more valves is out of specification: Adjust valve lash and retest.
1/1
13 Valve Lift Check 04 150 6
Check valve lift. See MEASURE VALVE LIFT in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
Lift on all valves within specification: GO TO 14 Lift on one or more valves is out of specification: Reset clearance to specification after measuring lift. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
1/1
14 Pistons, Rings, Cylinder Liners Check
At this point, the most likely cause of the low engine compression pressure is one of the following failures in the piston, 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 with pistons, rings, and/or liners or valve guides: Repair problems as necessary.
1/1
CTM170 (14MAY03)
04-150-6

051403
PN=140
E2 - Engine Misfires/Runs Irregularly
RG41221,0000119 1917OCT021/1
E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
1/1
Before using this diagnostic procedure, make the following checks that could cause or be mistaken as miss/rough running: 1. Check for intake manifold air leaks 2. Check for mechanical problems 3. Check for transmission problems 4. Check for engine Accessories, such as A/C, cycling on and off 5. Check for electromagnetic interference (EMI) from improperly installed radios etc.
04 150 7
1/1
2 Active DTC Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic 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 of the DTCs have a SPN of 636 or 637, diagnose those first
1/1
3 Engine Performance Test
1. Ignition ON, engine idling. 2. Observe engine performance.
Not running rough: GO TO 4 Running rough: GO TO 6

1/1
CTM170 (14MAY03)
04-150-7

051403
PN=141

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, verify complaint and try to reproduce conditions of miss/rough running complaint.
1/1
5 Active DTC Test 04 150 8
1. Ignition ON, engine idling 2. Read DTCs
No active DTCs: GO TO 6 Active DTCs present: Diagnose DTCs. If any of the DTCs have a SPN of 636 or 637, diagnose those first.
1/1
6 Head Gasket Failure Test
Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No sign of head gasket failure: GO TO 7 Signs of head gasket failure found: Replace head gasket and retest.
1/1
7 Cylinder Misfire Check
Perform the Cylinder Misfire Test. For instructions, see ENGINE TEST INSTRUCTIONS - CYLINDER MISFIRE TEST in Section 04, Group 160 earlier in this manual.
Single cylinder misfires: GO TO 8 Random or all cylinder misfire: See F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 - FUEL SUPPLY SYSTEM CHECK - TIER 2 in this Group.
1/1
CTM170 (14MAY03)
04-150-8

051403
PN=142

8 Compression Pressure Check Check the compression pressure. See ENGINE TEST INSTRUCTIONS COMPRESSION TEST in Section 04, Group 160 later in this manual. Compression pressure within specification: GO TO 9 Compression pressure is not within specification: GO TO 12
1/1
Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 - FUEL SUPPLY SYSTEM CHECK - TIER 2 in this Group.
Fuel supply system OK: GO TO 10
04 150 Fuel supply system 9 problem found: Repair fuel supply system problem and retest.
1/1
10 Fuel Delivery Line Check
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 the injection pump 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 the other side. 4. If air does not flow freely, there are restriction in the fuel line.
Lines are not restricted: GO TO 11 Lines are restricted: Repair or replace lines and retest.
1/1
CTM170 (14MAY03)
04-150-9

051403
PN=143

11 Fuel Injection Nozzle Check Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group. Injection nozzles test OK: Faulty injection pump. Have injection pump repaired by an authorized diesel repair station or replace pump. Faulty injection nozzle(s) found: Repair or replace injection nozzle(s). See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
04 150 10
1/1
1/1
13 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 (CTM 104).
Valve clearance within specification: GO TO 14 Valve clearance out of specification: Adjust valves to specification and retest.
1/1
CTM170 (14MAY03)
04-150-10

051403
PN=144

14 Valve Lift Test Check valve lift. See MEASURE VALVE LIFT in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). Lift on all valves within specification: GO TO 15 Lift on one or more valves is out of specification: Reset clearance to specification after measuring lift. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
04 150 11
1/1
15 Piston, Rings, Cylinder Liner Check
At this point, the most likely cause of the low engine compression pressure is one of the following failures in the piston, 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 with pistons, rings, and/or liners or valve guides: Repair problems as necessary.
1/1
CTM170 (14MAY03)
04-150-11

051403
PN=145
E3 - Engine Does Not Develop Full Power
RG41221,000011A 1918OCT021/1
E3 - Engine Does Not Develop Full Power Diagnostic Procedure
1/1
04 150 12
Before using the diagnostic procedure, ensure that: 1. There are no problems with transmission 2. There are no engine mechanical problems 3. There is not an excessive load on the engine 4. There is no unbalanced ballast 5. The air and fuel filters are not restricted or plugged 6. Fuel quality is OK
1/1
2 Active DTC Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORin Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Ignition ON, engine OFF 5. Read DTCs using DST or SERVICE ADVISOR.
No DTCs present: GO TO 3 DTCs present: Go to appropriate diagnostic procedure.
NOTE: Look for DTCs that indicate a fuel derate is or has been in effect.
1/1
CTM170 (14MAY03)
04-150-12

051403
PN=146

3 Exhaust Emission Test 1. Operate engine at full load rated speed. 2. Under these conditions, determine type of exhaust emitted. Small amount or no exhaust smoke: GO TO 4 Heavy white exhaust smoke: See E4 - ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE diagnostic procedure later in this Group. Heavy black or gray exhaust smoke: See E5 - ENGINE EMITS EXCESSIVE BLACK or GRAY EXHAUST SMOKE diagnostic procedure later in this 04 Group. 150 13
1/1
4 Torque Curve Selection Check
The ECU on 4.5/6.8L engines has the ability to operate on multiple torque curves. To check that the engine is operating on the correct torque curve under the operating conditions where there is a low power complaint: 1. Recreate the conditions of the low power complaint. 2. Read the Torque Curve Parameter
Correct torque curve number displayed for corresponding operating conditions: GO TO 5 Incorrect torque curve number displayed for corresponding operating conditions: Refer to machine manual to determine components that if faulty could prevent the correct torque curve from being selected OR Faulty torque curve select wiring
NOTE: For explanation of this parameter, see DATA PARAMETER DESCRIPTION in Section 04, Group 160 later in this manual.
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
5 Governor Droop Mode Selection Check
1. Operate engine and attempt to recreate the low power condition. 2. Read the Desired Speed Governor parameter and the Maximum Speed Governor parameter.
Correct governor selection: GO TO 6 Incorrect governor selection: Refer to machine manual to determine components that if faulty could prevent the correct governor from being selected OR Faulty governor select wiring
1/1
3. Compare governor selection to the appropriate governor mode chart. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM170 (14MAY03)
04-150-13

051403
PN=147

6 Throttle Test 1. Operate engine at full load rated speed. 2. At these operating conditions, read the Throttle Position data parameter. 97% or above: GO TO 7 Below 97%: Refer to machine manual and perform the throttle calibration procedure; then retest.
1/1
04 150 14
7 Turbocharger Boost Pressure Check
Check the Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE (TURBO BOOST) in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Intake manifold pressure within range or above, compared to boost specification: GO TO 8 Intake manifold pressure below range compared to boost specification: GO TO 9
1/1
Check the fuel supply system by referring to chart F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 - FUEL SUPPLY SYSTEM CHECK - TIER 2 in this Group.
Fuel supply system is OK: Engine appears to be delivering full power. Check for vehicle problems that could cause an excessive load on the engine. Fuel supply system problem found: Repair fuel supply system problem and retest.
1/1
9 Cylinder Misfire Check
Perform the Cylinder Misfire Test. For instructions, see ENGINE TEST INSTRUCTIONS - CYLINDER MISFIRE TEST in Section 04, Group 160 earlier in this manual.
All cylinders within specification: GO TO 10 Random or all cylinder misfire: See E2 - ENGINE MISFIRES/RUNS IRREGULARLY earlier in this Group.
1/1
CTM170 (14MAY03)
04-150-14

051403
PN=148

10 Compression and Misfire Test Check the compression pressure. See ENGINE TEST INSTRUCTIONS COMPRESSION TEST in Section 04, Group 160 later in this manual. Compression pressure within specification: GO TO 11 Compression pressure is not within specification: GO TO 14
1/1
11 Checking Potential Causes of Low Boost 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 SEVEN-STEP INSPECTION in Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
None of the above problems found: GO TO 12 Problem found: Repair problem and retest.
04 150 15
1/1
Check the fuel supply system by referring to chart F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 - FUEL SUPPLY SYSTEM CHECK - TIER 2 in this Group.
Fuel supply system is OK: GO TO 13 Fuel supply system problem found: Repair fuel supply system problem and retest.
1/1
13 Fuel Injection Nozzles Test
Test fuel injection nozzles. See TEST FUEL INJECTION NOZZLES in Group 090 of this manual.
Injection nozzles test good: Faulty injection pump OR Faulty ECU Faulty injection nozzle(s) found: Repair or replace faulty injection nozzles.
1/1
CTM170 (14MAY03)
04-150-15

051403
PN=149

1/1
15 Valve Lash Check 04 150 16
1. Ensure there are no engine mechanical problems and that there isnt something drawing excessive engine power 2. Ensure that valve lash is correctly adjusted. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
16 Valve Lift Test
1/1
CTM170 (14MAY03)
04-150-16

051403
PN=150

17 Piston, Rings, Cylinder Liner Check At this point, the most likely cause of the low engine compression pressure is one of the following failures in the piston, 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 with pistons, rings, and/or liners or valve guides: Repair problems as necessary.
1/1
04 150 17
CTM170 (14MAY03)
04-150-17

051403
PN=151
E4 - Engine Emits Excessive White Exhaust Smoke
RG41221,000011B 1918OCT021/1
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 smoke causes a burning sensation to the eyes. If engine emits a less heavy, bluish exhaust smoke see L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
04 150 18
1/1
Before using this diagnostic procedure, ensure that: 1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY or CHECK FUEL SUPPLY QUALITY - TIER 2 later in this Group. 2. Ensure engine coolant temperature is not extremely low.

1/1
2 Head Gasket Failure Test
Check for a failed head gasket. See CHECK FOR HEAD GASKET FAILURES in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No signs of head gasket failure: GO TO 3 Signs of head gasket failure are found: See HEAD GASKET INSPECTION AND REPAIR SEQUENCE in Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
CTM170 (14MAY03)
04-150-18

051403
PN=152

3 Compression Pressure Test Check compression pressure. See ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in Section 04, Group 160 later in this manual. All cylinders score within 10% of each other: GO TO 4 One or more cylinders scored 10% or lower than the rest: Test low cylinder(s) to verify low compression. See TEST ENGINE COMPRESSION PRESSURE in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Investigate problems related to low compression on low 04 cylinder(s). 150 19
1/1
4 Fuel Supply Pressure Check
Check fuel pressure. See CHECK FUEL SUPPLY PRESSURE later in this Group.
Fuel pressure within specification: GO TO 5 Fuel pressure below specification: Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 FUEL SUPPLY SYSTEM CHECK - TIER 2 later in this Group.
1/1
5 Fuel Injection Nozzle Check
Injection nozzles test OK: Faulty injection pump. Faulty injection nozzle(s) found: Repair or replace injection nozzle(s). See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
1/1
CTM170 (14MAY03)
04-150-19

051403
PN=153

6 Piston Ring Check
1/1
7 Valve Lash Check 04 150 20
Check Valve Lash. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 of 4.5 L and 6.8 L Diesel Engines Repair Manual (CTM 104).
1/1
8 Valve Lift Check
1/1
CTM170 (14MAY03)
04-150-20

051403
PN=154

9 Piston, Rings, Cylinder Liners Check At this point, the most likely cause of the low engine compression pressure is one of the following failures in the piston, 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 with pistons, rings, and/or liners or valve guides: Repair problems as necessary.
1/1
04 150 21
CTM170 (14MAY03)
04-150-21

051403
PN=155
E5 - Engine Emits Excessive Black Or Gray Smoke
RG41221,000011C 1918OCT021/1
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 less heavy, bluish exhaust smoke see L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Manual (CTM 104).
04 150 22
1/1
Before using this diagnostic procedure, ensure that: 1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY or CHECK FUEL SUPPLY QUALITY - TIER 2 later in this Group. 2. Ensure engine is not excessively loaded 3. Ensure air filter is not restricted or plugged
No problem found: GO TO 2 Problems 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 the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual.
Correct torque curve number displayed: GO TO 3 Incorrect torque curve number displayed: Adjust the torque curve using the diagnostic software. See ENGINE TEST INSTRUCTIONS EXCAVATOR TORQUE CURVE CHANGE TEST in Section 04, Group 160 later in this manual.
2. Using the ECU diagnostic software, read the Torque Curve Parameter with the engine running. 3. Compare the Torque Curve Parameter to the appropriate torque chart. See EXCAVATORS - TORQUE CURVE SELECTION in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-150-22

051403
PN=156

3 Air Intake and Exhaust Test Check for intake and exhaust restrictions and air leaks. See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS and TEST FOR INTAKE AIR LEAKS and CHECK FOR EXHAUST AIR LEAKS in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). No restrictions or leaks found: GO TO 4 Restrictions or leaks found: Repair or replace components as necessary.
1/1
4 Turbocharger Check
Check for turbocharger failure. See TURBOCHARGER SEVEN-STEP INSPECTION in Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No turbocharger failure found: GO TO 5 Turbocharger failure found: Follow appropriate repair procedure in Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
04 150 23
1/1
5 Valve Lash Check
Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
Valve lash on all valves within specification: GO TO 6 Valve lash on one or more valves out of specification: Adjust valve lash and retest
1/1
6 Fuel Return Line Check
Check for restricted fuel return line and fittings.
No restriction found: GO TO 7 Restriction found: Repair and retest

1/1
CTM170 (14MAY03)
04-150-23

051403
PN=157

7 Fuel Injection Nozzle Check Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group. Injection nozzles test OK: Faulty injection pump. Faulty injection nozzle(s) found: Repair or replace injection nozzle(s). See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
1/1
04 150 24
CTM170 (14MAY03)
04-150-24

051403
PN=158
E6 - Engine Will Not Crank
Symptom
Problem
Solution
Engine Will Not Crank
Weak battery Corroded or loose battery connections Defective main switch or start safety switch Starter solenoid defective Starter defective Start circuit defective Engine is seized up
Replace battery. Clean battery terminals and connections. Repair switch as required.
Replace solenoid. Replace starter. Check wiring, fuses, and relays. Check by rotating engine by hand.
04 150 25
RG41221,000011D 1909MAY011/1
E7 - Engine Idles Poorly
Symptom
Problem
Solution
E7 - Engine Idles Poorly
Poor fuel quality
Drain fuel and replace with quality fuel of the proper grade. Check hose and pipe connections for tightness; repair as required. See AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS in Section 6, Group 200 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See E2 - ENGINE MISFIRES/RUNS IRREGULARLY earlier in this Group.
Air leak on suction side of air intake system
Electronic control system problem or basic engine problem
RG41221,000011E 1909MAY011/1
CTM170 (14MAY03)
04-150-25

051403
PN=159
E8 - Abnormal Engine Noise
Symptom
Problem
Solution
E8 - Abnormal Engine Noise
Worn main or connecting rod bearings
04 150 26
Determine bearing clearance. See CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS in Section 6, Group 200 or CRANKSHAFT , MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS in Section 6, Group 200 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Check crankshaft end play. See CHECK CRANKSHAFT END PLAY in Section 2, Group 040 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Check bearing clearance; replace bearings and bearing cap screws as required. See CRANKSHAFT , MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS in Section 6, Group 200 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Inspect piston pins and bushings. See INSPECT PISTON PINS AND BUSHINGS in Section 2, Group 030 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Inspect pistons. See PRELIMINARY LINER, PISTON, AND ROD CHECKS in Section 2, Group 030 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Excessive crankshaft end play
Loose main bearing caps
Worn connecting rod bushings and piston pins
Scored pistons
RG41221,000011F 1909MAY011/2
CTM170 (14MAY03)
04-150-26

051403
PN=160

Symptom Problem
Solution
Worn timing gears or excess back lash
Check timing gear back lash. See MEASURE TIMING GEAR BACKLASH in Section 2, Group 050 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Check and adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section 2, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Inspect camshaft. See VISUALLY INSPECT CAMSHAFT in Section 2, Group 050 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Inspect rocker arm shafts. See DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY in Section 2, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See L2 - ENGINE OIL PRESSURE LOW in Section 4, Group 150 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See TURBOCHARGER SEVEN-STEP INSPECTION in Section 2, Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Excessive valve clearance
Worn camshaft
04 150 27
Worn rocker arm shaft(s)
Insufficient engine lubrication
Turbocharger noise
RG41221,000011F 1909MAY012/2
CTM170 (14MAY03)
04-150-27

051403
PN=161
E10 - Analog Throttle (B) Does Not Respond
NOTE: This procedure is necessary for OEM applications only. For other applications, check for Diagnostic Trouble Codes (DTCs) and follow the corresponding procedure.
Symptom Problem Solution
E10 - Analog Throttle (B) Does Not Respond
Active DTC Check
Read DTCs on DST or SERVICE ADVISOR. Go to the diagnostic procedure for the corresponding DTC. See T6 - ANALOG THROTTLE (B) INPUT LOW DIAGNOSTIC PROCEDURE in Group 160 of this manual.
04 150 28
Analog Throttle (B) Check
RG41221,000005B 1918OCT021/1
CTM170 (14MAY03)
04-150-28

051403
PN=162
04 150 29
CTM170 (14MAY03)
04-150-29

051403
PN=163
F1 - Fuel Supply System Check - Tier 1
04 150 30
APrimary Filter BFinal Filter Inlet CTransfer Pump
DFinal Filter EFinal Filter Outlet
FTransfer Pump Connector GFuel Line Between Final Filter and Injection Pump
HInjection Pump
The callouts in this illustration are referred to throughout F1-FUEL SUPPLY CHECK - TIER 1 diagnostic procedure to clearly identify various locations on the fuel system. For fuel system theory of
operation information, see FUEL SYSTEM OPERATION - TIER 1 in Section 03, Group 130 earlier in this manual.
RG41221,0000120 1909MAY011/2
CTM170 (14MAY03)
04-150-30

051403
RG10776
UN19JUN00
PN=164
04 150 31
1921JUN00
Electronic Transfer Pump The ECU maintains a constant fuel pressure for a given speed by controlling the duty cycle of the Pulse Width Modulated (PWM) signal between the
ECU and transfer pump. When fuel pressure increases, the ECU decreases the duty cycle. When fuel pressure decreases, the ECU increases the duty cycle. Transfer pump duty cycle and fuel pressure can be monitored on the ECU diagnostic software.
RG41221,0000120 1909MAY012/2
CTM170 (14MAY03)
04-150-31

051403
PN=165
RG10752
RG41221,0000203 1918OCT021/1
F1 - Fuel Supply System Check - Tier 1 Diagnostic Procedure
1/1
1 Preliminary Check 04 150 32
NOTE: For wiring and theory of operation information, see F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 supporting information
Before using this diagnostic procedure, check the following: 1. If fuel system has been recently opened (filter changed, line removed etc.) perform fuel system bleed procedure. See BLEED THE FUEL SYSTEM later in this Group and retest. 2. Check for air leaks from loose or damaged fuel lines and fittings. 3. Check for ruptured fuel lines. 4. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY TIER 1 later in this Group. 5. Check for air in the fuel system. See TEST FOR AIR IN FUEL - TIER 1 later in this Group.
No problem found: GO TO 2 Problem found: Repair and retest
1/1
2 Engine Performance Check
1. Ignition ON, engine running 2. Observe engine performance.
Engine runs: GO TO 4 Engine cranks but wont start: GO TO 3

1/1
CTM170 (14MAY03)
04-150-32

051403
PN=166

3 Fuel Pressure Check During Prime Cycle
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORin Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Read the fuel pressure parameter using DST or SERVICE ADVISOR.
Consistently above 150 kPa (1.50 bar) (22 psi): GO TO 8 Consistently below 150 kPa (1.50 bar) (22 psi): GO TO 5
NOTE: The electronic transfer pump runs for 40 seconds at key ON to prime the fuel system. Fuel pressure must be read within the first 40 seconds after key ON.
04 150 33
1/1
4 Fuel Pressure Check (Running)
1. Ignition ON, engine running 2. Read the fuel pressure parameter using DST or SERVICE ADVISOR.
Between 70-90 kPa (0.7-0.9 bar) (10.1-13.0 psi): GO TO 8 Consistently below 70 kPa (0.7 bar) (10.1 psi): GO TO 5 Consistently above 90 kPa (0.9 bar) (13.0 psi): GO TO 14
1/1
5 Restricted Fuel Supply Line Check
Remove the fuel supply lines between the fuel tank and the primary filter (A) and the line between the primary filter and the final filter (D) and determine if there are any restrictions.
No restrictions found: GO TO 6 Restrictions found: Repair or replace components as needed.

1/1
6 Primary Fuel Filter Check
Check for damaged, dirty, or plugged primary fuel filter.
Primary fuel filter OK: GO TO 7 Primary fuel filter dirty or damaged: Clean or replace primary fuel filter and retest.
1/1
CTM170 (14MAY03)
04-150-33

051403
PN=167

7 Final Fuel Filter Check
Check for damaged, dirty, or plugged final fuel filter.
Final fuel filter OK: GO TO 12 Final fuel filter dirty or damaged: Replace final fuel filter and retest.
1/1
04 150 34
8 Restricted Injection Pump Fuel Supply Line Check
Remove the fuel supply line (G) between the final filter and the fuel injection pump and determine if there are any restrictions.
No restrictions found: GO TO 9 Restrictions found: Repair and replace components as needed.

1/1
9 Fuel at Injectors Check
1. Ignition OFF 2. Using two open ended wrenches, loosen fuel line connections at the fuel inlet of the injector. 3. Place shop rag around the fuel line fitting at the injector. 4. Ignition ON, engine cranking or running 5. Observe fuel line at open fitting for fuel flow.
Fuel flow is present: GO TO 11 No or little fuel flow is present: GO TO 10
1/1
10 Fuel Injection Lines Check
Check all fuel injection lines for damage or restrictions.
No damaged or restricted fuel injection line(s) found: Faulty fuel injection pump. Damaged or restricted fuel injection line(s) found: Repair or replace fuel line(s) as needed.
1/1
CTM170 (14MAY03)
04-150-34

051403
PN=168

Injection nozzles test OK: Faulty injection pump. Have injection pump repaired by an authorized diesel repair station or replace pump. Faulty injection nozzle(s) found: Repair or replace injection nozzle(s). See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
04 150 35
1/1
12 Transfer Pump Power Wire Check
1. Ignition OFF 2. Disconnect transfer pump connector (F) 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between the power terminal (terminal A) of the transfer pump connector on the engine harness and a good chassis ground.
Positive voltage: GO TO 13 NO voltage: Open or short in transfer pump power wire.
NOTE: Voltage must be read within the first 40 seconds after key ON NOTE: This voltage does NOT need to be battery voltage.
1/1
13 Transfer Pump Ground Wire Check
1. Transfer pump connector still disconnected. 2. Ignition ON, engine OFF 3. Using a multimeter, measure voltage between the ground terminal (terminal B) of the transfer pump connector and battery voltage.
At or near battery voltage: Faulty transfer pump connector OR Faulty transfer pump. Below battery voltage: Open in ground transfer pump ground wire.
1/1
CTM170 (14MAY03)
04-150-35

051403
PN=169

14 Transfer Pump Wiring Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between: Terminal 22 and all other terminals in the ECU connector (except 67). Terminal 67 and all other terminals in the ECU connector (except 22).
Greater than 20k ohms: Restriction in fuel line (G) between final filter and injection pump. Less than 20k ohms: Short to voltage in transfer pump wiring
1/1
04 150 36
CTM170 (14MAY03)
04-150-36

051403
PN=170
F2 - Excessive Fuel Consumption
Symptom
Problem
Solution
Excessive Fuel Consumption
Poor fuel quality
Drain fuel and replace with quality fuel of the proper grade. Reduce engine load Replace air cleaner element as required. Determine cause of low compression and repair as required. Locate source of leak and repair as required.
Engine overloaded Air cleaner restricted or dirty
Compression too low
Leaks in fuel supply system
04 150 37
RG41221,0000121 1909MAY011/1
F3 - Fuel in Oil
Symptom
Problem
Solution
Fuel in Oil
Faulty injection pump front seal
Replace front seal.
RG41221,0000122 1916AUG011/1
CTM170 (14MAY03)
04-150-37

051403
PN=171
APrimary Filter BFinal Filter Inlet CTransfer Pump
DFinal Filter EFinal Filter Outlet
FTransfer Pump Connector GFuel Line Between Final Filter and Injection Pump
HInjection Pump
The callouts in this illustration are referred to throughout F4 - FUEL SUPPLY CHECK - TIER 2 diagnostic procedure to clearly identify various
locations on the fuel system. For fuel system theory of operation information, see FUEL SYSTEM OPERATION - TIER 2 in Group 130 of this manual.
RG41221,0000205 1908JAN031/2
CTM170 (14MAY03)
04-150-38

051403
RG11714
UN01JUN01
04 150 38
PN=172
04 150 39
1921JUN00
Electronic Transfer Pump There are two types of fuel transfer pumps available on the tier 2 engines; Closed Loop and Open Loop. The Closed Loop pump uses the ECU and a fuel pressure sensor to control the fuel pressure at any give speed or load. The Open Loop pump does not have a fuel pressure sensor. This system uses a constant voltage to the transfer pump and a
pressure regulating device. For more information on Closed Loop versus Open Loop systems, see ELECTRONIC FUEL TRANSFER PUMP in Section 03, Group 140 earlier in this manual. Some Applications use a remote mounted fuel transfer pump. These applications use ring terminals foe the electrical connections on the pump. The power still originates from the same terminals on the ECU connector.
RG41221,0000205 1908JAN032/2
CTM170 (14MAY03)
04-150-39

051403
PN=173
RG10752
RG41221,0000206 1916AUG011/1
F4 - Fuel Supply System Check - Tier 2 Diagnostic Procedure
1/1
1 Preliminary Check 04 150 40
Before using this diagnostic procedure, check the following: 1. If fuel system has been recently opened (filter changed, line removed etc.) perform fuel system bleed procedure. See BLEED THE FUEL SYSTEM later in this Group and retest. 2. Check for air leaks from loose or damaged fuel lines and fittings. 3. Check for ruptured fuel lines. 4. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY TIER 2 later in this Group. 5. Check for air in the fuel system. See TEST FOR AIR IN FUEL - TIER 2 later in this Group.
No problem found: GO TO 2 Problem found: Repair and retest
1/1
2 Fuel Control System Check
Decide if this application is using a Closed Loop or Open Loop fuel control system. All closed loop systems use a fuel pressure sensor (C) to control the amount of fuel provided by the fuel transfer pump. Open loop systems do not use a fuel pressure sensor. Locate the final fuel filter and check for a sensor.
No fuel pressure sensor found: GO TO 3 Fuel pressure sensor found: GO TO 3
RG10768 UN15JAN03
Fuel Pressure Sensor on Final Fuel Filter

1/1
CTM170 (14MAY03)
04-150-40

051403
PN=174

3 Engine Performance Check
1. Ignition ON, engine running 2. Observe engine performance.
Engine runs on Closed Loop System: GO TO 6 Engine runs on Open Loop System: GO TO 7 Engine cranks but wont start on Closed Loop System: GO TO 4 Engine cranks but wont start on Open Loop System: GO TO 5
04 150 41
1/1
4 Fuel Pressure Check During Prime Cycle on Closed Loop Systems
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORin Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Read the fuel pressure parameter using DST or SERVICE ADVISOR.
Consistently above 150 kPa (1.50 bar) (22 psi): GO TO 11 Consistently below 150 kPa (1.50 bar) (22 psi): GO TO 8
NOTE: The electronic transfer pump runs for 40 seconds at key ON to prime the fuel system. Fuel pressure must be read within the first 40 seconds after key ON.
1/1
5 Fuel Pressure Check During Prime Cycle on Open Loop Systems
1. Ignition OFF 2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to spare outlet port on the final fuel filter. 3. Ignition ON, engine cranking 4. Using gauge, read pressure.
Positive Pressure: GO TO 11 Negative or NO Pressure: GO TO 8
1/1
CTM170 (14MAY03)
04-150-41

051403
PN=175

6 Fuel Pressure Check (Running) on Closed Loop Systems
1. Ignition ON, engine running 2. Read the fuel pressure parameter using DST or SERVICE ADVISOR.
Between 70-90 kPa (0.7-0.9 bar) (10.1-13.0 psi): GO TO 11 Consistently below 70 kPa (0.7 bar) (10.1 psi): GO TO 8 Consistently above 90 kPa (0.9 bar) (13.0 psi): GO TO 17
1/1
04 150 42
7 Fuel Pressure Check (Running) on Open Loop Systems
1. Ignition OFF 2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to spare outlet port on the final fuel filter. 3. Ignition ON, engine running at fast idle. 4. Using gauge, read pressure.
Between 1-83 kPa (0.01-0.8 bar) (0.15-12.0 psi): GO TO 11 Consistently below 1 kPa (0.01 bar) (0.15 psi): GO TO 8
1/1
8 Restricted Fuel Supply Line Check
Remove the fuel supply lines between the fuel tank and the primary filter (A) and the line between the primary filter and the final filter (D) and determine if there are any restrictions.
No restrictions found: GO TO 9 Restrictions found: Repair or replace components as needed.

1/1
9 Primary Fuel Filter Check
Check for damaged, dirty, or plugged primary fuel filter.
Primary fuel filter OK: GO TO 10 Primary fuel filter dirty or damaged: Clean or replace primary fuel filter and retest.
1/1
CTM170 (14MAY03)
04-150-42

051403
PN=176

10 Final Fuel Filter Check
Check for damaged, dirty, or plugged final fuel filter.
Final fuel filter OK: GO TO 15 Final fuel filter dirty or damaged: Replace final fuel filter and retest.
1/1
11 Restricted Injection Pump Fuel Supply Line Check
Remove the fuel supply line (G) between the final filter and the fuel injection pump and determine if there are any restrictions.
No restrictions found: GO TO 12 Restrictions found: Repair and replace components as needed.

1/1
04 150 43
12 Fuel at Injectors Check
1. Ignition OFF 2. Using two open ended wrenches, loosen fuel line connections at the fuel inlet of the injector. 3. Place shop rag around the fuel line fitting at the injector. 4. Ignition ON, engine cranking or running 5. Observe fuel line at open fitting for fuel flow.
Fuel flow is present: GO TO 14 No or little fuel flow is present: GO TO 13
1/1
13 Fuel Injection Lines Check
Check all fuel injection lines for damage or restrictions.
No damaged or restricted fuel injection line(s) found: Faulty fuel injection pump. Damaged or restricted fuel injection line(s) found: Repair or replace fuel line(s) as needed.
1/1
CTM170 (14MAY03)
04-150-43

051403
PN=177

Injection nozzles test OK: Faulty injection pump. Have injection pump repaired by an authorized diesel repair station or replace pump. Faulty injection nozzle(s) found: Repair or replace injection nozzle(s). See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
04 150 44
1/1
15 Transfer Pump Power Wire Check
1. Ignition OFF 2. Disconnect transfer pump connector (F) 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between the power terminal of the transfer pump connector on the engine harness and a good chassis ground.
Positive voltage: GO TO 16 NO voltage: Open or short in transfer pump power wire.
NOTE: Voltage must be read within the first 40 seconds after key ON
1/1
16 Transfer Pump Ground Wire Check
1. Transfer pump connector still disconnected. 2. Ignition ON, engine OFF 3. Using a multimeter, measure voltage between the ground terminal (terminal B) of the transfer pump connector and battery voltage.
At or near battery voltage: Faulty transfer pump connector OR Faulty transfer pump. Below battery voltage: Open in transfer pump ground wire.
1/1
CTM170 (14MAY03)
04-150-44

051403
PN=178

17 Transfer Pump Wiring Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between: Terminal 22 and all other terminals in the ECU connector (except 67). Terminal 67 and all other terminals in the ECU connector (except 22).
Greater than 20k ohms: Restriction in fuel line (G) between final filter and injection pump. Less than 20k ohms: Short to voltage in transfer pump wiring
1/1
04 150 45
CTM170 (14MAY03)
04-150-45

051403
PN=179
F5 - Fuel Injection Nozzle Check
The F5 - Fuel Injection Nozzle Check provides a list of possible failures and there solutions. This list below provides references to assist in the diagnosis and repair of the nozzle. Operation - See FUEL INJECTION NOZZLE OPERATION in Section 03, Group 130 earlier in this manual. Removal - See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual. Cleaning - See CLEAN FUEL INJECTION NOZZLES and CLEAN FUEL INJECTION NOZZLE BORE in Section 02, Group 090 earlier in this manual.
Symptom Problem
04 150 46
Performance Tests - See TEST FUEL INJECTION NOZZLE in Section 02, Group 090 earlier in this manual. Disassembly - See DISASSEMBLE FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual. Adjusting - See ADJUST FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual. Installing Seals - See INSTALL SEALS ON FUEL INJECTION NOZZLE in Section 02, Group 090 earlier in this manual. Installation - See INSTALL FUEL INJECTION NOZZLES in Section 02, Group 090 earlier in this manual.
Solution
Failed Carbon Stop Seal Washer
Nozzle replaced without using new seal or washer Carbon stop seal groove not cleaned when new seal was installed.
Clean groove and install new seal and washer. Clean groove and install new seal.
Incorrect Opening Pressure
Improper adjustment
Adjust opening pressure. See TEST FUEL INJECTION NOZZLE in Section 02, Group 090 of this manual. Replace spring Clean orifices. Replace injection nozzle Adjust lift screw. Clean orifices. Replace injection nozzle Replace injection nozzle. Clean orifice.
Broken spring Nozzle Will Not Open Plugged orifices Chipped orifices Bottomed lift screw Poor Spray Pattern Plugged orifices Chipped orifices Cracked nozzle tip Poor Atomization Plugged orifice
RG41221,000005D 1918OCT021/3
CTM170 (14MAY03)
04-150-46

051403
PN=180

Symptom Problem
Solution
Chipped orifice Cracked nozzle tip Inconsistent Chatter Spring components misaligned Varnish on valve Deposit in seat area Bent valve Distorted body No Chatter Spring components misaligned Varnish on valve Deposit in seat area Bent valve Valve seat eroded or pitted
Replace injection nozzle Replace injection nozzle. Adjust opening pressure. Clean guide area. Clean seat. Replace nozzle. Replace nozzle. Adjusting opening pressure. Clean guide area. Clean seat. Replace nozzle. Lap valve to seat. Replace nozzle as necessary. Lap valve to seat. Replace nozzle as necessary. Replace nozzle. Replace nozzle. Clean seat. Lap valve to seat. Replace nozzle as necessary. Lap tip to seat. Replace nozzle as necessary. See TEST FUEL INJECTION NOZZLE in Section 02, Group 090 of this manual. Replace injection nozzle Replace injection nozzle
04 150 47
Tip seat pitted
Seat interference angle worn Distorted body Seat Leakage Deposits in seat area Valve seat eroded or pitted
Tip seat pitted
Valve not free
Distorted body Cracked tip
RG41221,000005D 1918OCT022/3
CTM170 (14MAY03)
04-150-47

051403
PN=181

Symptom Problem
Solution
High Leak-Off
Wear or scratched at guide
Lap valve to guide. Replace nozzle as necessary. Clean Guide Area Clean nozzle. Lap valve to guide. Replace injection nozzle as necessary.
Low Leak-Off
Varnish on valve Insufficient clearance
RG41221,000005D 1918OCT023/3
04 150 48
CTM170 (14MAY03)
04-150-48

051403
PN=182
04 150 49
CTM170 (14MAY03)
04-150-49

051403
PN=183
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR

CAN Low CAN High CAN Shield 21
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
44 42
E F G
04 150 50
D C A J H B
D C E B Switched Voltage A Static Ground
Diagnostic Connector
C C CAN Terminator This diagnostic procedure should be used if communication between the Diagnostic Scan Tool (DST) or SERVICE ADVISOR and the Engine Control Unit (ECU) cannot be established. For more
ECU Connector
information on CAN, see CONTROLLED AREA NETWORK (CAN) in Section 03, Group 130 earlier in this manual.
RG41221,0000123 1918OCT021/1
CTM170 (14MAY03)
04-150-50

051403
PN=184
RG11727
1923OCT02
B B A C
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR
RG41221,0000124 1918OCT021/1
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR Diagnostic Procedure
1/1
1 Connection Check
IMPORTANT: Do not force probes into connector terminals or damage will result. Use the JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur.
No faulty connection(s): GO TO 2 Faulty connection(s): Repair connection and retest.
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector, diagnostic connector, and the CAN terminator looking for dirty, damaged, or poorly positioned terminals.
04 150 51
1/1
2 Intermittent Fault Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORin Group 160 later in this manual. 2. Make sure all communication cables are properly connected 3. Ignition ON, engine OFF 4. Start the ECU diagnostic software
Cant communicate with ECU: GO TO 3 Communicates with ECU: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
CTM170 (14MAY03)
04-150-51

051403
PN=185

3 Sensor Voltage Test
1. Ignition OFF 2. Disconnect ECT sensor For sensor location, see ELECTRONIC CONTROL SYSTEM OVERVIEW - TIER 1 or ELECTRONIC CONTROL SYSTEM OVERVIEW - TIER 2 in Section 03, Group 140 earlier in this manual. 3. Ignition ON 4. Using a multimeter, measure the voltage between both terminals of the selected sensor harness connector
4.5 V or above: GO TO 5 Below 4.5 V: GO TO 4
04 150 52
1/1
4 Power Supply Test
1. Ignition OFF 2. Disconnect ECU connector 3. Ignition ON 4. Using a multimeter, measure the voltage between a good chassis ground and terminal 19 in the harness end of the ECU connector
10.0 V or above: Faulty ECU power wiring OR Faulty ECU Below 10.0 V: Faulty ECU power fuse OR Key-on signal wire open or shorted to ground OR Faulty ignition switch OR Faulty key-on power fuse
1/1
5 PDM Power Light Test
1. Ignition ON 2. Note the power light on the Parallel Port Data Module (PDM)
Power light is Green: GO TO 8 Power light is Red or OFF: GO TO 6
1/1
CTM170 (14MAY03)
04-150-52

051403
PN=186

6 Open in Diagnostic Ground Connector Wire Test
1. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector 3. Using a multimeter, measure the voltage between the ground terminal and the power terminal (terminals A and B) in the diagnostic connector on the main harness.
Substantially less than battery voltage: GO TO 7 At or near battery voltage: Faulty diagnostic cable between diagnostic connector and PDM OR Faulty Parallel Port Data Module (PDM)
1/1
7 Harness Power and Ground Wire Test
1. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector on main harness. 3. Probe terminal A in diagnostic connector with test light connected to battery voltage.
Light ON: Faulty diagnostic connector OR Open or short to ground in diagnostic connector power wire. Light OFF: Faulty diagnostic connector OR Open in diagnostic connector ground wire.
04 150 53
1/1
8 Open in Harness Circuit Test
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 connectors between: CAN low terminal D in the diagnostic connector and terminal 21 in the ECU connector CAN high terminal C in the diagnostic connector and terminal 44 in the ECU connector
Both measurements 5 ohms or less: GO TO 9 One or more measurements greater than 5 ohms: Open in harness circuit OR Connector terminals in wrong position
1/1
CTM170 (14MAY03)
04-150-53

051403
PN=187

9 CAN Resistance Test
1. Ignition OFF 2. ECU and diagnostic connector still disconnected. 3. Using a multimeter, measure resistance between terminals C and D in the harness end of the diagnostic connector.
Between 45 - 75 ohms: GO TO 10 Less than 45 or greater than 75 ohms: Faulty or missing CAN terminator connector OR Open or short in CAN wiring harness
1/1
04 150 54
10 CAN High and Low Voltage Test
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 measurements between 1.5 - 3.5 volts: Faulty ECU/Cab Harness connection OR Faulty diagnostic cable OR Faulty diagnostic connector OR Faulty Parallel Port Data Module (PDM) OR Faulty diagnostic software/computer configuration OR Faulty ECU Either measurement less than 1.5 or greater than 3.5 volts: CAN wiring shorted to ground or voltage OR Faulty ECU
1/1
CTM170 (14MAY03)
04-150-54

051403
PN=188
04 150 55
CTM170 (14MAY03)
04-150-55

051403
PN=189
D2 - Diagnostic Gauge Does Not Communicate With ECU

CAN Low CAN High CAN Shield 21 44 42
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
H G
A B C D
04 150 56
F E
B G F E D
Switched Voltage Static Ground
Diagnostic Gauge Connector B A A B B A C C C CAN Terminator
ECU Connector the diagnostic gauge shows the following error codes or it can not communicate with the ECU: EE-error ACP-Err/No Addr ACP-Err/Bus EP ACP-Err/Bus Error
NOTE: For more information on CAN, see CONTROLLED AREA NETWORK (CAN) in Group 130 earlier in this manual.
Internal Diagnostic Gauge Errors The D2 - Diagnostic Gauge Does Not Communicate With ECU diagnostic procedure should be followed if
RG41221,000020B 1918OCT021/1
CTM170 (14MAY03)
04-150-56

051403
PN=190
RG11739
1923OCT02
D2 - Diagnostic Gauge Does Not Communicate With ECU
RG41221,000020D 1918OCT021/1
D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure
1/1
1 Connection Check
IMPORTANT: Do not force probes into connector terminals or damage will result. Use the JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur.
No faulty connection(s): GO TO 2 Faulty connection(s): Repair connection and retest.
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors, diagnostic gauge connector, and the CAN terminator connector looking for dirty damaged, or poorly positioned terminals.
04 150 57
1/1
1. Ignition OFF 2. Ignition ON
Error or no power found in diagnostic gauge: GO TO 3 No error found and power present in diagnostic gauge: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
3 Sensor Voltage Test
1. Ignition OFF 2. Disconnect any of the following: MAT sensor ECT sensor 3. Ignition ON 4. Using a multimeter, measure the voltage between both terminals of the selected sensor harness connector.
4.5 V or above: GO TO 5 Below 4.5 V: GO TO 4
1/1
CTM170 (14MAY03)
04-150-57

051403
PN=191

4 Power Supply Test
1. Ignition OFF 2. Disconnect ECU connector. 3. Ignition ON 4. Using a multimeter, measure the voltage between a good ground and terminal 19 in the harness end of the ECU connector.
10.0 V or above: Faulty ECU power wiring OR Faulty ECU Below 10.0 V: Faulty ECU power fuse OR Key-on signal wire open or short to ground OR Faulty ignition switch OR Faulty key-on power fuse
1/1
04 150 58
5 Diagnostic Gauge Power Test
1. Ignition ON 2. View diagnostic gauge
Gauge has power: GO TO 8 Gauge does not have power: GO TO 6

1/1
6 Open in Diagnostic Gauge Connector Ground Wire Test
1. Ignition OFF 2. Disconnect the diagnostic gauge from the diagnostic gauge connector. 3. Ignition ON 4. Using a multimeter, measure voltage between the switched voltage terminal and the ground terminal (terminals D and E) of the harness end of the diagnostic gauge connector.
Substantially less than battery voltage: GO TO 7 At or near battery voltage: Open in diagnostic gauge ground wire.
1/1
7 Open in Diagnostic Gauge Connector Power Wire Test
1. Ignition OFF 2. Disconnect the diagnostic gauge connector. 3. Probe terminal D in the diagnostic gauge connector with a test light connected to battery voltage.
Light ON: Open or short to ground in diagnostic gauge power wire. Light OFF: Open in diagnostic gauge connector ground wire.
1/1
CTM170 (14MAY03)
04-150-58

051403
PN=192

8 Open in Harness Circuit Test
1. Ignition OFF 2. Disconnect the ECU connector and the diagnostic cable from the diagnostic connector. 3. Using a multimeter, measure resistance on the harness end of both connectors between: Terminal B in the diagnostic gauge connector and terminal 21 in the ECU connector. Terminal G in the diagnostic gauge connector and terminal 44 in the ECU connector.
All measurements 5 ohms or less: GO TO 9 One or more measurements greater than 5 ohms: Open in harness circuit OR Connector terminals in wrong position
04 150 59
1/1
9 CAN Resistance Test
1. Ignition OFF 2. ECU and diagnostic connectors still disconnected. 3. Using a multimeter, measure resistance between terminals B and G in the harness end of the diagnostic connector.
Between 45-75 ohms: GO TO 10 Less than 45 or greater than 75 ohms: Faulty or missing CAN terminator connector(s) OR Open or short in CAN wiring harness
1/1
10 CAN High and Low Voltage Test
1. Ignition OFF 2. Reconnect the 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 measurements between 1.5 - 3.5 V: Faulty ECU connection OR Faulty diagnostic gauge connection OR Faulty diagnostic software/computer configuration OR Faulty ECU Either measurement less than 1.5 V or greater than 3.5 V: CAN wiring shorted to ground or power OR Faulty ECU
1/1
CTM170 (14MAY03)
04-150-59

051403
PN=193
A1 - Intake Air Heater Check
Switched Voltage
Air Heater Relay Return
Air Heater Indicator Light
Air Heater Relay Enable

04 150 60
63
37
47
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
NOTE: For further wiring information on the air heater and air heater relay, refer to machine manual.
Intake Air Heater The intake air heater is located between the intake pipe and intake manifold. Its function is to heat the intake air during cold starting conditions. Its operation time is dependent on the fuel temperature for most applications (some applications use manifold air temperature) when the ECU detects at key-on. The table below explains this relationship. When the ECU sends battery voltage out of terminal 63 to the air heater relay, the solenoid in the relay
activates, and the air heater turns ON. At this time, the ECU will illuminate the air heater indicator light. When the ECU stops sending battery voltage out of terminal 63, the solenoid deactivates, and the air heater turns OFF. At this time, the ECU will turn the air heater indicator light OFF. To ensure full utilization of the intake air heater, the operator should wait until the light goes out before starting the engine. Anytime the engine cranks but does not start, a key-off/key-on cycle will be required before preheating is allowed again.
DPSG,RG40854,677 1918OCT021/1
CTM170 (14MAY03)
04-150-60

051403
PN=194
RG11111
ECU Connector
1908JUN00
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
A1 - Intake Air Heater Check
NOTE: The air heater indicator light is the same light that trouble codes are displayed on. The air heater will run for 5 additional seconds after the light turns OFF.
Intake Air Heater Operation - Combines Fuel Temperature -1C (30.2F) -5C (23F) -10C (14F) -15C (5F) -20C (-4F) and below Light ON Time 5 seconds 10 seconds 15 seconds 20 seconds 25 seconds
Intake Air Heater Operation - Telehandler Fuel Temperature 5C (41F) 0C (32F) -5C (23F) -10C (14F) -15C (5F) -20C (-4F) and below -25C (-13F) and below Light ON Time 5 seconds 10 seconds 15 seconds 20 seconds 25 seconds 30 seconds 45 seconds
Intake Air Heater Operation - Tractors Fuel Temperature -1C (30.2F) -2C (28.4F) -3C (26.6F) -4C (24.8F) -5C (23F) and below Light ON Time 5 seconds 10 seconds 15 seconds 20 seconds 25 seconds
04 150 61
Intake Air Heater Operation - Marine Manifold Air Temperature 5C (41F) 0C (32F) -5C (23F) -10C (14F) and below Light ON Time 5 seconds 10 seconds 20 seconds 30 seconds
Intake Air Heater Operation - OEM Fuel Temperature -1C (30.2F) -5C (23F) -10C (14F) -15C (5F) -20C (-4F) and below Light ON Time 5 seconds 10 seconds 15 seconds 20 seconds 25 seconds
RG41221,0000125 1909MAY011/1
A1 - Intake Air Heater Check Diagnostic Procedure
1/1
CTM170 (14MAY03)
04-150-61

051403
PN=195

1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. Use the JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur. No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s)
NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER CHECK supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector, air heater relay connector, and air heater connector looking for dirty, damaged, or poorly positioned terminals.
1/1
04 150 62
2 Air Heater Indicator Light Check
NOTE: Do not run engine during this diagnostic procedure. NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER CHECK 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 indicator light wiring OR Faulty air heater indicator light
1/1
3 Active DTC Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORin Group 160 later in this manual. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Key ON, engine OFF 5. Read DTCs using DST or SERVICE ADVISOR.
No active DTC(s) present: GO TO 4 Active DTC(s) present: Go to appropriate diagnostic procedure
1/1
CTM170 (14MAY03)
04-150-62

051403
PN=196

4 Engine Coolant Temperature Check
1. Key ON, engine OFF 2. Read the fuel temperature parameter. On Marine applications, read the manifold air temperature parameter. 3. Compare the temperature to the corresponding temperature specification table. See A1 - INTAKE AIR HEATER CHECK earlier in this Group.
Temperature is below the specification to turn the air heater ON: GO TO 5 Temperature is above the specification to turn the air heater ON: No air heater-related problem found
1/1
5 Voltage at Air Heater Check
1. Key OFF 2. Using a multimeter, measure the voltage between the air heater power stud and a good chassis ground while turning key ON (engine OFF)
At or near battery voltage: GO TO 6 No voltage detected: GO TO 7
04 150 63
NOTE: Voltage must be read as key is turned ON
1/1
6 Air Heater Check
1. Key OFF 2. Using a multimeter, measure the temperature of air heater housing with temperature probes. 3. Key ON, engine OFF 4. Continue to monitor temperature of air heater housing
Temperature increases: No air heater related problem found Temperature does not increase Faulty air heater
1/1
CTM170 (14MAY03)
04-150-63

051403
PN=197

7 Air Heater Relay Check
1. Key OFF 2. Listen for air heater relay to click while turning key ON (engine OFF)
Relay clicks: Faulty power wire to relay OR Faulty wire between relay and heater OR Faulty air heater relay Relay does not click: Faulty air heater enable wire OR Faulty relay ground OR Faulty relay
04 150 64
1/1
CTM170 (14MAY03)
04-150-64

051403
PN=198
Check Fuel Supply Quality - Tier 1
04 150 65
The quality of diesel fuel affects engine performance. Check your operators manual for correct fuel specifications.
Poor quality or contaminated fuel will make the engine hard to start, misfire, run rough or produce low power. If poor quality or contaminated fuel is suspected, perform the following:
RG41221,0000127 1918OCT021/2
CTM170 (14MAY03)
04-150-65

051403
RG10778
UN22MAY00
PN=199

1. Check primary (if equipped) and final fuel filters for serviceability. If filter is equipped with a water separator, empty and clean separator bowl. 2. Start engine and operate under load, observing engine performance. 3. Reduce engine speed to idle and shutdown engine. 4. Disconnect fuel line from inlet side of primary fuel filter (if equipped) or inlet side of final filter on engines without primary filter. If performance improves, fuel is contaminated or not of the proper grade. Check fuel source. 5. Connect a hose to inlet port. 6. Submerge hose in a container of clean, good quality fuel meeting engine specifications. 7. Operate engine under load and observe performance.
04 150 66
RG41221,0000127 1918OCT022/2
CTM170 (14MAY03)
04-150-66

051403
PN=200
Check Fuel Supply Quality - Tier 2
UN01JUN01
The quality of diesel fuel affects engine performance. Check your operators manual for correct fuel specifications. Poor quality or contaminated fuel will make the engine hard to start, misfire, run rough or produce low power. If poor quality or contaminated fuel is suspected, perform the following: 1. Check primary and final fuel filters for serviceability. If filter is equipped with a water separator, empty and clean separator bowl. 2. Start engine and operate under load, observing engine performance.
3. Reduce engine speed to idle and shutdown engine. 4. Disconnect fuel line from inlet side of primary fuel filter. 5. Connect a hose to inlet port. 6. Submerge hose in a container of clean, good quality fuel meeting engine specifications. 7. Operate engine under load and observe performance. If performance improves, fuel is contaminated or not of the proper grade. Check fuel source.
RG41221,0000128 1920OCT021/1
CTM170 (14MAY03)
04-150-67

051403
RG11715
04 150 67
PN=201
Test for Fuel Drain Back

Fuel draining back through the fuel system may cause hard starting. This procedure will determine if air is entering the system at connections and allowing fuel to siphon back to the fuel tank. 1. Disconnect fuel supply and return lines at fuel tank. IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including the fuel transfer pump, fuel injection pump, fuel filters, and water separator (if equipped). 3. Securely plug off the end of the fuel return pipe. CAUTION: Maximum air pressure should be 100 kPa (1 bar) (14.5 psi) when performing this test. 4. Using a low pressure air source, pressurize the fuel system at the fuel supply line. 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks.
04 150 68
NOTE: Connections may allow air to enter the system without allowing fuel to leak out.
6. If any leaks are found, take necessary steps to repair. 7. Reconnect supply and return lines and prime system. 8. Start engine and run for approximately 10 minutes. 9. Allow engine to sit overnight and try starting the following morning.
RG41221,0000129 1909MAY011/1
CTM170 (14MAY03)
04-150-68

051403
PN=202
Test for Air in Fuel - Tier 1
04 150 69
NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: If engine cranks but wont start, see BLEED THE FUEL SYSTEM later in this Group.
Air in the fuel system will make the engine hard to start, run rough, misfire or produce low power. Additionally, it can cause excessive smoke and knocking.
Whenever the fuel system is opened for repair, it must be bled to remove any air that has entered the system. 1. Disconnect fuel return line end of fuel leak-off line assembly. Connect a clear plastic hose to end of leak-off line assembly and place opposite end of hose in a suitable container filled with fuel as shown.
RG41221,000012A 1920OCT021/2
CTM170 (14MAY03)
04-150-69

051403
PN=203
RG10777
UN22MAY00

2. Operate engine and check for air bubbles in container. If bubbles are present, bleed the fuel system and repeat test. See BLEED THE FUEL SYSTEM later in this Group. 3. If bubbles are still present, check the following: Check for loose fuel fittings from the suction side of the fuel supply pump to the fuel tank to include all lines and filters. Check fuel tank suction tube (if equipped) and welded joints for cracks or holes. Perform any necessary repairs, bleed fuel system and repeat test.
RG41221,000012A 1920OCT022/2
04 150 70
CTM170 (14MAY03)
04-150-70

051403
PN=204
Test for Air in Fuel - Tier 2
UN01JUN01
04 150 71
NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual. NOTE: If engine cranks but wont start, see BLEED THE FUEL SYSTEM later in this Group.
Air in the fuel system will make the engine hard to start, run rough, misfire or produce low power. Additionally, it can cause excessive smoke and knocking. Whenever the fuel system is opened for repair, it must be bled to remove any air that has entered the system. 1. Disconnect fuel return line end of fuel leak-off line assembly. Connect a hose to end of leak-off line assembly and place opposite end of hose in a suitable container filled with fuel as shown.
2. Operate engine and check for air bubbles in container. If bubbles are present, bleed the fuel system and repeat test. See BLEED THE FUEL SYSTEM later in this Group. 3. If bubbles are still present, check the following: Check for loose fuel fittings from the suction side of the fuel supply pump to the fuel tank to include all lines and filters. Check fuel tank suction tube (if equipped) and welded joints for cracks or holes. Perform any necessary repairs, bleed fuel system and repeat test.
RG41221,000012B 1920OCT021/1
CTM170 (14MAY03)
04-150-71

051403
RG11716
PN=205
Check Fuel Supply Pressure

IMPORTANT: Before disconnecting any fuel line, completely clean any debris from around the fitting. DO NOT allow debris to enter fuel line. 1. Remove the fuel pressure sensor (A) from the final fuel filter base. See REPLACE FUEL PRESSURE SENSOR in Section 02, Group 110 earlier in this manual. 2. Connect a 0-1000 kPa (0-150 psi) gauge to the sensor port on the filter base.
04 150 72
Check Fuel Supply Pressure - Tier 1
Specification Tier 1 - Fuel Transfer Pump PressureRunning .......................................... 7090 kPa (0.70.9 bar) (10.113.0 psi) Tier 2- Fuel Transfer Pump PressureRunning ...................................... 100110 kPa (1.01.1 bar) (14.516.0 psi)
Check Fuel Supply Pressure - Tier 2

AFuel Pressure Sensor
4. If engine can not be started, perform bleed procedure. See BLEED THE FUEL SYSTEM later in this Group. 5. Reinstall the fuel pressure sensor. See REPLACE FUEL PRESSURE SENSOR in Section 02 Group 110 earlier in this manual.
RG11717A
UN22JAN03
3. Start engine. Fuel transfer pump should maintain minimum pressure shown in specification.
RG,115,JW7707 1920OCT021/1
CTM170 (14MAY03)
04-150-72

051403
RG10780
UN23OCT02
PN=206
Bleed the Fuel System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Any time the fuel system has been opened up for service (lines disconnected, filters removed, pump or nozzles replace, or after the engine has run out of fuel), it will be necessary to bleed air from the system. This fuel system can only be bled by the electronic transfer pump or at the injection nozzles. BLEEDING SHOULD NOT BE PERFORMED at any location on the Bosch VP44 injection pump.
High Pressure Fluids
X9811
UN23AUG88
04 150 73
RG41221,0000109 1920OCT021/4
CTM170 (14MAY03)
04-150-73

051403
PN=207
Observable Diagnostics and Tests NOTE: For information on Tier 1 vs. Tier 2 applications, see ENGINE APPLICATION CHART in Group 001 earlier in this manual.
Bleed Using Electronic Transfer Pump - Tier 1 The bleed is automatically performed by a small orifice (A) inside the filter base connected to the overflow valve (B) on injection pump. This system allows air to escape continually through the fuel return line (C) when ignition is ON. 1. Ignition ON 2. Allow 40 seconds for electronic transfer pump to complete priming 3. If additional system bleeding is required, bleed the circuit by loosening fuel line connections at injection nozzles. See procedure, BLEED FUEL SYSTEM AT FUEL INJECTION NOZZLES later in this Group.
Bleed Fuel System (VP44 Pump) - Tier 1
ABleed Orifice in Final Fuel Filter Base BOverflow Valve CFuel Return Line
UN04MAY00
04 150 74
RG41221,0000109 1920OCT022/4
Bleed Using Electronic Transfer Pump - Tier 2 The bleed is automatically performed by a small orifice (A) inside the filter base connected to the overflow valve (B) on injection pump. This system allows air to escape continually through the fuel return line (C) when ignition is ON. 1. Ignition ON 2. Allow 40 seconds for the electronic transfer pump to complete priming
Bleed Fuel System (VP44) - Tier 2
3. If additional system bleeding is required, bleed the circuit by loosening fuel line connections at injection nozzles. See procedure, BLEED FUEL SYSTEM AT FUEL INJECTION NOZZLES later in this Group.
ABleed Orifice in Final Fuel Filter Base BFuel Return Line
RG41221,0000109 1920OCT023/4
CTM170 (14MAY03)
04-150-74

051403
RG11719A
UN20JUN01
PN=208
RG10721D

Bleed Fuel System at Fuel Injection Nozzles 1. Place throttle lever in half-throttle position. On engines equipped with electronic fuel shut-off solenoid, energize solenoid. IMPORTANT: Always use a backup wrench when loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage. 2. Using two open-end wrenches, loosen two fuel line connections at injection nozzles. 3. Crank engine for 15 seconds (but do not start engine) until fuel free from bubbles flows out of loosened connection. Retighten connection to specifications.
Specification Fuel Injection Nozzle Delivery LinesTorque ................................................................. 27 Nm (20 lb-ft)
UN08JAN97
Nozzle Fuel Pressure Line
RG7725
04 150 75
4. Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system.
RG41221,0000109 1920OCT024/4
CTM170 (14MAY03)
04-150-75

051403
PN=209
Test for Cylinder Misfire (Engine Running)

NOTE: Use this procedure only if DST or SERVICE ADVISOR is not available.
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes and nozzles which could inject fluids under high pressure. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 1. Operate engine at intermediate speed with no load. 2. Place a shop towel around nozzle-to-line connection to absorb escaping fuel. 3. Slowly loosen the fuel pressure line at one of the nozzles until fuel escapes at the connection (fuel not opening nozzle valve). If engine speed changes, the cylinder is probably working satisfactory. If engine speed does not change, a cylinder is faulty. 4. Tighten fuel lines to specifications.
Specification FUEL INJECTION NOZZLE DELIVERY LINESTorque ............................................ 27 Nm (20 lb-ft)
04 150 76
5. Repeat test for each remaining cylinder. 6. Remove faulty injection nozzles and repair as required. See REMOVE FUEL INJECTION NOZZLES in Group 090 earlier in this manual.
DPSG,RG40854,23 1925NOV981/1
CTM170 (14MAY03)
04-150-76

051403
PN=210
Group 160
Trouble Code Diagnostics and Tests

About this Group of the Manual
This section of the manual contains necessary information to diagnose the electronic control system. Use this information in conjunction with the 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). See the 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104) for: Removal of base engine components Base engine repair procedures Base engine disassembly Base engine inspection Base engine assembly SPECIFICATIONS contains useful information, such as ECU terminal identification and a system wiring schematic. IMPORTANT: Under NO circumstances, should the Engine Control Unit (ECU) be opened.
Parts such as sensors, actuators, connectors, and wiring harnesses are serviceable and available. To help diagnose electronic control system problems, Section 6, Group 210 DIAGNOSTIC
NOTE: Instruction is given throughout the diagnostic charts to make resistance and voltage measurements in the ECU connector. Note that these measurements are always made in the harness end of the connector. Measurements should never be made in the ECU end of the connection.
04 160 1
RG,RG34710,1552 1930SEP971/1
Electrical Concepts
Tests will include making measurements of voltage and resistance and making checks for open circuits and short circuits. An understanding of the following concepts is required to use the diagnostic procedures: Voltage (volts) Current (amps) Resistance (ohms) Open Circuit Short Circuit
RG,RG34710,1553 1930SEP971/1
CTM170 (14MAY03)
04-160-1

051403
PN=211
Using a Digital Multimeter

It is recommended that a digital multimeter (JT07306 or equivalent with an analog display) be used to make the required measurements in the diagnostic procedures. A knowledge of the operation of the particular meter used is assumed. Instructions for measuring voltages take the following form: Measure voltage from Point A (+) to Point (B) (-) In this example, the positive test lead from the volt-ohm input of the meter should be connected to Point A and the negative test lead from the common input of the meter should be connected to Point B. Unless otherwise stated, all voltage measurements are direct current (D.C.). In making a resistance measurement, be careful to use the correct resistance range on the meter. Disconnect appropriate connectors or turn off key switch, as directed by diagnostic procedures later in this group.
Digital Multimeter
04 160 2
RG,RG34710,1554 1930SEP971/1
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
DPSG,RG40854,37 1915DEC981/6
CTM170 (14MAY03)
04-160-2

051403
PN=212
RG11126
UN19JUN00

RG9891 UN06JAN99
High Resistance Circuit

AUnwanted Resistance
Definition of Circuit Malfunctions 1. High Resistance Circuit:
A circuit having unwanted resistance (A) that causes a voltage drop and reduces current flow.
DPSG,RG40854,37 1915DEC982/6 RG9892 UN06JAN99
04 160 3
Open Circuit
ABreak or Separation in Circuit
2. Open Circuit: A circuit having a break or a separation (A) that prevents current from flowing in the circuit.
Grounded Circuit
AVoltage Wire in Contact with Machine Frame
3. Grounded Circuit: A voltage wire in contact with the machine frame (A), providing continuity with the battery ground terminal.
DPSG,RG40854,37 1915DEC984/6
CTM170 (14MAY03)
04-160-3

051403
PN=213
Shorted Circuit
04 160 4
4. Shorted Circuit: A wire-to-wire contact of two adjacent wires that provides unwanted continuity between the two wires. 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 the battery negative terminal). Ground wire shorted to another ground wire (wires of zero voltage).
NOTE: This type of short does not create an observable malfunction. Therefore, no further explanation for trouble shooting is necessary.
Locations of Circuit Malfunctions

AControlling Switch BLoad
Locations of Circuit Malfunctions: In a Simple Electrical Circuit the circuit malfunctions occur 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 the same four circuit malfunctions. Sometimes component malfunctions can easily be confused with circuit
malfunctions. Therefore, care must be exercised when isolating the cause of the problem. Example: A component may not operate before disconnecting an electrical connection, but it operates after reconnecting the connector. Reason: Oxidation of the terminals created High Resistance and a voltage drop that prevents the proper amount of current flow to the component. Disconnecting and reconnecting the connector, removed some oxidation and re-established good continuity through the connector.
DPSG,RG40854,37 1915DEC986/6
CTM170 (14MAY03)
04-160-4

051403
RG9894
UN06JAN99
PN=214
Troubleshooting Circuit Malfunctions

RG9896 UN06JAN99
Troubleshooting Circuit Malfunctions

ABattery BSwitch CComponent Terminal DUnwanted Resistance ECircuit Connector FOpen Circuit GCircuit Connector HComponent Terminal ILoad (Lamp) JGround
1. High Resistance Circuit: A High Resistance circuit can result in slow, dim or no component operation (for example: loose, corroded, dirty or oily terminals, gauge of wire too small or broken strands of wire). 2. Open Circuit: An Open circuit results in no component operation because the circuit is incomplete (for example: broken wire, terminals disconnected, open protective device or open switch). Do the following to isolate the location of a High Resistance or Open circuit: a. With the controlling switch (B) closed (on) and the load (I) connected into the circuit, check for
proper voltage at a location easily accessible between (C) and (H). If voltage is low, move toward the voltage source (A) to locate the point of voltage drop. If voltage is correct, move toward the load (I) and ground terminal (J) to locate the voltage drop.
04 160 5
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 the component after completing the repair.
DPSG,RG40854,38 1915DEC981/4
CTM170 (14MAY03)
04-160-5

051403
PN=215

RG9897 UN06JAN99
Ground Circuit
AFuse A Terminal BFuse B Terminal CSwitch DComponent Terminal EWire Terminal FGrounded Circuit GComponent Terminal HLoad (Lamp)
3. Ground Circuit: A Grounded circuit (F) results in no component operation and the fuse or circuit breaker opens (for example: a power wire contacting the machine frame, chassis or component housing).
04 160 6
b. Disconnect the load (H) at component terminal (G). c. With the controlling switch (C) open (off), check for continuity to ground between (D) and (E). If there is continuity, there is a grounded circuit between (D) and (E). Repair the circuit.
Do the following to isolate the location of a Grounded circuit: a. Switch (C) must be open (off). Check for continuity to ground between (B) and (C). If there is continuity, there is a grounded circuit between (B) and (C). Repair the circuit. No continuity, go to step b.
NOTE: The example is grounded between (D) and (E) at (F).

Perform an operational check-out on the component after completing the repair.
DPSG,RG40854,38 1915DEC982/4
CTM170 (14MAY03)
04-160-6

051403
PN=216
Shorted Circuit
4. Shorted Circuit: Machines equipped with several electronic control devices contain wiring harnesses that can become shorted by one of the following ways shown above. 1. Battery wire from fuse (F1) is shorted at (A) to another 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) to another 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 a ground 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 the sensor ground wire. Result: The sensor signal is distorted.1 Do the following to isolate a Shorted Circuit: a. Review the machine electrical schematic to identify the circuits for the component that does not operate. b. Disconnect the components at each end of the circuits, to single out the affected wires. c. To prevent damage to connector terminals, obtain mating connector terminals from repair parts. DO NOT force meter probes into connector terminals.
RG9898
UN06JAN99
04 160 7
1 The sensor signal voltage goes out of range and a fault code may be restored. The controller may shut down or provide limited operation for its function.
DPSG,RG40854,38 1915DEC983/4
CTM170 (14MAY03)
04-160-7

051403
PN=217

d. Connect the meter leads across two of the affected circuits. The meter should show no continuity between the two circuits. Repeat the check across another combination of two circuits until all affected circuits have been checked. e. Then, connect a meter lead to each affected circuit one at a time and touch the other meter leads to all terminals in the connector. The meter should show no continuity between any two circuits. Example: A 37 pin connector contains three wires to a sensor. With one meter probe attached to each of the three wires, one at a time, touch the other meter probe to the remaining 36 wires. If there is continuity between any two wires, the circuit is shorted. Repair the circuit. f. Alternate Method to Check for Shorted Circuit. With the components disconnected at each end of the suspected circuits, turn the key switch on. Connect one meter lead to a good frame ground. With the other meter probe, touch each of the suspected circuits one at a time. If there is a voltage reading, the circuit is shorted to another voltage wire. Repair the circuit. g. Repair the Shorted Circuit as follows: Wires not in a loom: Wrap individual wires with electrical tape or replace the damaged wire and band as required. Wires in a loom: If hot spots exist in shorted area of the harness, replace the harness. If hot sports are not noticeable, install a new wire of proper gauge between the last two connections. Use tie bands to secure the wire to outside of the harness. h. Perform an operational check-out on the component after completing the repair.
04 160 8
DPSG,RG40854,38 1915DEC984/4
CTM170 (14MAY03)
04-160-8

051403
PN=218
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR
04 160 9
ADiagnostic Connector Mate BJohn Deere Controller Cable
CMagiKey D26 Pin MagiKey Connector
E25 Pin MagiKey Connector FPC Cable
GPC Connector
DS10023 ECU Communication Hardware Kit or JDIS121 - ECU Communication Hardware Kit is required to connect the DST or SERVICE ADVISOR to the ECU. Please refer to your John Deere Dealer website for obtaining the latest version of software. The diagnostic connector is a black, circular connector with a square mounting flange and a dust cap. There are nine available pins. Depending on application, the location of the diagnostic connector may vary. On OEM the connector is located near the ECU on the engine wiring harness. 1. Locate diagnostic connector on engine and remove dust cap.
2. Connect John Deere Controller Cable (B) to the diagnostic connector on the engine harness using the diagnostic connector mate (A). 3. Connect the other end of the John Deere Controller Cable (B) to the MagiKey (C) module at the 26 pin MagiKey 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 the Diagnostic Scan Tool (DST) or SERVICE ADVISOR installed through the PC connector (G). 6. Key ON, engine off or running, verify that power light on MagiKey is illuminated green.
RG41221,000020E 1920OCT021/2
CTM170 (14MAY03)
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RG11737A
UN18MAY01
PN=219

7. Start the diagnostic software and select the appropriate application. 8. Connect to the application. The CAN light on the MagiKey should illuminate red when the connection to the ECU is made. 9. If DST or SERVICE ADVISOR does not connect see D1 - ECU DOES NOT COMMUNICATE WITH DST OR SERVICE ADVISOR DIAGNOSTIC PROCEDURE in Group 150 of this manual. 10. If power to the PDM is lost during cranking the engine for the Compression Test, use the Power Adapter. The Power Adapter connects between the PDM and the 26 pin MagiKey connector. 11. When finished, replace the dust cap on the diagnostic connector.
04 160 10
Power Adapter
RG41221,000020E 1920OCT022/2
CTM170 (14MAY03)
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RG12277
UN22APR02
PN=220
Engine Configuration Data Parameters on Diagnostic Gauge

Accessing Engine Configuration Data Parameters:
1919JAN01 RG11647
1. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. Select E-Config sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the E-Configsub-menu to view Engine Configuration Parameters by pressing either the right or the left touch switch until desired parameter is found. The numbers next to the parameters correspond to the number on the graph. 4. In order to exit E-Config sub-menu, simultaneously press the right and left touch switch
ADiagnostic Gauge BTouch Switches CLights
04 160 11
UN28OCT99
DPSG,OUOD007,2840 1921OCT991/2
CTM170 (14MAY03)
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PN=221
RG10031

Engine Configuration Parameter Description Parameter Displayed on Diagnostic Gauge Speed 1 Units RPM Description Stationary low idle speed of engine which includes influences due to engine temperature and other stationary changes. This is point 1 on the engine configuration map. Torque 1 equals the desired torque of the ECU divided by the reference torque. Engine speed at point 2 of the engine configuration map. This is defined as the kick-in point for which torque is reduced to zero. Torque 2 equals the desired torque of the ECU divided by the reference torque. Engine speed at point 3 of the engine configuration map. Points 3, 4, and 5 are optional and can be located anywhere between points 1 and 2. Torque 3 equals the desired torque of the ECU divided by the reference torque. Engine speed at point 4 of the engine configuration map. Points 3, 4, and 5 are optional and can be located anywhere between points 1 and 2. Torque 4 equals the desired torque of the ECU divided by the reference torque. Engine speed at point 5 of the configuration map. Points 3, 4, and 5 are optional and can be located anywhere between points 1 and 2. Torque 5 equals the desired torque of the ECU divided by the reference torque. Engine speed of high idle. Torque 6 equals the desired torque of the ECU divided by the reference torque. Equals the change of torque between points 2 and 6 divided by the change of engine speed between points 2 and 6. This parameter is the 100% reference value for all defined indicated engine torque parameters. It is only defined once and doesnt change if a difference engine torque map becomes valid. The maximum engine speed above point 6 allowed by the engine control during a momentary high idle override. This duration is limited by the maximum momentary override time limit. The maximum time limit allowed to override the engines high idle speed. The minimum engine speed that the engine will allow when operating in a speed control/limit mode The maximum engine speed that the engine will allow when operating in a speed control/limit mode. The minimum engine torque that the engine will allow when operating in a torque control/limit mode. The maximum engine torque that the engine will allow when operating in a torque control/limit mode.
Torque 1 Speed 2 Torque 2 Speed 3 Torque 3 Speed 4 04 160 12 Torque 4 Speed 5 Torque 5 Speed 6 Torque 6 Gov Gain Ref Torque
% RPM % RPM % RPM % RPM % RPM % % Nm (ft-lbs)
Speed 7
RPM
Time Limit Lo Limit Hi Limit Low Limit Hi Limit
sec RPM RPM % %
DPSG,OUOD007,2840 1921OCT992/2
CTM170 (14MAY03)
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PN=222
Viewing Active DTCs on Diagnostic Gauge

Accessing Active Diagnostic Trouble Codes (DTCs): 1. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. Select SrvcCodes sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the Srvc Codes sub-menu to view active DTCs by pressing either the right or the left touch switch until all codes are found. 4. In order to exit SrvcCodes sub menu, simultaneously press the right and left touch switch
ADiagnostic Gauge BTouch Switches CLights 04 160 13
DPSG,OUOD007,2842 1915NOV001/1
Viewing Stored DTCs on Diagnostic Gauge

Accessing Stored Diagnostic Trouble Codes (DTCs): 1. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. Select DM2Codes sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the DM2Codessub-menu to view stored DTCs by pressing either the right or the left touch switch until all codes are found.
NOTE: If No Data is on the gauge, there are no stored codes.

4. In order to exit DM2Codes sub menu, simultaneously press the right and left touch switch
DPSG,OUOD007,2842 1921OCT991/1
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PN=223
RG10031
UN28OCT99
RG10031
UN28OCT99
Clearing Stored DTCs on Diagnostic Gauge

Clearing Stored Diagnostic Trouble Codes (DTCs): 1. Scroll through the main menu of engine parameters by pressing either the right or the left touch switch 2. Select DM2Codes sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the DM2Codessub-menu to view stored DTCs by pressing either the right or the left touch switch until all codes are found.
04 160 14
NOTE: If No Data is on the gauge, there are no stored codes.

4. In order to clear codes, simultaneously press the right and 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 for at least 8 seconds.
NOTE: If the switch is held for less than 8 seconds, the sub menu will be exited.
6. If the display reads *Send* **DM3 *, the codes are now cleared. In order to exit DM2Codes sub menu, simultaneously press the right and left touch switch
RG40854,000006A 1923JAN011/1
CTM170 (14MAY03)
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PN=224
RG10031
UN28OCT99
Blinking DTCs Using Diagnostic Blink Code Connector

NOTE: Illustration shows location of connectors on OEM applications. For location information on non-OEM applications, refer to machine manual.
On OEM applications that have a Fault Lamp, the ECU has the ability to display DTCs using blinking sequence of the fault lamp. To retrieve DTCs from the ECU using the blink code method:
NOTE: The ECU blinks the codes in 2-digit codes only. In order to convert the codes to SPN/FMI codes, see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU later in this Group.
1. Locate and uncap the 4way METRI-PACK diagnostic blink code connector (A). 2. Using a short piece of wire, jump terminals A and B in the diagnostic blink code connector together. 3. Turn the ignition switch ON. 4. The Fault Lamp will begin to flash a code number. For example, flash three times...short pause...flash two times...long pause. This example is code 32. 5. The ECU begins the flashing sequence by flashing a code 32, this indicates the start of blinking active codes. If there are any active DTCs, the ECU will flash its 2digit number. If there is more than one active DTC, the ECU will flash each code in numerical order. If there are no active DTCs, the Fault Lamp will flash a code 88. 6. Following the active codes, the Fault Lamp will flash a code 33, this indicates the start of blinking stored codes. If there are any stored DTCs, the Fault Lamp will flash its 2digit number. If there is more than one stored DTC, the ECU will flash each code in numerical order. If there are no stored DTCs, the Fault Lamp will flash a code 88. 7. Once complete, the above sequence will be repeated.
ADiagnostic Blink Code Connector BDiagnostic Connector CECU
RG11754A
UN13JUL01
04 160 15
METRI-PACK is a trademark of Packard Electric Inc.
RG41221,0000215 1920OCT021/2
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PN=225

8. When complete, turn ignition OFF, remove jumper wire, and recap the diagnostic reader connector. As an example, if an engine had an active DTC 18 and stored DTC 53, the flashing sequence would be:
04 160 16
RG41221,0000215 1920OCT022/2
flash flash flash flash flash flash flash flash
three times...short pause two times...long pause one time...short pause eight times...long pause three times...short pause three times...long pause five times...short pause three times
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PN=226
04 160 17
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PN=227
Data Parameter Description

Following is a list of the data parameters that can be read on the Diagnostic Scan Tool (DST). The DST consists of a Windows (95 or 98) or NT compatible computer, DS10023 ECU Communication Hardware Kit or JDIS121 - ECU Communication Hardware Kit,
Parameter Air Heater Time Remaining Analog Throttle (A) Input Voltage Analog Throttle (B) Input Voltage Analog Throttle (C) Input Voltage 04 160 18 Battery Voltage Commanded Power Commanded Torque Crank Improper Pattern Indicator Units sec volts volts volts volts kW (HP) Nm (lb-ft) %
and JDIS122 ECU Communication Software Kit, available from John Deere. Included in the list below is a brief description of each parameter, the range of possible readings, and each parameters unit of measurement.
Description Amount of time the air heater will continue to heat the air prior to starting. Optional component, not included on all applications. The voltage from the analog throttle (A) position sensor (potentiometer). Optional component, not included on all applications. The voltage from analog throttle (B) position sensor (potentiometer). Optional component, not included on all applications. The voltage from analog throttle (C) position sensor (potentiometer). Switched battery voltage may vary depending on application ECU calculates power based on engine fueling. ECU calculates torque based on engine fueling. "0" reading means that there is NO improper pattern. Between 0100, the crankshaft position sensor signal pattern becomes progressively more improper. When 100 is reached, a trouble code is thrown. "0" reading means that there is NO noise. Between 0100, the noise on the crankshaft position sensor signal becomes progressively worse. When 100 is reached, a trouble code is thrown. The speed of the crank timing wheel. When status is 15, the ECU is receiving ALL of the signal. When the status is below 15, it means that the ECU is not receiving all of the signal. When status is 15, the ECU is receiving ALL of the signal. When the status is below 15, it means that the ECU is not receiving all of the signal. The cruise accelerate function has been activated. This should increase the speed at which cruise is set. The cruise brake function has been activated. This will cancel the cruise when the brake is applied until operator resumes operation. The cruise clutch function has been activated. This will cancel the cruise when the clutch is applied until operator resumes operation. The cruise coast function has been activated. This should decrease the speed at which cruise is set. Confirms that cruise is ON/OFF depending on the operators command. Confirms that the function chosen by the operator is activated: hold, accelerate, coast, resume, set, throttle override. The operator has turn the cruise ON/OFF.
Crank Position Input Noise Indicator
Crank Position Sensor Speed Crank Position Status Crank Position Status Cruise Accelerate Switch Cruise Brake Switch Cruise Clutch Switch Cruise Coast Switch Cruise Control Active Cruise Control State Cruise Control On/Off Switch
a
rpm N/A
a
N/Aa N/Aa N/Aa N/Aa N/Aa N/Aa N/Aa N/Aa
N/A = Not Applicable
RG41221,000012D 1923APR031/4
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PN=228

Parameter Cruise Resume Switch Cruise Set Switch Desired Speed Governor Curve ECU Boot Block Part Number ECU Configuration File Part Number ECU EOL Data Part Number ECU Fuel Shutoff ECU Part Number ECU Serial Number ECU Software Assembly Part Number ECU Software Part Number Engine Coolant Temperature Units N/A
a
Description The cruise resume function has been activated. This will reset the cruise to the speed at which cruise was at prior to using the brake or clutch. The cruise set function has been activated. This should lock the current engine speed in when switch is activated. The mode selected is dependent on the application. See APPLICATION SPECIFICATIONS in Section 6, Group 210 of this manual. Part number for the Engine Control Unit (ECU) boot block. Part number for the configuration file in the ECU. Part number for the data programmed into the ECU at the end of the assembly line. EOL = End of Line ECU commands the pump to stop fueling if a problem is detected. Part number for the Engine Control Unit (ECU) hardware. Serial number for the Engine Control Unit (ECU). Part number for the Engine Control Unit (ECU) software assembly. Part number for the Engine Control Unit (ECU) operating software. Engine Coolant Temperature value. NOTE: If there is an active fault for the ECT circuit, the ECT value displayed will be the limp-home value. Engine Coolant Temperature sensor input voltage to the ECU Total hours the ECU has run on an engine. 04 160 19
N/Aa N/Aa N/Aa N/Aa N/A

a
N/Aa N/Aa N/Aa N/A

a
N/Aa C (F) volts hr -minsec % N/Aa kPa (psi) volts C (F) N/Aa rpm
Engine Coolant Temperature Input Voltage Engine Hourmeter
Engine Load at Current Speed Engine Model Number Engine Oil Pressure Engine Oil Pressure Input Voltage Engine Oil Temperature Engine Serial Number Engine Speed
a
Percentage of load on the engine at a given speed. The model number for the engine. Engine Oil pressure value Oil Pressure sensor input voltage to the ECU Engine Oil temperature value Serial number for the engine. The speed that the crankshaft position sensor detects the crank timing wheel to be moving at.
RG41221,000012D 1923APR032/4
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PN=229

Parameter Fuel Mode Fuel Pressure - Actual Fuel Pressure - Desired Fuel Pressure Input Voltage Fuel System Part Number Fuel System Serial Number Fuel Temperature Fuel Usage Rate Manifold Absolute Pressure Units N/A
a
Description This code explains the operation mode of the engine. Fuel supply pressure at the final fuel filter housing in the actual state. Fuel supply pressure at the final fuel filter housing in the desired state. This is the pressure the ECU is commanding the pump to provide. Fuel Pressure sensor input voltage to the ECU. The part number for the fuel system used on the engine. The serial number for the fuel system used on the engine. Fuel temperature value. Total amount of fuel the ECU has commanded the pump control unit to deliver during the total hours shown by the Engine Hour Meter parameter. Manifold Air Pressure value (boost pressure). NOTE: If there is an active fault for the MAP circuit, the MAP value displayed will be the limp-home value. Manifold Air Temperature value.
kPa (psi) kPa (psi) volts N/Aa N/A

a
C (F) L (gal) kPa (psi) C (F)
04 160 20
Manifold Air Temperature
NOTE: If there is an active fault for the MAP circuit, the MAP value displayed will be the limp-home value.
Manifold Air Temperature Input Voltage Maximum Speed Governor Curve Option Assembly Part Number volts N/A
a
Manifold Air Temperature sensor input voltage to the ECU. The mode selected is dependent on the application. See APPLICATION SPECIFICATIONS in Section 6, Group 210 of this manual. Part number that describes all of the options on the entire vehicle. This includes the Performance Option Part Number and the Vehicle Option Part Number. These are the engine performance specific options relate to power and torque. Pump Control Unit stops fueling if a problem is detected internal to the pump. "0" reading means that there is NO improper pattern. Between 0100, the event sensor signal pattern becomes progressively more improper. When 100 is reached, a trouble code is thrown. "0" reading means that there is NO noise. Between 0100, the noise on the event sensor signal becomes progressively worse. When 100 is reached, a trouble code is thrown. The speed of the event timing wheel.
N/Aa
Performance Option Part Number Pump Fuel Shutoff Pump Position Sensor Improper Pattern Indicator Pump Position Sensor Input Noise Indicator Pump Position Sensor Speed
a
N/Aa N/Aa %
rpm
RG41221,000012D 1923APR033/4
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PN=230

Parameter Pump Position Sensor Status Pump Self Test Pump Speed Pump Status Pump Timing - Actual Pump Timing - Commanded Pump Timing Duty Cycle Pump Timing - Start of Pumping Sensor Supply #1 Voltage Sensor Supply #2 Voltage Throttle Position Throttle Type Units N/A
a
Description When status is 15, the ECU is receiving ALL of the signal. When the status is below 15, it means that the ECU is not receiving all of the signal. The injection pump performs a test on all internal components. The speed of the timing wheel internal to the injection pump. Current status of the pump - engine running or stopped. Timing of the injection pump. Timing commanded to the injection pump from the ECU. The ECU controls the duty cycle to maintain a constant fuel pressure at a given speed. The angle at which the pump starts to pump fuel. Voltage that ECU supplies sensors on voltage supply #1 Voltage that ECU supplies sensors on voltage supply #2 Percentage of throttle being used. Level 4 Electronic Fuel Systems operate with several different types of throttles. Throttle Type displays the type being used on this application at the current time. 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 maximum fuel. See APPLICATION SPECIFICATIONS in Section 6, Group 210 of this manual. Transfer pump runs in open or closed loop mode Percentage of duty cycle that the pump is performing at. These are the vehicle specific options for the engine like fuel derates, shutdowns, sensor thresholds, ect. The serial number of the vehicle that this engine is located in. Vehicle speed calculated by ECU from the wheel speed PWM signal Vehicle speed ECU receives over the CAN bus via another electronic controller. 04 160 21
N/Aa rpm N/Aa degrees degrees % degrees volts volts % N/Aa
Torque Curve Number
N/Aa
Transfer Pump Control Status Transfer Pump Duty Cycle Vehicle Option Part Number Vehicle Serial Number Vehicle Speed - Calculated Vehicle Speed - CAN
a
N/Aa % N/Aa N/Aa km/hr (mi/hr) km/hr (mi/hr)
RG41221,000012D 1923APR034/4
CTM170 (14MAY03)
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PN=231
Engine Test InstructionsCylinder Misfire Test

NOTE: The availability of this test is dependent on the version of software in the ECU. If this test is unavailable, see TEST FOR CYLINDER MISFIRE (ENGINE RUNNING) in Section 4, Group 150 earlier in this manual.
For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. The Cylinder Misfire Test is used to compare the output of each cylinder relative to each of the other cylinders. The test will help identify problems such as an engine misfire or irregularly running engine. During the test, the Engine Control Unit (ECU) will disable a cylinder, then accelerate the engine with a fixed amount of fuel and measure the time taken to accelerate the engine from one speed to the next with that cylinder disabled. The ECU will then repeat the procedure for the remaining cylinders. The Cylinder Misfire Test cannot determine if an engine is delivering low power. The test results are only a guide to help determine if there is a problem in a cylinder. The results alone should not be used as a conclusive reason for replacing the injection pump or nozzles. Other information such as the results of a Compression Test, Cylinder Cutout Test, and other engine diagnostic procedures should be used to accurately determine the source of an engine problem. Before executing the Cylinder Misfire Test Warm engine to normal operating temperature Repair the cause of any Diagnostic Trouble Codes (DTCs) Remove any load to the engine that may change during the test. For example, turn the air conditioner off. Performing the Cylinder Misfire Test 1. Engine idling - 0% throttle 2. Select Cylinder Misfire Test on the DST or SERVICE ADVISOR. 3. Follow instruction given by the diagnostic software. The software will instruct that the throttle lever be moved from low idle position to wide open throttle position, then back to low idle position 6 times.
04 160 22
NOTE: On most Marine applications, either throttle may be used to run this test. However, on some early applications, only analog throttle (B) can run this test. In this situation the connectors for analog throttle (A) and analog throttle (B) need to be switched to allow operation from analog throttle (A). After this test is completed, the connectors need to be switched back.
The diagnostic software will inform the test operator if the test was not successfully completed. If the test was successfully completed, the results will be displayed on the screen. Results shown will represent each cylinders performance as a percentage in relation to the average of all cylinders. If any cylinder is above or below the average by more than 10%, that indicates the cylinder is contributing too much (above average) or not contributing enough (below average).
NOTE: The ECU will not allow the test to run if there are any active DTCs.
RG,RG34710,1561 1921OCT021/2
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Trouble Code Diagnostics and Tests NOTE: It is recommended that the test be run at least 3 times to ensure repeatable, accurate results.
The Compression Test should be performed to help determine the cause of the problem in the cylinder(s) that was above or below average.
RG,RG34710,1561 1921OCT022/2
04 160 23
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PN=233
Engine Test InstructionsCompression Test

NOTE: The availability of this test is dependent on the version of software in the ECU. If this test is unavailable, see TEST ENGINE COMPRESSION PRESSURE in Section 4, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104).
For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. The Compression Test is used to compare the compression of each cylinder to the average compression of all cylinders. The test will help determine if a cylinder has low compression compared to all other cylinders. During the test, the Engine Control Unit (ECU) will disable the engine from starting (by not activating the high pressure solenoid valve in the injection pump), then measure the time it takes the piston of each cylinder to accelerate through and past TDC. A piston that accelerated faster than the rest would indicate that cylinder has lower compression than the other cylinders. The Compression Test cannot determine the true compression pressure of any cylinder, it can only compare each cylinder to the average. The test results are only a guide to help determine if a cylinder has lower compression. The results alone should not be used as a conclusive reason for performing any major engine work. Other information such as the results of the Cylinder Misfire Test, Cylinder Cutout Test, and other engine diagnostic procedures should be used to accurately determine the source of an engine problem. Before executing the Compression Test Warm engine to normal operating temperature Further engine diagnostics should be performed to determine the cause of low compression. Repair the cause of any Diagnostic Trouble Codes (DTCs)
Ensure that the battery and starter are in good working condition Performing the Compression Test 1. Key ON, engine OFF.
04 160 24
2. Select Compression Test on the DST or SERVICE ADVISOR. 3. Follow instruction given by the diagnostic software. The software will instruct that the engine be cranked for up to 15 seconds. Typically, it should take less than 5 seconds. The DST or SERVICE ADVISOR. should be observed carefully for instructions during the test. The diagnostic software will inform the test operator if the test was not successfully completed. If the test was successfully completed, the results will be displayed on the screen. Results shown will represent each cylinders compression as a percentage in relation to the average of all cylinders. If any cylinder is more than 10% below the rest, that indicates the cylinders compression is lower than the rest.
NOTE: It is recommended that the test be run at least 3 times to ensure repeatable, accurate results.
RG,RG34710,1562 1921OCT021/1
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PN=234
Engine Test Instructions Cylinder Cutout Test

NOTE: The availability of this test is dependent on the version of software in the ECU.
For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. The Cylinder Cutout Test is used to aid in identifying a cylinder that is having a problem or to help in diagnosing mechanical or intermittent problems. During the test, the Engine Control Unit (ECU) will disable the cylinder(s) that the technician selects. This test can be performed while operating the vehicle under the conditions that the problem occurs. The Cylinder Cutout Test can not determine if an engine is developing low power. The test is only a guide to help determine if there is a problem in a cylinder. The results alone should not be used as a conclusive reason for replacing the injection pump or nozzles. Other information such as the results of a Compression Test and other engine diagnostic procedures should be used to accurately determine the source of the engine problem. Before executing the Cylinder Cutout Test Warm engine to normal operating temperature Repair the cause of any Diagnostic Trouble Codes (DTCs)
Ensure that the battery and starter are in good working condition Performing the Cylinder Cutout Test 1. Engine idling or under the conditions that the problem occurred. 2. Select Cylinder Cutout Test on the DST or SERVICE ADVISOR. 3. Follow instructions given by the DST or SERVICE ADVISOR. 4. Select the cylinder to be cut out. 5. Observe engine operation and the parameters on the DST or SERVICE ADVISOR. These parameters include: engine load at current speed, engine speed, and manifold air temperature. 6. Use this data and observations to help in the diagnosis of the problem.
04 160 25
NOTE: It is recommended that the test be run at least 3 times to ensure repeatable, accurate results.
DPSG,RG40854,358 1921OCT021/1
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Engine Test Instructions - Excavator Torque Curve Change Test

Torque curve adjustment may be necessary for excavators operating in high altitude areas. By selecting the altitude derate option, undesired observable symptoms such as excessive black smoke can be significantly reduced or eliminated. Torque curve adjustment can only be accomplished with the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. Performing the Torque Curve High-altitude Adjustment 1. Ignition ON, engine off. 2. Select Excavator Torque Curve Change Test on the DST or SERVICE ADVISOR. 3. Select the option that corresponds to the desired operation. 1. Normal operation 2. Altitude derate
04 160 26
RG41221,000005E 1921OCT021/1
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PN=236
Engine Test Instructions - Tractor Torque Curve Change Test

Torque curve adjustment may be necessary for tractors while operating on a dynamometer. This test allows the user to select the highest torque curve available on the tractor in order to simulate the max power. Torque curve adjustment can only be accomplished with the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR in Group 160 later in this manual. Performing the Torque Curve Dynamometer Adjustment
04 160 27
1. Ignition ON, engine off. 2. Select Tractor Torque Curve Change Test on the DST or SERVICE ADVISOR. 3. Select the option that corresponds to the desired operation. 1. Normal operation 2. Dynamometer setup
RG41221,000005F 1921OCT021/1
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Reprogramming Engine Control Unit (ECU)

John Deere Ag and Construction dealers are able to reprogram ECUs using SERVICE ADVISOR. See REPROGRAMMING ENGINE CONTROL UNIT USING SERVICE ADVISOR later in this Group. OEM Distributors are able to reprogram ECUs using Diagnostic Scan Tool (DST). See REPROGRAMMING ENGINE CONTROL UNIT USING DST later in this Group.
04 160 28
RG41221,0000092 1904NOV021/1
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Downloading Payload File For DST

IMPORTANT: The Engine Serial Number (ESN) for the engine that this instruction is to be performed on is required for downloading the proper payload file.
NOTE: An Internet connection will be needed for steps 1 - 12.

1. Start Internet browser (Internet Explorer version 5.5 or later).
04 160 29
RG41221,0000097 1904NOV021/11
Web Address
2. In the address line (A) type in http://sds.deere.com and press theEnter key. Log in as required.
Continued on next page RG41221,0000097 1904NOV022/11
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RG12617
1918SEP02
PN=239
Obtaining Valid License
04 160 30
Validating License
NOTE: Steps 3 - 5 only need to be completed the first time this instruction is performed.
3. A license file is required for each computer that will reprogram ECUs. Download the license file to gain
permissions. Click on License(B). A screen will appear while validating license.
RG41221,0000097 1904NOV023/11
RG12630
1919SEP02
Grant Always Screen
4. Click on Grant Always (G).
RG41221,0000097 1904NOV024/11
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RG12613
1920SEP02
RG12629
1919SEP02
PN=240
Verification Successful
5. Click OK (H) when license verification has completed.

RG41221,0000097 1904NOV025/11
RG12631
1919SEP02
6. Click on Download button (O). A screen will appear as the system verifies that a valid license file is present.
RG41221,0000097 1904NOV026/11
Selecting Engine for ECU Type
7. Scroll down and click on Engine (P).

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RG12632
1919SEP02
RG12579
1906SEP02
04 160 31
PN=241
Enter Engine Serial Number (ESN)
8. Click once in the ESN text box (Q) so the cursor is in the box. Type in the ESN into the text field. If you are replacing the current ECU, GO TO 9. If you are
04 160 32
reprogramming the existing ECU, click Download (R) and GO TO 11.
RG41221,0000097 1904NOV028/11
RG12618
1918SEP02
Replacing ECU
9. If the current machine is being replaced, check the Replacing the ECU box (E).
current ECU, the software will tie the engine serial number to the new ECU serial number.
10. Enter in the new ECUs serial number (F) located on the ECU label and click Download.
NOTE: Sometimes the original ECU will not be available for reprogramming. When a new ECU is being programmed to replace the
RG41221,0000097 1904NOV029/11
CTM170 (14MAY03)
04-160-32

051403
RG12701A
1914OCT02
PN=242

11. In the File Download window ensure that the Save this file to disk button (S) is selected and click OK (T).
File Download
RG12619
1918SEP02
04 160 33
RG41221,0000097 1904NOV0210/11
Save As Window
Download Complete
RG41221,0000097 1904NOV0211/11
CTM170 (14MAY03)
04-160-33

051403
RG12621
1918SEP02
12. The Save As window will appear. The file must be saved in C:\SDS\PAYLOADSN\ECU folder. Click on the pull down menu arrow (A) and navigate to the ECU folder (U). Ensure that file name (V) is the correct number and click Save (W). When the file has been successfully downloaded the Download Complete window will appear, click OK (X). Close the Internet browser.
RG12620
1918SEP02
PN=243
Reprogramming Engine Control Unit (ECU) With DST

IMPORTANT: Diagnostic Scan Tool (DST) Version 4.1 or later must be installed prior to performing the following instructions.
NOTE: Internet connection is not required to program an engine control unit.

1. If payload file has not been downloaded to computer, download now. See DOWNLOADING PAYLOAD FILE FOR DST earlier in this Group. 2. Ignition ON, engine OFF.
04 160 34
3. Connect computer with DST to the Diagnostic Connector on the engine.
RG41221,0000098 1904NOV021/9
DST Main Screen
4. Start the DST software. Click on Reprogram JD (Y).
RG41221,0000098 1904NOV022/9
CTM170 (14MAY03)
04-160-34

051403
RG12622
1918SEP02
PN=244

5. Click on the proper payload (A) and click OK (B).
Selecting Payload file for Reprogramming
RG12623
1918SEP02
04 160 35
RG41221,0000098 1904NOV023/9
Status Bar
RG41221,0000098 1904NOV024/9
7. If the ECU is being replaced, the above message will appear. If you have the old ECU, connect to it
and click YES. If the old ECU is not available, click NO.
RG41221,0000098 1904NOV025/9
CTM170 (14MAY03)
04-160-35

051403
RG12702
1911OCT02
RG12624
1918SEP02
6. A progress bar will appear while reprogramming the ECU. If the engine is equipped with warning alarms, these may come on while in process of reprogramming and should be ignored.
PN=245
8. If the ECU is being replaced, the software will notice that the engine serial number does not match the ECU serial number. This message lets
the user know that the ECU expects a different engine serial number to match its ECU serial number. Click OK to continue.
RG41221,0000098 1904NOV026/9
04 160 36
Payload Processor Completed
RG41221,0000098 1904NOV027/9
CTM170 (14MAY03)
04-160-36

051403
RG12625
1918SEP02
9. When reprogramming the ECU has been successfully completed, the Payload Processor window will appear. Click OK.
RG12703
1914OCT02
PN=246

RG12626 1918SEP02
Return File Message
Automatic E-mail Generated
10. A return file is created when reprogramming an ECU is completed. The MFT window will appear showing the return file to send back. Click OK. This will automatically generate an E-mail
message with the proper E-mail address. Click Send (C). The next time the mail application is connected to the mail server the message will be sent.
RG41221,0000098 1904NOV028/9
CTM170 (14MAY03)
04-160-37

051403
RG12627
1924SEP02
04 160 37
PN=247
Exit DST Software
11. Once the E-mail has been successfully sent, click Exit (D) to close DST.
12. Disconnect computer from diagnostic connector and start engine to ensure proper operation.
RG41221,0000098 1904NOV029/9
CTM170 (14MAY03)
04-160-38

051403
RG12628
04 160 38
1918SEP02
PN=248
Downloading Payload File For SERVICE ADVISOR

NOTE: An Internet connection will be needed for steps 1 - 15.
1. Start SERVICE ADVISOR
RG41221,0000094 1904NOV021/16
04 160 39
2. Select vehicle model (A) with the proper serial number range or if PIN is known select the PIN tab and enter PIN number. Click OK.
CTM170 (14MAY03)
04-160-39

051403
RG12571
1906SEP02
RG41221,0000094 1904NOV022/16
PN=249
3. Describe Problem window will appear, click OK (C).

04 160 40
RG41221,0000094 1904NOV023/16 RG12573 1906SEP02
4. Click on JD Web tab (D). In the upper right hand corner click on Connect to Network button (E). Select network connection type and click OK.
CTM170 (14MAY03)
04-160-40

051403
RG12572
1906SEP02
PN=250
NOTE: Menu options may vary on the SERVICE ADVISORmenu.

5. If the Engine Serial number (ESN) is available click on "Software Delivery System" button (S) and skip
to step 10. With the PIN number only available click on "Equipment Information" (F) button.
RG12574
1906SEP02
04 160 41
RG41221,0000094 1904NOV025/16
6. Enter PIN number (I) if not already filled in, and select Machine Configuration (J). Equipment detail
information for this vehicle will appear on the screen.

CTM170 (14MAY03)
04-160-41

051403
RG12575
1906SEP02
PN=251
04 160 42
7. Hold left mouse button down and drag across the ESN so that it is highlighted. Click the right mouse
button and select "Copy" (L) or record the ESN for later use.
RG41221,0000094 1904NOV027/16 RG12577 1906SEP02
8. Click on the Home button (M) within SERVICE ADVISOR to go back to the menu.
RG41221,0000094 1904NOV028/16
9. Click on Software Delivery System button (S). Login if necessary.
RG12576
1906SEP02
RG41221,0000094 1904NOV029/16
CTM170 (14MAY03)
04-160-42

051403
PN=252
RG12578
1906SEP02
Obtaining Valid License
RG12614
1906SEP02
RG12612
1906SEP02
Validating License
04 160 43
Figure B
NOTE: Steps 10 - 12 only need to be completed the first time this instruction is performed.
10. A license file is required for each computer that will reprogram ECUs. Download the license file to
gain permissions. Click on License (B). A screen will appear while validating license. If the screen appears as Figure B allowing the option to download only, then skip to Step 13.
RG41221,0000094 1904NOV0210/16
CTM170 (14MAY03)
04-160-43

051403
RG12616
1906SEP02
PN=253
11. Click on Grant Always (G).

04 160 44
RG41221,0000094 1904NOV0211/16
12. Click OK (H) when license verification has been completed.
RG41221,0000094 1904NOV0212/16
CTM170 (14MAY03)
04-160-44

051403
RG12615
1906SEP02
RG12613
1920SEP02
PN=254
13. Click on Download button (O). A screen will appear as the system verifies that a valid license file is present.
RG12579
1906SEP02
04 160 45
RG41221,0000094 1904NOV0213/16
14. Scroll down and click on Engine (P).
RG41221,0000094 1904NOV0214/16
15. Click once in the ESN text box (Q) so the cursor is in the box. Type in the ESN or Right click and select "Paste" to copy the ESN into the text field.
If you are replacing the ECU, go to step 16. If you reprogramming the existing ECU, click "Download" (R) and go to step 18.
RG41221,0000094 1904NOV0215/16
CTM170 (14MAY03)
04-160-45

051403
RG12581
1906SEP02
RG12580
1906SEP02
PN=255
Replacing ECU
16. If the current machine is being replaced, check the Replacing the ECU box (E).
04 160 46
IMPORTANT: Service ADVISOR software must be closed and reopened prior to programming the ECU. 18. After downloading the ECU payload to the computer, exit SERVICE ADVISOR
NOTE: Sometimes the original ECU will not be available for reprogramming. When a new ECU is being programmed to replace the current ECU, the software will tie the engine serial number to the new ECU serial number.
17. Enter in the new ECUs serial number (F) located on the ECU label and click Download.
RG41221,0000094 1904NOV0216/16
CTM170 (14MAY03)
04-160-46

051403
RG12701A
1914OCT02
PN=256
Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR

IMPORTANT: Ignition ON, engine OFF. Connect computer with SERVICE ADVISORto the Diagnostic Connector in the cab or on the engine.
RG41221,0000099 1904NOV021/8
04 160 47
NOTE: Internet connection is not required to program an engine control unit.

1. Start SERVICE ADVISOR. Select vehicle model (A) with the proper serial number range or if PIN is
known select the PIN tab and enter PIN number. Click OK.
RG12571
1906SEP02
RG41221,0000099 1904NOV022/8
CTM170 (14MAY03)
04-160-47

051403
PN=257
2. Describe Problem window will appear, click OK (C).

04 160 48
RG41221,0000099 1904NOV023/8
RG12572
1906SEP02
3. Click on Readings pull down menu and select Program Controller (X).
CTM170 (14MAY03)
04-160-48

051403
RG12582
1906SEP02
PN=258
RG12583
1906SEP02
04 160 49
4. Select radio button for "Component" (T). Select the proper payload file for engine ECU (U).
5. Click once on "Engine Control Unit" (V) and click on "Program Controller" (W).
RG41221,0000099 1904NOV025/8 RG12584 1906SEP02
6. A progress bar will appear while reprogramming the ECU. The engine warning light may come on and a warning may sound while in process of reprogramming and should be ignored.
RG41221,0000099 1904NOV026/8
CTM170 (14MAY03)
04-160-49

051403
PN=259
7. If the ECU is being replaced, the above message will appear. If you have the old ECU, connect to it
and click YES. If the old ECU is not available, click NO.
04 160 50
RG41221,0000099 1904NOV027/8
8. If the ECU is being replaced, the software will notice that the engine serial number does not match the ECU serial number. This message lets the user know that the ECU expects a different engine serial number to match its ECU serial number. Click OK to continue.
9. Disconnect computer from diagnostic connector and start vehicle to ensure proper operation.
RG41221,0000099 1904NOV028/8
CTM170 (14MAY03)
04-160-50

051403
RG12703
1914OCT02
RG12702
1911OCT02
PN=260
Diagnostic Trouble Codes (DTCs)

There are several different methods of displaying both stored and active DTCs from the ECU. 2-DIGIT CODES Most John Deere applications display DTCs as a 2-digit or a 3-digit code read from an on-board display. To translate 2-digit or 3-digit codes into SPN/FMI code for diagnosing, see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU - Ascending 2-Digit/3-Digit Codes later in this Group. SPN/FMI CODES SPN/FMI codes are written from the SAE J1939 standard as a two part code. The first part is called the Suspect Parameter Number (SPN). Typically, it contains between 2 and 4 digits. The SPN identifies the system or the component that has the failure; for example SPN 110 indicates a failure in the engine coolant temperature circuit. The second part of the code is called the Failure Mode Identifier (FMI) code. The FMI contains 2 digits. The FMI identifies the type of failure that has occurred; for example FMI 3 indicates value above normal. In order to determine the exact failure, both the SPN and FMI are required. Combining SPN 110 with FMI 3 yields engine coolant temperature input voltage high. On all applications with the Level 4 Engine Control Unit (ECU), the ECU transmits SPN/FMI codes over the Controller Area Network (CAN). This allows for service tools such as the DST, SERVICE ADVISOR, and the Diagnostic Gauge to display active and stored DTCs. When using DST or SERVICE ADVISOR the codes will be displayed in a 000000.00 format. For example, SPN 110 FMI 3 will be displayed as 000110.03. WARNING LAMP On some applications, there is a warning lamp (also referred to as the Air Heater Indicator light) that is used when a code becomes active. When a code is active, this lamp will either blink or stay on solid. A solid light indicates that the ECU is taking extreme measures to protect the engine. A blinking light indicates that the ECU has detected a fault and engine performance may be affected. CLEARING STORED DTCS Stored DTCs can be cleared through the OEM instrument panel, through the Diagnostic Scan Tool (DST) or SERVICE ADVISOR. For more information on clearing DTCs using the diagnostic code reader on the instrument panel, see CLEARING STORED DTCS ON DIAGNOSTIC GAUGE earlier in this Group.
04 160 51
SERVICE ADVISOR is a trademark of Deere & Company SERVICE ADVISOR
DPSG,RG40854,467 1921OCT021/1
CTM170 (14MAY03)
04-160-51

051403
PN=261
Listing of Diagnostic Trouble Codes (DTCs) on ECU

Ascending SPN/FMI Codes
DTCs Listing in Ascending SPN/FMI Codes SPN FMI 2-Digit Code 000028 03 13 04 14 000029 03 15 04 16 000084 02 91 000091 03 11 04 12 09 000094 01 58 03 27 04 28 18 57 000097 00 16 000100 01 75 03 23 04 24 18 74 000105 00 56 03 25 04 26 16 55 000107 00 000110 00 63 03 18 04 19 15 61 16 62 000111 01 64 000158 17 54 000174 00 67 15 33/53 16 71 31 98 000189 00 31 48 000190 00 42 16 42 000620 03 21 04 22 000627 04 76 000629 13 34 19 34 000632 02 37 05 86 000636 02 44 08 43 10 44 Definition Throttle Volts High Throttle Volts Low Throttle Volts High Throttle Volts Low Vehicle Speed Mismatch Throttle Volts High Throttle Volts Low Throttle Invalid Fuel Supply Pressure Extremely Low Fuel Supply Pressure Input Voltage High Fuel Supply Pressure Input Voltage Low Fuel Supply Pressure Moderately Low Water in Fuel Continuously Detected Water in Fuel Detected Engine Oil Pressure Extremely Low Engine Oil Pressure Input Voltage High Engine Oil Pressure Input Voltage Low Engine Oil Pressure Moderately Low Manifold Air Temperature Extremely High Manifold Air Temperature Input Voltage High Manifold Air Temperature Input Voltage Low Manifold Air Temperature Moderately High Air Filter Differential Pressure Engine Coolant Temperature Extremely High Engine Coolant Temperature Input Voltage High Engine Coolant Temperature Input Voltage Low Engine Coolant Temperature High Least Severe Engine Coolant Temperature Moderately High Engine Coolant Level Low ECU Power Down Error Fuel Temperature High Most Severe Fuel Temperature High Least Severe Fuel Temperature High Moderately Severe Fuel Temperature Sensor Faulty Engine Speed Derate Engine Speed Derate Engine Overspeed Extreme Engine Overspeed Moderate Sensor Supply Voltage High Sensor Supply Voltage Low ECU Unswitched Power Missing ECU Error ECU to Pump Communication Error Fuel Shutoff Error Fuel Shutoff Non-Functional Pump Position Input Noise Pump Position Input Missing Pump Position Input Pattern Error
04 160 52
RG41221,0000130 1911MAY011/4
CTM170 (14MAY03)
04-160-52

051403
PN=262

000637 02 08 10 03 05 02 09 02 31 31 02 02 07 11 12 19 31 07 11 31 03 04 03 04 31 31 02 31 13 39 38 39 Crank Position Input Noise Crank Position Input Missing Crank Position Input Pattern Error Inlet Air Heater Signal High Inlet Air Heater Signal Low Calculated Vehicle Speed Input Noise Vehicle Speed Invalid/Missing Auxiliary Engine Shutdown Switch Signal Invalid Auxiliary Engine Shutdown Switch Active External Engine Derate Switch Active Tire Size Error Pump Detected Defect Attempting to Fuel Without Command Pump Supply Voltage Out of Range Pump Self Test Error Pump Detected Communication Error Pump Initiated Engine Protection ECU/Pump Timing Moderately Out of Sync ECU/Pump Speed Out of Sync ECU/Pump Timing Extremely Out of Sync Sensor Supply 1 Voltage High Sensor Supply 1 Voltage Low Sensor Supply 2 Voltage High Sensor Supply 2 Voltage Low Engine Shutdown Warning Engine Shutdown Pump Power Relay Fault Fuel Derate Security Violation
000729 000810 000898 000970 000971 001069 001076 001077
92 77 83 84 93 66 35 68 97 96 36 95 87 94 21 22 51 52 82 89 47
001078
001079 001080 001109 001110 001485 001569 002000
04 160 53
RG41221,0000130 1911MAY012/4
CTM170 (14MAY03)
04-160-53

051403
PN=263

Ascending 2-Digit Codes
DTCs Listing in Ascending 2-Digit Codes 2-Digit Code SPN FMI 11 000091 03 12 000091 04 13 000028 03 14 000028 04 15 000029 03 16 000029 04 18 000110 03 19 000110 04 21 001079 03 22 001079 04 23 000100 03 24 000100 04 27 000094 03 28 000094 04 31 001080 03 32 001080 04 32 NAa NAa 33 000174 15 33 NAa NAa 34 000629 19 35 001077 07 36 001077 31 37 000632 02 38 000637 08 39 000637 02/10 42 000190 00/16 43 000636 08 44 000636 02/10 47 001569 31 48 000189 31 53 000174 15 54 000158 17 57 000094 18 58 000094 01 61 000111 01 62 000110 16 63 000110 00 66 001076 02 67 000174 00 68 001077 11 71 000174 16 74 000100 18 75 000100 01 76 000627 04 77 000898 09 86 000632 05 87 001078 11 88 NAa NAa 89 001485 02 a Not Applicable Definition Throttle Volts High Throttle Volts Low Throttle Volts High Throttle Volts Low Throttle Volts High Throttle Volts Low Engine Coolant Temperature Input Voltage High Engine Coolant Temperature Input Voltage Low Sensor Supply 1 Voltage High Sensor Supply 1 Voltage Low Engine Oil Pressure Input Voltage High Engine Oil Pressure Input Voltage Low Fuel Supply Pressure Input Voltage High Fuel Supply Pressure Input Voltage Low Sensor Supply 2 Voltage High Sensor Supply 2 Voltage Low When reading blink codes, signifies start of active fault codes. Fuel Temperature High Least Severe When reading blink codes, signifies start of previously active fault codes. ECU to Pump Communication Error Attempting to Fuel Without Command Pump Initiated Engine Protection Fuel Shutoff Error Crank Position Input Missing Crank Position Input Noise/Crank Position Input Pattern Error Engine Overspeed Extreme/Engine Overspeed Moderate Pump Position Input Missing Pump Position Input Noise/Event Sensor Input Pattern Error Fuel Derate Engine Speed Derate Fuel Temperature High Least Severe ECU Power Down Error Fuel Supply Pressure Moderately Low Fuel Supply Pressure Extremely Low Engine Coolant Level Low Engine Coolant Temperature Moderately High Engine Coolant Temperature Extremely High Pump Detected Defect Fuel Temperature High Most Severe Pump Supply Voltage Out of Range Fuel Temperature High Moderately Severe Engine Oil Pressure Moderately Low Engine Oil Pressure Extremely Low ECU Unswitched Power Missing Vehicle Speed Invalid/Missing Fuel Shutoff Error ECU/Pump Engine Speed Out of Sync When reading blink codes, signifies that no fault codes are in buffer. Pump Power Relay Fault
04 160 54
RG41221,0000130 1911MAY013/4
CTM170 (14MAY03)
04-160-54

051403
PN=264

91 92 93 94 95 96 97 98 000084 000810 001069 001078 001078 001077 001077 000174 02 02 02 31 07 19 12 31 Vehicle Speed Mismatch Calculated Vehicle Speed Input Signal Noise Tire Size Error ECU/Pump Timing Extremely Out of Sync ECU/Pump Timing Moderately Out of Sync Pump Detected Communication Error Pump Self Test Error Fuel Temperature Sensor Faulty
RG41221,0000130 1911MAY014/4
04 160 55
CTM170 (14MAY03)
04-160-55

051403
PN=265
Diagnostic Procedure
Diagnosis of the electronic control system should be performed according to the following procedure: 1. Make sure all engine mechanical and other systems not related to the electronic control system are operating properly. 2. Read and record DTC(s). 3. Go to the diagnostic chart that corresponds to the DTC(s) present.
NOTE: After using the DST or SERVICE ADVISOR, always replace the dust cap on the diagnostic connector.
IMPORTANT: Care should be used during diagnostic procedures to avoid damaging the terminals of connectors, sensors, and actuators. Probes should not be poked into or around the terminals or damage will result. Probes should only be touched against the terminals to make measurements. It is recommended that JT07328 Connector Adapter Test Kit be used to make measurements in connectors, sensors, and actuators. These adapters will ensure that terminal damage does not occur.
04 160 56
NOTE: If more than one DTC is present, go to the chart corresponding to the lowest number DTC and diagnose that problem to correction unless directed to do otherwise.
4. If no DTC(s) are present, proceed to the appropriate symptom diagnostic chart in Group 150 of this Section. 5. After any repairs are made, recheck to make sure all DTCs have been eliminated.
RG,RG34710,1564 1930SEP971/1
CTM170 (14MAY03)
04-160-56

051403
PN=266
Intermittent Fault Diagnostics

Intermittent faults are problems that periodically go away. A problem such as a loose terminal that intermittently doesnt make contact is a likely cause of an intermittent fault. Other intermittent faults may be set only under certain operating conditions such as heavy load, extended idle, etc. When diagnosing intermittent faults, take special note of the condition of wiring and connectors since a high percentage of intermittent problems originate here. Check for loose, dirty, or disconnected connectors. Inspect the wiring routing looking for possible shorts caused by contact with external parts (for example, rubbing against sharp sheet metal edges). Inspect the connector vicinity looking for wires that have pulled out of connector terminals, damaged connectors, poorly positioned terminals, and corroded or damaged terminals. Look for broken wires, damaged splices, and wire-to-wire shorts. Use good judgement if component replacement is thought to be required. includes a function called Recording. This function permits the recording of data parameter values during a diagnostic session. If a DTC sets during a certain diagnostic session, the parameters can be played back and observed to see what each parameters value was when the DTC occurred. If a faulty connection or wire is suspected to be the cause of the intermittent problem: clear DTCs, then check the connection or wire by wiggling it while watching the DST or SERVICE ADVISOR to see if the fault resets. To check the connection between the harness and a sensor or the harness and the ECU, use JT07328 Connector Adapter Test Kit. Insert the male end of the appropriate test adapter into the female end of the ECU or sensor connector terminal. There should be moderate resistance when the test adapter is inserted into the terminal. If the connection is loose, replace the female terminal. Possible Causes of Intermittent Faults: Faulty connection between sensor or actuator and harness. Faulty contact between terminals in connector. Faulty terminal/wire connection. Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc. can cause faulty signals to be sent to the ECU. Faulty ground feedback problems.
04 160 57
NOTE: The ECU is the component LEAST likely to fail.

Suggestions for diagnosing intermittent faults: If diagnostic chart indicates that the problem is intermittent, try to reproduce the operating conditions that were present when the DTC set. The Diagnostic Scan Tool (DST) or SERVICE ADVISOR can be used to help locate intermittent problems, as it
RG,RG34710,1565 1930SEP971/1
CTM170 (14MAY03)
04-160-57

051403
PN=267
T1 - Multi-state Throttle Input High

Instrument Panel Connector
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
J K L M N C
X B G W A D E F V U T S
S Sensor Ground
24
R High/Low Idle Input 49
S R
04 160 58 A B A B
Throttle Switch Connector JOHN DEERE Instrument Panel
ECU Connector Multi-state Throttle Switch The multi-state throttle is used when a few fixed engine speeds are desired. Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. On some applications, there is a bump up and a bump down feature. This allows for high and low idle to be controlled. There are three types of multi-state throttles; Dual-state, Tri-state, and Ramp. All of these throttles are wired exactly the same. The only difference is the actual switch that is used to control the engine speed. For information on each of these throttles, see MEASURING THROTTLE POSITION in Section 03, Group 140 earlier in this manual. On certain applications, an additional throttle is used in addition to the multi-state throttle. If the desired
engine speed of the additional throttle is greater than the multi-state throttle, the multi-state throttle will be overridden. When the desired engine speed of the multi-state throttle is greater than the additional throttle, the multi-state throttle will be in total control. This code will set if: The multi-state throttle input voltage exceeds the maximum threshold. The voltage is higher than what is 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 will ignore the input from the multi-state throttle, and will use the input values from another throttle.
RG41221,0000135 1921OCT021/2
CTM170 (14MAY03)
04-160-58

051403
PN=268
RG11722
1923OCT02

If the multi-state throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000135 1921OCT022/2
04 160 59
CTM170 (14MAY03)
04-160-59

051403
PN=269
T1 - Multi-state Throttle Input High
RG41221,0000136 1927APR021/1
T1 - Multi-State Throttle Input High Diagnostic Procedure
1/1
1 Connection Check 04 160 60
IMPORTANT: Do not force probes into connector terminals or damage will result. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur.
No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s).
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the multi-state throttle connector looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs. 5. Ignition ON, engine OFF 6. Move the multi-state switch through all the positions. 7. Read DTCs using DST or SERVICE ADVISOR.
000091.03 reoccurs: GO TO 3 000091.03 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-60

051403
PN=270

3 Throttle Position Input Shorted Test
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. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Using the ECU diagnostic software, read DTCs
000091.03 reoccurs: GO TO 4 000091.04 occurs: Faulty multi-state throttle switch connector OR Faulty multi-state throttle switch
1/1
4 Throttle Position Ground Circuit Open Test
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 terminal (terminal B) and a good chassis ground.
4.0 - 6.0 volts: Open in multi-state switch 04 ground circuit 160 OR 61 Faulty ECU connection OR Faulty ECU Below 4.0 volts: Open in multi-state switch 5 V input circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-61

051403
PN=271
T2 - Multi-state Throttle Input Low

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
J K L M N C
X B G W A D E F V U T S
S Sensor Ground
24
R High/Low Idle Input 49
S R
04 160 62 A B A B
Throttle Switch Connector JOHN DEERE Instrument Panel
ECU Connector Multi-state Throttle Switch The multi-state throttle is used when a few fixed engine speeds are desired. Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. On some applications, there is a bump up and a bump down feature. This allows for high and low idle to be controlled. There are three types of multi-state throttles; Dual-state, Tri-state, and Ramp. All of these throttles are wired exactly the same. The only difference is the actual switch that is used to control the engine speed. For information on each of these throttles, see MEASURING THROTTLE POSITION in Section 03, Group 140 earlier in this manual. On certain applications, an additional throttle is used in addition to the multi-state throttle. If the desired
engine speed of the additional throttle is greater than the multi-state throttle, the multi-state throttle will be overridden. When the desired engine speed of the multi-state throttle is greater than the additional throttle, the multi-state throttle will be in total control. This code will set if: The multi-state throttle input voltage drops below the minimum threshold. The voltage is lower than what is 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 will ignore the input from the multi-state throttle, and will use the input values from another throttle.
RG41221,0000137 1921OCT021/2
CTM170 (14MAY03)
04-160-62

051403
PN=272
RG11722
1923OCT02

If the multi-state throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000137 1921OCT022/2
04 160 63
CTM170 (14MAY03)
04-160-63

051403
PN=273
T2 - Multi-state Throttle Input Low
RG41221,0000138 1921OCT021/1
T2 - Multi-State Throttle Input Low Diagnostic Procedure
1/1
1 Connection Check 04 160 64
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the multi-state throttle connector looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs. 5. Ignition ON, engine OFF 6. Move the multi-state switch through all the positions. 7. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-64

051403
PN=274

3 Throttle Position Wiring Test
1. Ignition OFF 2. Disconnect multi-state throttle switch at two wire connector behind instrument panel. 3. Make note of any DTCs, then clear all DTCs 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read DTCs
000091.04 reoccurs: Short to ground in multi-state input circuit OR Open in multi-state input circuit OR Faulty ECU 000091.03 occurs: Faulty multi-state throttle switch connector OR Faulty multi-state throttle switch.
04 160 65
1/1
CTM170 (14MAY03)
04-160-65

051403
PN=275
T3 - Analog Throttle (A) Input High

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
J K L M N C
X B G W A F V E S U T R
C L M
Sensor Return Sensor Input Sensor 5V
24 31 53
D P
CLM
04 160 66
Analog Throttle (A) Sensor Connector Analog Throttle (A) Sensor A B C JOHN DEERE Instrument Panel A B C
ECU Connector
NOTE: Wiring schematic shows OEM engine applications only. For wiring information on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Analog Throttle Position Sensor The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle. The throttle input voltage normally varies between 1.0 and 4.0 volts depending on throttle position. Analog throttle voltage at low idle will be approximately 1.0 volt and 4.0 volts at high idle. The ECU has the ability to learn different voltages for low and high idle, so the voltages above may change depending on application. This code will set if:
The analog throttle (A) input voltage exceeds the sensors high voltage specification. The voltage is higher than what is physically possible for the throttle lever to achieve. For OEM applications, the analog throttle (A) input voltage specification is 4.7 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the analog throttle (A) input voltage specification. If this code sets, the following will occur: If more than one throttle is available, the ECU will ignore the input from the analog throttle, and will use the input values from another throttle. If the analog throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000139 1921OCT021/1
CTM170 (14MAY03)
04-160-66

051403
PN=276
RG11723
1916MAY01
T3 - Analog Throttle (A) Input High
RG41221,000013A 1921OCT021/1
T3 - Analog Throttle (A) Input High Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the analog throttle (A) connector looking for dirty, damaged, or poorly positioned terminals.
04 160 67
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Analog Throttle (A) in the idle position. 5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR.
4.7 volts or greater: GO TO 4 Below 4.7 volts: GO TO 3
NOTE: For OEM applications, the high analog throttle (A) input voltage is 4.7V. For the high voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-160-67

051403
PN=277

3 Throttle Travel Voltage Test
1. Slowly operate analog throttle (A) through its full travel. 2. Using the ECU diagnostic software, read the analog throttle (A) input voltage.
Goes above 4.7 volts: Faulty analog throttle (A) sensor connector OR Open in analog throttle (A) sensor ground circuit OR Faulty analog throttle (A) sensor Never goes above 4.7 volts: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 68
1/1
1. Ignition OFF 2. Disconnect analog throttle (A) sensor connector. 3. Ignition ON, Engine OFF 4. Using the ECU diagnostic software, read the analog throttle (A) input voltage.
0.3 volts or less: GO TO 5 Above 0.3 volts: Short to voltage in analog throttle (A) input circuit OR Faulty ECU
NOTE: For OEM applications, the low analog throttle (A) input voltage is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
1. Ignition OFF 2. Analog throttle (A) sensor connector still disconnected. 3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in the analog throttle (A) sensor connector.
Light ON: Faulty analog throttle (A) sensor connector OR Faulty analog throttle (A) sensor Light OFF: Open in analog throttle (A) ground circuit
1/1
CTM170 (14MAY03)
04-160-68

051403
PN=278
04 160 69
CTM170 (14MAY03)
04-160-69

051403
PN=279
T4 - Analog Throttle (A) Input Low

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
J K L M N C
X B G W A F V E S U T R
C L M
Sensor Return Sensor Input Sensor 5V
24 31 53
D P
CLM
04 160 70
Analog Throttle (A) Sensor Connector Analog Throttle (A) Sensor A B C JOHN DEERE Instrument Panel A B C
ECU Connector
The analog throttle (A) input voltage drops below the sensors low voltage specification. The voltage is lower than what is physically possible for the throttle lever to achieve. For OEM applications, the low analog throttle (A) input voltage specification is 0.3 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the analog throttle (A) input voltage specification. If this code sets, the following will occur: If more than one throttle is available, the ECU will ignore the input from the analog throttle, and will use the input values from another throttle. If the analog throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,000013B 1921OCT021/1
CTM170 (14MAY03)
04-160-70

051403
PN=280
RG11723
1916MAY01
T4 - Analog Throttle (A) Input Low
RG41221,000013C 1921OCT021/1
T4 - Analog Throttle (A) Input Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the analog throttle (A) connector looking for dirty, damaged, or poorly positioned terminals.
04 160 71
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Throttle (A) in the idle position. 5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR.
0.3 volts or less: GO TO 4 Above 0.3 volts: GO TO 3
1/1
CTM170 (14MAY03)
04-160-71

051403
PN=281

1. Slowly operate analog throttle (A) through its full travel. 2. Using the ECU diagnostic software, read the analog throttle (A) input voltage.
Goes below 0.3 volts: Faulty analog throttle (A) sensor connector OR Open in analog throttle (A) sensor ground circuit OR Faulty analog throttle (A) sensor Never goes above 0.3 volts: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 72
1/1
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 (terminals B and C) in the analog throttle (A) sensor connector on the engine harness. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read the analog throttle (A) input voltage.
Below 4.7 volts: GO TO 5 4.7 volts or greater: Faulty analog throttle (A) sensor connector OR Faulty analog throttle (A) sensor
1/1
CTM170 (14MAY03)
04-160-72

051403
PN=282

5 Throttle Position 5V Supply Test
1. Ignition OFF 2. Remove jumper wire. 3. Ignition ON, engine OFF 4. Using a multimeter, measure the voltage between the analog throttle (A) ground terminal and the 5 V Supply terminal (terminals A and C) in the analog throttle (A) sensor connector on the engine harness.
4.0-6.0 volts: Open in analog throttle (A) input circuit OR Short to ground in analog throttle (A) input circuit OR Faulty ECU connector OR Faulty ECU Below 4.0 volts: Open in analog throttle (A) 5 V Supply circuit OR Short to ground in analog throttle (A) 5 V Supply circuit OR 04 Faulty ECU connector 160 OR 73 Faulty ECU
1/1
CTM170 (14MAY03)
04-160-73

051403
PN=283
T5 - Analog Throttle (B) Input High
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Throttle Emulator
510
A B C Analog Throttle (B) Sensor Connector
4700 04 160 74
Analog Throttle (B) Sensor
A B C
A B C
Sensor Return 2
46
Analog Throttle (B) Input 28 Sensor 5V 03
ECU Connector
The analog throttle (B) input voltage exceeds the sensors high voltage specification. The voltage is higher than what is physically possible for the throttle lever to achieve. For OEM applications, the analog throttle (B) input voltage specification is 4.7 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the analog throttle (B) input voltage specification. If this code sets, the following will occur: If more than one throttle is available, the ECU will ignore the input from the analog throttle, and will use the input values from another throttle. If the analog throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,000013D 1921OCT021/1
CTM170 (14MAY03)
04-160-74

051403
RG11726
1916MAY01
PN=284
T5 - Analog Throttle (B) Input High
RG41221,000013E 1921OCT021/1
T5 - Analog Throttle (B) Input High Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection ECU connectors and the analog throttle (B) sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 75
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Analog Throttle (B) in the idle position. 5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR.
4.7 volts or greater: GO TO 4 Below 4.7 volts: GO TO 3
NOTE: For OEM applications, the high analog throttle (B) input voltage is 4.7V. For the high voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-160-75

051403
PN=285

1. Slowly operate analog throttle (B) through its full travel. 2. Using the diagnostic software, read the analog throttle (B) input voltage.
Goes above 4.7 volts: Faulty analog throttle (B) sensor connector OR Open in analog throttle (B) sensor ground circuit OR Faulty analog throttle (B) sensor Never goes above 4.7 volts: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 76
1/1
1. Ignition OFF 2. Disconnect analog throttle (B) sensor connector. 3. Ignition ON, Engine OFF 4. Using the ECU diagnostic software, read the analog throttle (B) input voltage.
0.3 volts or less: GO TO 5 Above 0.3 volts: Short to voltage in analog throttle (B) input circuit OR Faulty ECU
NOTE: For OEM applications, the low analog throttle (B) input voltage is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
1. Ignition OFF 2. Analog throttle (B) sensor connector disconnected. 3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in the analog throttle (B) sensor connector on the engine harness.
Light ON: Faulty analog throttle (B) sensor connector OR Faulty analog throttle (B) sensor Light OFF: Open in analog throttle (B) ground circuit
1/1
CTM170 (14MAY03)
04-160-76

051403
PN=286
04 160 77
CTM170 (14MAY03)
04-160-77

051403
PN=287
T6 - Analog Throttle (B) Input Low
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Throttle Emulator
510
A B C Analog Throttle (B) Sensor Connector
4700 04 160 78
Analog Throttle (B) Sensor
A B C
A B C
Sensor Return 2
46
Analog Throttle (B) Input 28 Sensor 5V 03
ECU Connector
The analog throttle (B) input voltage drops below the sensors low voltage specification. The voltage is lower than what is physically possible for throttle lever to achieve. For OEM applications, the low analog throttle (B) input voltage specification is 0.3 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low analog throttle (B) input voltage specification. If this code sets, the following will occur: If more than one throttle is available, the ECU will ignore the input from the analog throttle, and will use the input values from another throttle. If the analog throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,000013F 1921OCT021/1
CTM170 (14MAY03)
04-160-78

051403
RG11726
1916MAY01
PN=288
T6 - Analog Throttle (B) Input Low
RG41221,0000140 1921OCT021/1
T6 - Analog Throttle (B) Input Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors and the analog throttle (B) sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 79
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Analog Throttle (B) in the idle position. 5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR.
0.3 volts or less: GO TO 4 Above 0.3 volts: GO TO 3
1/1
CTM170 (14MAY03)
04-160-79

051403
PN=289

1. Slowly operate analog throttle (B) through its full travel. 2. Using the ECU diagnostic software, read the analog throttle (B) input voltage.
Goes below 0.3 volts: Faulty analog throttle (B) sensor connector OR Open in analog throttle (B) sensor ground circuit OR Faulty analog throttle (B) sensor Never goes above 0.3 volts: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 80
1/1
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 (terminals B and C) in the analog throttle (B) sensor connector on the engine harness. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read the analog throttle (B) input voltage.
Below 4.7 volts: GO TO 5 4.7 volts or greater: Faulty analog throttle (B) sensor connector OR Faulty analog throttle (B) sensor
1/1
CTM170 (14MAY03)
04-160-80

051403
PN=290

5 Throttle Position 5 V Supply Test
1. Ignition OFF 2. Remove jumper wire. 3. Ignition ON, engine OFF 4. Using a multimeter, measure the voltage between the analog throttle (B) ground terminal and the 5 V Supply terminal (terminals A and C) in the analog throttle (B) sensor connector on the engine harness.
4.0-6.0 volts: Open in analog throttle (B) input circuit OR Short to ground in analog throttle (B) input circuit OR Faulty ECU connector OR Faulty ECU Below 4.0 volts: Open in analog throttle (B) 5 V Supply circuit OR Short to ground in analog throttle (B) 5 V Supply circuit OR 04 Faulty ECU connector 160 OR 81 Faulty ECU
1/1
CTM170 (14MAY03)
04-160-81

051403
PN=291
T7 - CAN Throttle Invalid

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
44 42
E F G
04 160 82
D C A J H B
C C CAN Terminator CAN (Controller Area Network) Throttle CAN (Controller Area Network) throttle is information sent to the ECU by another controller over CAN of the desired throttle position. This code will set if: The ECU either does not receive throttle information over CAN, or the information received is not valid.
ECU Connector If this code sets, the following will occur:
If more than one throttle is available, the ECU will ignore the input from the CAN throttle, and will use the input values from another throttle. If the CAN throttle is the only throttle or all additional throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000145 1921OCT021/1
CTM170 (14MAY03)
04-160-82

051403
PN=292
RG11727
1923OCT02
B B A C
T7 - CAN Throttle Invalid
RG41221,0000146 1927APR021/1
T7 - CAN Throttle Invalid Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connector looking for dirty, damaged, or poorly positioned terminals.
04 160 83
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs. 5. Ignition ON, engine running 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-83

051403
PN=293

3 Application Related DTCs Test
If application has other machine controllers communicating on the CAN bus, check those controllers for CAN related DTCs.
No CAN related DTCs found on other controllers: GO TO 4 Found CAN related DTCs found on other controllers: Refer to diagnostic procedure for that controller.
1/1
04 160 84
4 Resistance Between CAN High and Low Test
1. Ignition OFF 2. Using a multimeter, measure resistance between terminals C and D in the harness end of the diagnostic connector.
Between 45-75 ohms: GO TO 5 Less than 45 or greater than 75 ohms: Faulty or missing CAN terminator connector(s) OR Open or short in CAN wiring harness.
1/1
5 CAN Wiring Shorted to Ground or Voltage Test
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 measurements between 1.5-3.5 volts: Faulty ECU connector OR Other connector in the CAN system OR Faulty ECU. Either measurement less than 1.5 or greater than 3.5 volts: CAN wiring shorted to ground or voltage OR Another controller in the CAN system is faulty OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-84

051403
PN=294
04 160 85
CTM170 (14MAY03)
04-160-85

051403
PN=295
T11 - Excavator Throttle Reference Voltage High
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Throttle Reference To Pump and Valve Controller Throttle Input
51 27
04 160 86
Throttle Ground
49
ECU Connector
NOTE: For more Excavator throttle wiring information, refer to machine manual.
Excavator Throttle The Excavator uses an analog throttle to measure throttle position. This throttle is connected to the Pump and Valve controller, which sends throttle input information to the ECU through a dedicated wire. Since the ECU uses and Pump and Valve controller do not share a common ground, a throttle voltage reference wire and a throttle ground wire accompany the throttle input wire. The ECU
calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. This code will set if: The excavator throttle reference voltage to the ECU exceeds 4.2 volts. If this code sets, the following will occur: The ECU will default excavator reference throttle voltage to 3.75 volts.
RG41221,0000147 1921OCT021/1
CTM170 (14MAY03)
04-160-86

051403
RG11728
1916MAY01
PN=296
T11 - Excavator Throttle Reference Voltage High
RG41221,0000148 1921OCT021/1
T11 - Excavator Throttle Reference Voltage High Diagnostic Procedure
NOTE: This procedure is only used to diagnose the Excavator Throttle.
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLE REFERENCE VOLTAGE HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the throttle sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 87
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs
000028.03 reoccurs when engine is off and running: GO TO 3 000028.03 reoccurs only when engine is running: GO TO 4 000028.03 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first.
5. Read DTCs using DST or SERVICE ADVISOR. Ignition ON, engine OFF Ignition ON, engine running
1/1
CTM170 (14MAY03)
04-160-87

051403
PN=297

3 Throttle Reference Wire Test
1. Ignition OFF 2. Disconnect ECU connector. 3. Using a multimeter, measure voltage between terminal 51 in the ECU connector on the engine harness and the ground stud of the Pump and Valve controller.
3.9 volts or less: GO TO 4 Greater than 3.9 volts: Short to power in throttle reference wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
4 Ground Test 04 160 88
There is a difference between grounds of the ECU and Pump and Valve controller. Check for loose ground connections at each controller.
1/1
CTM170 (14MAY03)
04-160-88

051403
PN=298
04 160 89
CTM170 (14MAY03)
04-160-89

051403
PN=299
T12 - Excavator Throttle Reference Voltage Low
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
51 27
04 160 90
Throttle Ground
49
ECU Connector
calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. This code will set if: The excavator throttle reference voltage to the ECU goes below 2.7 volts. If this code sets, the following will occur: The ECU will default excavator reference throttle voltage to 3.75 volts.
RG41221,0000149 1921OCT021/1
CTM170 (14MAY03)
04-160-90

051403
RG11728
1916MAY01
PN=300
T12 - Excavator Throttle Reference Voltage Low
RG41221,000014A 1921OCT021/1
T12 - Excavator Throttle Reference Voltage Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLE REFERENCE VOLTAGE LOW supporting information.
04 160 91
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs.
1/1
CTM170 (14MAY03)
04-160-91

051403
PN=301

3 Throttle Reference Wire Test
1. Ignition OFF 2. Disconnect the ECU connector. 3. Using a multimeter, measure voltage between terminal 51 in the harness end of the ECU connector and the ground stud of the Pump and Valve controller.
3.5 volts or greater: GO TO 4 Less than 3.5 volts: Open in throttle reference wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
4 Ground Test 04 160 92
There is a difference between the grounds of the ECU and Pump and Valve controller. Check for loose ground connections at each controller.
1/1
CTM170 (14MAY03)
04-160-92

051403
PN=302
04 160 93
CTM170 (14MAY03)
04-160-93

051403
PN=303
T13 - Excavator Throttle Ground Voltage High
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
51 27
04 160 94
Throttle Ground
49
ECU Connector
calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. This code will set if: The excavator throttle ground voltage to the ECU exceeds 3.0 volts. If this code sets, the following will occur: The ECU will default excavator throttle ground voltage to 0 volts.
RG41221,000014B 1921OCT021/1
CTM170 (14MAY03)
04-160-94

051403
RG11728
1916MAY01
PN=304
T13 - Excavator Throttle Ground Voltage High
RG41221,000014C 1921OCT021/1
T13 - Excavator Throttle Ground Voltage High Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLE GROUND VOLTAGE HIGH supporting information.
04 160 95
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs. 5. Read DTCs using DST or SERVICE ADVISOR. Ignition ON, engine OFF Ignition ON, engine running
1/1
CTM170 (14MAY03)
04-160-95

051403
PN=305

3 Throttle Ground Wire Test
1. Ignition OFF 2. Disconnect the ECU connector. 3. Disconnect Pump and Valve controller connector. 4. Using a multimeter, measure resistance between terminal 49 in the harness end of the ECU connector and the corresponding ground terminal of the Pump and Valve controller connector.
770 ohms or less: GO TO 4 Greater than 770 ohms: Short to power in throttle ground wire between ECU and 750 ohm resistor OR Open in throttle ground wire OR Faulty 750 ohm resistor OR Faulty ECU connector OR Faulty ECU
04 160 96
1/1
4 Pump and Valve Controller Test
1. Ignition OFF 2. ECU connector still disconnected. 3. Using a multimeter, measure resistance between terminal 49 in the harness end of the 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 Valve controller connector OR Faulty Pump and Valve controller
1/1
5 Ground Test
There is a difference between grounds of the ECU and Pump and Valve controller. Check for loose ground connection at each controller.
1/1
CTM170 (14MAY03)
04-160-96

051403
PN=306
04 160 97
CTM170 (14MAY03)
04-160-97

051403
PN=307
T14 - Excavator Throttle Ground Voltage Low
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
51 27
04 160 98
Throttle Ground
49
ECU Connector
calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. This code will set if: The excavator throttle ground voltage to the ECU goes below 2.0 volts. If this code sets, the following will occur: The ECU will default excavator throttle ground voltage to 0 volts.
RG41221,000014D 1921OCT021/1
CTM170 (14MAY03)
04-160-98

051403
RG11728
1916MAY01
PN=308
T14 - Excavator Throttle Ground Voltage Low
RG41221,000014E 1921OCT021/1
T14 - Excavator Throttle Ground Voltage Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLE GROUND VOLTAGE LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connector and the throttle sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 99
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs. 5. Read DTCs using DST or SERVICE ADVISOR. Ignition ON, engine OFF Ignition ON, engine running
1/1
CTM170 (14MAY03)
04-160-99

051403
PN=309

3 Throttle Ground Test
1. Ignition OFF 2. Disconnect the ECU connector. 3. Using a multimeter, measure resistance between terminal 49 in the harness end of the ECU connector and the corresponding ground terminal of the Pump and Valve controller connector.
730 ohms or greater: GO TO 4 Less than 730 ohms: Short to ground in throttle ground wire between ECU and resistor OR Faulty ECU connector OR Faulty ECU
1/1
4 Ground Test 04 160 ,100
1/1
CTM170 (14MAY03)
04-160-100

051403
PN=310
04 160 ,101
CTM170 (14MAY03)
04-160-101

051403
PN=311
T15 - Excavator Throttle Input Voltage High
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
51 27
04 160 ,102
Throttle Ground
49
ECU Connector
calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. This code will set if: The excavator throttle input voltage to the ECU exceeds 4.9 volts. If this code sets, the following will occur: The ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,000014F 1921OCT021/1
CTM170 (14MAY03)
04-160-102

051403
RG11728
1916MAY01
PN=312
T15 - Excavator Throttle Input Voltage High
RG41221,0000150 1921OCT021/1
T15 - Excavator Throttle Input Voltage High Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUT VOLTAGE HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connector and the throttle sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 ,103
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs.
1/1
CTM170 (14MAY03)
04-160-103

051403
PN=313

3 Throttle Signal Wire Test
1. Ignition OFF 2. Disconnect the ECU connector. 3. Using a multimeter, measure voltage between terminal 27 in the harness end of the ECU connector and the ground pin of the Pump and Valve controller.
4.0 volts or less: GO TO 4 Greater than 4.0 volts: Short to power in throttle signal wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
1/1
CTM170 (14MAY03)
04-160-104

051403
PN=314
04 160 ,105
CTM170 (14MAY03)
04-160-105

051403
PN=315
T16 - Excavator Throttle Input Voltage Low
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
51 27
04 160 ,106
Throttle Ground
49
ECU Connector
calculates the differences in controller grounds in order to determine the throttle request by the Pump and Valve controller. This code will set if: The excavator throttle input voltage to the ECU goes below 0.1 volts. If this code sets, the following will occur: The ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000151 1921OCT021/1
CTM170 (14MAY03)
04-160-106

051403
RG11728
1916MAY01
PN=316
T16 - Excavator Throttle Input Voltage Low
RG41221,0000152 1921OCT021/1
T16 - Excavator Throttle Input Voltage Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT VOLTAGE LOW supporting information.
04 160 ,107
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs
1/1
CTM170 (14MAY03)
04-160-107

051403
PN=317

3 Throttle Signal Wire Test
1. Ignition OFF 2. Disconnect the ECU connector. 3. Using a multimeter, measure voltage between terminal 27 in the harness end of the ECU connector and the ground pin of the Pump and Valve controller.
1.0 volts or greater: GO TO 4 Less than 1.0 volts: Open in throttle signal wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
There is a difference between grounds of the ECU and MCX controller. Check for loose ground connection at each controller.
1/1
CTM170 (14MAY03)
04-160-108

051403
PN=318
04 160 ,109
CTM170 (14MAY03)
04-160-109

051403
PN=319
T17 - Analog Throttle (C) Input High
04 160 ,110
Analog Throttle (C) Position Sensor The analog throttle (C) position sensor is a variable resistor (potentiometer) used to measure the position of the cruise throttle. The throttle input voltage normally varies between 0.75 and 4.25 volts depending on throttle position. This code will set if: The analog throttle (C) input voltage exceeds the sensors high voltage specification. The voltage is higher than what is physically possible for the throttle lever to achieve. For OEM applications, the high analog throttle (C) input voltage specification is 4.8 volts.
For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high analog throttle (C) input voltage specification. If this code sets, the following will occur: The ECU will ignore the input from the cruise analog throttle, and it will use the input values from the hand and foot analog throttles. When this code is set, the ECU will limit the inputs of the hand and foot analog throttles from exceeding 1500 rpm. The ECU will set a BLINKING warning light. If the hand and foot analog throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000141 1921OCT021/1
CTM170 (14MAY03)
04-160-110

051403
PN=320
RG10828
1923JUN00
T17 - Analog Throttle (C) Input High
RG41221,0000142 1921OCT021/1
T17 - Analog Throttle (C) Input High Diagnostic Procedure
NOTE: If DTC 000028.03 is accompanied with DTC 001079.03, follow the DTC 001079.03 diagnostic chart first.
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE (C) INPUT HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the analog throttle (C) sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 ,111
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Throttle (C) in the idle position 5. Read the analog throttle (C) voltage parameter on DST or SERVICE ADVISOR.
4.8 V or greater: GO TO 4 Below 4.8 V: GO TO 3
NOTE: For OEM applications, the high analog throttle (C) input voltage is 4.8V. For the high voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-160-111

051403
PN=321

1. Slowly operate the analog throttle (C) through its full travel. 2. Using the ECU diagnostic software, read the analog throttle (C) voltage parameter.
Goes above 4.8 V: Faulty analog throttle (C) sensor connector OR Open in analog throttle (C) sensor ground circuit OR Faulty analog throttle (C) sensor Never goes above 4.8 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group
04 160 ,112
1/1
1. Ignition OFF 2. Disconnect analog throttle (C) sensor connector 3. Ignition ON, engine OFF 4. Using the ECU diagnostic software, read the analog throttle (C) voltage parameter.
0.2 V or less: GO TO 5 Above 0.2 V: Short to voltage in analog throttle input circuit OR Faulty ECU
NOTE: For OEM applications, the low analog throttle (C) input voltage is 0.2V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
1. Ignition OFF 2. Analog throttle (C) sensor connector disconnected 3. Using a test light connected to battery (+), probe the ground terminal in analog throttle (C) sensor connector.
Light ON: Faulty analog throttle (C) sensor connector OR Faulty analog throttle (C) sensor Light OFF: Open in analog throttle (C) ground circuit
1/1
CTM170 (14MAY03)
04-160-112

051403
PN=322
04 160 ,113
CTM170 (14MAY03)
04-160-113

051403
PN=323
T18 - Analog Throttle (C) Input Low
04 160 ,114
Analog Throttle (C) Position Sensor The analog throttle (C) position sensor is a variable resistor (potentiometer) used to measure the position of the cruise throttle. The throttle input voltage normally varies between 0.75 and 4.25 volts depending on throttle position. This code will set if: The analog throttle (C) input voltage drops below the sensors low voltage specification. The voltage is lower than what is physically possible for the throttle lever to achieve. For OEM applications, the low analog throttle (C) input voltage specification is 0.2 volts.
For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low analog throttle (C) input voltage specification. If this code sets, the following will occur: The ECU will ignore the input from the cruise analog throttle, and it will use the input values from the hand and foot analog throttles. When this code is set, the ECU will limit the inputs of the hand and foot analog throttles from exceeding 1500 rpm. The ECU will set a BLINKING warning light. If the hand and foot analog throttles are also faulted, the ECU will use a default limp-home throttle value that will only allow idle engine speed.
RG41221,0000143 1921OCT021/1
CTM170 (14MAY03)
04-160-114

051403
PN=324
RG10828
1923JUN00
T18 - Analog Throttle (C) Input Low
RG41221,0000144 1921OCT021/1
T18 - Analog Throttle (C) Input Low Diagnostic Procedure
NOTE: If DTC 000028.04 is accompanied with DTC 001079.04, follow the DTC 001079.04 diagnostic chart first.
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE (C) INPUT LOW supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the analog throttle (C) sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 ,115
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Throttle (C) in the idle position 5. Read the analog throttle (C) voltage parameter
0.2 V or less: GO TO 4 Above 0.2 V: GO TO 3
1/1
CTM170 (14MAY03)
04-160-115

051403
PN=325

1. Slowly operate the analog throttle (C) through its full travel. 2. Using the ECU diagnostic software, read the analog throttle (C) voltage parameter.
Goes below 0.2 V: Faulty analog throttle (C) sensor connector OR Open in analog throttle (C) sensor ground circuit OR Faulty analog throttle (C) sensor Never goes below 0.2 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group
04 160 ,116
1/1
1. Ignition OFF 2. Disconnect analog throttle (C) sensor connector 3. Install a jumper wire between the 5 V supply terminal and the input terminal (terminals C and D) in the analog throttle (C) sensor connector. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read the analog throttle (C) voltage parameter.
Below 4.8 V: GO TO 5 4.8 V or greater: Faulty analog throttle (C) sensor connector OR Faulty analog throttle sensor
1/1
CTM170 (14MAY03)
04-160-116

051403
PN=326

5 Throttle Position 5 V Supply Test
1. Ignition OFF 2. Remove jumper wire between the two terminals 3. Ignition ON, engine OFF 4. Using a multimeter, measure the voltage between the throttle ground terminal and the 5 V supply terminal (terminals A and D) in the analog throttle (C) sensor connector.
4.0 - 6.0 V: Open in analog throttle (C) input circuit OR Short to ground in analog throttle (C) input circuit OR Faulty ECU connection OR Faulty ECU Below 4.0 V: Open in analog throttle (C) 5 V supply circuit OR Short to ground in analog throttle (C) 5 V supply circuit OR 04 Faulty ECU connection 160 OR ,117 Faulty ECU
1/1
CTM170 (14MAY03)
04-160-117

051403
PN=327
000028.03 Throttle Voltage High
Throttle voltage is above the specification.

Diagnostic Trouble Codes (DTCs) assigned to throttles change per application. Choose the application from the list below and go to the corresponding diagnostic procedure earlier in this Group.
Application Excavator OEM 04 160 ,118 Tractor Diagnostic Procedure T11 - Excavator Throttle Reference Voltage High T5 - Analog Throttle (B) Input High T17 - Analog Throttle (C) Input High
RG41221,00000B3 1921JAN031/1
000028.04 Throttle Voltage Low
Throttle voltage is below the specification.

Application Excavator OEM Tractor Diagnostic Procedure T12 - Excavator Throttle Reference Voltage Low T6 - Analog Throttle (B) Input Low T18 - Analog Throttle (C) Input Low
RG41221,00000B4 1921JAN031/1
CTM170 (14MAY03)
04-160-118

051403
PN=328
Throttle voltage is above the specification.

Application Excavator Marine OEM Tractor Diagnostic Procedure T13 - Excavator Throttle Ground Voltage High T5 - Analog Throttle (B) Input High T3 - Analog Throttle (A) Input High T5 - Analog Throttle (B) Input High 04 160 ,119
RG41221,00000B5 1921JAN031/1

Application Excavator Marine OEM Tractor Diagnostic Procedure T14 - Excavator Throttle Ground Voltage Low T6 - Analog Throttle (B) Input Low T4 - Analog Throttle (A) Input Low T6 - Analog Throttle (B) Input Low
RG41221,00000B6 1921JAN031/1
CTM170 (14MAY03)
04-160-119

051403
PN=329
000084.02 Vehicle Speed Mismatch
To Wheel Speed Sensor BCU 43 21L BIF
11
04 160 ,120 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
1908JUN00
ECU Connector
Vehicle Speed The wheel speed sensor is an inductive type sensor that is mounted on the rear axle. As teeth on the axle rotate past the sensor, AC signals are generated. The frequency of these signals are proportional to the wheel speed. The signal from the sensor is sent to the Basic Control Unit (BCU). The BCU sends a Pulse Width Modulated (PWM) signal to the Basic Informator (BIF) and ECU. Wheel speed is also delivered to the ECU over CAN from the BIF. Both inputs to the ECU must be the same.
DTC 000084.02 will set if: The wheel speed from the BCU (PWM signal) and the BIF (CAN) do not match at the ECU. If DTC 000084.02 sets, the following will occur: ECU will limit engine speed to 1950 rpm. DTC 000084.02 may also cause DTC 001069.02 to set. This code will clear once DTC 000084.02 is repaired. The ECU will set a BLINKING warning light.
RG41221,0000153 1921OCT021/1
CTM170 (14MAY03)
04-160-120

051403
PN=330
RG10760
000084.02 Vehicle Speed Mismatch
The wheel speed from the BCU (PWM signal) and the BIF (CAN) do not match at the ECU.
RG41221,0000158 1907MAY021/1
000084.02 Vehicle Speed Mismatch Diagnostic Procedure
NOTE: If 000084.02 is accompanied with 000810.02, follow that diagnostic procedure first.
04 160 ,121
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000084.02 VEHICLE SPEED MISMATCH supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU, BIF, and BCU connectors looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Read DTCs using DST or SERVICE ADVISOR.
000084.02 reoccurs: GO TO 3 000084.02 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-121

051403
PN=331

3 CAN Vehicle Speed Check
1. Drive vehicle under normal operating conditions 2. Read the CAN vehicle speed parameter
Greater than 0 km/hr (0 mph): GO TO 5 0 km/hr (0 mph): GO TO 4

1/1
4 BCU to BIF PWM Wire Check
1. Ignition OFF 2. Disconnect BCU connector and BIF connector. 3. Using multimeter, measure resistance between terminal 43 of BCU connector and terminal 21L of BIF connector.
5 ohms or less: Possible CAN error follow vehicle CAN diagnostic procedure Greater than 5 ohms: Open in wheel speed sensor wire between BCU and BIF wire.
04 160 ,122
1/1
5 Calculated Vehicle Speed Check
1. Drive vehicle under normal operating conditions 2. Read the calculated vehicle speed parameter
Greater than 0 rpm: Tire size misprogrammed in BIF 0 rpm: GO TO 6

1/1
6 BCU to ECU PWM Wire Check
1. Ignition OFF 2. Disconnect ECU connector and BCU connector. 3. Using multimeter, measure resistance between terminal 11 of ECU connector and terminal 43 of BCU connector.
5 ohms or less: Faulty ECU connector OR Faulty ECU Greater than 5 ohms: Open in wheel speed sensor wire between ECU and BCU.
1/1
CTM170 (14MAY03)
04-160-122

051403
PN=332
04 160 ,123
CTM170 (14MAY03)
04-160-123

051403
PN=333

Application Excavator Marine 04 160 ,124 OEM Telehandler Tractor Diagnostic Procedure T15 - Excavator Throttle Signal Voltage High T3 - Analog Throttle (A) Input High T1 - Multi-state Throttle Input High T3 - Analog Throttle (A) Input High T3 - Analog Throttle (A) Input High
RG41221,00000B7 1921JAN031/1
CTM170 (14MAY03)
04-160-124

051403
PN=334

Application Excavator Marine OEM Telehandler Tractor Diagnostic Procedure T16 - Excavator Throttle Signal Voltage Low T4 - Analog Throttle (A) Input Low T2 - Multi-state Throttle Input Low T4 - Analog Throttle (A) Input Low T4 - Analog Throttle (A) Input Low 04 160 ,125
RG41221,00000B8 1921JAN031/1
000091.09 Throttle Invalid
ECU received invalid or missing throttle information.

Application Combine Diagnostic Procedure T7 - CAN Throttle Invalid
RG41221,00000B9 1921JAN031/1
CTM170 (14MAY03)
04-160-125

051403
PN=335
000094.01 Fuel Supply Pressure Extremely Low

Fuel Pressure Sensor B C A
A C B B A C
Fuel Pressure Sensor Connector B C A 5V Supply Fuel Pressure Input Sensor Ground
46
26
03
1916MAY01
051403
04 160 ,126
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Fuel Pressure Sensor The fuel pressure sensor, is located in the fuel filter housing and uses a pressure transducer to measure fuel pressure before the injection pump. As fuel pressure increases, the input voltage to the ECU increases. For further fuel pressure sensor information, see MEASURING PRESSURE in Section 03, Group 140 earlier in this manual. DTC 000094.01 will set if:
The ECU senses that fuel pressure is below -11 kPa (-0.11 bar) (-1.6 psi) with engine speed above low idle for more than 30 seconds. If DTC 000094.01 sets, the following will occur: On OEM applications, the ECU will derate the engine 150 rpm per minute until the engine is running at 1200 rpm. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. The ECU will set a BLINKING stop lamp. The code will not clear unless a key-on/key-off cycle is performed.
RG41221,0000157 1921OCT021/1
CTM170 (14MAY03)
04-160-126

PN=336
RG10753A
000094.01 Fuel Supply Pressure Extremely Low
The ECU senses that fuel pressure is below specification with engine speed above low idle for more than 30 seconds.
RG41221,0000159 1921OCT021/1
000094.01 Fuel Supply Pressure Extremely Low Diagnostic Procedure
NOTE: If DTC 000094.01 is accompanied with DTC 000094.03 or 000094.04, follow that diagnostic procedure before DTC 000094.01.
1/1
04 160 ,127
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000094.01 FUEL SUPPLY PRESSURE EXTREMELY LOW supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector, fuel pressure sensor connector, and the transfer pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Fuel Supply Pressure Test
NOTE: For wiring and theory of operation information, see DTC 000094.01 FUEL SUPPLY PRESSURE EXTREMELY LOW supporting information
Under the conditions where DTC 000094.01 occurs, measure fuel pressure. See CHECK FUEL SUPPLY PRESSURE in Group 150 of this manual.
Fuel pressure within specification: Verify that fuel pressure sensor 5 V supply, input, and ground circuits are OK. If fuel pressure sensor circuits are OK, replace fuel pressure sensor and retest Fuel pressure below specification: Low fuel pressure problem. See F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 FUEL SUPPLY SYSTEM CHECK - TIER 2 in Group 150 of this manual.
1/1
CTM170 (14MAY03)
04-160-127

051403
PN=337
000094.03 Fuel Supply Pressure Input Voltage High

A C B B A C
46
26
03
1916MAY01
051403
04 160 ,128
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Fuel Pressure Sensor The fuel pressure sensor, is located in the fuel filter housing and uses a pressure transducer to measure fuel pressure before the injection pump. As fuel pressure increases, the input voltage to the ECU increases. For further fuel pressure sensor information, see MEASURING PRESSURE in Section 03, Group 140 earlier in this manual. DTC 000094.03 will set if: The fuel pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a pressure that is higher than what is physically possible for fuel pressure.
For OEM applications, the high fuel pressure input voltage specification is 4.0 volts for more than 30 seconds. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high fuel pressure input voltage specification. If DTC 000094.03 sets, the following will occur: The ECU will run the engine with a default fuel pressure of -12 kPa (-0.12 bar) (-1.74 psi). The ECU will set codes DTC 000094.01 and 000094.18. The ECU will derate the engine 150 rpm per minute until the engine is running at 1200 rpm. The ECU will set a BLINKING warning light and set a BLINKING stop lamp when DTC 000094.01 is set. The code will not clear unless a key-on/key-off cycle is performed.
RG41221,000015A 1921OCT021/1
CTM170 (14MAY03)
04-160-128

PN=338
RG10753A
000094.03 Fuel Supply Pressure Input Voltage High
The fuel pressure input voltage exceeds the sensors high voltage specification.
RG41221,000015C 1921OCT021/1
000094.03 Fuel Supply Pressure Input Voltage High Diagnostic Procedure
NOTE: If DTC 000094.03 is accompanied with DTC 001080.03, follow that diagnostic procedure before DTC 000094.03.
1/1
04 160 ,129
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000094.03 FUEL SUPPLY PRESSURE INPUT VOLTAGE HIGH supporting information
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine running. 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-129

051403
PN=339

3 Fuel Pressure Signal Shorted Check
1. Ignition OFF 2. Disconnect fuel pressure sensor connector. 3. Ignition ON, engine OFF 4. Read fuel pressure input voltage.
0.1 V or below: GO TO 4 Above 0.1 V: Short to voltage in fuel pressure sensor signal circuit OR Faulty ECU
1/1
04 160 ,130
4 Fuel Pressure Ground Circuit Open Test
1. Ignition ON, engine OFF 2. Fuel pressure sensor still disconnected. 3. Probe fuel pressure sensor ground (terminal A) in sensor harness connector with a test light connected to battery voltage.
Light ON: Faulty fuel pressure sensor OR Faulty ECU connection OR Faulty ECU Light OFF: Open in fuel pressure sensor ground circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-130

051403
PN=340
04 160 ,131
CTM170 (14MAY03)
04-160-131

051403
PN=341
000094.04 Fuel Supply Pressure Input Voltage Low

A C B B A C
46
26
03
1916MAY01
051403
04 160 ,132
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Fuel Pressure Sensor The fuel pressure sensor, is located in the fuel filter housing and uses a pressure transducer to measure fuel pressure before the injection pump. As fuel pressure increases, the input voltage to the ECU increases. For further fuel pressure sensor information, see MEASURING PRESSURE in Section 03, Group 140 earlier in this manual. DTC 000094.04 will set if: The fuel pressure input voltage drops below the sensors low voltage specification. The voltage corresponds to a pressure that is lower than what is physically possible for fuel pressure.
For OEM applications, the low fuel pressure input voltage specification is 0.1 volts for more than 30 seconds. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low fuel pressure input voltage specification. If DTC 000094.04 sets, the following will occur: The ECU will run the engine with a default fuel pressure of -12 kPa (-0.12 bar) (-1.74 psi). The ECU will set codes DTC 000094.01 and 000094.18. The ECU will derate the engine 150 rpm per minute until the engine is running at 1200 rpm. The ECU will set a BLINKING warning light and set a BLINKING stop lamp when DTC 000094.01 is set. The code will not clear unless a key-on/key-off cycle is performed.
DPSG,RG40854,497 1921OCT021/1
CTM170 (14MAY03)
04-160-132

PN=342
RG10753A
000094.04 Fuel Supply Pressure Input Voltage Low
The fuel pressure input voltage drops below the sensors low voltage specification.
RG41221,000015E 1921OCT021/1
000094.04 Fuel Supply Pressure Input Voltage Low Diagnostic Procedure
1/1
04 160 ,133
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000094.04 FUEL SUPPLY PRESSURE INPUT VOLTAGE LOW supporting information
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-133

051403
PN=343

3 Transfer Pump Operation Check
1. Ignition OFF 2. Wait 5-10 seconds 3. Ignition ON, engine OFF 4. Listen for transfer pump operation
Pump ON: GO TO 5 Pump OFF: GO TO 4
NOTE: Transfer pump runs for only 40 seconds after key ON
1/1
04 160 ,134
4 Voltage to Transfer Pump Check
1. Ignition OFF 2. Disconnect transfer pump connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between the terminals of the harness side of the transfer pump connector
Positive voltage: Faulty transfer pump connector OR Faulty transfer pump NO voltage: Faulty transfer pump wiring OR Faulty ECU connector OR Faulty ECU
1/1
5 Fuel Pressure Wiring Test
1. Ignition OFF 2. Disconnect fuel pressure sensor connector 3. Install a jumper wire between fuel pressure sensor 5 V supply and fuel pressure sensor input (terminals B and C) in sensor harness connector 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read fuel pressure input voltage.
Below 4.0 V: GO TO 6 4.0 V or greater: Faulty fuel pressure sensor connector OR Faulty fuel pressure sensor
1/1
CTM170 (14MAY03)
04-160-134

051403
PN=344

6 Fuel Pressure 5 V Supply Test
1. Ignition OFF 2. Remove jumper wire 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between fuel pressure sensor 5 V supply terminal (terminal B) in sensor harness connector and a good chassis ground
4.0 - 6.0 V: Open in fuel pressure sensor input circuit OR Short to ground in fuel pressure sensor input circuit OR Faulty ECU connector OR Faulty ECU Below 4.0 V: Open in fuel pressure sensor 5 V supply circuit OR Short to ground in fuel pressure sensor 5 V supply circuit OR Faulty ECU connector OR Faulty ECU
1/1
04 160 ,135
CTM170 (14MAY03)
04-160-135

051403
PN=345
000094.18 Fuel Supply Pressure Moderately Low

A C B B A C
46
26
03
1916MAY01
051403
04 160 ,136
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Fuel Pressure Sensor The fuel pressure sensor, is located in the fuel filter housing and uses a pressure transducer to measure fuel pressure before the injection pump. As fuel pressure increases, the input voltage to the ECU increases. For further fuel pressure sensor
information, see MEASURING PRESSURE in Section 03, Group 140 earlier in this manual. DTC 000094.18 will set if: The ECU senses that fuel pressure is below -1 kPa (-0.01 bar) (-.15 psi) at any engine speed for more than 30 seconds. If DTC 000094.18 sets, the following will occur: The ECU will not derate the engine. The ECU will set a BLINKING warning light.
RG41221,0000161 1921OCT021/1
CTM170 (14MAY03)
04-160-136

PN=346
RG10753A
000094.18 Fuel Supply Pressure Moderately Low
The ECU senses that fuel pressure is below specification at any engine speed for more than 30 seconds.
RG41221,0000160 1907MAY021/1
000094.18 Fuel Supply Pressure Moderately Low Diagnostic Procedure
NOTE: If DTC 000094.18 is accompanied with DTC 000094.03 or 000094.04, follow that diagnostic procedure before DTC 000094.18.
1/1
04 160 ,137
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000094.18 FUEL SUPPLY PRESSURE MODERATELY LOW supporting information
1/1
2 Fuel Supply Pressure Test
NOTE: For wiring and theory of operation information, see DTC 000094.18 FUEL SUPPLY PRESSURE MODERATELY LOW supporting information
Under the conditions where DTC 000094.18 occurs, measure fuel pressure. See CHECK FUEL SUPPLY PRESSURE in Group 150 of this manual.
Fuel pressure within specification: Verify that fuel pressure sensor 5 V supply, input, and ground circuits are OK. If fuel pressure sensor circuits are OK, replace fuel pressure sensor and retest Fuel pressure below specification: Low fuel pressure problem. See F1 - FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 FUEL SUPPLY SYSTEM CHECK - TIER 2 in Group 150 of this manual.
1/1
CTM170 (14MAY03)
04-160-137

051403
PN=347
000097.00 Water in Fuel Continuously Detected

To Switched Power
Water in Fuel Sensor Connector Water in Fuel Sensors A B C A B C A B C Swithed Power Water in Fuel Input Sensor Ground 24 33
04 160 ,138
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Water in Fuel (WIF) Sensor The WIF sensor uses the resistance of water and fuel to detect the presence of water in the fuel system. This uses the principle that water is a better conductor of electricity than fuel is. Because of this, the water in fuel sensor will read a lower voltage when water is present than when it is not present. For further WIF sensor information, see WATER IN FUEL (WIF) SENSOR in Section 03, Group 140. DTC 000097.00 will set if: The WIF limit is above a predetermined quantity for longer than 3 minutes. If DTC 000097.00 sets, the following will occur:
Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 80% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,0000060 1921OCT021/1
CTM170 (14MAY03)
04-160-138

051403
PN=348
RG12715
1923OCT02
000097.00 Water in Fuel Continuously Detected
The WIF limit is above a predetermined quantity for longer than 3 minutes.
RG41221,0000061 1921OCT021/1
000097.00 Water in Fuel Continuously Detected Diagnostic Procedure

04 160 ,139
1/1
1 Connection Check
No faulty connection(s): GO TO 2 Faulty Connections: Repair faulty connection(s).
NOTE: For wiring and theory of operation , see DTC 000097.00 WATER IN FUEL CONTINUOUSLY DETECTED supporting information.
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Moisture Buildup Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out. 5. Operate engine in normal use 6. Read DTCs using DST or SERVICE ADVISOR.
000097.00 reoccurs: GO TO 3 000097.00 doesnt reoccur: Problem was most likely caused by moisture build up over time. Monitor the sediment bowl for moisture periodically, drain as needed.
1/1
CTM170 (14MAY03)
04-160-139

051403
PN=349

3 Water in Fuel (WIF) Circuit and Sensor Test
Check the following items that can cause water in the fuel: Poor fuel quality or water in fuel storage tank Loose fuel tank cap Missing or damaged fuel tank cap seal Excessive condensation build up in fuel tank Loose or damaged fuel filter or sediment bowl
Cause of water in fuel located: Repair problem, drain sediment bowl, and retest No cause of water in fuel located: Verify that WIF sensor input and ground circuits are OK. If WIF sensor circuits are OK, replace WIF sensor and retest
1/1
04 160 ,140
CTM170 (14MAY03)
04-160-140

051403
PN=350
04 160 ,141
CTM170 (14MAY03)
04-160-141

051403
PN=351
000097.16 Water in Fuel Detected

To Switched Power
Water in Fuel Sensor Connector Water in Fuel Sensors A B C A B C A B C Swithed Power Water in Fuel Input Sensor Ground 24 33
04 160 ,142
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Water in Fuel (WIF) Sensor The WIF sensor uses the resistance of water and fuel to detect the presence of water in the fuel system. This uses the principle that water is a better conductor of electricity than fuel is. Because of this, the water in fuel sensor will read a lower voltage when water is present than when it is not present. For further WIF sensor information, see WATER IN FUEL (WIF) SENSOR in Section 03, Group 140. DTC 000097.16 will set if:
The WIF limit is above a predetermined quantity for longer than 20 seconds. If DTC 000097.16 sets, the following will occur: Engine might not be able to develop full power Engine may be difficult to start
RG41221,0000062 1921OCT021/1
CTM170 (14MAY03)
04-160-142

051403
PN=352
RG12715
1923OCT02
000097.16 Water in Fuel Detected
The WIF limit is above a predetermined quantity for longer than 20 seconds.
RG41221,0000063 1921OCT021/1
000097.16 Water in Fuel Detected Diagnostic Procedure

04 160 ,143
1/1
1 Connection Check
No faulty connection(s): GO TO 2 Faulty Connections: Repair faulty connection(s).
NOTE: For wiring and theory of operation , see DTC 000097.16 WATER IN FUEL DETECTED supporting information.
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Moisture Buildup Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out. 5. Operate engine in normal use 6. Read DTCs using DST or SERVICE ADVISOR.
000097.16 reoccurs: GO TO 3 000097.16 doesnt reoccur: Problem was most likely caused by moisture build up over time. Monitor the sediment bowl for moisture periodically, drain as needed.
1/1
CTM170 (14MAY03)
04-160-143

051403
PN=353

3 Water in Fuel (WIF) Circuit and Sensor Test
Check the following items that can cause water in the fuel: Poor fuel quality or water in fuel storage tank Loose fuel tank cap Missing or damaged fuel tank cap seal Excessive condensation build up in fuel tank Loose or damaged fuel filter or sediment bowl
Cause of water in fuel located: Repair problem, drain sediment bowl, and retest No cause of water in fuel located: Verify that WIF sensor input and ground circuits are OK. If WIF sensor circuits are OK, replace WIF sensor and retest
1/1
04 160 ,144
CTM170 (14MAY03)
04-160-144

051403
PN=354
04 160 ,145
CTM170 (14MAY03)
04-160-145

051403
PN=355
000100.01 Engine Oil Pressure Extremely Low

Oil Pressure Sensor B C A
A C B B A C
Oil Pressure Sensor Connector B C A 5V Supply Oil Pressure Input Sensor Ground
46
04
03
1916MAY01
051403
04 160 ,146
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Oil Pressure Switch
Sensor Ground Oil Pressure Input
33
46
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
NOTE: Wiring schematic shows OEM engine and some Combine applications only. For wiring information on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
Oil Pressure Sensor The oil pressure sensor is a pressure transducer connected to the main oil galley. As engine oil pressure increases, the oil pressure sensor input voltage increases. The ECU monitors oil pressure in order to protect the engine in case of a low oil
pressure condition. For further oil pressure sensor information, see MEASURING PRESSURE in Group 140 earlier in this manual. On some applications an oil pressure switch is used to detect a loss of oil pressure. Oil pressure causes the contacts in the switch to close. When oil pressure drops below the minimum pressure threshold the switch will open. When the engine is not running, the switch is open. For further oil pressure switch information, see MEASURING PRESSURE in Section 03, Group 140. DTC 000100.01 will set if:
RG41221,0000163 1921OCT021/2
CTM170 (14MAY03)
04-160-146

PN=356
RG12716
1923OCT02
RG10754A

For engines with an oil pressure sensor, the ECU senses an oil pressure below 41 kPa (0.41 bar) (6.0 psi) at an engine speed above low idle. For engines with an oil pressure switch, the ECU senses that the oil pressure switch is open after the engine is above cranking RPM for several seconds. If DTC 000100.01 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Shutdown Feature: The derate feature will go into effect when the code is set and the engine will shut down after 30 seconds. With Derate Feature: On OEM applications, the engine derates 60% per minute until the engine is running at 40% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
04 160 ,147
RG41221,0000163 1921OCT022/2
CTM170 (14MAY03)
04-160-147

051403
PN=357
000100.01 Engine Oil Pressure Extremely Low
Oil Pressure drops below specification.
RG41221,0000164 1907MAY021/1
000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure

04 160 ,148
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the oil pressure sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Oil Pressure Check
NOTE: For wiring and theory of operation information, see DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW supporting information
Under the conditions where DTC 000100.01 occurs, measure engine oil pressure. See CHECK ENGINE OIL PRESSURE in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Oil pressure within specification: Verify that oil pressure sensor 5 V supply, input, and ground circuits are OK. If oil pressure sensor circuits are OK, replace oil pressure sensor and retest. Oil pressure below specification: Low oil pressure problem. See L2 - ENGINE OIL PRESSURE LOW in Group 150 of 4.5 and 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
CTM170 (14MAY03)
04-160-148

051403
PN=358
04 160 ,149
CTM170 (14MAY03)
04-160-149

051403
PN=359
000100.03 Engine Oil Pressure Input Voltage High

A C B B A C
46
04
03
1916MAY01
051403
04 160 ,150
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Oil Pressure Sensor The oil pressure sensor is a pressure transducer connected to the main oil galley. As engine oil pressure increases, the oil pressure sensor input voltage increases. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition. For further oil pressure sensor information, see MEASURING PRESSURE in Group 140 earlier in this manual. DTC 000100.03 will set if:
The oil pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a pressure that is higher than what is physically possible for oil pressure. For OEM applications, the high oil pressure input voltage specification is 4.9 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high oil pressure input voltage specification. If DTC 000100.03 sets, the following will occur: The ECU will run the engine with a default oil pressure of 260 kPa (2.6 bar) (37.5 psi). ECUs low oil pressure engine protection feature disabled. The ECU will set a BLINKING warning light.
RG41221,0000166 1921OCT021/1
CTM170 (14MAY03)
04-160-150

PN=360
RG10754A
000100.03 Engine Oil Pressure Input Voltage High
The oil pressure input voltage exceeds the sensors high voltage specification.
RG41221,0000167 1921OCT021/1
000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure
1/1
04 160 ,151
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000100.03 ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-151

051403
PN=361

3 Oil Pressure Input Shorted Test
1. Ignition OFF 2. Disconnect oil pressure sensor connector 3. Ignition ON, engine OFF 4. Using the ECU diagnostic software, read oil pressure input voltage.
0.3 V or below: GO TO 4 Above 0.3 V: Short to voltage in oil pressure sensor input circuit OR Faulty ECU
NOTE: For OEM applications, the low oil pressure input voltage specification is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
04 160 ,152
4 Oil Pressure Ground Circuit Open Test
Probe oil pressure sensor ground (terminal A) of the sensor connector on the engine harness with a test light connected to battery voltage.
Light ON: Faulty oil pressure sensor OR Faulty ECU connection OR Faulty ECU Light OFF: Open in oil pressure sensor ground circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-152

051403
PN=362
04 160 ,153
CTM170 (14MAY03)
04-160-153

051403
PN=363
000100.04 Engine Oil Pressure Input Voltage Low

A C B B A C
46
04
03
1916MAY01
051403
04 160 ,154
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Oil Pressure Switch
Sensor Ground Oil Pressure Input
33
46
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Oil Pressure Sensor The oil pressure sensor is a pressure transducer connected to the main oil galley. As engine oil pressure increases, the oil pressure sensor input voltage increases. The ECU monitors oil pressure in order to protect the engine in case of a low oil
pressure condition. For further oil pressure sensor information, see MEASURING PRESSURE in Group 140 earlier in this manual. On some applications an oil pressure switch is used to detect a loss of oil pressure. Oil pressure causes the contacts in the switch to close. When oil pressure drops below the minimum pressure threshold the switch will open. When the engine is not running, the switch is open. For further oil pressure switch information, see MEASURING PRESSURE in Section 03, Group 140. DTC 000100.04 will set if:
RG41221,0000169 1921OCT021/2
CTM170 (14MAY03)
04-160-154

PN=364
RG12716
1923OCT02
RG10754A

The oil pressure input voltage drops below the sensors low voltage specification. The voltage corresponds to a pressure that is lower than what is physically possible for oil pressure. For OEM applications, the low oil pressure input voltage specification is 0.3 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for the low oil pressure input voltage specification. If DTC 000100.04 sets, the following will occur: For engines with an oil pressure sensor: The ECU will run the engine with a default oil pressure of 260 kPa (2.6 bar) (37.5 psi). ECUs low oil pressure engine protection feature disabled. For engines with an oil pressure switch, the ECU will set a BLINKING warning light.
RG41221,0000169 1921OCT022/2
04 160 ,155
CTM170 (14MAY03)
04-160-155

051403
PN=365
000100.04 Engine Oil Pressure Input Voltage Low
The oil pressure input voltage drops below the sensors low voltage specification.
RG41221,000016A 1921OCT021/1
000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure

04 160 ,156
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the oil pressure sensor connector, looking for dirty, damaged, or poorly positioned terminals.
1/1
1/1
CTM170 (14MAY03)
04-160-156

051403
PN=366

3 Oil Sensor Check
Determine whether an oil pressure sensor or an oil pressure switch is being used.
Oil pressure sensor being used: GO TO 4 Oil pressure switch being used: GO TO 6
1/1
4 Oil Pressure Sensor and Connector Test
1. Ignition OFF 2. Disconnect oil pressure sensor connector 3. Install a jumper wire between 5 V supply and input terminals (terminals B and C) in oil pressure sensor connector on the engine harness. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read oil pressure input voltage
Below 4.9 V: GO TO 5
04 160 4.9 V or greater: ,157 Faulty oil pressure sensor connection OR Faulty oil pressure sensor
1/1
5 Oil Pressure 5V Supply Test
1. Ignition OFF 2. Remove jumper wire 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between the 5 V supply (terminal B) of the oil pressure sensor connector on the engine harness and a good chassis ground
4.0 - 6.0 V: Open in oil pressure sensor input circuit OR Short to ground in oil pressure sensor input circuit OR Faulty ECU connection OR Faulty ECU Below 4.0 V: Open in oil pressure sensor 5 V supply circuit OR Short to ground in oil pressure sensor 5 V supply circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-157

051403
PN=367

6 Oil Pressure Switch Short in Wire Check
1. Ignition OFF 2. Disconnect the oil pressure switch connector and the ECU connector. 3. Using a multimeter, measure resistance between terminal 33 in the ECU connector on the engine harness and: All other terminals in the ECU connector on the engine harness. A good chassis ground.
All measurements greater than 2000 ohms: Faulty oil pressure switch OR Faulty ECU Any measurement less than 2000 ohms: Short in oil pressure input wire with low resistance.
1/1
04 160 ,158
CTM170 (14MAY03)
04-160-158

051403
PN=368
04 160 ,159
CTM170 (14MAY03)
04-160-159

051403
PN=369
000100.18 Engine Oil Pressure Moderately Low

A C B B A C
46
04
03
1916MAY01
051403
04 160 ,160
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Oil Pressure Sensor The oil pressure sensor is a pressure transducer connected to the main oil galley. As engine oil pressure increases, the oil pressure sensor input voltage increases. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition. For further oil pressure sensor information, see MEASURING PRESSURE in Group 140 earlier in this manual.
DTC 000100.18 will set if: The ECU detects that oil pressure is below 71 kPa (7.1 bar) (10.3 psi) at any engine speed. If DTC 000100.18 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 80% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,000016C 1921OCT021/1
CTM170 (14MAY03)
04-160-160

PN=370
RG10754A
000100.18 Engine Oil Pressure Moderately Low
The ECU detects that oil pressure is below specification at any engine speed.
RG41221,000016D 1907MAY021/1
000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure

04 160 ,161
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000100.18 ENGINE OIL PRESSURE MODERATELY LOW supporting information
1/1
2 Oil Pressure Check
NOTE: For wiring and theory of operation information, see DTC 000100.18 ENGINE OIL PRESSURE MODERATELY LOW supporting information
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See CHECK ENGINE OIL PRESSURE in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Oil pressure within specification: Low oil pressure problem. See L2 - ENGINE OIL PRESSURE LOW in Group 150 of 4.5 and 6.8 L Diesel Engines Base Engine Manual (CTM 104). Oil pressure below specification: Verify that oil pressure sensor 5 V supply, input, and ground circuits are OK. If oil pressure sensor circuits are OK, replace oil pressure sensor and retest.
1/1
CTM170 (14MAY03)
04-160-161

051403
PN=371
000105.00 Manifold Air Temperature Extremely High

MAT Sensor t MAT Sensor Connector MAT Ground
B A B A
MAT Input
50
24
1 04 160 ,162
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Manifold Air Temperature (MAT) Sensor The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. The MAT sensor is used to measure the temperature of the intake air. The MAT sensors variable resistance causes the input voltage to the ECU to vary. Higher intake air temperatures result in lower MAT input voltages to the ECU; lower temperatures result in higher voltages. For further MAT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC 000105.00 will set if:
The ECU senses a manifold air temperature on OEM applications above 100C (212F). For manifold air pressure specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000105.00 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Shutdown Feature: The derate feature will go into effect when the code is set and the engine will shut down after 30 seconds. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 60% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,000017B 1922OCT021/1
CTM170 (14MAY03)
04-160-162

051403
RG11730
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=372
000105.00 Manifold Air Temperature Extremely High
The ECU senses a manifold air temperature above specification.
RG41221,0000180 1907MAY021/1
000105.00 Manifold Air Temperature Extremely High Diagnostic Procedure

04 160 ,163
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD AIR TEMPERATURE EXTREMELY HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the MAT sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Failures Causing High MAT Check
NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD AIR TEMPERATURE EXTREMELY 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 MAT located: Repair problem and retest. No cause of high MAT located: Verify that MAT sensor input and ground circuits are OK. If MAT sensor circuits are OK, replace MAT sensor and retest.
1/1
CTM170 (14MAY03)
04-160-163

051403
PN=373
000105.03 Manifold Air Temperature Input Voltage High

B A B A
MAT Input
50
24
1 04 160 ,164
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Manifold Air Temperature (MAT) Sensor The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. The MAT sensor is used to measure the temperature of the intake air. The MAT sensors variable resistance causes the input voltage to the ECU to vary. Higher intake air temperatures result in lower MAT input voltages to the ECU; lower temperatures result in higher voltages. For further MAT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140. DTC 000105.03 will set if:
The manifold air temperature input voltage exceeds the sensors high voltage specification. The voltage corresponds to a temperature that is lower than what is physically possible for manifold air temperature. For OEM applications, the high manifold air temperature input voltage specification is 4.9 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high manifold air temperature input voltage specification. If DTC 000105.03 sets, the following will occur: The ECU will use a default limp-home MAT value of 60C (140F). ECUs high manifold air temperature engine protection feature disabled. The ECU will set a BLINKING warning light.
RG41221,000017C 1922OCT021/1
CTM170 (14MAY03)
04-160-164

051403
RG11730
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=374
000105.03 Manifold Air Temperature Input Voltage High
The manifold air temperature input voltage exceeds the sensors high voltage specification.
RG41221,0000183 1922OCT021/1
000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure

04 160 ,165
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1/1
000105.03 reoccurs: GO TO 3 000105.03 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-165

051403
PN=375

3 MAT Sensor and Connector Test
1. Ignition OFF 2. Disconnect MAT sensor connector 3. Install a jumper wire between both terminals in the MAT sensor connector on the engine harness. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read manifold air temperature input voltage
Above 0.3 V: GO TO 4 0.3 V or below: Faulty MAT sensor connector OR Faulty MAT sensor
1/1
04 160 ,166
4 MAT Sensor Open Ground Circuit Test
1. Ignition OFF 2. Remove jumper wire between both terminals. 3. Install jumper wire between MAT input terminal (terminal A) of the sensor connector on the engine harness and a good chassis ground. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read manifold air temperature input voltage
Above 0.3 V: Open in MAT sensor input circuit OR Faulty ECU connection OR Faulty ECU 0.3 V or below: Open in MAT sensor ground circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-166

051403
PN=376
04 160 ,167
CTM170 (14MAY03)
04-160-167

051403
PN=377
000105.04 Manifold Air Temperature Input Voltage Low

B A B A
MAT Input
50
24
1 04 160 ,168
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Manifold Air Temperature (MAT) Sensor The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. The MAT sensor is used to measure the temperature of the intake air. The MAT sensors variable resistance causes the input voltage to the ECU to vary. Higher intake air temperatures result in lower MAT input voltages to the ECU; lower temperatures result in higher voltages. For further MAT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140. DTC 000105.04 will set if:
The manifold air temperature input voltage drops below the sensors low voltage specification. The voltage corresponds to a temperature that is higher than what is physically possible for manifold air temperature. For OEM applications, the low manifold air temperature input voltage specification is 0.3 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for the low manifold air temperature input voltage specification. If DTC 000105.04 sets, the following will occur: The ECU will use a MAT default limp-home MAT value of 60C (140F). ECUs high manifold air temperature engine protection feature disabled. The ECU will set a BLINKING warning light.
RG41221,000017D 1922OCT021/1
CTM170 (14MAY03)
04-160-168

051403
RG11730
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=378
000105.04 Manifold Air Temperature Input Voltage Low
The manifold air temperature input voltage drops below the sensors low voltage specification.
RG41221,0000185 1922OCT021/1
000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure

04 160 ,169
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-169

051403
PN=379

3 MAT Sensor Test
1. Ignition OFF 2. Disconnect MAT sensor connector. 3. Ignition ON, engine OFF 4. Using the ECU diagnostic software, read manifold air temperature input voltage
Below 4.9 V: Short to ground in MAT sensor input circuit OR Faulty ECU connector OR Faulty ECU 4.9 V or greater: Faulty MAT sensor connector OR Faulty MAT sensor
1/1
04 160 ,170
CTM170 (14MAY03)
04-160-170

051403
PN=380
04 160 ,171
CTM170 (14MAY03)
04-160-171

051403
PN=381
000105.16 Manifold Air Temperature Moderately High

B A B A
MAT Input
50
24
1 04 160 ,172
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Manifold Air Temperature (MAT) Sensor The MAT sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. The MAT sensor is used to measure the temperature of the intake air. The MAT sensors variable resistance causes the input voltage to the ECU to vary. Higher intake air temperatures result in lower MAT input voltages to the ECU; lower temperatures result in higher voltages. For further MAT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140. DTC 000105.16 will set if: The ECU senses a manifold air temperature on OEM applications above 100C (212F). For
manifold air temperature specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000105.16 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 80% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,000017E 1922OCT021/1
CTM170 (14MAY03)
04-160-172

051403
RG11730
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=382
000105.16 Manifold Air Temperature Moderately High
The ECU senses a manifold air temperature above specification.
RG41221,0000181 1907MAY021/1
000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure

04 160 ,173
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD AIR TEMPERATURE MODERATELY HIGH supporting information.
1/1
2 Failures Causing High MAT Check
NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD 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 MAT located: Repair problem and retest. No cause of high MAT located: Verify that MAT sensor input and ground circuits are OK. If MAT sensor circuits are OK, replace MAT sensor and retest.
1/1
CTM170 (14MAY03)
04-160-173

051403
PN=383
000107.00 Air Filter Differential Pressure

Air Vacuum Switch P
Sensor Ground Air Vacuum Input
32
46
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 04 160 ,174
ECU Connector Air Vacuum Switch The air vacuum switch is located on the clean side of the air filter. Higher air pressure causes the contacts on the air vacuum switch to close. DTC 000107.00 will set if:
The ECU senses a high air pressure from the air vacuum switch. If DTC 000107.00 sets, the following will occur: ECU will set a BLINKING warning light. Engine performance will not be effected.
RG41221,000017F 1922OCT021/1
CTM170 (14MAY03)
04-160-174

051403
RG11731
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=384
000107.00 Air Filter Differential Pressure
The ECU senses a high air pressure from the air vacuum switch.
RG41221,0000187 1922OCT021/1
000107.00 Air Filter Differential Pressure Diagnostic Procedure

04 160 ,175
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR FILTER DIFFERENTIAL PRESSURE supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the air filter switch connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Air Filter Restriction Test
Check air filter for restrictions.
Restriction found in air filter: Replace, or clean as needed. No problem found with air filter: GO TO 3
1/1
CTM170 (14MAY03)
04-160-175

051403
PN=385

3 Air Intake Restriction Test
Under the conditions where DTC 000107.00 occurs, inspect air intake system on suction side of turbo. Looking specifically at the air filter element and for any source of blockage of the air intake system. See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Restriction found in intake system: Replace, repair, or clean components as needed. No problem found with intake system: GO TO 4
1/1
04 160 ,176
4 Air Vacuum Switch Test
Verify air vacuum switch is functioning correctly.
Air vacuum switch is failed closed: Replace switch and retest. Air vacuum switch functions correctly: Verify that the air vacuum switch wiring is OK.
1/1
CTM170 (14MAY03)
04-160-176

051403
PN=386
04 160 ,177
CTM170 (14MAY03)
04-160-177

051403
PN=387
000110.00 Engine Coolant Temperature Extremely High

ECT Sensor t ECT Sensor Connector ECT Ground
B A B A
ECT Input
06
46
1 04 160 ,178
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or in the rear of the cylinder head. It is used to measure the coolant temperature. The ECTs variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC 000110.00 will set if:
The ECU senses a coolant temperature on OEM applications above 118C (244F). For most severe engine coolant temperature specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000110.00 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Shutdown Feature: The derate feature will go into effect when the code is set and the engine will shut down after 30 seconds. With Derate Feature: On OEM applications, the engine derates 60% per minute until the engine is running at 40% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,0000171 1922OCT021/1
CTM170 (14MAY03)
04-160-178

051403
RG10755A
1916MAY01
PN=388
000110.00 Engine Coolant Temperature Extremely High
The ECU senses a coolant temperature above specification.
RG41221,0000170 1922OCT021/1
000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure

04 160 ,179
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the ECT sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 ECT Sensor and Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH supporting information
Under the conditions where DTC 000110.00 occurs, using a temperature gauge, verify that engine coolant temperature is above the extremely high specification.
NOTE: On OEM applications, the most severe ECT specification is 118C (244F). For the most severe ECT spec on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
Temperature at or above specification: Engine overheating problem. See C1 ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Temperature significantly less than specification: Verify that ECT sensor input and ground circuits are OK. If ECT sensor circuits are OK, replace ECT sensor and retest
1/1
CTM170 (14MAY03)
04-160-179

051403
PN=389
000110.03 Engine Coolant Temperature Input Voltage High

B A B A
ECT Input
06
46
1 04 160 ,180
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or rear of cylinder head. It is used to measure the coolant temperature. The ECTs variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC 000110.03 will set if:
The engine coolant temperature input voltage exceeds the sensors high voltage specification. The voltage corresponds to a temperature that is lower than what is physically possible for engine coolant temperature. For OEM applications, the high engine coolant temperature input voltage specification is 4.9 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for the high engine coolant temperature input voltage specification. If DTC 000110.03 sets, the following will occur: When in start mode, the ECU will default the ECT to -30C (-22F). When in running mode, the ECU will default the ECT to 90C (194F). ECUs high ECT engine protection feature disabled. The ECU will set a BLINKING warning light.
RG41221,0000173 1922OCT021/1
CTM170 (14MAY03)
04-160-180

051403
RG10755A
1916MAY01
PN=390
000110.03 Engine Coolant Temperature Input Voltage High
The engine coolant temperature input voltage exceeds the sensors high voltage specification.
RG41221,0000174 1922OCT021/1
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure
1/1
04 160 ,181
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1/1
1/1
CTM170 (14MAY03)
04-160-181

051403
PN=391

3 Engine Coolant Temperature (ECT) Sensor and Connector Test
1. Ignition OFF 2. Disconnect ECT sensor connector 3. Install a jumper wire between both terminals in the ECT sensor connector on the engine harness. 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read engine coolant temperature input voltage
Above 0.3 V: GO TO 4 0.3 V or below: Faulty ECT sensor connector OR Faulty ECT sensor
NOTE: For OEM applications, the low engine coolant temperature input voltage specification is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
04 160 ,182
1/1
4 Engine Coolant Temperature (ECT) Open Ground Test
1. Ignition OFF 2. Remove jumper wire between both terminals 3. Install jumper wire between ECT input terminal (terminal A) of the sensor connector on the engine harness and a good chassis ground 4. Ignition ON, engine OFF 5. Using the ECU diagnostic software, read engine coolant temperature input voltage
Above 0.3 V: Open in ECT input sensor circuit OR Faulty ECU connection OR Faulty ECU 0.3 V or below: Open in ECT sensor ground circuit OR Faulty ECU connection OR Faulty ECU
NOTE: For OEM applications, the low engine coolant temperature input voltage specification is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-160-182

051403
PN=392
04 160 ,183
CTM170 (14MAY03)
04-160-183

051403
PN=393
000110.04 Engine Coolant Temperature Input Voltage Low

B A B A
ECT Input
06
46
1 04 160 ,184
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing. It is used to measure the coolant temperature. The ECTs variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC 000110.04 will set if:
The engine coolant temperature input voltage drops below the sensors low voltage specification. The voltage corresponds to a temperature that is higher than what is physically possible for engine coolant temperature . For OEM applications, the low engine coolant temperature input voltage specification is 0.3 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for the low engine coolant temperature input voltage specification. If DTC 000110.04 sets, the following will occur: When in start mode, the ECU will default the ECT to -30C (-22F). When in running mode, the ECU will default the ECT to 90C (194F). ECUs high ECT engine protection feature disabled. The ECU will set a BLINKING warning light.
RG41221,0000176 1922OCT021/1
CTM170 (14MAY03)
04-160-184

051403
RG10755A
1916MAY01
PN=394
000110.04 Engine Coolant Temperature Input Voltage Low
The engine coolant temperature input voltage drops below the sensors low voltage specification.
RG41221,0000177 1922OCT021/1
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure
1/1
04 160 ,185
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1/1
1/1
CTM170 (14MAY03)
04-160-185

051403
PN=395

3 Engine Coolant Temperature (ECT) Sensor Test
1. Ignition OFF 2. Disconnect ECT sensor connector 3. Ignition ON, engine OFF 4. Using the ECU diagnostic software read engine coolant temperature input voltage
Below 4.9 V: Short to ground in ECT sensor input circuit OR Faulty ECU 4.9 V or greater: Faulty ECT sensor
NOTE: For OEM applications, the high engine coolant temperature input voltage specification is 4.9V. For the high voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
04 160 ,186
CTM170 (14MAY03)
04-160-186

051403
PN=396
04 160 ,187
CTM170 (14MAY03)
04-160-187

051403
PN=397
000110.15 Engine Coolant Temperature High Least Severe

B A B A
ECT Input
06
46
1 04 160 ,188
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
ECT (Engine Coolant Temperature) Sensor The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or at the rear of the cylinder head. It is used to measure the coolant temperature. The ECTs variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual.
DTC 000110.15 will set if: The ECU senses engine coolant temperature on OEM applications above 108C (226F). For moderately high engine coolant temperature specification, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000110.15 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 95% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,0000207 1922OCT021/1
CTM170 (14MAY03)
04-160-188

051403
RG10755A
1916MAY01
PN=398
000110.15 Engine Coolant Temperature High Least Severe
The ECU senses engine coolant temperature above specification.
RG41221,0000209 1922OCT021/1
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure

04 160 ,189
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information
1/1
2 Engine Coolant Temperature (ECT) Sensor and Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information
Under the conditions where DTC 000110.15 occurs, using a temperature gauge, verify that engine coolant temperature is above the moderately high specification.
NOTE: On OEM applications, the high least severe ECT specification is 108C (226F). For the high least severe ECT spec on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-160-189

051403
PN=399
000110.16 Engine Coolant Temperature Moderately High

B A B A
ECT Input
06
46
1 04 160 ,190
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor (temperature sensitive resistor) mounted on the thermostat housing or at the rear of the cylinder head. It is used to measure the coolant temperature. The ECTs variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower ECT input voltages to the ECU; lower temperatures result in higher voltages. For further ECT sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual.
DTC 000110.16 will set if: The ECU senses engine coolant temperature on OEM applications above 113C (235F). For moderately high engine coolant temperature specification, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000110.16 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 40% per minute until the engine is running at 60% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,000017A 1922OCT021/1
CTM170 (14MAY03)
04-160-190

051403
RG10755A
1916MAY01
PN=400
000110.16 Engine Coolant Temperature Moderately High
The ECU senses engine coolant temperature above specification.
RG41221,0000179 1922OCT021/1
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure

04 160 ,191
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE COOLANT TEMPERATURE MODERATELY HIGH supporting information
1/1
2 Engine Coolant Temperature (ECT) Sensor and Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE COOLANT TEMPERATURE MODERATELY HIGH supporting information
Under the conditions where DTC 000110.16 occurs, using a temperature gauge, verify that engine coolant temperature is above the moderately high specification.
NOTE: On OEM applications, the moderately high ECT specification is 113C (235F). For the moderately high ECT spec on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM170 (14MAY03)
04-160-191

051403
PN=401
000111.01 Engine Coolant Level Low

Loss of Coolant Switch T
Sensor Ground Loss of Coolant Input
30
24
1 04 160 ,192
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Loss of Coolant Temperature Switch The loss of coolant temperature switch is a normally open temperature sensitive switch. When engine coolant is at the proper level, the temperature sensitive end of the switch is submerged in coolant, and the switch contacts will be open. If coolant level drops, the switch will no longer be submerged causing the temperature of the switch to rise beyond the point that causes the switch contacts to close. This causes the ECU to sense continuity to ground through the external shutdown/derate input terminal. DTC 000111.01 will set if: The loss of coolant temperature switch contacts close causing the ECU to sense continuity to ground through the external shutdown/derate input terminal. If DTC 000111.01 sets, the following occur:
Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Shutdown Feature: The derate feature will go into effect when the code is set and the engine will shut down after 30 seconds. With Derate Feature: On OEM applications, the engine derates 40% per minute until the engine is running at 60% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,0000188 1922OCT021/1
CTM170 (14MAY03)
04-160-192

051403
RG11732
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=402
000111.01 Engine Coolant Level Low
Engine coolant level drops below specification.
RG41221,000018A 1922OCT021/1
000111.01 Engine Coolant Level Low Diagnostic Procedure

04 160 ,193
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE COOLANT LEVEL LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the loss of coolant temperature switch connector, looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Coolant Level Test
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first strop to relieve pressure before removing completely. Check coolant level.
Coolant level OK: GO TO 3 Coolant level low: Determine cause of low coolant level, repair problem and retest.
1/1
CTM170 (14MAY03)
04-160-193

051403
PN=403

1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR earlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all active DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Read DTCs using DST or SERVICE ADVISOR.
04 160 ,194
1/1
4 Loss of Coolant Temperature Switch Test
1. Ignition OFF 2. Disconnect loss of coolant temperature switch connector. 3. Ignition ON, engine OFF 4. Using the ECU diagnostic software, read DTCs.
000111.01 reoccurs: Short to ground in loss of coolant temperature switch input circuit. 000111.01 doesnt reoccur: Faulty loss of coolant temperature switch.
1/1
CTM170 (14MAY03)
04-160-194

051403
PN=404
04 160 ,195
CTM170 (14MAY03)
04-160-195

051403
PN=405
000158.17 ECU Power Down Error
Battery Fuse
Ignition Switch VSW
VBat
04 160 ,196 1
68
23
19
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
1923OCT02
051403
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
DTC 000158.17 will set if: ECU is unable to complete proper power down procedures after detecting key off conditions. The
ECU detects voltage on the switched voltage input wire to the ECU. If DTC 000158.17 sets, the following will occur: Vehicle battery may be drained, because ECU will not power down.
RG41221,0000213 1922OCT021/1
CTM170 (14MAY03)
04-160-196

PN=406
RG10761
ECU Connector
000158.17 ECU Power Down Error
ECU is unable to complete proper power down procedures after detecting key off conditions.
RG41221,0000212 1922OCT021/1
000158.17 ECU Power Down Error Diagnostic Procedure

04 160 ,197
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU POWER DOWN ERROR supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connectors and the ignition power circuit, looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Cycle ignition OFF for 10 seconds, then back ON 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-197

051403
PN=407

3 Wiring Test
1. Ignition OFF 2. Disconnect the ECU connector 3. Using a multimeter, measure voltage between terminal 19 of the ECU wiring harness connector and a good chassis ground.
Measurement above 3.0 volts: Faulty ignition switch circuit OR ECU key-on power supply shorted to voltage OR Faulty Ignition switch Measurement below 3.0 volts: Faulty ECU connection OR Faulty ECU
04 160 ,198
1/1
CTM170 (14MAY03)
04-160-198

051403
PN=408
04 160 ,199
CTM170 (14MAY03)
04-160-199

051403
PN=409
000174.00 Fuel Temperature High Most Severe

Pump Connector 1 2 3 4
4 9 9 4 5 8 8 5
Pump CAN Low Pump CAN High Pump CAN Shield Limp Home Fuel Shutoff Crank Speed Out PSG Power
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Rotary Injection Pump
5 9 8 7
3 2
04 160 ,200
PSG Enable
62
86 Rotary Pump Relay 85
30
87 To Battery Fuse
ECU Connector
Bosch VP44 Rotary Injection Pump The Bosch VP44 rotary injection pump is controlled by a pump control unit that monitors information received from sensors inside the pump. It also acquires information from the ECU over a CAN bus and other dedicated wires between the ECU and pump. This helps the pump control unit to provide for the accurate quantity and timing of fuel delivery to the engine.
DTC 000174.00 will set if: The ECU senses fuel temperature on OEM applications above 75C (167F). For the most severe fuel temperature specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000174.00 sets, the following will occur: DTC 001077.31 will also be present. DTC 001569.31 will also be present. Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual.
RG41221,000018C 1915MAY011/2
CTM170 (14MAY03)
04-160-200

051403
PN=410
RG10757A
1923OCT02

With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,000018C 1915MAY012/2
04 160 ,201
CTM170 (14MAY03)
04-160-201

051403
PN=411
000174.00 Fuel Temperature High Most Severe
The ECU senses fuel temperature above specification.
RG41221,000018D 1915MAY011/1
000174.00 Fuel Temperature High Most Severe Diagnostic Procedure

04 160 ,202
1/1
1 Preliminary Check
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL TEMPERATURE HIGH MOST SEVERE supporting information
Before using this diagnostic procedure, make the following checks that could cause high fuel temperatures: 1. Ensure that the fuel level in the fuel tank is not extremely low. 2. Ensure that the fuel cooler is clean.
No problems found: GO TO 2 Problem found: Repair and retest.
1/1
2 Connection Check
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the injection pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
CTM170 (14MAY03)
04-160-202

051403
PN=412

Determine fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in Group 150 of this manual.
Fuel pressure within specification: GO TO 4 Fuel pressure below specification: Determine cause of low supply pressure. See F1 FUEL SUPPLY SYSTEM CHECK - TIER 1 or F4 FUEL SUPPLY SYSTEM CHECK - TIER 2 in Group 150 of this manual. Repair and retest.
1/1
4 Fuel Return Lines Restriction Check
Check return fuel lines for restriction between fuel tank and: Overflow valve on injection pump Fuel leak off line at injection nozzles
Fuel return lines NOT restricted: Faulty injection pump overflow valve OR Faulty fuel cooler OR Faulty injection pump Restriction found in either fuel return line: Determine the cause of restriction Repair and retest
1/1
04 160 ,203
CTM170 (14MAY03)
04-160-203

051403
PN=413
000174.15 Fuel Temperature High Least Severe

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,204
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
DTC 000174.15 will set if: The ECU senses fuel temperature on OEM applications above 65C (149F). For the high least severe fuel temperature specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000174.15 sets, the following will occur: The ECU will not derate the engine. The ECU will set a BLINKING warning light.
RG41221,000018F 1922OCT021/1
CTM170 (14MAY03)
04-160-204

051403
PN=414
RG10757A
1923OCT02
000174.15 Fuel Temperature High Least Severe
The ECU senses fuel temperature above specification.
RG41221,0000190 1922OCT021/1
000174.15 Fuel Temperature High Least Severe Diagnostic Procedure

04 160 ,205
1/1
1 Preliminary Check
NOTE: For wiring and theory of operation information, see DTC 000174.15 FUEL TEMPERATURE HIGH LEAST SEVERE supporting information
1/1
2 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000174.15 FUEL TEMPERATURE HIGH LEAST SEVERE supporting information Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the injection pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
CTM170 (14MAY03)
04-160-205

051403
PN=415

1/1
04 160 ,206
1/1
CTM170 (14MAY03)
04-160-206

051403
PN=416
04 160 ,207
CTM170 (14MAY03)
04-160-207

051403
PN=417
000174.16 Fuel Temperature High Moderately Severe

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,208
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
Bosch VP44 Rotary Injection Pump The Bosch VP44 rotary injection pump is controlled by a pump control unit that monitors information received from sensors inside the pump. It also acquires information from the ECU over a CAN bus and other dedicated wires between the ECU and pump. This helps the pump control unit to provide for the accurate quantity and timing of fuel delivery to the engine. DTC 000174.16 will set if:
The ECU senses fuel temperature inside the injection pump on OEM applications above 73C (163F). For moderately high fuel temperature specifications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 000174.16 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 75% per minute until the engine is running at 25% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,0000192 1922OCT021/1
CTM170 (14MAY03)
04-160-208

051403
PN=418
RG10757A
1923OCT02
000174.16 Fuel Temperature High Moderately Severe
The ECU senses fuel temperature inside the injection pump above specification.
RG41221,0000193 1915MAY011/1
000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure

04 160 ,209
1/1
1 Preliminary Check
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL TEMPERATURE HIGH MODERATELY SEVERE supporting information
1/1
2 Connection Check
1/1
CTM170 (14MAY03)
04-160-209

051403
PN=419

1/1
04 160 ,210
1/1
CTM170 (14MAY03)
04-160-210

051403
PN=420
04 160 ,211
CTM170 (14MAY03)
04-160-211

051403
PN=421
000174.31 Fuel Temperature Sensor Faulty

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,212
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
The fuel temperature input voltage is outside the range of what is physically possible for fuel temperature. If DTC 000174.31 sets, the following will occur: DTC 001077.31 will also be present. DTC 001569.31 will also be present. Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,0000195 1915MAY011/1
CTM170 (14MAY03)
04-160-212

051403
PN=422
RG10757A
1923OCT02
000174.31 Fuel Temperature Sensor Faulty
The fuel temperature input voltage is outside the range of what is physically possible for fuel temperature.
RG41221,0000196 1915MAY011/1
000174.31 Fuel Temperature Sensor Faulty Diagnostic Procedure
NOTE: Other DTCs may be active with DTC 000174.31. If either DTC 000629.19 or 001077.19 is active, follow that diagnostic chart first.
1/1
04 160 ,213
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000174.31 FUEL TEMPERATURE SENSOR FAULTY supporting information
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the fuel injection pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000174.31 FUEL TEMPERATURE SENSOR FAULTY supporting information
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine running or cranking for 15 seconds 6. Read DTCs using DST or SERVICE ADVISOR.
000174.31 reoccurs: Faulty injection pump 000174.31 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-213

051403
PN=423
000189.00 Engine Speed Derate
The ECU detects a condition that requires an engine speed derate.

Engine Speed Derate The engine speed derate trouble code is set to indicate that the ECU has detected a condition such as low fuel pressure and is limiting the engine speed. DTC 000189.00 will set if:
04 160 ,214
If DTC 000189.00 sets, the following will occur: The ECU will limit engine speed in an attempt to protect the engine. If DTC 000189.00 sets: If DTC 000094.01 is active, see DTC 000094.01 FUEL SUPPLY PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE Check for other stored or active DTCs that indicate the reason for the speed derate.
The ECU detects a condition that requires an engine speed derate. The ECU senses fuel pressure below -11 kPa (-0.11 bar) (-1.6 psi) with engine speed above low idle for more than 30 seconds.
DPSG,RG40854,213 1922OCT021/1
CTM170 (14MAY03)
04-160-214

051403
PN=424
000189.31 Engine Speed Derate
The ECU detects a condition that requires an engine speed derate.

Engine Speed Derate The engine speed derate trouble code is set to indicate that the ECU has detected a condition such as low fuel pressure and is limiting the engine speed. DTC 000189.31 will set if: The ECU detects a condition that requires an engine speed derate. The ECU senses fuel pressure below -11 kPa (-0.11 bar) (-1.6 psi) with engine speed above low idle for more than 30 seconds.
If DTC 000189.31 sets, the following will occur: The ECU will limit engine speed in an attempt to protect the engine. If DTC 000189.31 sets: If DTC 000094.01 is active, see DTC 000094.01 FUEL SUPPLY PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE Check for other stored or active DTCs that indicate the reason for the speed derate.
04 160 ,215
RG41221,00000A9 1918DEC021/1
CTM170 (14MAY03)
04-160-215

051403
PN=425
000190.00 Engine Overspeed Extreme
The ECU detects that engine speed exceeds 3400 rpm.

Crankshaft Position Sensor The crankshaft position sensor is located on the front of the crankshaft, behind the pressed-on crank gear. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The ECU uses the crankshaft position input to determine engine speed and precise piston position in relation to the firing order. The crank timing wheel is composed of 46 evenly spaced teeth and 2 missing
teeth. The missing teeth help the ECU to determine Top-Dead-Center (TDC). DTC 000190.00 will set if: The ECU detects that engine speed exceeds 3400 rpm. If DTC 000190.00 sets, the following will occur: The ECU commands the PSG to shut fuel off until engine speed is below 2600 rpm. The ECU will set a BLINKING warning light.
04 160 ,216
DPSG,RG40854,213 1922OCT021/1
CTM170 (14MAY03)
04-160-216

051403
PN=426
000190.16 Engine Overspeed Moderate
The ECU detects that engine speed exceeds 3000 rpm.

Crankshaft Position Sensor The crankshaft position sensor is located on the front of the crankshaft, behind the pressed-on crank gear. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The ECU uses the crankshaft position input to determine engine speed and precise piston position in relation to the firing order. The crank timing wheel is composed of 46 evenly spaced teeth and 2 missing
teeth. The missing teeth help the ECU to determine Top-Dead-Center (TDC). DTC 000190.16 will set if: The ECU detects that engine speed exceeds 3000 rpm. If DTC 000190.16 sets, the following will occur: The ECU commands the PSG to shut fuel off until engine speed is below 2600 rpm. The ECU will set a BLINKING warning light.
04 160 ,217
DPSG,RG40854,213 1922OCT021/1
CTM170 (14MAY03)
04-160-217

051403
PN=427
000620.03 Sensor Supply Voltage High

Fuel Press Sensor
Fuel Press Sensor Input
04 160 ,218 1
5V Supply
Sensor Ground
26
03
24
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Sensor Supply Voltage The ECU supplies voltage to a few different sensors depending on the application. The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECUs memory to determine the value of the parameter the sensor was measuring. In addition, the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. DTC 000620.03 will set if:
The ECU detects a voltage that is higher than 5.5 volts on the ECU 5 volt sensor supply circuit. If DTC 000620.03 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply input voltage. The ECU will set a BLINKING warning light.
RG41221,0000197 1922OCT021/1
CTM170 (14MAY03)
04-160-218

051403
RG11733
1916MAY01
PN=428
000620.03 Sensor Supply Voltage High
The ECU detects a voltage above specification on the ECU 5 volt sensor supply circuit.
RG41221,0000198 1922OCT021/1
000620.03 Sensor Supply Voltage High Diagnostic Procedure

04 160 ,219
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR SUPPLY VOLTAGE HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and all of the sensor connectors using this 5V supply, looking for dirty, damaged, or poorly positioned terminals.
1/1
1/1
CTM170 (14MAY03)
04-160-219

051403
PN=429

3 Sensor Supply Wire Check for Short
1. Ignition OFF 2. Disconnect ECU connector 3. Using multimeter, measure resistance between terminal 3 in the ECU connector on the engine harness and all other terminals in the harness end of the ECU connector.
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Short to voltage in sensor supply wire
1/1
04 160 ,220
CTM170 (14MAY03)
04-160-220

051403
PN=430
04 160 ,221
CTM170 (14MAY03)
04-160-221

051403
PN=431
000620.04 Sensor Supply Voltage Low

Fuel Press Sensor
04 160 ,222 1
5V Supply
Sensor Ground
26
03
24
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector Sensor Supply Voltage The ECU supplies voltage to a few different sensors depending on the application. The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECUs memory to determine the value of the parameter the sensor was measuring. In addition, the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. DTC 000620.04 will set if:
The ECU detects a voltage that is lower than 4.44 volts on the ECU 5 volt sensor supply circuit. If DTC 000620.04 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply input voltage. The ECU will set a BLINKING warning light.
RG41221,0000199 1922OCT021/1
CTM170 (14MAY03)
04-160-222

051403
RG11733
1916MAY01
PN=432
000620.04 Sensor Supply Voltage Low
The ECU detects a voltage below specification on the ECU 5 volt sensor supply circuit.
RG41221,000019A 1922OCT021/1
000620.04 Sensor Supply Voltage Low Diagnostic Procedure

04 160 ,223
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR SUPPLY VOLTAGE LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and all of the sensor connectors using this 5V supply, looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Sensor Check
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition OFF 6. Disconnect the Fuel Pressure Sensor 7. Ignition ON, engine running 8. Read DTCs using DST or SERVICE ADVISOR.
000620.04 reoccurs: GO TO 4 000620.04 doesnt reoccur: GO TO 3
1/1
CTM170 (14MAY03)
04-160-223

051403
PN=433

1. Ignition ON, engine OFF 2. Reconnect the Fuel Pressure Sensor while monitoring DTCs.
000620.04 reoccurs: Faulty Fuel Pressure Sensor Replace and retest 000620.04 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
04 160 ,224
4 Sensor Supply Short to Ground Check
1. Ignition OFF 2. Disconnect the ECU connector 3. Using a multimeter, measure resistance between terminal 3 in the ECU connector and: A good chassis ground Terminal 1 in the ECU connector on the engine harness Terminal 24 in the ECU connector on the engine harness Terminal 46 in the ECU connector on the engine harness
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Sensor 5 volt supply circuit shorted to ground
1/1
CTM170 (14MAY03)
04-160-224

051403
PN=434
04 160 ,225
CTM170 (14MAY03)
04-160-225

051403
PN=435
000627.04 ECU Unswitched Power Missing
Battery Fuse
Ignition Switch VSW
VBat
04 160 ,226 1
68
23
19
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
1923OCT02
051403
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
DTC 000627.04 will set if:
The ECU does not detect battery voltage. If DTC 000627.04 sets, the following will occur: The engine will not start or run. The ECU will set a BLINKING warning light.
RG41221,000019C 1922OCT021/1
CTM170 (14MAY03)
04-160-226

PN=436
RG10761
ECU Connector
000627.04 ECU Unswitched Power Missing
The ECU does not detect battery voltage.
RG41221,000019D 1915MAY011/1
000627.04 ECU Unswitched Power Missing Diagnostic Procedure

04 160 ,227
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000627.04 ECU UNSWITCHED POWER MISSING supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and all ECU grounds looking for dirty, damaged, or poorly positioned terminals.
1/1
2 ECU and ECU Connector Test
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure voltage between a good chassis ground and: Terminal 23 in the ECU connector on the engine harness Terminal 68 in the ECU connector on the engine harness
Voltage is substantially less than battery voltage: GO TO 3 Voltages are at or near battery voltage on both terminals: Faulty ECU connection OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-227

051403
PN=437

3 Battery Voltage Check
Using a multimeter, measure battery voltage at the battery terminals.
Voltage within specification for battery: Faulty ECU power supply fuse OR Faulty ECU connection OR Open or short in ECU power circuit Voltage substantially less than battery voltage: Faulty battery or charging system
04 160 ,228
1/1
CTM170 (14MAY03)
04-160-228

051403
PN=438
04 160 ,229
CTM170 (14MAY03)
04-160-229

051403
PN=439
000629.13 ECU Error

Engine Control Unit (ECU) The ECU error fault code can only occur because of an incorrectly programmed ECU or a faulty ECU. DTC 000629.13 will set if: The ECU detects an internal problem. If DTC 000629.13 sets, the following will occur: The engine will not start or run.
DPSG,RG40854,619 1922OCT021/1
04 160 ,230
CTM170 (14MAY03)
04-160-230

051403
PN=440
000629.13 ECU Error
The ECU detects an internal problem.
RG41221,000019E 1915MAY011/1
000629.13 ECU Error Diagnostic Procedure

04 160 ,231
1/1
1 Connection Check
NOTE: For theory of operation information, see DTC 000629.13 ECU ERROR supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000629.13 ECU ERROR supporting information.
1. Verify that controllers on vehicle are in correct location and connected to the correct wiring harness 2. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 3. Ignition ON, engine OFF 4. Start the ECU diagnostic software 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine running or cranking for 15 seconds 7. Read DTCs using DST or SERVICE ADVISOR.
000629.13 reoccurs: Faulty ECU connector OR Faulty ECU 000629.13 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-231

051403
PN=441
000629.19 ECU to Pump Communication Error

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,232
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
DTC 000629.19 will set if: The ECU does not receive CAN messages from the injection pump. If DTC 000629.19 sets, the following will occur: If no other codes are present, the ECU will allow the pump to run at low throttle. If other codes are present, the ECU might shut down the engine. The ECU will set a BLINKING stop lamp.
RG41221,00001A0 1922OCT021/1
CTM170 (14MAY03)
04-160-232

051403
PN=442
RG10757A
1923OCT02
000629.19 ECU to Pump Communication Error
The ECU does not receive CAN messages from the injection pump.
RG41221,00001A1 1922OCT021/1
000629.19 ECU to Pump Communication Error Diagnostic Procedure
NOTE: Other DTCs may be active with 000629.19. If 001485.02 is active also, follow that diagnostic chart first.
04 160 ,233
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000629.19 ECU TO PUMP COMMUNICATION ERROR supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the injection pump harness connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000629.19 ECU TO PUMP COMMUNICATION ERRORsupporting information.
1/1
CTM170 (14MAY03)
04-160-233

051403
PN=443

3 Open in PSG Power Circuit Wire Test
1. Ignition OFF 2. Disconnect injection pump connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between terminal 7 in the injection pump connector on the engine harness and a good chassis ground
Approximately battery voltage: GO TO 4 Substantially less than battery voltage: Open in PSG power circuit
1/1
04 160 ,234
4 Pump Communication Wiring Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between: Terminal 1 in the injection pump connector and terminal 59 in the ECU connector on the engine harness Terminal 2 in the injection pump connector and terminal 58 in the ECU connector on the engine harness
Both measurements 5 ohms or less: GO TO 5 Either measurement greater than 5 ohms: Faulty CAN wiring between injection pump and the ECU
1/1
5 Pump CAN Low Wire Check for Short
1. Ignition OFF 2. Keep ECU and pump connectors disconnected 3. Using a multimeter, measure resistance between terminal 59 in the ECU connector and: A good ground All other terminals in the ECU connector
All measurements greater than 20k ohms: GO TO 6 Either measurement less than 20k ohms: Pump CAN Low wire shorted to ground or another wire in harness
1/1
6 Pump CAN High Wire Check for Short
1. Ignition OFF 2. Keep ECU and pump connectors disconnected 3. Using a multimeter, measure resistance between terminal 58 in the ECU connector and: A good ground All other terminals in the ECU connector
All measurements greater than 20k ohms: Faulty injection pump connector OR Faulty injection pump Either measurement less than 20k ohms: Pump CAN High wire shorted to ground or another wire in harness
1/1
CTM170 (14MAY03)
04-160-234

051403
PN=444
04 160 ,235
CTM170 (14MAY03)
04-160-235

051403
PN=445
000632.02 Fuel Shutoff Error

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,236
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
Bosch VP44 Rotary Injection Pump The Bosch VP44 rotary injection pump is controlled by a pump control unit that monitors information received from sensors inside the pump. It also acquires information from the ECU over a CAN bus and other dedicated wires between the ECU and pump. This helps the pump control unit to provide
for the accurate quantity and timing of fuel delivery to the engine. DTC 000632.02 will set if: The pump control unit (PSG) detects a fuel shutoff voltage that does not match the information being communicated over CAN. If DTC 000632.02 sets, the following will occur: The engine will shut down or may not restart. The ECU will set a BLINKING warning light.
RG41221,00001A3 1915MAY011/1
CTM170 (14MAY03)
04-160-236

051403
PN=446
RG10757A
1923OCT02
000632.02 Fuel Shutoff Error
The pump control unit (PSG) detects a fuel shutoff voltage that does not match the information being communicated over CAN.
RG41221,00001A4 1922OCT021/1
000632.02 Fuel Shutoff Error Diagnostic Procedure

04 160 ,237
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000632.02 FUEL SHUTOFF ERROR supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the fuel injection pump harness connector looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine running or cranking 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-237

051403
PN=447

3 Voltage at Injection Pump Check
1. Ignition OFF 2. Disconnect injection pump connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between a good chassis ground and terminal 5 in the injection pump connector on the engine harness
Battery voltage present: GO TO 4 No battery voltage present: Faulty injection pump connector OR Faulty injection pump
1/1
04 160 ,238
4 Fuel Shutoff Wire Check for Short to Voltage
1. Ignition OFF 2. Using a multimeter, measure resistance between terminal 18 in the ECU connector and all other terminals in the ECU connector on the engine harness
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Short to voltage in fuel shutoff wire
1/1
CTM170 (14MAY03)
04-160-238

051403
PN=448
04 160 ,239
CTM170 (14MAY03)
04-160-239

051403
PN=449
000632.05 Fuel Shutoff Non-Functional

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,240
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
Bosch VP44 Rotary Injection Pump The Bosch VP44 rotary injection pump is controlled by a pump control unit that monitors information received from sensors inside the pump. It also acquires information from the ECU over a CAN bus and other dedicated wires between the ECU and
pump. This helps the pump control unit to provide for the accurate quantity and timing of fuel delivery to the engine. DTC 000632.05 will set if: The ECU does not detect a change in engine speed during a period of time after the key is turned off. If DTC 000632.05 sets, the following will occur: No change in engine performance will be detected. The ECU will set a BLINKING warning light.
RG41221,00001A6 1922OCT021/1
CTM170 (14MAY03)
04-160-240

051403
PN=450
RG10757A
1923OCT02
000632.05 Fuel Shutoff Non-Functional
The ECU does not detect a change in engine speed during a period of time after the key is turned off.
RG41221,00001A7 1915MAY011/1
000632.05 Fuel Shutoff Non-Functional Diagnostic Procedure
NOTE: This DTC will appear only as a stored trouble code.
04 160 ,241
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000632.05 FUEL SHUTOFF NON-FUNCTIONAL supporting information.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Ignition OFF 7. Ignition ON, engine OFF 8. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-241

051403
PN=451

3 Open in Fuel Shutoff Wire Check
1. Ignition OFF 2. Disconnect ECU and injection pump connectors 3. Using a multimeter, measure resistance between terminal 18 in the harness end of the ECU connector and terminal 5 in the harness end of the injection pump connector.
Less than 5 ohms: GO TO 4 Greater than 5 ohms: Open in fuel shutoff wire
1/1
04 160 ,242
4 Fuel Shutoff Wire Check for Short
1. Ignition OFF 2. Using multimeter, measure resistance between terminal 18 in the harness end of the ECU connector and a good chassis ground
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Short to ground in fuel shutoff wire
1/1
CTM170 (14MAY03)
04-160-242

051403
PN=452
04 160 ,243
CTM170 (14MAY03)
04-160-243

051403
PN=453
000636.02 Pump Position Input Noise
Pump Position Sensor
Pump Position Sensor Connector Pump Position Return

B A B A
Pump Position Input 10 36
04 160 ,244
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Pump Position Sensor The pump position sensor is located behind the injection pump. It is an inductive type pickup sensor that detects slots in the injection pump gear. The ECU uses the pump position input to determine cylinder identification to keep the pump in time with the engine. The injection pump gear is composed of 12 evenly spaced slots with one additional notch offset to tell the ECU that cylinder #1 is approaching Top-Dead-Center. For further pump position sensor information, see MEASURING ENGINE SPEED in Section 03, Group 140 earlier in this manual.
DTC 000636.02 will set if: The ECU detects excessive noise (extra pulses) on the Pump Position input. If DTC 000636.02 sets, the following will occur: If a crankshaft position sensor trouble code accompanies DTC 000636.02, the engine will die and wont restart until at least one of the two codes is repaired. ECU will use only the crankshaft position sensor input to determine piston position. The moment that the trouble codes sets, the engine may hesitate or die, but it will re-start. Prolonged cranking time may be required to start the engine. The ECU will set a BLINKING warning light.
RG41221,00001A9 1922OCT021/1
CTM170 (14MAY03)
04-160-244

051403
PN=454
RG10758
1921JUN01
000636.02 Pump Position Input Noise
The ECU detects excessive noise (extra pulses) on the Pump Position input.
RG41221,00001AA 1922OCT021/1
000636.02 Pump Position Input Noise Diagnostic Procedure

04 160 ,245
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP POSITION INPUT NOISE supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the pump position sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Warm engine 7. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-245

051403
PN=455

3 Noise Detection Test
1. 000636.02 is most likely caused by radiated or conducted electrical "noise" from some part of the machine. This problem may be caused by loose electrical ground 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 pump position sensor wiring Check wiring for proper pin location in the pump position sensor and ECU connectors 2. Other possible causes of 000636.02: Electromagnetic interference (EMI) from an incorrectly installed 2-way radio Interference from some radar source Possible burrs on the pump position timing wheel. Notches should have clean, square edges.
1/1
04 160 ,246
CTM170 (14MAY03)
04-160-246

051403
PN=456
04 160 ,247
CTM170 (14MAY03)
04-160-247

051403
PN=457
000636.08 Pump Position Input Missing

B A B A
04 160 ,248
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
DTC 000636.08 will set if: The ECU does not detect the Pump Position input. If DTC 000636.08 sets, the following will occur: If a crankshaft position sensor trouble code accompanies DTC 000636.08, the engine will die and wont restart until at least one of the two codes is repaired. ECU will use only the crankshaft position sensor input to determine piston position. The moment that the trouble codes sets, the engine may hesitate or die, but it will re-start. Prolonged cranking time may be required to start the engine. The ECU will set a BLINKING warning light.
RG41221,00001AC 1922OCT021/1
CTM170 (14MAY03)
04-160-248

051403
PN=458
RG10758
1921JUN01
000636.08 Pump Position Input Missing
The ECU does not detect the Pump Position input.
RG41221,00001AD 1922OCT021/1
000636.08 Pump Position Input Missing Diagnostic Procedure

04 160 ,249
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP POSITION INPUT MISSING supporting information.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make notes of any DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-249

051403
PN=459

3 Pump Position Sensor Test
1. Ignition OFF 2. Disconnect pump position sensor connector 3. Using a multimeter, measure resistance between both terminals of the pump position sensor connector on the engine harness.
Between 2500 and 3500 ohms: GO TO 4 Below 2500 ohms or above 3500 ohms: Faulty pump position sensor
1/1
04 160 ,250
4 Open in Pump Position Sensor Input and Return Wires Check
1. Ignition OFF 2. Disconnect pump position sensor connector 3. Disconnect ECU connector 4. Using a multimeter, measure resistance between: Terminal A of the pump position sensor connector AND terminal 10 in the ECU connector on the engine harness Terminal B of the pump position sensor connector AND terminal 36 in the ECU connector on the engine harness
Both measurements 5 ohms or less: GO TO 5 Either measurement greater than 5 ohms: Open in pump position sensor input wire OR Open in pump position sensor return wire OR Terminals A and B in the pump position sensor harness connector possibly inverted
1/1
5 Pump Position Sensor Wiring Check
1. Ignition OFF 2. Pump position sensor connector and ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 10 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals the ECU connector
All measurements greater than 2k ohms: GO TO 6 Any measurement less than 2k ohms: Short in pump position input wire to wire with low resistance
1/1
CTM170 (14MAY03)
04-160-250

051403
PN=460

6 Pump Position Sensor Return Wiring Check
1. Ignition OFF 2. Pump position sensor connector and ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 36 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals the ECU connector
All measurements greater than 2k ohms: Faulty pump position sensor connector OR Damaged pump position sensor OR Faulty ECU connector OR Faulty ECU Any measurement less than 2k ohms: Faulty pump position sensor return wiring harness
04 160 ,251
1/1
CTM170 (14MAY03)
04-160-251

051403
PN=461
000636.10 Pump Position Input Pattern Error

B A B A
04 160 ,252
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
DTC 000636.10 will set if: The ECU detects an improper pattern on the Pump Position input. If DTC 000636.10 sets, the following will occur: If a crankshaft position sensor trouble code accompanies DTC 000636.10, the engine will die and wont restart until at least one of the two codes is repaired. ECU will use only the crankshaft position sensor input to determine piston position. The moment that the trouble codes sets, the engine may hesitate or die, but it will re-start. Prolonged cranking time may be required to start the engine. The ECU will set a BLINKING warning light.
RG41221,00001AF 1922OCT021/1
CTM170 (14MAY03)
04-160-252

051403
PN=462
RG10758
1921JUN01
000636.10 Pump Position Input Pattern Error
The ECU detects an improper pattern on the Pump Position input.
RG41221,00001B0 1922OCT021/1
000636.10 Pump Position Input Pattern Error Diagnostic Procedure

04 160 ,253
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP POSITION INPUT PATTERN ERROR supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-253

051403
PN=463

3 Pump Position Sensor Test
1. Ignition OFF 2. Disconnect pump position sensor connector 3. Using a multimeter, measure resistance between both terminals of the pump position sensor connector on the engine harness
Between 2500 and 3500 ohms: GO TO 4 Below 2500 ohms or above 3500 ohms: Faulty pump position sensor
1/1
04 160 ,254
4 Open in Pump Position Input or Return Wire Test
1. Ignition OFF 2. Disconnect pump position sensor connector 3. Disconnect ECU connector 4. Using a multimeter, measure resistance between: Terminal A of the pump position sensor connector AND terminal 10 in the ECU connector on the engine harness Terminal B of the pump position sensor connector AND terminal 36 in the ECU connector on the engine harness
Both measurements 5 ohms or less: GO TO 5 Either measurement greater than 5 ohms: Open in pump position sensor input wire OR Open in pump position sensor return wire OR Terminals A and B in the pump position sensor harness connector possibly inverted
1/1
5 Pump Position Sensor Input Wiring Check
1. Ignition OFF 2. Pump position sensor connector and ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 10 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals in the ECU connector
All measurements greater than 2k ohms: GO TO 6 Any measurement less than 2k ohms: Faulty pump position sensor input wiring harness
1/1
CTM170 (14MAY03)
04-160-254

051403
PN=464

6 Pump Position Sensor Return Wiring Check
1. Ignition OFF 2. Pump position sensor connector and ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 36 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals in the ECU connector
All measurements greater than 2k ohms: GO TO 7 Any measurement less than 2k ohms: Faulty pump position sensor return wiring harness
1/1
7 Pump Position Sensor and Timing Wheel Check
1. Remove pump position sensor from injection pump Inspect sensor for cracks, corrosion, or any foreign material on the end of the sensor. 2. Inspect the pump timing wheel notches for burrs or chips.
All components OK: GO TO 8 Fault found in a component: Repair or replace component as needed
04 160 ,255
1/1
8 Cam and Crank Timing Test
1. Ignition OFF 2. Remove timing cover 3. Check timing between camshaft, crankshaft, and injection pump gears. See INSTALL CAMSHAFT in Group 050 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
All gears in time: Faulty pump position sensor connector OR Faulty ECU connector OR Faulty ECU One or more gears out of time: Make necessary adjustments to ensure correct timing. See INSTALL CAMSHAFT in Group 050 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
CTM170 (14MAY03)
04-160-255

051403
PN=465
000637.02 Crankshaft Position Input Noise
Crank Position Sensor
Crank Sensor Connector Crank Position Return

B A B A
Crank Position Input 9 34
04 160 ,256
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
1918MAY00
ECU Connector
Crankshaft Position Sensor The crankshaft position sensor is located on the front of the crankshaft, behind the pressed-on crank gear. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The ECU uses the crankshaft position input to determine engine speed and precise piston position in relation to the firing order. The crank timing wheel is composed of 48 evenly spaced teeth and 2 gaps between the teeth missing. The missing gaps help the ECU to determine Top-Dead-Center (TDC). For further crankshaft position sensor information, see MEASURING ENGINE SPEED in Section 03, Group 140. DTC 000637.02 will set if:
The ECU detects excessive noise (extra pulses) on the crankshaft position input. If DTC 000637.02 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If a pump position sensor trouble code accompanies DTC 000637.02, the engine will die and wont restart until at least one of the two codes is repaired. ECU will use only the pump position sensor input to determine piston position. The moment that the trouble codes sets, the engine may hesitate or die, but it will re-start. Prolonged cranking may be required to start engine.
RG41221,00001B2 1922OCT021/2
CTM170 (14MAY03)
04-160-256

051403
PN=466
RG10759

The ECU will set a BLINKING stop lamp.
RG41221,00001B2 1922OCT022/2
04 160 ,257
CTM170 (14MAY03)
04-160-257

051403
PN=467
000637.02 Crankshaft Position Input Noise
The ECU detects excessive noise (extra pulses) on the crankshaft position input.
RG41221,00001B3 1922OCT021/1
000637.02 Crankshaft Position Input Noise Diagnostic Procedure

04 160 ,258
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANKSHAFT POSITION INPUT NOISE supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and the crankshaft position sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Warm engine 7. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-258

051403
PN=468

3 Crank Signal Noise Test
1. 000637.02 is most likely caused by radiated or conducted electrical "noise" from some part of the machine. This problem may be caused by loose electrical ground 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 crankshaft position sensor wiring Check wiring for proper pin location in the crankshaft position sensor and ECU connectors 2. Other possible causes of 000637.02: Electromagnetic interference (EMI) from an incorrectly installed 2-way radio Interference from some radar source Possible broken teeth on the crankshaft timing ring
04 160 ,259
1/1
CTM170 (14MAY03)
04-160-259

051403
PN=469
000637.08 Crankshaft Position Input Missing

B A B A
04 160 ,260
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
1918MAY00
ECU Connector
The ECU does not detect the crankshaft position input. If DTC 000637.08 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If a pump position sensor trouble code accompanies DTC 000637.08, the engine will die and wont restart until at least one of the two codes is repaired. ECU will use only the pump position sensor input to determine piston position. The moment that the trouble codes sets, the engine may hesitate or die, but it will re-start. Prolonged cranking may be required to start engine.
RG41221,00001B5 1922OCT021/2
CTM170 (14MAY03)
04-160-260

051403
PN=470
RG10759

RG41221,00001B5 1922OCT022/2
04 160 ,261
CTM170 (14MAY03)
04-160-261

051403
PN=471
000637.08 Crankshaft Position Input Missing
The ECU does not detect the crankshaft position input.
RG41221,00001B6 1922OCT021/1
000637.08 Crankshaft Position Input Missing Diagnostic Procedure

04 160 ,262
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANKSHAFT POSITION INPUT MISSING supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-262

051403
PN=472

3 Crankshaft Position Sensor Check
1. Ignition OFF 2. Remove crankshaft position sensor from timing gear cover. See REPLACE CRANKSHAFT POSITION SENSOR in Section 02, Group 110 earlier in this manual. 3. Inspect sensor tip for damage, such as cracks or debris
No signs of damage: GO TO 4 Damage to sensor: Determine and repair the cause of damage to sensor Replace sensor and retest
1/1
4 Crankshaft Position Sensor Resistance Check
1. Ignition OFF 2. Disconnect crankshaft position sensor connector 3. Using a multimeter, measure resistance between both terminals of the crankshaft position sensor
Measurement between 2500 and 3500 ohms: GO TO 5 Measurement below 2500 ohms or above 3500 ohms: Faulty crankshaft position sensor
04 160 ,263
1/1
5 Open in Crankshaft Position Sensor Input and Return Wire Check
1. Ignition OFF 2. Disconnect crankshaft position sensor connector 3. Disconnect ECU connector 4. Using a multimeter, measure resistance between: Terminal A of the crankshaft position sensor connector AND terminal 9 in the ECU connector on the engine harness Terminal B of the crankshaft position sensor connector AND terminal 34 in the ECU connector on the engine harness
Both measurements 5 ohms or less: GO TO 6 Either measurement greater than 5 ohms: Open in crankshaft position sensor input wire OR Open in crankshaft position sensor return wire OR Terminals A and B in the crankshaft position sensor harness connector possibly inverted
1/1
CTM170 (14MAY03)
04-160-263

051403
PN=473

6 Crankshaft Position Input Wiring Check
1. Ignition OFF 2. Crankshaft position sensor connector and ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 9 in the , ECU connector on the engine harness and the following: A good chassis ground All other terminals in the ECU connector
All measurements greater than 2k ohms: GO TO 7 Any measurement less than 2k ohms: Short in crankshaft position input wire to wire with low resistance
1/1
04 160 ,264
7 Crankshaft Position Return Wiring Check
1. Ignition OFF 2. Crankshaft position sensor connector and ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 34 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals in the ECU connector
All measurements greater than 2k ohms: Faulty crankshaft position sensor connector OR Damaged crankshaft position sensor OR Faulty ECU connector OR Faulty ECU Any measurement less than 2k ohms: Faulty crankshaft position sensor return wiring harness
1/1
CTM170 (14MAY03)
04-160-264

051403
PN=474
04 160 ,265
CTM170 (14MAY03)
04-160-265

051403
PN=475
000637.10 Crankshaft Position Input Pattern Error

B A B A
04 160 ,266
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
1918MAY00
ECU Connector
The ECU detects an improper pattern on the crankshaft position input. If DTC 000637.10 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If a pump position sensor trouble code accompanies DTC 000637.10, the engine will die and wont restart until at least one of the two codes is repaired. ECU will use only the pump position sensor input to determine piston position. The moment that the trouble codes sets, the engine may hesitate or die, but it will re-start. Prolonged cranking may be required to start engine.
RG41221,00001B8 1922OCT021/2
CTM170 (14MAY03)
04-160-266

051403
PN=476
RG10759

RG41221,00001B8 1922OCT022/2
04 160 ,267
CTM170 (14MAY03)
04-160-267

051403
PN=477
000637.10 Crankshaft Position Input Pattern Error
The ECU detects an improper pattern on the crankshaft position input.
RG41221,00001B9 1922OCT021/1
000637.10 Crankshaft Position Input Pattern Error Diagnostic Procedure

04 160 ,268
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-268

051403
PN=478

3 Crankshaft Position Sensor Test
1. Ignition OFF 2. Disconnect crankshaft position sensor connector 3. Using a multimeter, measure resistance between both terminals of the crankshaft position sensor
Between 2500 and 3500 ohms: GO TO 4 Below 2500 ohms or above 3500 ohms: Faulty crankshaft position sensor
1/1
4 Open in Crankshaft Position Sensor Input and Return Check
1. Ignition OFF 2. Disconnect crankshaft position sensor connector 3. Disconnect ECU connector 4. Using a multimeter, measure resistance between: Terminal A of the crankshaft position sensor connector and terminal 9 in the ECU connector on the engine harness Terminal B of the crankshaft position sensor connector and terminal 34 in the ECU connector on the engine harness
Both measurements 5 ohms or less: GO TO 5 Either measurement greater than 5 ohms: Open in crankshaft position sensor input wire OR Open in crankshaft position sensor return wire OR Terminals A and B in the crankshaft position sensor harness connector possibly inverted
04 160 ,269
1/1
5 Crankshaft Sensor Input Wiring Check
1. Ignition OFF 2. Crankshaft position sensor connector and ECU connector still disconnected 3. Using a multimeter measure resistance between terminal 9 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals in the ECU connector
All measurements greater than 2k ohms: GO TO 6 Any measurement less than 2k ohms: Faulty crankshaft position sensor input wiring harness
1/1
CTM170 (14MAY03)
04-160-269

051403
PN=479

6 Crankshaft Sensor Return Wiring Check
1. Ignition OFF 2. Crankshaft position sensor connector and ECU connector still disconnected 3. Using a multimeter measure resistance between terminal 34 in the ECU connector on the engine harness and the following: A good chassis ground All other terminals in the ECU connector
All measurements greater than 2k ohms: GO TO 7 Any measurement less than 2k ohms: Faulty crankshaft position sensor return wiring harness
1/1
04 160 ,270
7 Crankshaft Sensor and Timing Wheel Check
1. Remove crankshaft position sensor 2. Inspect sensor for cracks, corrosion, or any foreign material on the end of the sensor 3. Inspect the crank timing wheel notches for burrs or chips
All components OK: GO TO 8 Fault found in a component: Repair or replace component as needed
1/1
8 Gear Timing Check
1. Ignition OFF 2. Remove timing cover 3. Check timing between camshaft, crankshaft, and injection pump gears. See INSTALL CAMSHAFT in Group 050 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
All gears in time: Faulty crankshaft position sensor connector OR Faulty ECU connector OR Faulty ECU One or more gears out of time: Make necessary adjustments to ensure correct timing. See INSTALL CAMSHAFT in Group 050 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
CTM170 (14MAY03)
04-160-270

051403
PN=480
04 160 ,271
CTM170 (14MAY03)
04-160-271

051403
PN=481
000729.03 Inlet Air Heater Signal High
TO +12V
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Air Heater Relay Enable 30 Air Heater Relay 87

04 160 ,272
63
86
85
37 47
Heater Coil
Air Heater The air heater is used to warm the engines air temperature prior to starting. The ECU reads engine coolant temperature at the key ON position. If the temperature is below 0C (32F) the ECU sends out battery voltage to energize the air heater relay coil. This activates the relay passing 12 volts to the heater coil. DTC 000729.03 will set if:
The ECU is not sending current to the air heater relay, but detects 12 volts going to the heater coil. DTC 000729.03 sets, the following will occur: Engine performance will not be effected while running. Hard starting may occur The ECU will set a BLINKING warning light.
RG41221,00001BD 1922OCT021/1
CTM170 (14MAY03)
04-160-272

051403
PN=482
RG11735
Switched Voltage
ECU Connector
1926JUN01
Air Heater Indicator Lamp
000729.03 Inlet Air Heater Signal High
The ECU is not sending current to the air heater relay, but detects 12 volts at the heater coil.
RG41221,00001BF 1922OCT021/1
000729.03 Inlet Air Heater Signal Low Diagnostic Procedure

04 160 ,273
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000729.03 INLET AIR HEATER SIGNAL HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors, air heater relay, and the air heater looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Ignition ON, engine OFF 2. Using a multimeter, measure voltage between the heater coil power stud and a good chassis ground.
Approximately battery voltage: GO TO 3 Substantially less than battery voltage: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-273

051403
PN=483

3 Air Heater Relay Return Wire Test
1. Ignition OFF 2. Disconnect the ECU connector 3. Using a multimeter, measure resistance between terminal 37 in the ECU connector on the engine harness and the following: Terminal 87 on the air heater relay Heater coil power stud
All measurements 5 ohms or less: GO TO 4 Either measurement greater than 5 ohms: Air heater relay return wire shorted to power.
1/1
4 Air Heater Relay Test 04 160 ,274
1. Ignition OFF 2. ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal 63 in the ECU connector and terminal 86 on the air heater relay on the engine harness
Measurements 5 ohms or less: Faulty air heater relay Measurements greater than 5 ohms: Air heater relay enable wire shorted to power
1/1
CTM170 (14MAY03)
04-160-274

051403
PN=484
04 160 ,275
CTM170 (14MAY03)
04-160-275

051403
PN=485
000729.05 Inlet Air Heater Signal Low
TO +12V
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Air Heater Relay Enable 30 Air Heater Relay 87

04 160 ,276
63
86
85
37 47
Heater Coil
Air Heater The air heater is used to warm the engines air temperature prior to starting. The ECU reads engine coolant temperature at the key ON position. If the temperature is below 0C (32F) the ECU sends out battery voltage to energize the air heater relay coil. This activates the relay passing 12 volts to the heater coil. DTC 000729.05 will set if:
The ECU is sending current to the air heater relay, but does not detect 12 volts going to the heater coil. DTC 000729.05 sets, the following will occur: Engine performance will not be effected while running. Hard starting may occur The ECU will set a BLINKING warning light.
RG41221,00001BE 1915MAY011/1
CTM170 (14MAY03)
04-160-276

051403
PN=486
RG11735
Switched Voltage
ECU Connector
1926JUN01
Air Heater Indicator Lamp
000729.05 Inlet Air Heater Signal Low
The ECU is sending current to the air heater relay, but does not detect 12 volts at the heater coil.
RG41221,00001C0 1922OCT021/1
000729.05 Inlet Air Heater Signal Low Diagnostic Procedure

04 160 ,277
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000729.05 INLET AIR HEATER SIGNAL LOW supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors, air heater relay, and the air heater looking for dirty, damaged, or poorly positioned terminals.
1/1
1/1
CTM170 (14MAY03)
04-160-277

051403
PN=487

3 Air Heater Relay Test
1. Cycle ignition from OFF to ON 2. Listen to air heater relay
Relay clicks: GO TO 4 Relay doesnt click: Open in air heater relay enable wire OR Open in air heater relay ground OR Faulty Relay
1/1
04 160 ,278
4 Air Heater Relay Voltage Test
1. Ignition ON, engine OFF 2. Using a multimeter, measure voltage between terminal 30 on the air heater relay and a good chassis ground
Approximately battery voltage: GO TO 5 Substantially less than battery voltage: Open in battery voltage supply wire OR Short to ground in battery voltage supply wire
1/1
5 Heater Coil Power Test
1. Ignition ON, engine OFF 2. Using a multimeter, measure voltage between the heater coil power stud and a good chassis ground
Approximately battery voltage: Open in air heater relay return wire Substantially less than battery voltage: Open in wire between air heater relay terminal 87 and the heater coil OR Short to ground in wire between air heater relay terminal 87 and the heater coil
1/1
CTM170 (14MAY03)
04-160-278

051403
PN=488
04 160 ,279
CTM170 (14MAY03)
04-160-279

051403
PN=489
000810.02 Calculated Vehicle Speed Input Signal Noise
11
04 160 ,280 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
1908JUN00
ECU Connector
Vehicle Speed The wheel speed sensor is an inductive type sensor that is mounted on the rear axle. As teeth on the axle rotate past the sensor, AC signals are generated. The frequency of these signals are proportional to the wheel speed. The signal from the sensor is sent to the Basic Control Unit (BCU). The BCU sends a Pulse Width Modulated (PWM) signal to the Basic Informator (BIF) and ECU. Wheel speed is delivered to the ECU over CAN from the BIF and by PWM from the BCU.
DTC 000810.02 will set if: ECU detects noise on the wheel speed sensor from the BCU. If DTC 000810.02 sets, the following will occur: ECU will limit engine speed to 1950 rpm. DTC 000810.02 may also cause DTC 000084.02 and DTC 001069.02 to set. These codes will clear once DTC 000084.02 is repaired. The ECU will set a BLINKING warning light.
RG41221,00001C2 1922OCT021/1
CTM170 (14MAY03)
04-160-280

051403
PN=490
RG10760
000810.02 Calculated Vehicle Speed Input Signal Noise
ECU detects noise on the wheel speed sensor from the BCU.
RG41221,00001C3 1922OCT021/1
000810.02 Calculated Vehicle Speed Input Signal Noise Diagnostic Procedure

04 160 ,281
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000810.02 CALCULATED VEHICLE SPEED INPUT SIGNAL NOISE supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU, BIF, and BCM connectors looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs 5. Engine running, vehicle moving under normal operating conditions. 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-281

051403
PN=491

3 Noise Test
1. 000810.02 is most likely caused by radiated or conducted electrical "noise" from some part of the machine. This problem may be caused by loose electrical ground or power connections anywhere on the machine. Things to check: All harness connectors Alternator connections Chassis ground connections, battery ground connections Corrosion, dirt, or paint can cause intermittent and "noisy" connections Check wiring harness for intermittent open and short circuits; particularly the wheel speed sensor wiring.
2. Other possible causes of 000810.02: Electromagnetic interference (EMI) from an incorrectly installed 2-way radio Interference from some radar source 04 160 ,282
1/1
CTM170 (14MAY03)
04-160-282

051403
PN=492
04 160 ,283
CTM170 (14MAY03)
04-160-283

051403
PN=493
000898.09 Vehicle Speed Invalid/Missing

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
44 42
E F G
04 160 ,284
D C A J H B
C C CAN Terminator CAN (Controller Area Network) Throttle CAN (Controller Area Network) throttle is information sent to the ECU by another controller over CAN about the desired throttle position. DTC 000898.09 will set if:
ECU Connector
ECU does not receive throttle information over CAN, or the information that is received is not valid. If DTC 000898.09 sets, the following will occur: The ECU limits engine to low idle (0% throttle) ECU will set a BLINKING warning light.
RG41221,00001C5 1915MAY011/1
CTM170 (14MAY03)
04-160-284

051403
PN=494
RG11727
1923OCT02
B B A C
000898.09 Vehicle Speed Invalid/Missing
ECU does not receive throttle information over CAN, or the information that is received is not valid.
RG41221,00001C6 1922OCT021/1
000898.09 Vehicle Speed Invalid/Missing Diagnostic Procedure

04 160 ,285
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000898.09 VEHICLE SPEED INVALID/MISSING supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors, diagnostic connector, and the CAN terminator looking for dirty, damaged, or poorly positioned terminals.
1/1
1/1
CTM170 (14MAY03)
04-160-285

051403
PN=495

3 CAN Codes Check
If application has other machine controllers communicating on the CAN bus, check those controllers for CAN related DTCs
No CAN related DTCs found on other controllers: GO TO 4 Found CAN related DTCs on other controllers: Refer to diagnostic procedures for controller Repair cause of throttle related DTC and retest
1/1
04 160 ,286
4 Machine Manual CAN Diagnostic Check
Refer to vehicle manual specific to your application and follow the CAN diagnostic section
Problem detected: Repair fault as needed and repair as needed No problems detected: Faulty ECU connector OR Faulty ECU
1/1
CTM170 (14MAY03)
04-160-286

051403
PN=496
04 160 ,287
CTM170 (14MAY03)
04-160-287

051403
PN=497
000970.02 Auxiliary Engine Shutdown Switch Signal Invalid

Application Controller
12
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 04 160 ,288
ECU Connector
Auxiliary Shutdown: The ECU has the ability to receive shutdown signals from other application controllers. When the ECU receives the signal from this controller, the ECU shuts the engine down for vehicle protection.
DTC 000970.02 will set if: The ECU reads an input voltage from the applications controller to be less than 0.5 volts or greater than 2.5 volts. If DTC 000970.02 will sets, the following will occur: The ECU will shut the engine down. The ECU will set a BLINKING stop lamp.
RG41221,00001C7 1922OCT021/1
CTM170 (14MAY03)
04-160-288

051403
RG11729
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=498
000970.02 Auxiliary Engine Shutdown Switch Signal Invalid
The ECU receives an invalid signal request from another controller to shut the engine down.
RG41221,00001CA 1922OCT021/1
000970.02 Auxiliary Engine Shutdown Switch Signal Invalid Diagnostic Procedure

04 160 ,289
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000970.02 AUXILIARY ENGINE SHUTDOWN SWITCH SIGNAL INVALID supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors and the corresponding application controller connector(s) looking for dirty, damaged, or poorly positioned terminals.
1/1
1/1
CTM170 (14MAY03)
04-160-289

051403
PN=499

3 Other Controller DTC Test
Check another controller for related DTCs.
Controller reports no related DTCs: GO TO 4 Controller has related DTCs: Refer to diagnostic procedures for controller. Repair cause of DTC and retest.
NOTE: Auxiliary shutdown signal originates from another controller.
1/1
4 Controller Test 04 160 ,290
1. Ignition OFF 2. Disconnect ECU connector 3. Ignition ON 4. Using a multimeter, measure voltage between terminal 12 in the ECU connector on the engine harness and a good chassis ground
Less than 0.5 V or greater than 2.5V: GO TO 5 Between 0.5 V and 2.5V: Wrong ECU for the vehicle OR Faulty ECU connector OR Faulty ECU OR Faulty auxiliary shutdown signal source controller
1/1
5 Open in Auxiliary Shutdown Signal Circuit Test
1. Ignition OFF 2. ECU connector still disconnected 3. Obtain wiring information for this application and determine the source of the auxiliary shutdown signal 4. Disconnect the connector that outputs the shutdown signal 5. Using a multimeter, measure the resistance between terminal 12 of the ECU connector on the engine harness and the originating shutdown signal terminal
5 ohms or less: GO TO 6 Greater than 5 ohms: Open in auxiliary shutdown signal circuit
1/1
CTM170 (14MAY03)
04-160-290

051403
PN=500

6 Short in Auxiliary Shutdown Signal Circuit Test
1. Ignition OFF 2. Using a multimeter measure resistance between terminal 12 in the ECU connector on the engine harness and All other terminals in that connector A good chassis ground
All measurements greater than 2k ohms: Faulty signal source controller wiring OR Faulty auxiliary shutdown controller connector OR Faulty auxiliary shutdown signal source controller Any measurement less than 2k ohms: Short in auxiliary shutdown signal circuit
04 160 ,291
1/1
CTM170 (14MAY03)
04-160-291

051403
PN=501
000970.31 Auxiliary Engine Shutdown Switch Active
Engine shutdown switch is active.
RG41221,00001CB 1915MAY011/2
Shutdown Signal
04 160 ,292
Sensor Ground
24
12
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
Auxiliary Engine Shutdown Switch On OEM applications, the engine shutdown switch is a normally open switch. When the property being measured exceeds a certain value, the switch will close. When the switch is closed, the voltage is
grounded, which will cause the ECU to shutdown the engine. DTC 000970.31 will set if: The ECU does not read an input voltage. If DTC 000970.31 sets, the following will occur: The ECU will shut the engine down. The ECU will set a BLINKING stop lamp.
RG41221,00001CB 1915MAY012/2
CTM170 (14MAY03)
04-160-292

051403
RG11734
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
PN=502
000971.31 External Engine Derate Switch Active
Engine derate switch is active.
RG41221,00001CC 1915MAY011/2
Derate Signal Sensor Ground

04 160 ,293
24
32
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
External Fuel Derate Switch On OEM applications, the external derate switch is a normally open switch. When property being measured exceeds a certain value, the switch will close. When the switch is closed, the voltage is grounded, which will cause the ECU to derate the engine. DTC 000971.31 will set if:
The ECU does not read an input voltage. If DTC 000971.31 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 80% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. The ECU will set a BLINKING warning light.
RG41221,00001CC 1915MAY012/2
CTM170 (14MAY03)
04-160-293

051403
RG11740
1916MAY01
PN=503
001069.02 Tire Size Error
11
04 160 ,294 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
1908JUN00
ECU Connector
Tire Size Tire size is in direct proportion to wheel speed in revolutions per kilometer. Wheel speed is supplied to the ECU in rpm and through several conversions the ECU outputs revolutions per kilometer. DTC 001069.02 will set if: ECU calculates a wheel speed of rev/km that does not match the available tire size option for the application.
If DTC 001069.02 sets, the following will occur: ECU will assume the largest tire size. ECU will limit engine speed to 1950 rpm when the vehicle is in top gear. ECU will set a BLINKING warning light.
RG41221,00001CF 1922OCT021/1
CTM170 (14MAY03)
04-160-294

051403
PN=504
RG10760
001069.02 Tire Size Error
ECU calculates a wheel speed of rev/km that does not match the available tire size option for the application.
RG41221,00001D0 1922OCT021/1
001069.02 Tire Size Error Diagnostic Procedure
NOTE: If 001069.02 is accompanied with 000084.02 and/or 000810.02, follow those diagnostic procedures first.
04 160 ,295
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001069.02 TIRE SIZE ERROR supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors, the BIF connector, BCU connector, and the wheel speed sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001069.02 TIRE SIZE ERROR supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs 5. Engine running, vehicle under normal operating conditions. 6. Read DTCs using DST or SERVICE ADVISOR.
001069.02 reoccurs: Reprogram tire size in BCU and BIF. 001069.02 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-295

051403
PN=505
001076.02 Pump Detected Defect

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,296
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
The high pressure solenoid within the pump is continuously energized. PSG unable to detect closure of the high pressure solenoid valve. Internal pump speed sensor is broken. If DTC 001076.02 sets, the following will occur: The ECU will set a BLINKING stop lamp. If the engine is not running when this code is set, it may not start. DTC 001077.31 will also be present. DTC 001569.31 will also be present. Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual.
RG41221,00001D2 1922OCT021/2
CTM170 (14MAY03)
04-160-296

051403
PN=506
RG10757A
1923OCT02

RG41221,00001D2 1922OCT022/2
04 160 ,297
CTM170 (14MAY03)
04-160-297

051403
PN=507
001076.02 Pump Detected Defect
The pump control unit (PSG) detects an internal problem.
RG41221,00001D3 1922OCT021/1
001076.02 Pump Detected Defect Diagnostic Procedure

04 160 ,298
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.02 PUMP DETECTED DEFECT supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors and the injection pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001076.02 PUMP DETECTED DEFECT supporting information.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic 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.
001076.02 reoccurs: Faulty injection pump connector OR Faulty injection pump 001076.02 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-298

051403
PN=508
04 160 ,299
CTM170 (14MAY03)
04-160-299

051403
PN=509
001077.07 Attempting to Fuel Without Command

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,300
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
for the accurate quantity and timing of fuel delivery to the engine. DTC 001077.07 will set if: The pump control unit informs the ECU that the high pressure solenoid valve is closed when the ECU is commanding the pump control unit to stop delivering fuel. If DTC 001077.07 sets, the following will occur: The ECU will not derate the engine. The ECU will set a BLINKING warning light.
RG41221,00001D5 1915MAY011/1
CTM170 (14MAY03)
04-160-300

051403
PN=510
RG10757A
1923OCT02
001077.07 Attempting to Fuel Without Command
The high pressure solenoid valve is closed when the ECU is commanding the pump to stop fueling.
RG41221,00001D6 1922OCT021/1
001077.07 Attempting to Fuel Without Command Diagnostic Procedure

04 160 ,301
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001077.07 ATTEMPTING TO FUEL WITHOUT COMMAND supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connector and the injection pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001077.07 ATTEMPTING TO FUEL WITHOUT COMMAND supporting information.
1/1
CTM170 (14MAY03)
04-160-301

051403
PN=511
001077.11 Pump Supply Voltage Out Of Range

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,302
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
pump. This helps the pump control unit to provide for the accurate quantity and timing of fuel delivery to the engine. DTC 001077.11 will set if: The pump control unit (PSG) senses an abnormal battery voltage. If DTC 001077.11 sets, the following will occur: Engine may not run. The ECU will set a BLINKING warning light.
RG41221,00001D8 1915MAY011/1
CTM170 (14MAY03)
04-160-302

051403
PN=512
RG10757A
1923OCT02
001077.11 Pump Supply Voltage Out Of Range
The pump control unit (PSG) senses an abnormal battery voltage.
RG41221,00001D9 1922OCT021/1
001077.11 Pump Supply Voltage Out Of Range Diagnostic Procedure

04 160 ,303
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001077.11 PUMP SUPPLY VOLTAGE OUT OF RANGE supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of ECU connectors and the injection pump connector looking for dirty, damaged, or poorly positioned terminals.
1/1
1/1
CTM170 (14MAY03)
04-160-303

051403
PN=513

3 Injection Pump Check
1. Ignition OFF 2. Disconnect injection pump connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between terminal 7 in the injection pump connector on the engine harness and a good chassis ground
Substantially greater or less than battery voltage: GO TO 4 Approximately battery voltage: Faulty injection pump connector OR Faulty injection pump
1/1
04 160 ,304
4 PSG Wire Between Relay and Battery Check
1. Ignition OFF 2. Disconnect PSG relay connector 3. Using a multimeter, measure voltage between terminal 30 in the PSG relay on the engine harness and a good chassis ground
Approximately battery voltage: GO TO 5 Substantially greater or less than battery voltage: Faulty PSG power circuit between PSG relay and the battery
1/1
5 Short in PSG Wire Check
1. Ignition OFF 2. Disconnect ECU connector while keeping injection pump connector and connector at PSG relay disconnected 3. Using a multimeter, measure resistance between terminal 35 in the ECU connector on the engine harness and the following: A good ground All other terminals in the ECU connector
Greater than 2k ohms: GO TO 6 Less than 2k ohms: PSG power circuit shorted to ground OR PSG power circuit shorted to another wire in the harness
1/1
6 Open in PSG Wire Check
1. Ignition OFF 2. Using a multimeter, measure resistance between terminal 35 in the ECU connector on the engine harness and the following: Terminal 7 of the injection pump connector Terminal 30 of the PSG relay
Less than 5 ohms: Faulty rotary pump relay connector OR Faulty rotary pump relay Greater than 5 ohms: Short in injection pump PSG power supply circuit
1/1
CTM170 (14MAY03)
04-160-304

051403
PN=514
04 160 ,305
CTM170 (14MAY03)
04-160-305

051403
PN=515
001077.12 Pump Self-Test Error

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,306
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
The pump control unit (PSG) determines that the internal components within the pump are not working properly. If DTC 001077.12 sets, the following will occur: The ECU will set a BLINKING warning light. DTC 001077.31 will also be present. DTC 001569.31 will also be present. Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
RG41221,00001DB 1922OCT021/1
CTM170 (14MAY03)
04-160-306

051403
PN=516
RG10757A
1923OCT02
001077.12 Pump Self-Test Error
The pump control unit (PSG) determines that the internal components within the pump are not working properly.
RG41221,00001DC 1915MAY011/1
001077.12 Pump Self-Test Error Diagnostic Procedure

04 160 ,307
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001077.12 PUMP SELF-TEST ERROR supporting information.
1/1
NOTE: For wiring and theory of operation information, see DTC 001077.12 PUMP SELF-TEST ERROR supporting information.
1/1
CTM170 (14MAY03)
04-160-307

051403
PN=517
001077.19 Pump Detected Communication Error

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,308
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
for the accurate quantity and timing of fuel delivery to the engine. DTC 001077.19 will set if: The pump is not receiving any inputs from the ECU over CAN when there is a speed being detected on the crank speed out wire. If DTC 001077.19 sets, the following will occur: If the engine is not running when this code is set, it may not start. The ECU will set a BLINKING warning light.
RG41221,00001DE 1922OCT021/1
CTM170 (14MAY03)
04-160-308

051403
PN=518
RG10757A
1923OCT02
001077.19 Pump Detected Communication Error
The pump is not receiving input from the ECU over CAN when speed is being detected on the crank speed out wire.
RG41221,00001DF 1922OCT021/1
001077.19 Pump Detected Communication Error Diagnostic Procedure

04 160 ,309
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001077.19 PUMP DETECTED COMMUNICATION ERROR supporting information.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make notes of any DTCs, then clear all DTCs 5. Ignition ON, engine cranking or running 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-309

051403
PN=519

3 Pump CAN Wiring Check
1. Ignition OFF 2. Disconnect the ECU and injection pump connectors 3. Using a multimeter, measure resistance between: Terminal 1 in the injection pump connector and terminal 59 in the ECU connector on the engine harness Terminal 2 in the injection pump connector and terminal 58 in the ECU connector on the engine harness
Both measurements less 5 ohms or less: GO TO 4 Either measurement greater than 5 ohms: Faulty CAN BUS wiring between injection pump and the ECU
1/1
04 160 ,310
4 Pump CAN Wiring Check for Short
1. Ignition OFF 2. ECU connector still disconnected. 3. Using a multimeter, measure resistance between a good chassis ground and: Terminal 1 in the injection pump connector on the engine harness Terminal 2 in the injection pump connector on the engine harness
Both measurements greater than 20k ohms: Faulty ECU connector OR Faulty ECU Either measurement less than 20k ohms: CAN BUS wiring between pump and ECU is shorted to ground
1/1
CTM170 (14MAY03)
04-160-310

051403
PN=520
04 160 ,311
CTM170 (14MAY03)
04-160-311

051403
PN=521
001077.31 Pump Initiated Engine Protection
Pump initiated fuel derate for engine protection.

Injection Pump Derate The pump control unit (PSG) has the ability to initiate protection to the injection pump and engine when it detects a problem within the pump. As a result, the pump derates the amount of fuel that it will send to the engine. DTC 001077.31 will set if:
04 160 ,312
Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual. With Derate Feature: On OEM applications, the engine derates 20% per minute until the engine is running at 50% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. If DTC 001077.31 sets: If DTC 000174.00 is active, see DTC 000174.00 FUEL TEMPERATURE HIGH MOST SEVERE DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 000174.31 is active, see DTC 000174.31 FUEL TEMPERATURE SENSOR FAULTY DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001076.02 is active, see DTC 001076.02 PUMP DETECTED DEFECT DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001077.12 is active, see DTC 001077.12 PUMP SELF-TEST ERROR DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001078.07 is active, see DTC 001078.07 ECU/PUMP MODERATELY OUT OF SYNC DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001078.31 is active, see DTC 001078.31 ECU/PUMP EXTREMELY OUT OF SYNC DIAGNOSTIC PROCEDURE earlier in this Group.
The PSG senses an extremely high fuel temperature. The PSG senses fuel temperature input voltage to be outside the range of what is physically possible for fuel temperature. The PSG senses the high pressure solenoid to be continuously energized, it is unable to detect closure of the high pressure solenoid valve, or the internal pump speed sensor is broken. The PSG detects that components within the pump are not working properly. The PSG senses a crank signal from the ECU that is out of range with respect to the internal timing within the pump. If DTC 001077.31 sets, the following will occur: The ECU will set a BLINKING warning light. If the engine is not running when this code is set, it may not start.
DPSG,RG40854,232 1930JUN991/1
CTM170 (14MAY03)
04-160-312

051403
PN=522
04 160 ,313
CTM170 (14MAY03)
04-160-313

051403
PN=523
001078.07 ECU/Pump Timing Moderately Out of Sync

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,314
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
DTC 001078.07 will set if: The pump control unit (PSG) senses a crank signal from the ECU that is moderately out of range with respect to the internal timing within the pump. If DTC 001078.07 sets, the following will occur: If the engine is not running when this code is set, it may not start. The ECU will set a BLINKING warning light. DTC 001077.31 will also be present. DTC 001569.31 will also be present. Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual.
RG41221,00001E1 1922OCT021/2
CTM170 (14MAY03)
04-160-314

051403
PN=524
RG10757A
1923OCT02

RG41221,00001E1 1922OCT022/2
04 160 ,315
CTM170 (14MAY03)
04-160-315

051403
PN=525
001078.07 ECU/Pump Timing Moderately Out of Sync
The pump control unit (PSG) senses a crank signal from the ECU that is moderately out of range with respect to the internal timing within the pump.
RG41221,00001E2 1922OCT021/1
001078.07 ECU/Pump Timing Moderately Out of Sync Diagnostic Procedure

04 160 ,316
NOTE: If DTC 001078.07 is accompanied with a DTC SPN 636 or 637, diagnose those codes first
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001078.07 ECU/PUMP TIMING MODERATELY OUT OF SYNC supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-316

051403
PN=526

3 Crank and Pump Position Noise and Crank Status Check
1. Engine running 2. While cranking observe pump position noise, crankshaft position noise, and crank status. See Pump Position/Crank parameters. For an explanation of these parameters, go to DATA PARAMETER DESCRIPTION in Group 160.
No crank or pump position noise detected OR crank status reaches 15: GO TO 5 Crank or pump position noise detected OR crank status doesnt reach 15: GO TO 4
1/1
4 Crank/Pump Position Failures
Inspect vehicle for possible failures that can cause these conditions: Bad electrical connections Damaged pump position or crankshaft position sensor Damaged injection pump gear or crank timing wheels Electro-magnetic interference from other electronic devices around vehicle
04 160 ,317
1/1
5 Check Crank Speed Out Wire for Short
1. Disconnect injection pump connector and ECU connector 2. Using multimeter, measure resistance between terminal 17 of the ECU connector and all terminals in the ECU connector on the engine harness
All measurements greater than 2k ohms: GO TO 6 Any measurement less than 2k ohms: Short in crank speed out wire
1/1
6 Open in Crank Speed Wire Check
1. Keep injection pump and ECU connectors disconnected 2. Using multimeter, measure resistance between terminal 17 of the ECU connector and terminal 8 of the injection pump connector on the engine harness
5 ohms or less: Injection pump mounted incorrectly. See INSTALL BOSCH VP44 FUEL INJECTION PUMP OR Faulty injection pump Greater than 5 ohms: Open in crank speed out wire
1/1
CTM170 (14MAY03)
04-160-317

051403
PN=527
001078.11 ECU/Pump Engine Speed Out of Sync

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,318
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
for the accurate quantity and timing of fuel delivery to the engine. DTC 001078.11 will set if: The ECU detects timing internal to the pump does not match engine speed. If DTC 001078.11 sets, the following will occur: Engine may run rough. Engine may be hard to start. The ECU will set a BLINKING warning light.
DPSG,RG40854,233 1930JUN991/1
CTM170 (14MAY03)
04-160-318

051403
PN=528
RG10757A
1923OCT02
001078.11 ECU/Pump Engine Speed Out of Sync
The ECU detects timing internal to the pump does not match engine speed.
RG41221,00001E3 1922OCT021/1
001078.11 ECU/Pump Engine Speed Out of Sync Diagnostic Procedure
04 160 ,319
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001078.11 ECU/PUMP SPEED OUT OF SYNC supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-319

051403
PN=529

No crank or pump position noise detected OR crank status reaches 15: GO TO 5 Crank or pump position noise detected OR crank status doesnt reach 15: GO TO 4
1/1
04 160 ,320
Inspect vehicle for possible failures that can cause these conditions: Bad electrical connection Damaged pump position sensor or crankshaft position sensor Damaged injection pump gear or crank timing wheels Electro-magnetic interference from other electronic devices around vehicle
1/1
1. Disconnect injection pump connector and ECU connector 2. Using multimeter, measure resistance between terminal 17 of the ECU connector and all other terminals in the ECU connector on the engine harness.
1/1
1. Keep injection pump and ECU connector s disconnected. 2. Using a multimeter, measure resistance between terminal 17 of the ECU connector and terminal 8 of the injection pump connector on the engine harness.
5 ohms or less: Injection pump mounted incorrectly OR Faulty injection pump Greater than 5 ohms: Open in crank speed out wire
1/1
CTM170 (14MAY03)
04-160-320

051403
PN=530
04 160 ,321
CTM170 (14MAY03)
04-160-321

051403
PN=531
001078.31 ECU/Pump Timing Extremely Out of Sync

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,322
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
DTC 001078.31 will set if: The pump control unit (PSG) senses a crank signal from the ECU that is extremely out of range with respect to the internal timing within the pump. If DTC 001078.31 sets, the following will occur: The ECU will set a BLINKING stop lamp. If the engine is not running when this code is set, it may not start. DTC 001077.31 will also be present. DTC 001569.31 will also be present. Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual.
RG41221,00001E5 1922OCT021/2
CTM170 (14MAY03)
04-160-322

051403
PN=532
RG10757A
1923OCT02

RG41221,00001E5 1922OCT022/2
04 160 ,323
CTM170 (14MAY03)
04-160-323

051403
PN=533
001078.31 ECU/Pump Timing Extremely Out of Sync
The pump control unit (PSG) senses a crank signal from the ECU that is extremely out of range with respect to the internal timing within the pump.
RG41221,00001E6 1922OCT021/1
001078.31 ECU/Pump Timing Extremely Out of Sync Diagnostic Procedure

04 160 ,324
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001078.31 ECU/PUMP TIMING EXTREMELY OUT OF SYNC supporting information.
1/1
1/1
CTM170 (14MAY03)
04-160-324

051403
PN=534

3 Fuel Pressure Check (Running) on Open Loop Systems
NOTE: For wiring and theory of operation information, see DTC 001078.31 ECU/PUMP TIMING EXTREMELY OUT OF SYNC supporting information. NOTE: If the engine being diagnosed is on a closed loop system skip this procedure and GO TO 4 . For more information on closed loop versus open loop systems, see ELECTRONIC FUEL TRANSFER PUMP in Section 03, Group 140 earlier in this manual.
1. Ignition OFF 2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to spare outlet port on the final fuel filter. 3. Ignition ON, engine running at fast idle 4. Using gauge, read pressure
Between 1-83 kPa (0.01-0.8 bar) (0.15-12.0 psi): GO TO 4 Consistently below 1 kPa (0.01 bar) (0.15 psi): See F4 - FUEL SUPPLY SYSTEM CHECK - TIER 2 for cause of low fuel pressure.
04 160 ,325
1/1
No crank or pump position noise detected OR crank status reaches 15: GO TO 6 Crank or pump position noise detected OR crank status does not reach 15: GO TO 5
1/1
Inspect vehicle for possible failures that can cause these conditions: Bad electrical connections Damaged pump position or crankshaft position sensor Damaged injection pump gear or crank timing wheels Electro-magnetic interference from other electronic devices around vehicle
1/1
CTM170 (14MAY03)
04-160-325

051403
PN=535

1. Disconnect injection pump connector and ECU connector 2. Using a multimeter, measure resistance between terminal 17 of the ECU connector and all other terminals in the ECU connector on the engine harness.
1/1
04 160 ,326
1. Keep injection pump and ECU connectors disconnected 2. Using a multimeter, measure resistance between terminal 17 of the ECU connector and terminal 8 of the injection pump connector on the engine harness.
5 ohms or less: Injection pump mounted incorrectly OR Faulty injection pump Greater than 5 ohms: Open in crank speed out wire
1/1
CTM170 (14MAY03)
04-160-326

051403
PN=536
04 160 ,327
CTM170 (14MAY03)
04-160-327

051403
PN=537
001079.03 Sensor Supply 1 Voltage High

Analog Throttle (A)
Analog Throttle (A) Input
MAT Sensor t
MAT Sensor Input
5V Supply
04 160 ,328 1
31
53
50
24
1921JUN01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Sensor Ground
ECU Connector
Sensor Supply Voltage The ECU supplies voltage to a few different sensors depending on the application. The ECU monitors the drop in voltage that the sensor causes and compares that drop to preprogrammed values in the ECUs memory to determine the value of the parameter the sensor was measuring. In addition,
the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. DTC 001079.03 will set if: The ECU detects a voltage that is higher than 5.5 volts on the ECU 5 volt sensor supply 1 circuit. If DTC 001079.03 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply 1 input voltage. The ECU will set a BLINKING warning light.
RG41221,00001E8 1916MAY011/1
CTM170 (14MAY03)
04-160-328

051403
RG10763A
PN=538
RG41221,00001E9 1922OCT021/1
001079.03 Sensor Supply 1 Voltage High Diagnostic Procedure

04 160 ,329
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR SUPPLY 1 VOLTAGE HIGH supporting information.
Before using this diagnostic procedure, perform a preliminary inspection of the ECU connector and all of the sensor connectors using this 5V supply looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make notes of any DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-329

051403
PN=539

3 Sensor Supply 1 Wire Check for Short
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminal 53 in the ECU connector and all other terminals in the ECU connector on the engine harness
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Short to voltage in sensor supply 1 wire
1/1
04 160 ,330
CTM170 (14MAY03)
04-160-330

051403
PN=540
04 160 ,331
CTM170 (14MAY03)
04-160-331

051403
PN=541
001079.04 Sensor Supply 1 Voltage Low

Analog Throttle (A)
Analog Throttle (A) Input
MAT Sensor t
MAT Sensor Input
5V Supply
04 160 ,332 1
31
53
50
24
1921JUN01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Sensor Ground
ECU Connector
the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. DTC 001079.04 will set if: The ECU detects a voltage that is lower than 4.44 volts on the ECU 5 volt sensor supply 1 circuit. If DTC 001079.04 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply 1 input voltage. The ECU will set a BLINKING warning light.
RG41221,00001EB 1916MAY011/1
CTM170 (14MAY03)
04-160-332

051403
RG10763A
PN=542
RG41221,00001EC 1922OCT021/1
001079.04 Sensor Supply 1 Voltage Low Diagnostic Procedure

04 160 ,333
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR SUPPLY 1 VOLTAGE LOW supporting information.
1/1
2 Sensor Check
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic 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 53 in the ECU connector. 7. Ignition ON, engine running 8. Read DTCs using DST or SERVICE ADVISOR.
1/1
CTM170 (14MAY03)
04-160-333

051403
PN=543

1. Ignition ON 2. Reconnect each of the sensors one at a time while monitoring DTCs. After each connection, monitor DTCs on the ECU diagnostic software.
001079.04 reoccurs: Sensor that reset the DTC is faulty Replace and retest 001079.04 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
04 160 ,334
4 Sensor Supply 1 Short to Ground Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance individually between terminal 53 in the ECU connector on the engine harness and: A good chassis ground Terminal 1 in the harness end of the ECU connector Terminal 24 in the harness end of the ECU connector Terminal 46 in the harness end of the ECU connector
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Sensor 5 volt supply circuit shorted to a ground
1/1
CTM170 (14MAY03)
04-160-334

051403
PN=544
04 160 ,335
CTM170 (14MAY03)
04-160-335

051403
PN=545

Engine Coolant Sensor t
Oil Press Sensor

Oil Press Sensor Input
Fuel Press Sensor

Analog Throttle (B)

Analog Throttle (B) Input
ECT Sensor Input
04 160 ,336
5V Supply
Sensor Ground
04
26
28
03
06
46
1916MAY01 RG10783A
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. DTC 001080.03 will set if: The ECU detects a voltage that is higher than 5.5 volts on the ECU 5 volt sensor supply 2 circuit. If DTC 001080.03 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply 2 input voltage. The ECU will set a BLINKING warning light.
RG41221,00001EE 1916MAY011/1
CTM170 (14MAY03)
04-160-336

051403
PN=546
RG41221,00001EF 1922OCT021/1
001080.03 Sensor Supply 2 Voltage High Diagnostic Procedure

04 160 ,337
1/1
1 Connection Check
1/1
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make notes of any DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Read DTCs using DST or SERVICE ADVISOR.
001080.03 reoccur: GO TO 3 001080.03 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM170 (14MAY03)
04-160-337

051403
PN=547

3 Sensor Supply 2 Check for Short
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminal 3 and all other terminals in the ECU connector on the engine harness
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Short to voltage in sensor supply 2 wire
1/1
04 160 ,338
CTM170 (14MAY03)
04-160-338

051403
PN=548
04 160 ,339
CTM170 (14MAY03)
04-160-339

051403
PN=549

Engine Coolant Sensor t
Oil Press Sensor

Oil Press Sensor Input
Fuel Press Sensor

Analog Throttle (B)

Analog Throttle (B) Input
ECT Sensor Input
04 160 ,340
5V Supply
Sensor Ground
04
26
28
03
06
46
1916MAY01
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
ECU Connector
the ECU monitors the exact voltage on the 5 volt supply circuit in order to ensure accurate readings. DTC 001080.04 will set if: The ECU detects a voltage that is lower than 4.4 volts on the ECU 5 volt sensor supply 2 circuit. If DTC 001080.04 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply 2 input voltage. The ECU will set a BLINKING warning light.
RG41221,00001F1 1916MAY011/1
CTM170 (14MAY03)
04-160-340

051403
RG10783A
PN=550
RG41221,00001F2 1922OCT021/1
001080.04 Sensor Supply 2 Voltage Low Diagnostic Procedure

04 160 ,341
1/1
1 Connection Check
1/1
CTM170 (14MAY03)
04-160-341

051403
PN=551

2 Sensor Test
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISORearlier in this Group. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic 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 3 in the ECU connector. See ECU TERMINAL IDENTIFICATION in Group 210 of this manual.
04 160 ,342
7. Ignition ON, engine running 8. Read DTCs using DST or SERVICE ADVISOR.
1/1
1. Ignition ON, engine OFF 2. Reconnect each of the sensors one at a time while reading DTCs. After each connection, monitor DTCs on the ECU diagnostic software.
001080.04 reoccurs: Sensor that reset the DTC is faulty Replace and retest 001080.04 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
4 Sensor Supply 2 Short to Ground Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminal 3 in the ECU connector on the engine harness and: A good chassis ground Terminal 1 in the harness end of the ECU connector Terminal 24 in the harness end of the ECU connector Terminal 46 in the harness end of the ECU connector
Greater than 20k ohms: Faulty ECU connector OR Faulty ECU Less than 20k ohms: Sensor 5 volt supply circuit shorted to a ground
1/1
CTM170 (14MAY03)
04-160-342

051403
PN=552
04 160 ,343
CTM170 (14MAY03)
04-160-343

051403
PN=553
001109.31 Engine Protection Shutdown Warning
The ECU will shut the engine down to protect the engine from damage.
Engine Shutdown Warning: This code informs the operator that the ECU will shut the engine down because it has detected a condition such as water in fuel, low oil pressure, high engine coolant temperature, ECU error or low coolant level. If the ECU is programmed with engine protection with shutdown, the ECU has shut the engine down within 30 seconds. Prior to shutdown, the engine will be derated. DTC 001109.31 will set if: ECU detects extremely low oil pressure. ECU detects extremely high engine coolant temperature. The ECU detects a loss of engine coolant.
If DTC 001109.31 sets, the following will occur: If the ECU has engine protection with shutdown, it will derate (according to relating DTC) the engine for 30 seconds and will shut the engine down. If DTC 001109.31 sets: If DTC 000100.01 is active, see DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 000110.00 is active, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group: If DTC 000111.01 is active, see DTC 000111.01 ENGINE COOLANT LEVEL LOW DIAGNOSTIC PROCEDURE earlier in this Group.
04 160 ,344
RG41221,0000210 1922OCT021/1
CTM170 (14MAY03)
04-160-344

051403
PN=554
001110.31 Engine Protection Shutdown
The ECU shut the engine down to protect the engine from damage.
Engine Protection Shutdown: This code informs the operator that the ECU shut the engine down because it has detected a condition such as low fuel pressure, low oil pressure, high engine coolant temperature, ECU error or low coolant level. If the ECU is programmed with engine protection with shutdown, the ECU has shut the engine down. DTC 001110.31 will set if: ECU detects extremely low oil pressure. ECU detects extremely high engine coolant temperature.
The ECU detects a loss of engine coolant. If DTC 001110.31 sets, the following will occur: The ECU will have shut the engine down. If DTC 001110.31 sets: If DTC 000100.01 is active, see DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 000110.00 is active, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group: If DTC 000111.01 is active, see DTC 000111.01 ENGINE COOLANT LEVEL LOW DIAGNOSTIC PROCEDURE earlier in this Group.
04 160 ,345
RG41221,0000211 1922OCT021/1
CTM170 (14MAY03)
04-160-345

051403
PN=555
001485.02 Pump Power Relay Fault

4 9 9 4 5 8 8 5
59 58 60 02 18 17 35
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
5 9 8 7
3 2
04 160 ,346
PSG Enable
62
30
87 To Battery Fuse
ECU Connector
pump. This helps the pump control unit to provide for the accurate quantity and timing of fuel delivery to the engine. DTC 001485.02 will set if: The ECU detects that the voltage at terminal 62 does not match the voltage at terminal 35. If DTC 001485.02 sets, the following will occur: Engine may not start. The ECU will set a BLINKING warning light.
RG41221,00001F4 1916MAY011/1
CTM170 (14MAY03)
04-160-346

051403
PN=556
RG10757A
1923OCT02
001485.02 Pump Power Relay Fault
The ECU detects different voltages at two separate terminals.
RG41221,00001F3 1922OCT021/1
001485.02 Pump Power Relay Fault Diagnostic Procedure

04 160 ,347
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001485.02 PUMP POWER RELAY FAULT supporting information.
1/1
Only 001485.02 reoccurs: GO TO 8 001485.02 and 000629.19 reoccur: GO TO 3 001485.02 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group
1/1
CTM170 (14MAY03)
04-160-347

051403
PN=557

3 Check for Battery Voltage Prior to Rotary Pump Relay
1. Disconnect rotary pump relay connector 2. Using a multimeter, measure voltage between terminal 30 in the rotary pump relay connector on the engine harness and a good chassis ground
Approximately battery voltage: GO TO 4 Significantly less than battery voltage: Blown fuse(s) OR Short to ground in power wire OR Open in PSG relay power wire
1/1
04 160 ,348
4 Open in Rotary Pump Ground Wire Check
1. Ignition ON, engine OFF 2. Using a multimeter, measure voltage between terminal 30 and terminal 85 in the rotary pump relay connector on the engine harness.
Approximately battery voltage: GO TO 5 Substantially less than battery voltage: Open in rotary pump relay ground wire
1/1
5 PSG Enable Wire Voltage Check
1. Ignition ON, engine OFF 2. Using a multimeter, measure voltage between terminal 86 in the rotary pump relay connector on the engine harness and a good chassis ground
Approximately battery voltage: GO TO 6 Substantially less than battery voltage: GO TO 7
1/1
6 PSG Power Wire Resistance Check
1. Ignition OFF 2. Disconnect injection pump connector 3. Using a multimeter, measure resistance between terminal 7 in the injection pump connector and terminal 30 in the rotary pump relay connector on the engine harness.
Less than 5 ohms: Faulty pump relay connector OR Faulty pump relay Greater than 5 ohms: Faulty PSG power wire
1/1
CTM170 (14MAY03)
04-160-348

051403
PN=558

7 PSG Enable Wire Resistance Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminal 62 in the ECU connector and terminal 86 in the pump relay connector on the engine harness.
Less than 5 ohms: Faulty ECU connector OR Faulty ECU Greater than 5 ohms: Faulty PSG enable wire
1/1
8 PSG Wire Voltage Check at Injection Pump
1. Ignition OFF 2. Disconnect injection pump connector 3. Using a multimeter, measure voltage between terminal 7 in the injection pump connector on the engine harness and a good chassis ground 4. Ignition ON, engine OFF 5. Measure voltage at same location
Approximately battery voltage with ignition ON 04 and OFF: 160 GO TO 10 ,349 No voltage with ignition OFF and approximately battery voltage with ignition ON: GO TO 9
1/1
9 Open in PSG Power Wire Check
1. Ignition OFF 2. Disconnect ECU connector and rotary pump relay connector 3. Using a multimeter, measure resistance between terminal 35 in the ECU connector and terminal 30 in the rotary pump relay connector on the engine harness.
Less than 5 ohms: Faulty ECU connector OR Faulty ECU Greater than 5 ohms: Open in PSG power wire
1/1
10 PSG Enable Wire Voltage Check
1. Ignition OFF 2. Disconnect pump relay connector 3. Using a multimeter, measure voltage between terminal 86 in the rotary pump relay connector on the engine harness and a good chassis ground. 4. Ignition ON, engine OFF 5. Measure voltage at same location
No voltage with ignition OFF and approximately battery voltage with ignition ON: GO TO 12 Approximately battery voltage with ignition ON and OFF: GO TO 11
1/1
CTM170 (14MAY03)
04-160-349

051403
PN=559

11 PSG Enable Wire Check for Short to Power
1. Ignition OFF 2. Disconnect ECU connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between terminal 86 in the pump relay connector on the engine harness and a good chassis ground
Substantially less than battery voltage: Faulty ECU connector OR Faulty ECU Approximately battery voltage: Short to power on PSG enable wire
1/1
12 PSG Power Wire Check for Short to 04 Power 160 ,350
1. Ignition OFF 2. Disconnect rotary pump relay connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between terminal 30 in the pump relay connector on the engine harness and a good chassis ground
Substantially less than battery voltage: Faulty pump relay Approximately battery voltage: Short to power on PSG power wire
1/1
CTM170 (14MAY03)
04-160-350

051403
PN=560
04 160 ,351
CTM170 (14MAY03)
04-160-351

051403
PN=561
001569.31 Fuel Derate
The ECU has commanded a fuel derate for engine protection.

Fuel Derate The fuel derate trouble code is information to the operator that the ECU has detected a condition such as low fuel pressure, high fuel pressure, water in fuel, low oil pressure, high manifold air temperature, high air filter restriction, high engine coolant temperature, or low coolant level, and is derating the engine by limiting the maximum amount of fuel available to the engine. DTC 001569.31 will set if: ECU detects a low oil pressure. ECU detects a high manifold air temperature. ECU detects a high engine coolant temperature. The ECU detects water in fuel above the threshold quantity for an extended period of time. The ECU detects a loss of engine coolant. ECU detects a high fuel temperature. ECU detects a problem with the crankshaft timing. ECU receives a request from another electronic control unit on the vehicle/application. ECU receives a signal from the PSG for a pump problem.
04 160 ,352
If DTC 001569.31 sets, the following will occur: The ECU will limit the amount of fuel available to the engine in an attempt to protect the engine. If more than one derate is active, the most severe derate will have priority. The ECU may set a BLINKING warning light or stop lamp. If DTC 001569.31 sets: If DTC 000097.00 is active, see DTC 000097.00 WATER IN FUEL CONTINUOUSLY DETECTED DIAGNOSTIC PROCEDURE earlier in this Group.
If DTC 000100.01 or 000100.18 is active, see one of the following procedures earlier in this Group: DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE DTC 000100.18 ENGINE OIL PRESSURE MODERATELY LOW DIAGNOSTIC PROCEDURE If DTC 000105.00 or 000105.16 is active, see earlier in this Group. DTC 000105.00 MANIFOLD AIR TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE DTC 000105.16 MANIFOLD AIR TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE If DTC 000110.00, 000110.15 or 000110.16 is active, see one of the following procedures earlier in this Group: DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE DTC 000110.15 ENGINE COOLANT TEMPERATURE HIGH LEAST SEVERE DIAGNOSTIC PROCEDURE DTC 000110.16 ENGINE COOLANT TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE If DTC SPN 000111.01 is active, see DTC 000111.01 ENGINE COOLANT LEVEL LOW DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 000174.00, 000174.16, or 000174.31 is active, see one of the following procedures earlier in this Group: DTC 000174.00 FUEL TEMPERATURE HIGH MOST SEVERE DIAGNOSTIC PROCEDURE DTC 000174.16 FUEL TEMPERATURE HIGH MODERATELY SEVERE DIAGNOSTIC PROCEDURE DTC 000174.31 FUEL TEMPERATURE SENSOR FAULTY DIAGNOSTIC PROCEDURE If DTC 000637.02, 000637.08, or 000637.10 is active, see one of the following procedures earlier in this Group:
DPSG,RG40854,320 1922OCT021/2
CTM170 (14MAY03)
04-160-352

051403
PN=562

DTC 000637.02 CRANKSHAFT POSITION INPUT NOISE DIAGNOSTIC PROCEDURE DTC 000637.08 CRANKSHAFT POSITION INPUT MISSING DIAGNOSTIC PROCEDURE DTC 000637.10 CRANKSHAFT POSITION INPUT PATTERN ERROR DIAGNOSTIC PROCEDURE If DTC 001076.02 is active, see DTC 001076.02 PUMP DETECTED DEFECT DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001077.12 is active, see DTC 001077.12 PUMP SELF-TEST ERROR DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001077.31 is active, see DTC 001077.31 PUMP INITIATED ENGINE PROTECTION earlier in this Group. If DTC 001078.07 is active, see DTC 001078.07 ECU/PUMP MODERATELY OUT OF SYNC DIAGNOSTIC PROCEDURE earlier in this Group. If DTC 001078.31 is active, see DTC 001078.31 ECU/PUMP EXTREMELY OUT OF SYNC DIAGNOSTIC PROCEDURE earlier in this Group.
04 160 ,353
DPSG,RG40854,320 1922OCT022/2
CTM170 (14MAY03)
04-160-353

051403
PN=563
002000.13 Security Violation
The ECU determines that it, OR another controller on the machine is not the right controller for this particular machine.
Security Violation When the ignition is first turned on, all of the controllers on the machine communicate with each other to make sure that all controllers are correct for the particular machine.
04 160 ,354
If DTC 002000.13 sets, the following will occur: The ECU will allow the engine to start, but will only allow low idle engine speed. The ECU will set a BLINKING warning light. If DTC 002000.13 sets: If one of the controllers on the machine has just been replaced, make sure the correct controller was installed. If all controllers on the machine are the correct part numbers, check to see if any of the controllers have active or stored CAN related DTCs. If they do, go to the appropriate diagnostic procedure.
DTC 002000.13 will set if: The ECU determines that it, OR another controller on the machine is not the right controller for this particular machine.
RG41221,00001F5 1916AUG011/1
CTM170 (14MAY03)
04-160-354

051403
PN=564
Section 05
Tools and Other Materials

Contents
Page
Group 170Electronic Fuel/Control System Repair Tools and Other Materials Group 090 - Electronic Fuel System Repair and Adjustment Essential Tools . . . .05-170-1 Fuel System Repair and Adjustment Service Equipment and Tools . . . . . . . . . . .05-170-3 Fuel System Repair and Adjustment Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-4 Group 110 - Electronic Engine Control System Repair Tools . . . . . . . . . . . . . . . . . .05-170-4 Control Repair and Adjustment Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-10
05
Group 180Diagnostic Service Tools Group 150/160 - Electronic Fuel System Diagnostic Tools . . . . . . . . . . . . . . . . . . . . .05-180-1
CTM170 (14MAY03)
05-1

051403
PN=1
Contents
05
CTM170 (14MAY03)
05-2

051403
PN=2
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials

Group 090 - Electronic Fuel System Repair and Adjustment Essential Tools
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
DPSG,OUO1004,2751 1904MAY001/9
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . JDG820 Used to rotate engine flywheel to lock engine at TDC to check high pressure fuel pump timing. Use with JDE81-4 Timing Pin.
UN05DEC97
05 170 1
DPSG,OUO1004,2751 1904MAY002/9
VP44 Timing Pin . . . . . . . . . . . . . . . . . . . . .KJD10233 Used to lock Bosch VP44 in-line fuel injection pump timing during removal and installation of pump.
UN16JUL01
DPSG,OUO1004,2751 1904MAY003/9 RG5068 UN05DEC97
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4 Used to lock flywheel at No. 1 TDC for injection pump timing.
Timing Pin
DPSG,OUO1004,2751 1904MAY004/9
CTM170 (14MAY03)
05-170-1

051403
RG11755
PN=567
RG7056

Injection Nozzle Puller . . . . . . . . . . . . . . . . . . JDE38B Remove injection nozzles. If JDE38B is not available, JDE38A Nozzle Puller with JDG716 Adapter can be used. JDG716 can be used with slide handle adapter from JDE38 or JDE38A to remove 9.5 mm nozzles without removing the rocker arm cover. JDG716-1 Repair Kit is available if leg of JDG716 Adapter is damaged.
JDE38B
DPSG,OUO1004,2751 1904MAY005/9 RG5084 UN23AUG88
05 170 2
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . . JDE39 Clean injection nozzle bore in cylinder head.
JDE39
DPSG,OUO1004,2751 1904MAY006/9 RG5224 UN23AUG88
Nozzle Cleaning Kit . . . . . . . . . . . . . . . . . . . . JDF13B Clean injection nozzles.
JDF13B
DPSG,OUO1004,2751 1904MAY007/9
CTM170 (14MAY03)
05-170-2

051403
PN=568
RG9478
UN12NOV98

Injection Nozzle Wrench . . . . . . . . . . . . . . . . . JDG949 Used to loosen or tighten lift adjusting screws on injection nozzles.
UN23NOV97
JDG949
DPSG,OUO1004,2751 1904MAY008/9
RG7644
Nozzle Carbon Stop Seal Installer . . . . .JD258 (JD-258) Used to install carbon stop seal in injection nozzle groove.
UN22JUL92
05 170 3
JD258 (JD-258)
DPSG,OUO1004,2751 1904MAY009/9
Fuel System Repair and Adjustment Service Equipment and Tools

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.
DPSG,OUO1004,2752 1904MAY001/5
Bosch Bench Mounted Nozzle Tester . . . . . . . . JT25510 Check nozzle opening pressure.
DPSG,OUO1004,2752 1904MAY002/5
CTM170 (14MAY03)
05-170-3

051403
PN=569
RG6254

Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . .KJD10109 Use with JT25510 Nozzle Tester to check nozzle opening pressure.
DPSG,OUO1004,2752 1904MAY003/5
Fuel Injection Nozzle Tester Adapter Set . . . . D01110AA Check nozzle opening pressure.
DPSG,OUO1004,2752 1904MAY004/5
OTC Portable Nozzle Tester . . . . . . . . . . . . D01109AA Check nozzle opening pressure.
DPSG,OUO1004,2752 1904MAY005/5
05 170 4
Fuel System Repair and Adjustment Other Materials

Number Name Use
AR54749 (U.S.)
Soap Lubricant
Apply to Bosch VP44 injection pump O-ring.
DPSG,OUO1004,2655 1918APR001/1
Group 110 - Electronic Engine Control System Repair Tools

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).
DPSG,OUO1004,2634 1910APR001/19
CTM170 (14MAY03)
05-170-4

051403
PN=570

RW25539 UN28AUG96
Terminal Extraction Tool . . . . . . . . . . . . . . . .JDG364 Used to extract WEATHER PACK terminals from electrical connectors.

1
Included in Technicians Electrical Repair Kit - JT07195B

DPSG,OUO1004,2634 1910APR002/19
WEATHER PACK Crimping Tool . . . . . . . . . . JDG783 Used to crimp WEATHER PACK male and female terminals on 14-20 gauge wires. This tool crimps both the wire and the seal retainer at the same time.
UN07MAR02
05 170 5
DPSG,OUO1004,2634 1910APR003/19
METRI-PACK Crimping Tool . . . . . . . . . . . . . JDG865 Used to crimp METRI-PACK male and female terminals on 14-20 gauge wires.
UN07MAR02
DPSG,OUO1004,2634 1910APR004/19
Packard Crimper . . . . . . . . . . . . . . . . . . . . . . JDG707 Used to crimp WEATHER PACK, METRIPACK, SUMITOMO, and YAZAKI male and female terminals on 12-20 gauge wires. This tool crimps the wire and the seal retainer separately.
DPSG,OUO1004,2634 1910APR005/19
CTM170 (14MAY03)
05-170-5

051403
RG11679
UN05FEB01
RW25542A
RW25542A
PN=571

Technicians Electrical Repair Kit . . . . . . . . . . JT07195B This kit is assembled with the most commonly used terminal extraction tools used to repair wiring harnesses on John Deere applications. This kit includes the following: JDG140 - CPC and Metrimate terminal extraction tool, JDG141 - CPC Blade Type terminal extraction tool, JDG361 - Deutsch 12-14 gauge terminal extraction/insertion tool, JDG362 - Deutsch 16-18 gauge terminal extraction/insertion tool, JDG364 WEATHERPACK terminal extraction tool, JDG776 Metripack terminal extraction tool - Wide, JDG777 METRI-PACK terminal extraction tool - Narrow, and JDG785 - Deutsch 6-8 gauge terminal extraction/insertion tool.
DPSG,OUO1004,2634 1910APR006/19
05 170 6
Technicians Electrical Repair Kit . . . . . . . . . . . JDG155 This kit is assembled with the most commonly used terminal extraction tools used to repair wiring harnesses on John Deere applications. This kit includes the following: JDG107 - Holding Plate, JDG139 - Sure-Seal terminal insertion tool, JDG140 - CPC and Metrimate terminal extraction tool, JDG141 - CPC Blade Type terminal extraction tool, JDG142 - Mate-N-Lock terminal extraction tool, JDG143 - Mate-N-Lock terminal extraction tool, JDG144 - Universal Crimping Pliers, JDG145 Electricians Pliers, JDG146 - Carrying Case, and JDG785 - Deutsch 6-8 gauge terminal extraction/insertion tool.
DPSG,OUO1004,2634 1910APR007/19
Electricians Pliers1 . . . . . . . . . . . . . . . . . . . . JDG145 Used to cut, strip, and splice wires.
Included in Technicians Electrical Repair Kit - JDG155

DPSG,OUO1004,2634 1910APR008/19
CTM170 (14MAY03)
05-170-6

051403
RG11686
UN13FEB01
PN=572
RW25558
UN29AUG96
RW25558
UN29AUG96

RW25541 UN20AUG96
METRI-PACK Extractor (Wide) . . . . . . . . . . . JDG776

1
Used to remove terminals from 56-Series, 280-Series, and 630-Series METRI-PACK connectors.

1

DPSG,OUO1004,2634 1910APR009/19 RW25541 UN20AUG96
METRI-PACK Extractor (Narrow)1 . . . . . . . . . . JDG777 Used to remove terminals from 150-Series METRI-PACK, SUMITOMO, and YAZAKI connectors.
05 170 7

1

DPSG,OUO1004,2634 1910APR0010/19
DEUTSCH Electrical Repair Tool Kit . . . . . . . .JDG359 Used to extract terminals from DEUTSCH electrical connectors. A special crimping tool is also included to crimp DEUTSCH terminals on wires. The following tools are included: JDG360 - Deutsch Terminal Crimping Tool, JDG361 - Deutsch 12-14 gauge terminal extraction/insertion tool (set of 2), JDG362 - Deutsch 16-18 gauge terminal extraction/insertion tool (set of 2), and JDG363 - Deutsch 20-24 gauge terminal extraction/insertion tool (set of 2)
UN06SEP96
DEUTSCH is a trademark of Deutsch Co.
DPSG,OUO1004,2634 1910APR0011/19
CTM170 (14MAY03)
05-170-7

051403
PN=573
RW25540

1214 Gauge Extractor (Set of Two)1 . . . . . . . . JDG361 Used to remove terminals on 12-14 gauge wires in DEUTSCH connectors.
UN22APR02
Deutsch Extraction Tool
Included in DEUTSCH Electrical Repair Kit - JDG359

DPSG,OUO1004,2634 1910APR0012/19
05 170 8
1618 Gauge Extractor (Set of Two)1 . . . . . . . . JDG362 Used to remove terminals on 16-18 gauge wires in DEUTSCH connectors.
UN22APR02

Continued on next page DPSG,OUO1004,2634 1910APR0013/19
CTM170 (14MAY03)
05-170-8

051403
RG12278
RG12278
PN=574

2024 Gauge Extractor (Set of Two)1 . . . . . . . JDG363 Used to remove terminals on 20-24 gauge wires in DEUTSCH connectors.
UN22APR02

DPSG,OUO1004,2634 1910APR0014/19
RG12278
Crimping Tool1 . . . . . . . . . . . . . . . . . . . . . . . JDG360 Used to crimp DEUTSCH closed barrel terminals on 12-24 gauge wires.
UN15MAR02
05 170 9
DPSG,OUO1004,2634 1910APR0015/19 RG10740 UN31MAY00
Terminal Extraction Tool . . . . . . . . . . . . . . . FKM10457 Used to extract female terminals from Level 1 and Level 4 Engine Control Unit (ECU) using Amp connectors.
FKM10457
DPSG,OUO1004,2634 1910APR0016/19 RG10739 UN26MAY00
Crimping Pliers1 . . . . . . . . . . . . . . . . . . . . . .JDG144 Universal crimp tool is used to crimp terminals on wires. It is recommended to use crimp tools specific for the terminal being crimped. If there is not a specified crimp tool, use this tool.
JDG144
Included in Technicians Electrical Repair Kit - JDG155

Continued on next page DPSG,OUO1004,2634 1910APR0017/19
CTM170 (14MAY03)
05-170-9

051403
RG12235
PN=575

RG10741 UN31MAY00
Terminal Extractor Tool . . . . . . . . . . . . . . . . JDG1369 Used to extract terminals from the Level 4 Electronic Engine Controller (ECU) connector on applications that use the Bosch VP44 fuel injection pump.
JDG1369
DPSG,OUO1004,2634 1910APR0018/19
AMP Crimping Tool . . . . . . . . . . . . . . . . . . . .JDG708 Used to crimp AMP terminals on wires.
05 170 10
JDG708
DPSG,OUO1004,2634 1910APR0019/19
Control Repair and Adjustment Other Materials

Number Name Use
JDT405 (U.S.) TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE) AT66865 (U.S.)
High Temperature Grease Pipe Sealant
Sensor O-rings. Apply to threads of oil pressure sensor.
Lubricant
Insulate electrical connectors.
LOCTITE is a registered trademark of Loctite Corp.
DPSG,OUO1004,2636 1910APR001/1
CTM170 (14MAY03)
05-170-10

051403
PN=576
RG10737
UN25MAY00
Group 180
Diagnostic Service Tools

Group 150/160 - Electronic Fuel System Diagnostic Tools
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the European Microfiche Tool Catalog (MTC) unless otherwise noted.
SERVICEGARD is a trademark of Deere & Company.
RG,RG34710,1605 1930SEP971/9
Fuel System Cap Plug Kit . . . . . . . . . . . . . . . . JDG998 Used to protect the fuel system from dirt and debris when disconnecting fuel system components during fuel transfer pump pressure check.
UN09OCT02
05 180 1
JDG998
RG,RG34710,1605 1930SEP972/9 RG5162 UN23AUG88
Universal Pressure Test Kit . . . . . . . . . . . . . . . JT05412 Used for testing engine oil pressure, intake manifold pressure (turbo boost), and fuel transfer pump pressure.
JT05412
RG,RG34710,1605 1930SEP973/9
CTM170 (14MAY03)
05-180-1

051403
RG8518
PN=577

ECU Communication Software Kit. . . . . . . . . . . . . . . . Please refer to your John Deere Dealer website for information on obtaining the latest version of software.
UN26NOV97
RG,RG34710,1605 1930SEP974/9
ECU Communication Hardware Kit . . . . . . . . . . JDIS121 Used with ECU Communication Software Kit. Together, the kits enable a Windows (95, 98, 2000, ME, and XP) or NT compatible computer to read information from the Engine Control Unit (ECU). The computer must be at least a 486/66 with 8 MB of RAM and an IEEE 1284 compliant parallel port. This kit allows communication with all John Deere applications that use one of the following diagnostic connectors: black 9-pin Deutsch diagnostic connector, gray 9-pin Deutsch diagnostic connector (early 8000 series tractors), or the flat 6-pin Weatherpack diagnostic connector (Lucas controllers). Not all of the components in this kit are shown to the right.
UN09JUL01
RG8554
05 180 2
RG,RG34710,1605 1930SEP975/9
ECU Communication Hardware Kit . . . . . . . . . DS10023 Used with ECU Communication Software Kit. Together, the kits enable a Windows (95, 98, 2000, ME, and XP) or NT compatible computer to read information from the Engine Control Unit (ECU). The computer must be at least a 486/66 with 8 MB of RAM and an IEEE 1284 compliant parallel port. This kit allows communication with all John Deere applications that use the black 9-pin Deutsch diagnostic connector. All of the components in this kit are shown to the right.
UN09JUL01
RG,RG34710,1605 1930SEP976/9
CTM170 (14MAY03)
05-180-2

051403
PN=578
RG11747
RG11747
Diagnostic Service Tools NOTE: Available from John Deere Distribution Service Center (DSC). United States and Canadian Agricultural dealers DO NOT ORDER without first contacting your Branch or TAM.
RG,RG34710,1605 1930SEP977/9
Digital Multimeter . . . . . . . . . . . . . . . . . . . . JT07306 Test electrical components for voltage, resistance, current flow, or temperature. It is especially good for measuring low voltage or high resistance circuits.
UN19JUN00
RG,RG34710,1605 1930SEP978/9
RG11126
Connector Adapter Test Kit . . . . . . . . . . . . . . . JT07328 Used with JT05791 Digital Multimeter to make voltage and resistance measurements in control system wiring harness connectors. Can also be used to test terminals for proper fit.
05 180 3
JT07328
RG,RG34710,1605 1930SEP979/9
CTM170 (14MAY03)
05-180-3

051403
RG8803
UN26NOV97
PN=579
05 180 4
CTM170 (14MAY03)
05-180-4

051403
PN=580
Section 06
Specifications
Contents
Page Page
Group 200Repair Specifications Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1 Metric Bolt and Cap Screw Torque Values . . .06-200-2 General OEM Engine Specifications - Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-3 General OEM Engine Specifications - Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-4 Electronic Fuel System Repair and Adjustment Specifications . . . . . . . . . . . . . .06-200-6 Electrical Engine Control Repair and Adjustment Specifications . . . . . . . . . . . . . .06-200-8 Group 210Diagnostic Specifications Fuel System Diagnostic Specifications . . . . . .06-210-1 Application Specifications . . . . . . . . . . . . . . . .06-210-2 Combines - Sensor Specifications . . . . . . . . . .06-210-3 Combines - Torque Curve Selection . . . . . . . .06-210-5 Combines - . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-6 Combines - ECU Terminal Identification . . . . .06-210-7 Excavators - Sensor Specifications . . . . . . . . .06-210-8 Excavators - Torque Curve Selection . . . . . .06-210-10 Excavators - . . . . . . . . . . . . . . . . . . . . . . . . .06-210-10 Excavators - ECU Terminal Identification . . .06-210-11 Marine - Sensor Specifications . . . . . . . . . . .06-210-12 Marine - Torque Curve Selection. . . . . . . . . .06-210-15 Marine - . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-15 Marine - ECU Terminal Identification . . . . . . .06-210-16 6.8 L Marine Application Electronic Control System Wiring Diagram . . . . . . . . . . . . . . .06-210-18 6.8 L Marine Application Wheel House Panel Electrical Wiring Diagram. . . . . . . . .06-210-19 6.8 L Marine Application Fly Bridge Panel Electrical Wiring Diagram. . . . . . . . . . . . . .06-210-20 OEM Engines - Sensor Specifications . . . . . .06-210-21 OEM Engines - Torque Curve Selection . . . .06-210-24 OEM Engines - With OC03041 Software or Later . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-25 OEM Engines - With OC03034 Software or Earlier . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-25 OEM Engines - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-27 6.8 L OEM Application Electronic Control System Wiring Diagram . . . . . . . . . . . . . . .06-210-28 CTM170 (14MAY03)
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-30 6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram - Continued . . . .06-210-31 Telehandlers - Sensor Specifications . . . . . .06-210-32 Telehandlers - Torque Curve Selection . . . . .06-210-34 Telehandlers - . . . . . . . . . . . . . . . . . . . . . . . .06-210-34 Telehandlers - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-35 Tractors - 6010 Series - Sensor Specifications. . . . . . . . . . . . . . . . . . . . . . .06-210-36 Tractors - 6010 Series - Torque Curve Selection . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-39 Tractors - 6010 Series - . . . . . . . . . . . . . . . .06-210-39 Tractors - 6010 Series - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-40 Tractors - 6020 Series - Sensor Specifications. . . . . . . . . . . . . . . . . . . . . . .06-210-42 Tractors - 6020 Series - Torque Curve Selection . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-44 Tractors - 6020 Series - . . . . . . . . . . . . . . . .06-210-45 Tractors - 6020 Series - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-46 Tractors - 7020 Series - Sensor Specifications. . . . . . . . . . . . . . . . . . . . . . .06-210-48 Tractors - 7020 Series - Torque Curve Selection . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-50 Tractors - 7020 Series - . . . . . . . . . . . . . . . .06-210-51 Tractors - 7020 Series - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-52
06
06-1

051403
PN=1
Contents
06
CTM170 (14MAY03)
06-2

051403
PN=2
Group 200
Repair Specifications
Unified Inch Bolt and Cap Screw Torque Values
06 200 1
Unified Inch Torque Values
DX,TORQ1 1920JUL941/1
CTM170 (14MAY03)
06-200-1

051403
PN=583
TS1656
1902APR97
Metric Bolt and Cap Screw Torque Values
06 200 2
Metric Torque Values
DX,TORQ2 1920JUL941/1
CTM170 (14MAY03)
06-200-2

051403
PN=584
TS1657
1902APR97
General OEM Engine Specifications - Tier 1

General OEM Engine Specifications ITEM ENGINE
4045DF150 4045TF150 4045TF250 4045HF150 6068DF150 6068TF150 6068TF250 6068HF150 6068HF250 Number of Cylinders Bore Stroke Displacement 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.6:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 861.0 mm (33.9 in.) 598 mm (23.5 in.) 854 mm (33.6 in.) 387 kg (851 lb) 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 861.0 mm (33.9 in.) 598 mm (23.5 in.) 980 mm (38.6 in.) 396 kg (872 lb) 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 861.0 mm (33.9 in.) 598 mm (23.5 in.) 980 mm (38.6 in.) 396 kg (872 lb) 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 861.0 mm (33.9 in.) 598 mm (23.5 in.) 980 mm (38.6 in.) 396 kg (872 lb) 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.6:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1117 mm (44.0 in.) 598 mm (23.5 in.) 956 mm (37.6 in.) 522 kg (1149 lb) 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1117 mm (44.0 in.) 598 mm (23.5 in.) 984 mm (38.7 in.) 533 kg (1172 lb) 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa 2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1117 mm (44.0 in.) 598 mm (23.5 in.) 984 mm (38.7 in.) 533 kg (1172 lb) 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1116 mm (43.9 in.) 623 mm (24.5 in.) 1009 mm (39.7 in.) 550 kg (1210 lb) 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1141 mm (44.9 in.) 623 mm (24.5 in.) 1009 mm (39.7 in.) 568 kg (1250 lb) 06 200 3
Compression Max. Crank Pressure Governor Regulation (Industrial) Governor Regulation (Generator) Oil Pressure Rated Speed Oil Pressure Low Idle Length Width Height Weight
DPSG,OUO1004,102 1928APR981/1
CTM170 (14MAY03)
06-200-3

051403
PN=585
General OEM Engine Specifications - Tier 2

ITEM Number of Cylinders Bore Stroke Displacement Compression Ratio Aspiration Engine Firing Order Valves Per Cylinder Valve Clearance (Cold) Intake (Checking) 4045TF275 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 Turbocharged 1-3-4-2 1 Intake 1 Exhaust 0.31-0.38 mm (0.012-0.015 in) 0.41-0.48 mm (0.016-0.019 in) 0.36 mm (0.014 in.) 0.46 mm (0.018 in.) 0.5 kPa (2 H2O) 1.50 mm (0.060 in.) 640 570 710 % 5% 82C (180F) 94C (202F) 8.5 L (9 qt) 70 kPa (10 psi) 4045HF275 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 Turbocharged 1-3-4-2 1 Intake 1 Exhaust 0.31-0.38 mm (0.012-0.015 in) 0.41-0.48 mm (0.016-0.019 in) 0.36 mm (0.014 in.) 0.46 mm (0.018 in.) 0.5 kPa (2 H2O) 1.50 mm (0.060 in.) 640 570 710 % 5% 82C (180F) 94C (202F) 8.5 L (9 qt) 70 kPa (10 psi) 4045HF475 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 Turbocharged 1-3-4-2 2 Intake 2 Exhaust 0.31-0.38 mm (0.012-0.015 in) 0.41-0.48 mm (0.016-0.019 in) 0.36 mm (0.014 in.) 0.46 mm (0.018 in.) 0.5 kPa (2 H2O) 1.50 mm (0.060 in.) 640 570 710 % 5% 82C (180F) 94C (202F) 8.5 L (9 qt) 70 kPa (10 psi) 6068TF275 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 Turbocharged 1-5-3-6-2-4 1 Intake 1 Exhaust 0.31-0.38 mm (0.012-0.015 in) 0.41-0.48 mm (0.016-0.019 in) 0.36 mm (0.014 in.) 0.46 mm (0.018 in.) 0.5 kPa (2 H2O) 1.50 mm (0.060 in.) 800 570 710 % 5% 82C (180F) 94C (202F) 11.3 L (12 qt) 70 kPa (10 psi) 6068HF275 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 Turbocharged 1-5-3-6-2-4 1 Intake 1 Exhaust 0.31-0.38 mm (0.012-0.015 in) 0.41-0.48 mm (0.016-0.019 in) 0.36 mm (0.014 in.) 0.46 mm (0.018 in.) 0.5 kPa (2 H2O) 1.50 mm (0.060 in.) 800 570 710 % 5% 82C (180F) 94C (202F) 11.3 L (12 qt) 70 kPa (10 psi)a 6068HF475 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 Turbocharged 1-5-3-6-2-4 2 Intake 2 Exhaust 0.31-0.38 mm (0.012-0.015 in) 0.41-0.48 mm (0.016-0.019 in) 0.36 mm (0.014 in.) 0.46 mm (0.018 in.) 0.5 kPa (2 H2O) 1.50 mm (0.060 in.) 800 570 710 % 5% 82C (180F) 94C (202F) 11.3 L (12 qt) 100 kPa (15 psi)b
Exhaust (Checking)
Intake (Adjusting)
Exhaust (Adjusting) Max. Crank Pressure Vibration Damper Maximum Radial Runout Battery Capacities (CCA) 12-Volt System 24-Volt System Governor Regulation (Industrial) Governor Regulation (Generator) Thermostat Start To Open Temperature Thermostat Fully Open Temperature Coolant Capacity Recommended Radiator Pressure Cap
a b
06 200 4
Pressure cap for 6068HF275 with VP44 fuel system for non gen-set applications is 100 kPa (15 psi) Pressure cap for 6068HF475 for gen-set applications is 70 kPa (10 psi)
RG,RG34710,5614 1926APR021/2
CTM170 (14MAY03)
06-200-4

051403
PN=586
ITEM Oil Pressure At Rated Speed, Full Load ( 15 psi) Oil Pressure At Low Idle (Minimum) Length Width Height Weight 4045TF275 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 4045HF275 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 4045HF475 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 6068TF275 345 kPa (50 psi) 105 kPa (15 psi) 1116 mm (43.9 in.) 623 mm (24.5 in.) 1012 mm (39.9 in.) 587 kg (1290 lb) 6068HF275 345 kPa (50 psi) 105 kPa (15 psi) 1123 mm (44.2 in.) 623 mm (24.5 in.) 1015 mm (40.0 in.) 587 kg (1290 lb) 6068HF475 345 kPa (50 psi) 105 kPa (15 psi) 1123 mm (44.2 in.) 608 mm (23.9 in.) 1044 mm (41.1 in.) 587 kg (1290 lb)
RG,RG34710,5614 1926APR022/2
06 200 5
CTM170 (14MAY03)
06-200-5

051403
PN=587
Electronic Fuel System Repair and Adjustment Specifications

Item Measurement Specification
Primary Fuel Filter Mounting Bracket-to-Cylinder Head Cap Screws Primary Fuel Filter Base-to Bracket Cap Screws Primary and Final Fuel Filter Fittings and Plugs Primary Fuel Filter Inlet Line Primary Fuel Filter Outlet Line Final Fuel Filter Mounting Bracket-to-Exhaust Manifold
Torque
74 Nm (54.5 lb-ft)
Torque
60 Nm (44 lb-ft)
Torque
9 Nm (6.5 lb-ft)
Torque Torque Torque
30 Nm (22 lb-ft) 30 Nm (22 lb-ft) 70 Nm (53 lb-ft)
Final Fuel Filter Base-to-Bracket Cap Torque Screws Final Fuel Filter Inlet Line
06 200 6
70 Nm (53 lb-ft)
Torque Torque Torque
30 Nm (22 lb-ft) 30 Nm (22 lb-ft) 25 Nm (18 lb-ft)
Final Fuel Filter Outlet Line Fuel Injection Pump Overflow Valve (VP44) Bosch VP44 Injection Pump Drive Gear Cap Screws Bosch VP44 Injection Pump Mounting Nuts Bosch VP44 Injection Pump Delivery Lines Bosch VP44 Injection Pump Supply Line Bosch VP44 Injection Pump Return Line Bosch VP44 Injection Pump Drive Gear-to-Pump Hub Screws
Torque
50 Nm (37 lb-ft)
Torque
50 Nm (35 lb-ft)
Torque
27 Nm (20 lb-ft)
Torque
27 Nm (20 lb-ft)
Torque
27 Nm (20 lb-ft)
Torque
48 Nm (35 lb-ft)
DPSG,OUO1004,2695 1905NOV021/3
CTM170 (14MAY03)
06-200-6

051403
PN=588
Item
Measurement
Specification
Bosch VP44 Injection Pump Drive Gear Cover Fuel Injection Nozzles (RE48786) New or Reconditioned Nozzle with New Internal Parts
Torque
6 Nm (4.4 lb-ft)
Opening Pressure for Setting
Opening Pressure for Checking (Minimum) Used Nozzle Opening Pressure for Checking (Minimum) Pressure Difference (Maximum)
25,51126,062 kPa (255260 bar) (37003780 psi) 24,683 kPa (246 bar) (3580 psi) 23,511 kPa (235 bar) (3410 psi) 700 kPa (7 bar) (100 psi)
Opening Pressure Difference between Cylinders
Fuel Injection Nozzle Tip
Spray Angle
144 Nozzle tip dry after 5 seconds. (Slight dampness permissible on used nozzles.)
06 200 7
Nozzle Valve/Seat Tightness Leakage Condition at Pressure Test of 2800 3500 kPa (2835 bar) (400500 psi) Fuel Injection Nozzle Return Leakage at Pressure Test of 10,300 kPa (103 bar) (1500 psi) Fuel Injection Nozzle Tip Orifice Fuel Injection Nozzle Tip Orifice Injection Nozzle Pressure Adjusting Screw Lock Nut Fuel Injection Nozzle Valve Needle Lift Fuel Injection Nozzle Lift Adjusting Screw Lock Nut Leakage
310 Drops/30 Seconds
Number of Orifices per Nozzle ID Torque
4 0.29 mm (0.0116 in.) 10 Nm (7 lb-ft)
Needle Lift (Based on Zero Lift)
3/4 Turn Counterclockwise
Torque
5 Nm (3.5 lb-ft) (42 lb-in.)
DPSG,OUO1004,2695 1905NOV022/3
CTM170 (14MAY03)
06-200-7

051403
PN=589
Item
Measurement
Specification
Fuel Injection Nozzle Hold-Down Clamp Cap Screws Fuel Leak-Off Hex Nut
Torque
40 Nm (30 lb-ft)
Torque
5 Nm (3.7 lb-ft) (44 lb-in.)
DPSG,OUO1004,2695 1905NOV023/3
Electrical Engine Control Repair and Adjustment Specifications

Coolant Temperature Sensor (In Thermostat Cover) Coolant Temperature Sensor (In Cylinder Head) Fuel Pressure Sensor (VP44 Pump)
06 200 8
Torque
15 Nm (11 lb-ft)
Torque
35 Nm (26 lb-ft)
Torque Torque Torque Torque
8 Nm (6 lb-ft) 14 Nm (10 lb-ft) 15 Nm (11 lb-ft) 14 Nm (10 lb-ft)
Pump Position Sensor (VP44 Pump) Oil Pressure Sensor Crankshaft Position Sensor
DPSG,OUO1004,2637 1905NOV021/1
CTM170 (14MAY03)
06-200-8

051403
PN=590
Group 210
Diagnostic Specifications
Fuel System Diagnostic Specifications
Fuel Transfer Pump Pressure Priming Closed Loop Systems (Fuel Pressure Sensor on Final Fuel Filter) Fuel Transfer Pump Pressure Cranking Closed Loop Systems (Fuel Pressure Sensor on Final Fuel Filter) Fuel Transfer Pump Pressure Running Closed Loop Systems (Fuel Pressure Sensor on Final Fuel Filter) Fuel Transfer Pump Pressure Open Loop Systems (No Fuel Pressure Sensor) Fuel Transfer Pump Pressure Open Loop Systems (No Fuel Pressure Sensor) Fuel Transfer Pump Pressure Open Loop Systems (No Fuel Pressure Sensor) Priming
-51350 kPa (-0.53.5 bar) (-7.4 51.0 psi)
-171230 kPa (-1.72.3 bar) (-25 33.0 psi)
70110 kPa (0.71.1 bar) (10.0 15.5 psi)
Above 0 kPa (Above 0 bar) (Above 0 psi)
Cranking
Running

06 210 1
DPSG,OUO1004,2762 1905NOV021/1
CTM170 (14MAY03)
06-210-1

051403
PN=591
Application Specifications
Below is an overview of the specifications listed for applications in the next few pages. Combines 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. Marine SENSOR SPECIFICATIONS TORQUE CURVE SELECTION GOVERNOR MODE SELECTION ECU TERMINAL IDENTIFICATION ELECTRONIC CONTROL SYSTEM WIRING DIAGRAM WHEEL HOUSE PANEL ELECTRICAL WIRING DIAGRAM FLY BRIDGE PANEL ELECTRICAL WIRING DIAGRAM VEHICLE WIRING - See Vehicle manual. OEM Engines SENSOR SPECIFICATIONS TORQUE CURVE SELECTION GOVERNOR MODE SELECTION WITH OC03041 SOFTWARE OR LATER GOVERNOR MODE SELECTION WITH OC03034 SOFTWARE OR EARLIER ECU TERMINAL IDENTIFICATION ELECTRONIC CONTROL SYSTEM WIRING DIAGRAM INSTRUMENT PANEL/ENGINE START COMPONENTS ELECTRICAL WIRING DIAGRAM Telehandler SENSOR SPECIFICATIONS TORQUE CURVE SELECTION GOVERNOR MODE SELECTION ECU TERMINAL IDENTIFICATION VEHICLE WIRING - See Vehicle manual. Tractors - 6010 Series SENSOR SPECIFICATIONS TORQUE CURVE SELECTION GOVERNOR MODE SELECTION ECU TERMINAL IDENTIFICATION VEHICLE WIRING - See Vehicle manual. Tractors - 6020 Series SENSOR SPECIFICATIONS TORQUE CURVE SELECTION GOVERNOR MODE SELECTION ECU TERMINAL IDENTIFICATION VEHICLE WIRING - See Vehicle manual. Tractors - 7020 Series SENSOR SPECIFICATIONS TORQUE CURVE SELECTION ECU TERMINAL IDENTIFICATION VEHICLE WIRING - See Vehicle manual.
06 210 2
RG41221,0000065 1922OCT021/1
CTM170 (14MAY03)
06-210-2

051403
PN=592
Combines - Sensor Specifications

The specifications shown below are voltage, pressure, and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor.
RG41221,0000332 1922OCT021/3
06 210 3
CTM170 (14MAY03)
06-210-3

051403
PN=593
Sensor Specifications for Combines Sensor Engine Coolant Temperature (ECT) SPN-FMI 000110.00 Measured Sensor Parameter Most Severe Temperature Out of Range Value Exceeds 115C (239F) Derate ECU derates engine 40% per minute until engine runs at 60% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 95% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 200 rpm per minute until engine runs at 1300 rpm. NAa NAa NAa ECU derates engine 10% per minute until engine runs at 50% of full power. NAa ECU derates engine 75% per minute until engine runs at 25% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 60% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. NAa
000110.03 000110.04 000110.16
High Input Voltage Low Input Voltage Moderately High Temperature Coolant Level Low
Above 4.9 Volts Below 0.3 Volts Exceeds 100C (212F)
Engine Coolant Level
000111.01
Coolant level is low or switch is faulty. 90 kPa (13 psi) (0.9 bar) Absolute Above 4.0 Volts Below 0.1Volts 100 kPa (14.5 psi) (1.0 bar) Absolute Exceeds 75C (167F)
Fuel Pressure
000094.01
Extremely Low Pressure
000094.03 000094.04 000094.18 Fuel Temperature 000174.00
High Input Voltage Low Input Voltage Moderately Low Pressure Extremely High Temperature High Least Severe Temperature Moderately High Temperature Fuel Temperature Sensor Faulty Extremely High Temperature High Input Voltage Low Input Voltage Moderately High Temperature Loss of Oil Pressure
000174.15 06 210 4 000174.16
Exceeds 65C (149F) Exceeds 73C (163F)
000174.31
Voltage out of Range
Manifold Air Temperature (MAT)
000105.00
Exceeds 100C (212F)
000105.03 000105.04 000105.16
Oil Pressure Switch (9450 Series ONLY)

a
000100.01
Oil pressure drops below the threshold for running condition.
Not Applicable
RG41221,0000332 1922OCT022/3
CTM170 (14MAY03)
06-210-4

051403
PN=594
Sensor Specifications for Combines 000100.04 VP44 Fuel Injection Pump 001076.02 Low Input Voltage Pump Detected Defect Switch is closed when key ON, engine OFF. Internal pump defect NAa ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power.
001077.12
Pump Self-Test Error
Internal pump defect
001077.31
Pump Requested Derate
Derate for any pump problem. Internal pump timing out of sync with engine. Internal pump timing out of sync with engine.
001078.07
ECU/Pump Out of Time Moderately ECU/Pump Out of Time Extremely
001078.31
Not Applicable
RG41221,0000332 1922OCT023/3
Combines - Torque Curve Selection

Torque Curve Selection for Level 4 Combines Torque Curve # on DST or SERVICE ADVISOR 1 2 16 17 Conditions Normal Operation Chopper OFF Derate (1550 Series ONLY) Transition Curve Cold Temperature Starting
06 210 5
RG41221,0000066 1922OCT021/1
CTM170 (14MAY03)
06-210-5

051403
PN=595
Combines Desired Speed for Level 4 Combines Governor Mode 0 Conditions Normal condition with Isochronous governor Max. Speed for Level 4 Combines Governor Mode 9 10 Conditions High speed governor - drooped Isochronous high speed governor in 3rd gear
RG41221,0000067 1922OCT021/1
06 210 6
CTM170 (14MAY03)
06-210-6

051403
PN=596
Combines - ECU Terminal Identification

ECU Terminal Function Air Filter Restriction Input Air Heater Relay Enable Air Heater Relay Return Battery Power Battery Power CAN High CAN Low Crank Sensor Input Crank Sensor Return Engine Coolant Temperature Input Fuel Pressure Sensor 5V Supply Fuel Pressure Sensor Input Fuel Pressure Sensor Return Fuel Transfer Pump Power Fuel Transfer Pump Power Manifold Air Temperature Input Oil Pressure Input Pump CAN High Pump CAN Low Pump CAN Shield Pump Crank Speed Out Pump Fuel Shutoff Pump Limp Home Pump Position Input Pump Position Sensor Return Pump Power Pump Relay Enable Sensor Return 1 Sensor Return 2 Sensor 5V Supply 1 Switched Power System Ground 3rd Gear Input
a
ECU Terminal # 32 63 37 23 68 44 21 9 34 6 3 26 24 22 67 50 33 58 59 60 17 18 2 10 36 35 62 24 46 3 19 1 30
Sensor Connector Terminal # B 86 87 Battery (+) Battery (+) NAa NAa A B A C B A A A A B 1 2 NAa 5 8 4 A B 7 86 Changes with each sensor Changes with each sensor Changes with each sensor NAa Battery (-) B 06 210 7
Not Applicable
RG41221,0000068 1922OCT021/1
CTM170 (14MAY03)
06-210-7

051403
PN=597
Excavators - Sensor Specifications

RG41221,000006A 1922OCT021/3
06 210 8
CTM170 (14MAY03)
06-210-8

051403
PN=598
Sensor Specifications for Excavators Sensor Engine Coolant Temperature (ECT) SPN-FMI 000110.00 Measured Sensor Parameter Most Severe Temperature Out of Range Value Exceeds 115C (239F) Derate ECU derates engine 20% per minute until engine runs at 75% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 95% of full power. ECU derates engine 4% per minute until engine runs at 90% of full power. ECU derates engine 200 rpm per minute until engine runs at 1200 rpm. NAa NAa NAa ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 75% per minute until engine runs at 25% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. 06 210 9
000110.03 000110.04 000110.15
High Input Voltage Low Input Voltage High Least Severe Temperature Moderately High Temperature Extremely Low Pressure
000110.16
Exceeds 113C (235F)
Fuel Pressure
000094.01
90 kPa (13 psi) (0.9 bar) Absolute Above 4.0 Volts Below 0.1Volts 100 kPa (14.5 psi) (1.0 bar) Absolute Exceeds 75C (167F)
High Input Voltage Low Input Voltage Moderately Low Pressure Extremely High Temperature Moderately High Temperature High Input Voltage Low Input Voltage Moderately High Temperature Pump Detected Defect
000174.16
Exceeds 73C (163F)
000105.03 000105.04 000105.16
Above 4.9 Volts Below 0.1Volts Exceeds 88C (190F)
VP44 Fuel Injection Pump
001076.02
001077.12
001077.31
Derate for any pump problem.
Not Applicable
RG41221,000006A 1922OCT022/3
CTM170 (14MAY03)
06-210-9

051403
PN=599
Sensor Specifications for Excavators 001078.07 ECU/Pump Out of Time Moderately ECU/Pump Out of Time Extremely Internal pump timing out of sync with engine. Internal pump timing out of sync with engine. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power.
001078.31
RG41221,000006A 1922OCT023/3
Excavators - Torque Curve Selection

Torque Curve Selection for Excavators Torque Curve # on DST or SERVICE ADVISOR 1 2 16 17 Conditions Normal (Nominal) Altitude Derate Transition Curve Cold Temperature Starting
06 210 10
RG41221,000006B 1922OCT021/1
Excavators Desired Speed for Excavators Governor Mode 0 Conditions Normal condition with Isochronous governor Max. Speed for Excavators Governor Mode 9 Conditions High speed governor - Drooped
RG41221,000006C 1922OCT021/1
CTM170 (14MAY03)
06-210-10

051403
PN=600
Excavators - ECU Terminal Identification

ECU Terminal Function Battery Power Battery Power CAN High CAN Low Check Engine Light Crank Sensor Input Crank Sensor Return Engine Coolant Temperature Input Fuel Pressure Sensor 5V Supply Fuel Pressure Sensor Input Fuel Pressure Sensor Return Fuel Transfer Pump Power Fuel Transfer Pump Power Manifold Air Temperature Input Pump CAN High Pump CAN Low Pump CAN Shield Pump Crank Speed Out Pump Fuel Shutoff Pump Limp Home Pump Position Input Pump Position Sensor Return Pump Power Pump Relay Enable Sensor Return 1 Sensor Return 2 Sensor 5V Supply 1 Switched Power System Ground Throttle Command Throttle Ground Throttle Reference
a
ECU Terminal # 23 68 44 21 47 9 34 6 3 26 24 22 67 50 58 59 60 17 18 2 10 36 35 62 24 46 3 19 1 27 49 51
Sensor Connector Terminal # Battery (+) Battery (+) NAa NAa NAa A B A C B A A A A 2 1 NAa 8 5 4 A B 7 86 Changes with each sensor Changes with each sensor Changes with each sensor NAa Battery (-) NAa NAa NAa 06 210 11
Not Applicable
RG41221,000006D 1922OCT021/1
CTM170 (14MAY03)
06-210-11

051403
PN=601
Marine - Sensor Specifications

RG41221,000006E 1922OCT021/3
06 210 12
CTM170 (14MAY03)
06-210-12

051403
PN=602
Sensor Specifications for Marine Sensor Analog Throttle (A) SPN-FMI 000091.03 Measured Sensor Parameter High Input Voltage Out of Range Value Above 4.7 volts Derate If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. ECU derates engine 60% per minute until engine runs at 40% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 95% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 150 rpm per minute until engine runs at 1200 rpm. NAa NAa NAa ECU derates engine 20% per minute until engine runs at 50% of full power. NAa ECU derates engine 75% per minute until engine runs at 25% of full power. 06 210 13
000091.04
Low Input Voltage
Below 0.3 volts
Analog Throttle (B)
000029.03
High Input Voltage
Above 4.7 volts
000029.04
Low Input Voltage
Below 0.3 volts
Engine Coolant Temperature (ECT)
000110.00
Most Severe Temperature
Exceeds 113C (235F)
000110.03 000110.04 000110.15
High Input Voltage Low Input Voltage High Least Severe Temperature Moderately High Temperature Coolant Level Low
000110.16
Exceeds 105C (221F)
Engine Coolant Level
000111.01
Coolant level is low or switch is faulty. 90 kPa (13 psi) (0.9 bar) Absolute Above 4.0 Volts Below 0.1Volts 100 kPa (14.5 psi) (1.09 bar) Absolute Exceeds 75C (167F)
Fuel Pressure
000094.01
High Input Voltage Low Input Voltage Moderately Low Pressure Extremely High Temperature High Least Severe Temperature Moderately High Temperature
000174.15 000174.16
Not Applicable
RG41221,000006E 1922OCT022/3
CTM170 (14MAY03)
06-210-13

051403
PN=603
Sensor Specifications for Marine Manifold Air Temperature (MAT) 000105.00 Extremely High Temperature High Input Voltage Low Input Voltage Moderately High Temperature Extremely Low Pressure Exceeds 62C (144F) ECU derates engine 20% per minute until engine runs at 60% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. NAa ECU derates engine 60% per minute until engine runs at 40% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 2% per minute until engine runs at 80% of full power. NAa ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power.
000105.03 000105.04 000105.16 Oil Pressure 000100.01
Above 4.9 Volts Below 0.3 Volts Exceeds 57C (135F) Oil pressure drops below the threshold for running condition Above 4.9 Volts Below 0.3 Volts Oil pressure drops below the threshold for running condition Water detected for longer than 3 minutes. Water detected for longer than 20 seconds. Internal pump defect
000100.03 000100.04 000100.18
High Input Voltage Low Input Voltage Moderately Low Pressure
Water in Fuel
000097.00
Water in Fuel Continuously Detected Water in Fuel Detected Pump Detected Defect
000097.16 VP44 Fuel Injection Pump 06 210 14 001076.02
001077.12
001077.31
001078.07
001078.31
Not Applicable
RG41221,000006E 1922OCT023/3
CTM170 (14MAY03)
06-210-14

051403
PN=604
Marine - Torque Curve Selection

Torque Curve Selection for Marine Torque Curve # on DST or SERVICE ADVISOR 1 Conditions Default
RG41221,000006F 1922OCT021/1
Marine Desired Speed for Marine Governor Mode 0 7 8 Conditions Desired/All speed governor Droop Low speed Governor - Droop Low speed Governor Isochronous Max. Speed for Marine Governor Mode 10 Conditions High speed governor Isochronous
RG41221,0000070 1922OCT021/1
06 210 15
CTM170 (14MAY03)
06-210-15

051403
PN=605
Marine - ECU Terminal Identification

ECU Terminal Function Air Heater Diagnostic Input Air Heater Relay Enable Analog Throttle (A) Input Analog Throttle (B) Input Analog Throttle (A) 5V Supply Analog Throttle (B) 5V Supply Analog Throttle (A) Sensor Ground Analog Throttle (B) Sensor Ground Battery Power Battery Power Bump Down Bump Enable Bump Up CAN High CAN Low CAN Shield Crank Sensor Input Crank Sensor Return Engine Coolant Temperature Input External Shutdown Signal 06 210 16 Fuel Pressure Sensor 5V Supply Fuel Pressure Sensor Input Fuel Pressure Sensor Return Fuel Transfer Pump Power Fuel Transfer Pump Power Isochronous Governor Loss of Coolant Switch Input Loss of Coolant Switch Return Low Idle Droop Manifold Air Temperature Input Oil Pressure Input Oil Pressure 5V Supply Oil Pressure Sensor Ground Pump CAN High Pump CAN Low Pump CAN Shield Pump Crank Speed Out
a
ECU Terminal # 29 63 31 28 53 3 24 46 23 68 39 37 38 44 21 42 9 34 6 12 3 26 46 22 67 5 30 46 27 50 4 3 46 58 59 60 17
Sensor Connector Terminal # 30 86 B B C C A A Battery (+) Battery (+) D B C NAa NAa NAa A B A A B C A A A B A B C A C B A 2 1 NAa 8
Not Applicable
RG41221,0000071 1922OCT021/2
CTM170 (14MAY03)
06-210-16

051403
PN=606
Pump Fuel Shutoff Pump Position Input Pump Position Sensor Return Pump Power Pump Relay Enable Sensor Return 1 Sensor Return 2 Sensor 5V Supply 1 Starter Kickback Switched Power System Ground Water in Fuel +12V Supply Water in Fuel Input Water in Fuel Return
a
18 10 36 35 62 24 46 3 25 19 1 19 33 24
5 A B 7 86 Changes with each sensor Changes with each sensor Changes with each sensor NAa NAa Battery (-) A B C
Not Applicable
RG41221,0000071 1922OCT022/2
06 210 17
CTM170 (14MAY03)
06-210-17

051403
PN=607
6.8 L Marine Application Electronic Control System Wiring Diagram

RG12801 1909JAN03
X05
B08
LOSS OF COOLANT SW
B09 X13
EXTERNAL SHUTDOWN
B A
X06
WATER IN FUEL SENSOR
OR
B09
WATER IN FUEL SENSOR PUMP
030
926
941
30
12
453
33
John Deere Level 4 Engine Control Unit (ECU)

X08
RING
A01
37
936
27 51
925 938
25 TERMINAL
427
63
432
29
415
453
33
38 39
955 BUMP UP 923 BUMP DOWN
K03
AIR HEATER CONTROL RELAY
AIR HEATER DIAGNOSTIC
LOW IDLE DROOP
STARTER KICKBACK
K04
082
AIR HEATER RELAY
BUMP ENABLE
X10
SPARE
X07
A B C D E F
418 HOME SPEED
050
002
050
X15
X18
A B C D
A A B C D
X16
HOME SPEED SELECT
050
X09
THROTTLE BUMPS
SE1
SE2
X14
SE4 - FOCUS 4 (ECU)
PSG HOME SPEED ENABLE
A01ECU Connector B01Transfer Pump B02Oil Pressure Sensor B03Fuel Pressure Sensor B04ECT Sensor B05MAT Sensor B06Pump Position Sensor B07Crankshaft Position Sensor
B08Loss of Coolant Switch B09Water in Fuel Sensor F02Fuse (20A) F03Fuse (10A) K01Fuel Pump Supply Relay K03Air Heater Control Relay K04Air Heater Relay X05Secondary Analog Throttle
X06Analog Throttle X07Performance Program Connector X08ECU Ground Ring Terminal X09Rotary Pump X10CAN Terminator
X11Diagnostic Connector X12Rotary Pump X13External Shutdown X14PSG Home Speed Enable X15Home Speed Select X16Throttle Bumps X18Fuel Heater
RG41221,00000AD 1902JAN031/1
CTM170 (14MAY03)
06-210-18

051403
PN=608
6.8 L Marine Application Wheel House Panel Electrical Wiring Diagram

RG12802 1907FEB03
UT
UT
012 012 422 002
432 Instrument Panel Pwr 020 Can Shield 904 Can H 905 Can L 012 IGN +12V OR +24V 412 ACC 422 Starter Relay Solenoid 002 Battery
5A
X12
Start Button Momentary OFF ON A C
422 012
A B C
A B Back Light Options 24V Back Light Option 24V Regulator

24V GND 12V
85 87 87A A
Wiring Supplied With JD Alternator
Key Switch
K1
86
002 462
Connect Dust Cap in Absence of Fly Bridge Panel
30 A
+12V
F1
30A 022 B
002
002
47 ohm
ALL B
OFF ON A
432
OFF B
Audible Alarm 6-Way Metri-Pack

A F E B C
Annunciator 6-Way Metri-Pack

C B E F A
Volt Meter 6-Way Metri-Pack

A F E B C
Oil Pressure 6-Way Metri-Pack

A F E B C
Coolant Temp 6-Way Metri-Pack

A F E B C
Tachometer Display 6-Way Metri-Pack A F E B C

929 925 442 050 411
HR/Diag Meter 8-Way Metri-Pack A H E D C

929 925 442 050 411
+12V OR +24V
904 905 020
X2
A B C G B F
904 905 020 929 925 442 050 411 411 050 442 925 929 929 925 442 050 411 929 925 442 050 411 929 925 442 050 411
S Ign
Back Lighting SPG +12V OR +24V DATA DATA +
Bat
Data + Data +12V or +24V SPG Back Lighting
G1
B
050
M1
Start Motor 12v
427
050
022
432
442 411
Jumper Used in Absense of Fly Bridge
020 905 904
Starter Kickback
A B SAE J1939/11 3-Way Deutsch Connector SAE J1939/11 3-Way Deutsch Terminal Back Light No Dimmer
A B Back Light Dimmer High (CW) Low
C B A
050 422 012 022 432
050 SPG
050
C B A
X4
SE4
Single Point Ground 050
SE4
SE3
SE3 SE3
050 SPG
050 SPG
SE3 SE3
SE1-Engine Start Components
SE2-Wheel House Panel
RG41221,00000AE 1902JAN031/1
CTM170 (14MAY03)
06-210-19

051403
PN=609
442 050 032
A B
422 012
Alt 12v
2 Coil Starter Relay 12v or 24v S
TVP (12v or 24v)
Output
N1
Out Coil
12V Back Light Options
KST
409
A B A B
A B A B
Twisted Shielded Pair

442
A B C A B C
929 925 442 050 411
929 925 442 050 411
929 925 442 050 411
929 925 442 050 411
929 925 442 050 411
A B Dimmer Option
6.8 L Marine Application Fly Bridge Panel Electrical Wiring Diagram

RG12803 1907JAN03 432 MURPHY PANEL POWER 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 Starter Relay Solenoid 002 BAT 432 MURPHY PANEL POWER 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 Starter Relay Solenoid 002 BAT 432 MURPHY PANEL POWER 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 Starter Relay Solenoid 002 BAT
Back Light Options STOP BUTTON MOMENTARY ENABLE DISABLE ENABLE B A C

012 432
START BUTTON OFF ON OFF B A C

422
24V Back Light Option 24V Regulator

GND 050 24V Back Lighting 411 12V 032
P01
C B E
411 452 050
P02
A
929
P03
A F
929 925
P04
A F
929 925
P05
A F
929 925
P06
A F
929 925 452
A B C F
925
A F
929 925
E
452
B C
050 411
E
452
B C
050 411
E
452
B C
050 411
E
452
B C
050 411
E
050
B C 12V Back Light Option
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
Back Lighting
Back Lighting
Back Lighting
Back Lighting
+12V OR +24V
Back Lighting
A B C A
5A
Data +
Data + Data -
Data + Data -
Data + Data -
Data + Data -
Data + Data -
Data -
SPG
SPG
SPG
SPG
SPG
SPG
A B C
929 925 452 050 411
929 925 452 050 411
929 925 452 050 411
929 925 452 050 411
B
452 442
A B Dimmer Option A B A B
012
SE2
432
SE2
422
Back Light No Dimmer
Back Light Dimmer High (CW) Low
SE2
SE2 SE2
SE3 - FLY BRIDGE PANEL
SE3 - FLY BRIDGE PANEL
RG41221,00000AF 1902JAN031/1
CTM170 (14MAY03)
06-210-20

051403
PN=610
OEM Engines - Sensor Specifications

RG41221,0000072 1922OCT021/3
06 210 21
CTM170 (14MAY03)
06-210-21

051403
PN=611
Sensor Specifications for OEM Engines Sensor Analog Throttle (A) SPN-FMI 000029.03 Measured Sensor Parameter High Input Voltage Out of Range Value Above 4.7 Volts Derate If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. ECU derates engine 60% per minute until engine runs at 40% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 95% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 150 rpm per minute until engine runs at 1200 rpm. Default fuel pressure 160 MPa (1600 bar) (23,206 psi) Default fuel pressure 160 MPa (1600 bar) (23,206 psi) NAa ECU derates engine 20% per minute until engine runs at 50% of full power. NAa
000029.04
Low Input Voltage
Below 0.3 Volts
Analog Throttle (B)
000028.03
High Input Voltage
Above 4.7 Volts
000028.04
Low Input Voltage
Below 0.3 Volts
000110.00
Exceeds 118C (244F)
000110.03 000110.04 000110.15
High Input Voltage Low Input Voltage Moderately High Temperature Moderately High Temperature Coolant Level Low
000110.16
Exceeds 113C (235F)
06 210 22
Coolant Level
000111.01
Coolant level is low or switch is faulty. 90 kPa (13 psi) (0.9 bar) Absolute Above 4.0 Volts
Fuel Pressure
000094.01
000094.03
High Input Voltage
000094.04
Low Input Voltage
Below 0.1 Volts
000094.18 Fuel Temperature 000174.00
Moderately Low Pressure Most Severe Temperature
100 kPa (14.5 psi) (1.0 bar) Absolute Exceeds 75C (167F)
000174.15
a
Moderately High Temperature
Exceeds 65C (149F)
Not Applicable
RG41221,0000072 1922OCT022/3
CTM170 (14MAY03)
06-210-22

051403
PN=612
Sensor Specifications for OEM Engines 000174.16 Moderately High Temperature High Input Voltage Low Input Voltage Moderately High Temperature Extremely Low Pressure Exceeds 73C (163F) ECU derates engine 75% per minute until engine runs at 25% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 60% per minute until engine runs at 40% of full power. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. ECU derates engine 20% per minute until engine runs at 50% of full power. 06 210 23
000105.03 000105.04 000105.16
Oil Pressure
000100.01
Oil pressure drops below threshold for running condition. Above 4.9 Volts Below 0.3 Volts Oil pressure drops below threshold for running condition. Internal pump defect
000100.03 000100.04 000100.18
001076.02
Pump Detected Defect
001077.12
001077.31
001078.07
001078.31
RG41221,0000072 1922OCT023/3
CTM170 (14MAY03)
06-210-23

051403
PN=613
OEM Engines - Torque Curve Selection

Torque Curve Selection for OEM Engines Torque Curve # on DST or SERVICE ADVISOR 1 16 17 Condition for Torque Curve Normal (Nominal) Transition Curve Cold Temperature Starting
RG41221,0000073 1922OCT021/1
06 210 24
CTM170 (14MAY03)
06-210-24

051403
PN=614
OEM Engines - With OC03041 Software or Later

NOTE: To determine the ECU software for this engine, read ECU Software Part Number using the diagnostic software. The later the software, the higher the number will be.
Desired Speed for OEM Engines Governor Mode 0 1 2 3 6 Conditions Normal Droop - (Default Gainset) Isochronous Droop- (Default Gainset) Normal Droop - (Selectable Gainset) Isochronous Droop- (Selectable Gainset) Engine Cruise 11 12 15 Desired Speed for OEM Engines Governor Mode 9 10 Conditions Normal Droop - (Default Gainset) Isochronous Droop- (Default Gainset) Normal Droop - (Selectable Gainset) Isochronous Droop- (Selectable Gainset) Absolute Maxspeed (used for speed derates)
RG41221,00000B0 1921JAN031/1
OEM Engines - With OC03034 Software or Earlier

NOTE: To determine the ECU software for this engine, read ECU Software Part Number using the diagnostic software. The earlier the software, the lower the number will be.
Desired Speed for OEM Engines Governor Mode 0 Conditions Normal Droop Max. Speed for OEM Engines Governor Mode 10 Conditions Isochronous high speed governor
06 210 25
RG41221,0000074 1922OCT021/1
CTM170 (14MAY03)
06-210-25

051403
PN=615
OEM Engines - ECU Terminal Identification

ECU Terminal Function Air Heater Indicator Air Heater Relay Enable Air Heater Relay Return Analog Throttle (A) Input Analog Throttle (B) Input Analog Throttle (A) 5V Supply Analog Throttle (B) 5V Supply Analog Throttle (A) Sensor Ground Analog Throttle (B) Sensor Ground Battery Power Blink Code Enable Bump Down Bump Enable Bump Up CAN High CAN Low CAN Shield Crankshaft Position Input Crankshaft Position Return 06 210 26 Crank Speed Out Cruise On Cruise Turn Around ECT Input ECT Sensor Ground Pump Position Input Pump Position Return External Derate External Shutdown Fuel Pressure Input Fuel Pressure 5V Supply Fuel Pressure Sensor Ground
a
ECU Terminal # OEM 47 63 37 31 28 53 3 24 46 23, 68 48 39 37 38 44 21 42 9 34 17 52 54 6 46 10 36 32 12 26 3 46
Sensor Connector Terminal # B NA

a
Circuit # OEM 474 429 923A 915 913 911 416A 414A 464A 022A,B 945 936A 923A 955A
Wire Color OEM Yellow White Orange Green Orange Brown Blue Yellow Blue Red Green Blue Orange Green Yellow Green Black Purple Gray White Yellow Brown Brown Yellow Green Orange White Brown Green Blue Yellow
NAa B B C C A A Battery (+) NA C A A NA

a a
904B 905B 020C 447 448 459 954 981 461 464A 445 443 939 941 475 416A 464A
NAa NA A B 8 NAa NAa A B A B NAa NAa C B A

a
Not Applicable
DPSG,RG40854,674 1916AUG011/1
CTM170 (14MAY03)
06-210-26

051403
PN=616
ECU Terminal Identification - Continued

ECU Terminal Function Fuel Shutoff Ground High/Low Idle Loss of Coolant Switch High/Low Idle Return MAT Input MAT Sensor Ground Oil Pressure Input Oil Pressure 5V Supply Oil Pressure Sensor Ground Override Shutdown PPC 5V Supply PPC Isochronous Governor Pump CAN High Pump CAN Low Pump CAN Shield PSG Enable PSG Power Remote Cruise Stop Lamp Switched Power Tachometer Transfer Pump Warning Lamp
a
ECU Terminal # OEM 18 1 49 30 24 50 24 4 3 46 33 3 5 58 59 60 62 35 61 25 19 56 22, 67 57
Sensor Connector Terminal # 5 Battery (-) A NAa
Circuit # OEM 471 050A 947 948 414A
Wire Color OEM Brown Black Purple Gray Yellow Orange Yellow Purple Blue Yellow Gray Blue Purple Yellow Green Black Orange Red Purple Orange Red White Purple Blue 06 210 27
A B C B A NAa A B 2 1 NAa 86 7 NA
a
463 414A 467 416A 464A 918 416A 937 504 505 010A 433 042A 917 473 012A 439 417A,B 916A
NAa BAT NAa A NAa
Not Applicable
DPSG,RG40854,674 1916AUG011/1
CTM170 (14MAY03)
06-210-27

051403
PN=617
6.8 L OEM Application Electronic Control System Wiring Diagram

RG11718 1924OCT02
Electronic Control System Wiring Diagram

B01Transfer Pump B02Oil Pressure Sensor B03Fuel Pressure Sensor B04ECT Sensor B05MAT Sensor B06Pump Position Sensor B07Crankshaft Position Sensor E02Air Heater Wait Lamp F02Fuse (20A) F03Fuse (10A) K01Fuel Pump Supply Relay X03Panel Connector X06ECU Connector X07Analog Throttle (B) Connector X08ECU Ground Ring Terminal X09CAN Terminator X11Diagnostic Connector X12Rotary Pump X13Fuel Heater X14Diagnostic Blink Codes X15Performance Program Connector
RG41221,0000076 1922OCT021/1
CTM170 (14MAY03)
06-210-28

051403
PN=618
06 210 29
CTM170 (14MAY03)
06-210-29

051403
PN=619
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram
RG12288 1923AUG02 464 SENSOR RETURN 2 020 CAN SHIELD 904 CAN H 905 CAN L
X1
012 IGN +12V OR +24V 412 ACC 422 STARTER RELAY SOLENOID 002 BAT
012 422 012 422 012 012 002 464
S1
S5
OFF B B
918
B1
ANALOG THROTTLE EMULATOR 4700 OHM 510 OHM
X2
A
RUN
ACC. OFF RUN START ST
OFF OVERRIDE SHUTDOWN
A C B A C B A
F1 V1
002 002 002 422
022
032
BAT
IGN
012
S3
BUMP ENABLE OFF BUMP OFF ENABLE A B C
TO ECU
X5
A10AB +12V
022 032
ACC
S4
ALL B HIGH IDLE LOW IDLE A C
S7
HIGH IDLE ADJ HIGH IDLE LOW IDLE
S8
HIGH IDLE ADJ HIGH IDLE LOW IDLE ANALOG THROTTLE A
OUT
OUTPUT BAT IGN
K1
050
GND A
2
409
S G1 G1 A M1 S
C B A
M1 A
022
947
947
012
OFF B
A C B A B A B A
B
050
X3
SE-1 ENGINE START COMPONENTS
TO ECU SINGLE POINT GROUND
050
414
414
923
947
947
936
955
050
TO TO TO ECU ECU ECU
TO ECU
TO ECU
TO ECU
TO ECU
947
TO ECU
414
REMOTE ON/OFF PLUG
TO ECU
SE-2 INSTRUMENT PANEL (CONTINUED NEXT PAGE)
B1Analog Throttle Emulator E1Back Light Regulator (24V) or Plug (12V) F1Fuse (10 Amp) F2Fuse (5 Amp) G1Alternator K1Starter Relay M1Starter Motor N1Transient Voltage Protector N2Voltage Regulator (for 24V Operation)
P1Optional Gauge P2Optional Gauge P3Oil Pressure Gauge P4Coolant Temperature Gauge P5Tachometer Display P6Hourmeter/Diagnostic Meter S1Ignition Key Switch S2Speed Select Switch (Momentary)
911 915 414
TVP (12V OR 24V)
N1
X6
947
923
S2
BUMP UP OFF BUMP DN
TO ECU
S3Bump Enable Switch (Momentary S4Dual State Throttle Switch S5Override Shutdown Switch (Momentary) S6Dimmer Control or Jumper Plug S7Tri-state Throttle Switch S8Ramp Throttle Switch V1Diode
X1Vehicle Harness Connector X2Alternator Harness Connector X3Single Point Ground X4CAN Terminator X5Analog Throttle Connector X6Remote On/Off Plug
RG41221,0000077 1922OCT021/1
CTM170 (14MAY03)
06-210-30

051403
PN=620
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram - Continued
06 210 31
B1Analog Throttle Emulator E1Back Light Regulator (24V) or Plug (12V) F1Fuse (10 Amp) F2Fuse (5 Amp) G1Alternator K1Starter Relay M1Starter Motor N1Transient Voltage Protector
N2Voltage Regulator (for 24V Operation) P1Optional Gauge P2Optional Gauge P3Oil Pressure Gauge P4Coolant Temperature Gauge P5Tachometer Display P6Hourmeter/Diagnostic Meter
S1Ignition Key Switch S2Speed Select Switch (Momentary) S3Bump Enable Switch (Momentary S4High-Low Speed Switch S5Override Shutdown Switch (Momentary) S6Dimmer Control or Jumper Plug
V1Diode X1Vehicle Harness Connector X2Alternator Harness Connector X3Single Point Ground X4CAN Terminator X5Analog Throttle Connector X6Remote On/Off Plug
RG41221,0000078 1922OCT021/1
CTM170 (14MAY03)
06-210-31

051403
PN=621
RG10040
1918MAY99
Telehandlers - Sensor Specifications

RG41221,0000012 1902AUG021/3
06 210 32
CTM170 (14MAY03)
06-210-32

051403
PN=622
Sensor Specifications for Telehandlers Sensor Analog Throttle (A) SPN-FMI 000091.03 Measured Sensor Parameter High Input Voltage Out of Range Value Above 4.7 volts Derate If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. ECU derates engine 60% per minute until engine runs at 40% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. ECU derates engine 200 rpm per minute until engine runs at 1200 rpm. Limit engine speed to 1200 rpm Limit engine speed to 1200 rpm NAa ECU derates engine 10% per minute until engine runs at 50% of full power. NAa ECU derates engine 75% per minute until engine runs at 25% of full power. NAa 06 210 33
000091.04
Low Input Voltage
Below 0.3 volts
000110.00
Exceeds 124C (255F)
000110.03 000110.04 000110.15
High Input Voltage Low Input Voltage High Least Severe Temperature Moderately High Temperature Extremely Low Pressure
000110.16
Exceeds 115C (239F)
Fuel Pressure
000094.01
90 kPa (13 psi) (0.9 bar) Absolute Above 4.0 Volts Below 0.1Volts 100 kPa (14.5 psi) (1.0 bar) Absolute Exceeds 75C (167F)
High Input Voltage Low Input Voltage Moderately Low Pressure Extremely High Temperature High Least Severe Temperature Moderately High Temperature Loss of Oil Pressure
000174.15 000174.16
Oil Pressure Switch
000100.01
Oil pressure drops below the threshold for running condition Below 0.3 Volts Internal pump defect
000100.04 VP44 Fuel Injection Pump 001076.02
Low Input Voltage Pump Detected Defect
NAa ECU derates engine 10% per minute until engine runs at 50% of full power.
Not Applicable
RG41221,0000012 1902AUG022/3
CTM170 (14MAY03)
06-210-33

051403
PN=623
Sensor Specifications for Telehandlers 001077.12 Pump Self-Test Error Internal pump defect ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power.
001077.31
001078.07
001078.31
RG41221,0000012 1902AUG023/3
Telehandlers - Torque Curve Selection

Torque Curve Selection for Telehandlers Torque Curve # on DST or SERVICE ADVISOR 06 210 34 0 1 Conditions Normal (Nominal) Cold Temperature Starting
RG41221,0000079 1923OCT021/1
Telehandlers Desired Speed for Telehandlers Governor Mode 0 8 Conditions Normal Droop Low speed governor Max. Speed for Telehandlers Governor Mode 9 Conditions Drooped high speed governor
RG41221,000007A 1923OCT021/1
CTM170 (14MAY03)
06-210-34

051403
PN=624
Telehandlers - ECU Terminal Identification

ECU Terminal Function Air Heater Relay Enable Air Heater Relay Return Battery Power Battery Power Blink Codes CAN High CAN Low Check Engine Light Crank Sensor Input Crank Sensor Return Engine Coolant Temperature Input Fuel Pressure Sensor 5V Supply Fuel Pressure Sensor Input Fuel Pressure Sensor Return Fuel Transfer Pump Power Fuel Transfer Pump Power Manifold Air Temperature Input Oil Pressure Input Pump CAN High Pump CAN Low Pump CAN Shield Pump Crank Speed Out Pump Fuel Shutoff Pump Limp Home Pump Position Input Pump Position Sensor Return Pump Power Pump Relay Enable Sensor Return 1 Sensor Return 2 Sensor 5V Supply 1 Stop Lamp Switched Power System Ground Throttle Input
a
ECU Terminal # 63 37 23 68 39 44 21 47 9 34 6 3 26 24 22 67 50 33 58 59 60 17 18 2 10 36 35 62 24 46 3 25 19 1 31
Sensor Connector Terminal # 86 87 Battery (+) Battery (+) NAa NAa NAa NAa A B A C B A A A A B 2 1 NAa 8 5 4 A B 7 86 Changes with each sensor Changes with each sensor Changes with each sensor NAa NAa Battery (-) NAa 06 210 35
Not Applicable
RG41221,000007B 1923OCT021/1
CTM170 (14MAY03)
06-210-35

051403
PN=625
Tractors - 6010 Series - Sensor Specifications

RG41221,000007C 1923OCT021/3
06 210 36
CTM170 (14MAY03)
06-210-36

051403
PN=626
Sensor Specifications for Tractors - 6010 Series Sensor Analog Throttle (A) SPN-FMI 000091.03 Measured Sensor Parameter High Input Voltage Out of Range Value Above 4.5 volts Derate If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. ECU derates engine 40% per minute until engine runs at 60% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 200 rpm per minute until engine runs at 1200 rpm. NAa NAa NAa ECU derates engine 10% per minute until engine runs at 50% of full power. NAa ECU derates engine 75% per minute until engine runs at 25% of full power. 06 210 37
000091.04
Low Input Voltage
Below 0.5 volts
Analog Throttle (B)
000029.03
High Input Voltage
Above 4.5 volts
000029.04
Low Input Voltage
Below 0.5 volts
Analog Throttle (C)
000028.03
High Input Voltage
Above 4.7 volts
000028.04
Low Input Voltage
Below 0.3 volts
000110.00
Exceeds 114C (237F)
000110.03 000110.04 000110.16
High Input Voltage Low Input Voltage Moderately High Temperature Extremely Low Pressure
Fuel Pressure
000094.01
80 kPa (11.5 psi) (0.8 bar) Absolute Above 4.7 Volts Below 0.9 Volts 100 kPa (14.5 psi) (1.0 bar) Absolute Exceeds 75C (167F)
000174.15 000174.16
Not Applicable
RG41221,000007C 1923OCT022/3
CTM170 (14MAY03)
06-210-37

051403
PN=627
Sensor Specifications for Tractors - 6010 Series Manifold Air Temperature (MAT) 000105.03 000105.04 000105.16 High Input Voltage Low Input Voltage Moderately High Temperature Extremely Low Pressure Above 4.8 Volts Below 0.1 Volts Exceeds 95C (203F) High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. NAa NAa NAa
Oil Pressure
000100.01
Oil pressure drops below the threshold for running condition. Above 4.9 Volts Below 0.3 Volts Oil pressure drops below the threshold for running condition. Internal pump defect
000100.03 000100.04 000100.18
001076.02
ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power.
001077.12
001077.31
001078.07 06 210 38
a
001078.31
Not Applicable
RG41221,000007C 1923OCT023/3
CTM170 (14MAY03)
06-210-38

051403
PN=628
Tractors - 6010 Series - Torque Curve Selection

Torque Curve Selection for 6010 Series Tractors Torque Curve # on DST or SERVICE ADVISOR 0, 10 11 12 13 14 15 16 Conditions Normal (Nominal) 15-16 km/hr 16-17 km/hr 17-18 km/hr 18-19 km/hr Greater than 19 km/hr Greater than 2 km/hr and PTO boost active
RG41221,000007D 1923OCT021/1
Tractors - 6010 Series Desire Speed on 6010 Series Tractors Governor Mode 0 1 Condition Normal droop Field cruise with isochronous governor Max. Speed on 6010 Series Tractors Governor Mode 9 10 11 Condition Normal Droop with isochronous governor Field cruise with isochronous governor Road Speed Limiting 06 210 39
RG41221,000007E 1923OCT021/1
CTM170 (14MAY03)
06-210-39

051403
PN=629
Tractors - 6010 Series - ECU Terminal Identification

ECU Terminal Function Air Heater Indicator Light Air Heater Relay Enable Air Heater Relay Return Battery Power Analog Throttle (A) Input Analog Throttle (B) Input Analog Throttle (C) Input Battery Power CAN High CAN Low CAN Shield Crank Sensor Input Crank Sensor Return Engine Coolant Temperature Input Fuel Pressure Sensor 5V Supply Fuel Pressure Sensor Input Fuel Pressure Sensor Return Fuel Transfer Pump Power Fuel Transfer Pump Power Oil Pressure Input 06 210 40 Oil Pressure 5V Supply Oil Pressure Sensor Ground PTO Speed - Front PTO Speed - Rear Pump CAN High Pump CAN Low Pump CAN Shield Pump Crank Speed Out Pump Fuel Shutoff Pump Limp Home Pump Position Input Pump Position Sensor Return Pump Power Pump Relay Enable Sensor Return 1 Sensor Return 2 Sensor 5V Supply 1
a
ECU Terminal # 47 63 37 23 31 28 5 68 44 21 42 9 34 6 3 26 24 22 67 4 3 24 7 8 58 59 60 17 18 2 10 36 35 62 24 46 3
Sensor Connector Terminal # NAa 86 87 Battery (+) B B B Battery (+) NAa NAa 3 A B A C B A A A C B A NAa NAa 2 1 NAa 8 5 4 A B 7 86 Changes with each sensor Changes with each sensor Changes with each sensor
Not Applicable
RG41221,000001C 1902AUG021/2
CTM170 (14MAY03)
06-210-40

051403
PN=630
Sensor 5V Supply 2 Switched Power System Ground Tach Output Wheel Speed Input
a
53 19 1 56 11
Changes with each sensor NAa Battery (-) NAa NAa
Not Applicable
RG41221,000001C 1902AUG022/2
06 210 41
CTM170 (14MAY03)
06-210-41

051403
PN=631

RG41221,0000348 1901APR021/3
06 210 42
CTM170 (14MAY03)
06-210-42

051403
PN=632
000091.04
Low Input Voltage
Below 0.5 volts
Analog Throttle (B)
000029.03
High Input Voltage
Above 4.5 volts
000029.04
Low Input Voltage
Below 0.5 volts
Analog Throttle (C)
000028.03
High Input Voltage
Above 4.7 volts
000028.04
Low Input Voltage
Below 0.3 volts
000110.00
Exceeds 118C (244F)
000110.03 000110.04 000110.16
Fuel Pressure
000094.01
80 kPa (11.5 psi) (0.8 bar) Absolute Above 4.0 Volts Below 0.3 Volts 100 kPa (14.5 psi) (1.09 bar) Absolute Exceeds 75C (167F)
000174.15 000174.16
Not Applicable
RG41221,0000348 1901APR022/3
CTM170 (14MAY03)
06-210-43

051403
PN=633
Sensor Specifications for Tractors - 6020 Series Oil Pressure 000100.01 Extremely Low Pressure Oil pressure drops below the threshold for running condition Above 4.9 Volts Below 0.3 Volts Oil pressure drops below the threshold for running condition Internal pump defect ECU derates engine 40% per minute until engine runs at 60% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power.
000100.03 000100.04 000100.18
001076.02
001077.12
001077.31
001078.07
001078.31
06 210 44
RG41221,0000348 1901APR023/3

Torque Curve Selection for Tractors - 6020 Series Torque Curve # on DST or SERVICE ADVISOR 0, 10 1 11 12 13 14 15 16 Conditions Normal (Nominal) Cold Temperature Starting 15-16 km/hr 16-17 km/hr 17-18 km/hr 18-19 km/hr Greater than 19 km/hr Greater than 2 km/hr and PTO boost active
RG41221,000007F 1923OCT021/1
CTM170 (14MAY03)
06-210-44

051403
PN=634
Tractors - 6020 Series Desire Speed on Tractors - 6020 Series Governor Mode 0 1 Condition Normal droop Field cruise with isochronous governor Max. Speed on Tractors - 6020 Series Governor Mode 9 10 11 Condition Normal Droop with isochronous governor Field cruise with isochronous governor Road Speed Limiting
RG41221,0000080 1923OCT021/1
06 210 45
CTM170 (14MAY03)
06-210-45

051403
PN=635

a
ECU Terminal # 47 63 37 23 31 28 5 68 44 21 42 9 34 6 3 26 24 22 67 4 3 24 7 8 58 59 60 17 18 2 10 36 35 62 24 46 3
Not Applicable
RG41221,0000081 1923OCT021/2
CTM170 (14MAY03)
06-210-46

051403
PN=636
a
53 19 1 56 11
Not Applicable
RG41221,0000081 1923OCT022/2
06 210 47
CTM170 (14MAY03)
06-210-47

051403
PN=637

RG41221,0000082 1923OCT021/3
06 210 48
CTM170 (14MAY03)
06-210-48

051403
PN=638
000091.04
Low Input Voltage
Below 0.5 volts
Analog Throttle (B)
000029.03
High Input Voltage
Above 4.5 volts
000029.04
Low Input Voltage
Below 0.5 volts
Analog Throttle (C)
000028.03
High Input Voltage
Above 4.7 volts
000028.04
Low Input Voltage
Below 0.3 volts
000110.00
Exceeds 118C (244F)
000110.03 000110.04 000110.16
Fuel Pressure
000094.01
80 kPa (11.5 psi) (0.8 bar) Absolute Above 4.0 Volts Below 0.3Volts 100 kPa (14.5 psi) (1.09 bar) Absolute Exceeds 75C (167F)
000174.15 000174.16
Not Applicable
RG41221,0000082 1923OCT022/3
CTM170 (14MAY03)
06-210-49

051403
PN=639
Sensor Specifications for Tractors - 7020 Series Oil Pressure 000100.01 Extremely Low Pressure Oil pressure drops below the threshold for running condition Above 4.9 Volts Below 0.3 Volts Oil pressure drops below the threshold for running condition Internal pump defect ECU derates engine 40% per minute until engine runs at 60% of full power. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power. ECU derates engine 10% per minute until engine runs at 50% of full power.
000100.03 000100.04 000100.18
001076.02
001077.12
001077.31
001078.07
001078.31
06 210 50
RG41221,0000082 1923OCT023/3

Torque Curve Selection for Tractors - 7020 Series Torque Curve # on DST or SERVICE ADVISOR 0, 10 11 12 13 14 15 16 Conditions Normal (Nominal) 15-16 km/hr 16-17 km/hr 17-18 km/hr 18-19 km/hr Greater than 19 km/hr Greater than 2 km/hr and PTO boost active
RG41221,000034D 1901APR021/1
CTM170 (14MAY03)
06-210-50

051403
PN=640
Tractors - 7020 Series Desire Speed on Tractors - 7020 Series Governor Mode 0 1 Condition Normal droop Field cruise with isochronous governor Max. Speed on Tractors - 7020 Series Governor Mode 9 10 11 Condition Normal Droop with isochronous governor Field cruise with isochronous governor Road Speed Limiting
RG41221,0000083 1923OCT021/1
06 210 51
CTM170 (14MAY03)
06-210-51

051403
PN=641

a
ECU Terminal # 47 63 37 23 31 28 5 68 44 21 42 9 34 6 3 26 24 22 67 4 3 24 7 8 58 59 60 17 18 2 10 36 35 62 24 46 3
Not Applicable
RG41221,0000084 1923OCT021/2
CTM170 (14MAY03)
06-210-52

051403
PN=642
a
53 19 1 56 11
Not Applicable
RG41221,0000084 1923OCT022/2
06 210 53
CTM170 (14MAY03)
06-210-53

051403
PN=643
06 210 54
CTM170 (14MAY03)
06-210-54

051403
PN=644
Index
Page Page
A
Abnormal Engine Noise . . . . . . . . . . . . . . .04-150-26 Active Diagnostic Trouble Codes View on Diagnostic Gauge . . . . . . . . . . .04-160-13 Adjust Injection Nozzles. . . . . . . . . . . . . . . . . . .02-090-38 Air Heater, Intake Theory of Operation . . . . . . . . . . . . . . . .03-140-23 Air in Fuel Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-69 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-71 Air Intake Heater Diagnostic Check . . . . . . . . . . . . . . . . . .04-150-60 All Speed Governing . . . . . . . . . . . . . . . . .03-140-25 AMP Connectors Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-19 Analog Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 ANalog Throttle B Does Not Respond . . . . . . . . . . . . . . . . .04-150-28 Application Chart . . . . . . . . . . . . . . . . . . . . .01-001-4 Application Specifications Combines . . . . . . . . . . . . . . . . . . . . . . . . .06-210-2 Excavators . . . . . . . . . . . . . . . . . . . . . . . .06-210-2 Marine. . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-2 OEM engines . . . . . . . . . . . . . . . . . . . . . .06-210-2 Telehandler. . . . . . . . . . . . . . . . . . . . . . . .06-210-2 Tractors 6010 Series . . . . . . . . . . . . . . . . . . . . . .06-210-2 6020 Series . . . . . . . . . . . . . . . . . . . . . .06-210-2 7020 Series . . . . . . . . . . . . . . . . . . . . . .06-210-2 Assemble Injection Nozzles. . . . . . . . . . . . . . . . . . .02-090-37
B
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-4 Black Exhaust Smoke. . . . . . . . . . . . . . . . .04-150-22 Bleed Fuel System . . . . . . . . . . . . . . . . . . .04-150-73 Blink Codes Reading DTCs . . . . . . . . . . . . . . . . . . . .04-160-15
C
CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-22 CAN Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 Circuit malfunctions Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-4 CTM170 (14MAY03)
Circuit Malfunctions Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 Clean High Pressure Washers Electrical Components . . . . . . . . . . . . . .02-110-6 Injection Nozzle Valve . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-34 Injection Nozzle Body . . . . . . . . . . . . . . .02-090-33 Injection Nozzles. . . . . . . . . . . . . . . . . . .02-090-24 Injector Bore . . . . . . . . . . . . . . . . . . . . . .02-090-24 Clearing Stored Diagnostic Trouble Codes Diagnostic Gauge . . . . . . . . . . . . . . . . . .04-160-14 Combines Application Specifications . . . . . . . . . . . . .06-210-2 Specifications ECU Terminal Identification . . . . . . . . . .06-210-7 Governor Mode Selection . . . . . . . . . . .06-210-6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Torque Curve Selection . . . . . . . . . . . . .06-210-5 Communicating Controlled Area Network . . . . . . . . . . . . .03-140-22 Communication Tool Connecting to . . . . . . . . . . . . . . . . . . . . . .04-160-9 Compression Test Engine Test Instructions . . . . . . . . . . . . .04-160-24 Connecting to DST . . . . . . . . . . . . . . . . . . . .04-160-9 Connecting to Service ADVISOR . . . . . . . . .04-160-9 Connector Repair AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-19 Blade Terminals . . . . . . . . . . . . . . . . . . .02-110-10 DEUTSCH . . . . . . . . . . . . . . . . . . . . . . .02-110-16 Metri-Pack Pull Type. . . . . . . . . . . . . . . .02-110-11 Metri-Pack Push Type. . . . . . . . . . . . . . .02-110-13 Weatherpack. . . . . . . . . . . . . . . . . . . . . . .02-110-7 Connectors Electrical Insulating Compund . . . . . . . . . .02-110-6 General Information . . . . . . . . . . . . . . . . .02-110-6 Remove Blade Terminals . . . . . . . . . . . .02-110-10 Repair AMP . . . . . . . . . . . . . . . . . . . . . .02-110-19 Repair DEUTSCH . . . . . . . . . . . . . . . . . .02-110-16 Repair Metri-Pack Pull Type . . . . . . . . . .02-110-11 Repair Metri-Pack Push Type . . . . . . . . .02-110-13 Repair Weatherpack . . . . . . . . . . . . . . . . .02-110-7 Control System Repair and Adjustment Other Material . .05-170-10 Theory of Operation . . . . . . . . . . . . . . . . .03-140-3 Wiring Diagram Marine Engines . . . . . . . . . . . . . . . . . .06-210-18 OEM Engines . . . . . . . . . . . . . . . . . . .06-210-28 Controlled Area Network. . . . . . . . . . . . . . .03-140-22 Controller Communication . . . . . . . . . . . . . . . . . . . .03-140-22 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Indx 1
Index-1
PN=1
Index
Page
Page
Engine Control Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-1 Theory of Operation. . . . . . . . . . . . . . .03-140-21 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Coolant temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Crank Position Sensor Measuring Speed . . . . . . . . . . . . . . . . . .03-140-16 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Cruise Control Operation . . . . . . . . . . . . . .03-140-23 Cylinder Cutout Test Engine Test Instructions . . . . . . . . . . . . .04-160-25 Cylinder Misfire Test Engine Test Instructions . . . . . . . . . . . . .04-160-22 Observable Instructions. . . . . . . . . . . . . .04-150-76
D
Data Parameter Description Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-18 Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-18 Derate Programs . . . . . . . . . . . . . . . . . . . .03-140-24 Application Specifications . . . . . . . . . . . . .06-210-2 DEUTSCH Connectors Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-16 Diagnostic Gauge Clearing Stored Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . .04-160-14 Diagnostics ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-56 ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-56 ACP-Err/No Addr . . . . . . . . . . . . . . . . .04-150-56 Does Not Communicate With ECU . . .04-150-56 EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-56 Engine Configuration Parameters . . . . . .04-160-11 Viewing Active Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Viewing Stored Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Diagnostic Procedure . . . . . . . . . . . . . . . . .04-160-56 Diagnostic Scan Tool Downloading Payload Files . . . . . . . . . . .04-160-29 Reprogramming ECU . . . . . . . . . . . . . . .04-160-34 Diagnostic Scan Tool (DST) Connecting to . . . . . . . . . . . . . . . . . . . . . .04-160-9 Data Parameter Description . . . . . . . . . .04-160-18 ECU Does Not Communicate With DST. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-50 Tests Compression Test . . . . . . . . . . . . . . . .04-160-24 Cylinder Cutout Test . . . . . . . . . . . . . .04-160-25 CTM170 (14MAY03)
Indx 2
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22 Excavator Torque Curve Change Test . . . . . . . . . . . . . . . . . . . . . . . . .04-160-26 TractorTorque Curve Change Test . . .04-160-27 Diagnostic Tools. . . . . . . . . . . . . . . . . . . . . .05-180-1 Diagnostic Trouble Codes Blinking Codes . . . . . . . . . . . . . . . . . . . .04-160-15 Diagnostic Trouble Codes (DTCs) Active Engine Service Codes, Viewing . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Active vs. Inactive . . . . . . . . . . . . . . . . . .03-140-26 Clearing Stored Codes . . . . . . . . . . . . . .03-140-26 Diagnostic Procedure . . . . . . . . . . . . . . .04-160-56 Display Format . . . . . . . . . . . . . . . . . . . .03-140-26 List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-52 List of 2-Digit. . . . . . . . . . . . . . . . . . . . . .04-160-54 Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-52 SPN/FMI . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 000028.03 . . . . . . . . . . . . . . . . . . . . .04-160-118 000028.04 . . . . . . . . . . . . . . . . . . . . .04-160-118 000029.03 . . . . . . . . . . . . . . . . . . . . .04-160-119 000029.04 . . . . . . . . . . . . . . . . . . . . .04-160-119 000084.02 . . . . . . . . . . . . . . . . . . . . .04-160-120 000091.03 . . . . . . . . . . . . . . . . . . . . .04-160-124 000091.04 . . . . . . . . . . . . . . . . . . . . .04-160-125 000091.09 . . . . . . . . . . . . . . . . . . . . .04-160-125 000094.01 . . . . . . . . . . . . . . . . . . . . .04-160-126 000094.03 . . . . . . . . . . . . . . . . . . . . .04-160-128 000094.04 . . . . . . . . . . . . . . . . . . . . .04-160-132 000094.18 . . . . . . . . . . . . . . . . . . . . .04-160-136 000097.00 . . . . . . . . . . . . . . . . . . . . .04-160-138 000097.16 . . . . . . . . . . . . . . . . . . . . .04-160-142 000100.01 . . . . . . . . . . . . . . . . . . . . .04-160-146 000100.03 . . . . . . . . . . . . . . . . . . . . .04-160-150 000100.04 . . . . . . . . . . . . . . . . . . . . .04-160-154 000100.18 . . . . . . . . . . . . . . . . . . . . .04-160-160 000105.00 . . . . . . . . . . . . . . . . . . . . .04-160-162 000105.03 . . . . . . . . . . . . . . . . . . . . .04-160-164 000105.04 . . . . . . . . . . . . . . . . . . . . .04-160-168 000105.16 . . . . . . . . . . . . . . . . . . . . .04-160-172 000107.00 . . . . . . . . . . . . . . . . . . . . .04-160-174 000110.00 . . . . . . . . . . . . . . . . . . . . .04-160-178 000110.03 . . . . . . . . . . . . . . . . . . . . .04-160-180 000110.04 . . . . . . . . . . . . . . . . . . . . .04-160-184 000110.15 . . . . . . . . . . . . . . . . . . . . .04-160-188 000110.16 . . . . . . . . . . . . . . . . . . . . .04-160-190 000111.01 . . . . . . . . . . . . . . . . . . . . .04-160-192 000158.17 . . . . . . . . . . . . . . . . . . . . .04-160-196 000174.00 . . . . . . . . . . . . . . . . . . . . .04-160-200 000174.15 . . . . . . . . . . . . . . . . . . . . .04-160-204 000174.16 . . . . . . . . . . . . . . . . . . . . .04-160-208 000174.31 . . . . . . . . . . . . . . . . . . . . .04-160-212 000189.00 . . . . . . . . . . . . . . . . . . . . .04-160-214 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Index-2
PN=2
Index
Page
Page
000189.31 . . . . . . . . . . . . . . . . . . . . .04-160-215 000190.00 . . . . . . . . . . . . . . . . . . . . .04-160-216 000190.16 . . . . . . . . . . . . . . . . . . . . .04-160-217 000620.03 . . . . . . . . . . . . . . . . . . . . .04-160-218 000620.04 . . . . . . . . . . . . . . . . . . . . .04-160-222 000627.04 . . . . . . . . . . . . . . . . . . . . .04-160-226 000629.13 . . . . . . . . . . . . . . . . . . . . .04-160-230 000629.19 . . . . . . . . . . . . . . . . . . . . .04-160-232 000632.02 . . . . . . . . . . . . . . . . . . . . .04-160-236 000632.05 . . . . . . . . . . . . . . . . . . . . .04-160-240 000636.02 . . . . . . . . . . . . . . . . . . . . .04-160-244 000636.08 . . . . . . . . . . . . . . . . . . . . .04-160-248 000636.10 . . . . . . . . . . . . . . . . . . . . .04-160-252 000637.02 . . . . . . . . . . . . . . . . . . . . .04-160-256 000637.08 . . . . . . . . . . . . . . . . . . . . .04-160-260 000637.10 . . . . . . . . . . . . . . . . . . . . .04-160-266 000729.03 . . . . . . . . . . . . . . . . . . . . .04-160-272 000729.05 . . . . . . . . . . . . . . . . . . . . .04-160-276 000810.02 . . . . . . . . . . . . . . . . . . . . .04-160-280 000898.09 . . . . . . . . . . . . . . . . . . . . .04-160-284 000970.02 . . . . . . . . . . . . . . . . . . . . .04-160-288 000970.31 . . . . . . . . . . . . . . . . . . . . .04-160-292 000971.31 . . . . . . . . . . . . . . . . . . . . .04-160-293 001069.02 . . . . . . . . . . . . . . . . . . . . .04-160-294 001076.02 . . . . . . . . . . . . . . . . . . . . .04-160-296 001077.07 . . . . . . . . . . . . . . . . . . . . .04-160-300 001077.11 . . . . . . . . . . . . . . . . . . . . .04-160-302 001077.12 . . . . . . . . . . . . . . . . . . . . .04-160-306 001077.19 . . . . . . . . . . . . . . . . . . . . .04-160-308 001077.31 . . . . . . . . . . . . . . . . . . . . .04-160-312 001078.07 . . . . . . . . . . . . . . . . . . . . .04-160-314 001078.11 . . . . . . . . . . . . . . . . . . . . .04-160-318 001078.31 . . . . . . . . . . . . . . . . . . . . .04-160-322 001079.03 . . . . . . . . . . . . . . . . . . . . .04-160-328 001079.04 . . . . . . . . . . . . . . . . . . . . .04-160-332 001080.03 . . . . . . . . . . . . . . . . . . . . .04-160-336 001080.04 . . . . . . . . . . . . . . . . . . . . .04-160-340 001109.31 . . . . . . . . . . . . . . . . . . . . .04-160-344 001110.31 . . . . . . . . . . . . . . . . . . . . .04-160-345 001485.02 . . . . . . . . . . . . . . . . . . . . .04-160-346 001569.31 . . . . . . . . . . . . . . . . . . . . .04-160-352 002000.13 . . . . . . . . . . . . . . . . . . . . .04-160-354 Stored Engine Service Codes, Viewing . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Theory of Operation . . . . . . . . . . . . . . . .04-160-51 Warning Light . . . . . . . . . . . . . . . . . . . . .03-140-26 2-Digit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 2-Digit/3-Digit Codes DTC 011 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 012 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 013 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 014 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 015 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 CTM170 (14MAY03)
DTC 016 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 018 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 019 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 021 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 022 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 023 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 024 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 027 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 028 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 031 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 032 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 033 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 034 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 035 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 036 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 037 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 038 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 039 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 042 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 043 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 044 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 047 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 048 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 053 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 054 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 057 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 058 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 061 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 062 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 063 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 066 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 067 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 068 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 071 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 074 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 075 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 076 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 077 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 086 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 087 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 088 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 089 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 091 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 092 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 093 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 094 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 095 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 096 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 097 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 DTC 098 . . . . . . . . . . . . . . . . . . . . . . .04-160-54 3-Digit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Indx 3
Index-3
PN=3
Index
Page
Page
Indx 4
Diagnostics Communication Problem ECU Does Not Communicate With Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . .04-150-56 ECU Does Not Communicate With DST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-50 ECU Does Not Communicate With Service ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-50 Electrical Circuit Malfunctions . . . . . . . . . .04-160-2 Electrical Circuit Troubleshooting . . . . . . .04-160-5 Fuel System Specifications . . . . . . . . . . . .06-210-1 Fuel system, low pressure Excessive fuel consumption. . . . . . . . .04-150-37 Fuel System, Low Pressure Fuel in Oil . . . . . . . . . . . . . . . . . . . . . .04-150-37 Observable Analog throttle (B) Does Not Respond . . . . . . . . . . . . . . . . . . . . .04-150-28 Fuel Injection Nozzle Check . . . . . . . .04-150-46 Observable Symptoms Abnormal Engine Noise . . . . . . . . . . . .04-150-26 Engine Cranks/Wont Start. . . . . . . . . . .04-150-2 Engine Does Not Develop Full Power . . . . . . . . . . . . . . . . . . . . . . .04-150-12 Engine Idles Poorly . . . . . . . . . . . . . . .04-150-25 Engine Misfires/Runs Irregularly . . . . . .04-150-7 Engine Will Not Crank . . . . . . . . . . . . .04-150-25 Enigne Emits Excessive Black or Gray Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Enigne Emits Excessive White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-18 Fuel Supply System Check Tier 1 . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . .04-150-38 Diesel Fuel Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Digital Multimeter How to Use. . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Disassemble Injection Nozzles. . . . . . . . . . . . . . . . . . .02-090-30 Downloading Payload Files Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-29 Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-39 Dual State Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12
E
ECU Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-1 CTM170 (14MAY03)
Self-Diagnosis. . . . . . . . . . . . . . . . . . . . .03-140-26 Theory of Operation . . . . . . . . . . . . . . . .03-140-21 Electrical Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-1 Electrical Connectors General Information . . . . . . . . . . . . . . . . .02-110-6 Remove Blade Terminals . . . . . . . . . . . .02-110-10 Repair AMP . . . . . . . . . . . . . . . . . . . . . .02-110-19 Repair DEUTSCH . . . . . . . . . . . . . . . . . .02-110-16 Repair Metri-Pack Pull Type . . . . . . . . . .02-110-11 Repair Metri-Pack Push Type . . . . . . . . .02-110-13 Repair Weathrepack . . . . . . . . . . . . . . . . .02-110-7 Electrical Insulating Compound. . . . . . . . . . .02-110-6 Electronic Control System Air Heater Operation . . . . . . . . . . . . . . . .03-140-23 Electronic Fuel Transfer Pump . . . . . . . .03-140-18 Overview Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Pump Control Unit . . . . . . . . . . . . . . . . .03-140-20 Terminology . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Theory of Operation . . . . . . . . . . . . . . . . .03-140-3 Wiring Diagram Marine Engines . . . . . . . . . . . . . . . . . .06-210-18 OEM Engines . . . . . . . . . . . . . . . . . . .06-210-28 Electronic Engine Control Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-4 Electronic Engine Control Repair and Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . .06-200-8 Electronic Tools . . . . . . . . . . . . . . . . . . . . . .05-170-4 Emissions Tier 1 vs. Tier 2 . . . . . . . . . . . . . . . . . . . .01-001-5 Engine Application Chart. . . . . . . . . . . . . . . . . . . .01-001-4 Derate Programs. . . . . . . . . . . . . . . . . . .03-140-24 Model Number . . . . . . . . . . . . . . . . . . . . .01-001-1 Application Specific . . . . . . . . . . . . . . . .01-001-4 Option Code Label . . . . . . . . . . . . . . . . . .01-001-3 Serial Number Plate . . . . . . . . . . . . . . . . .01-001-2 Engine Configuration Parameters . . . . . . . .04-160-11 Engine Control Unit Diagnostic Software Connecting to . . . . . . . . . . . . . . . . . . . .04-160-9 Data Parameter Description. . . . . . . . .04-160-18 DiagnosticTrouble Codes . . . . . . . . . . . .04-160-52 List of 2-Digit Codes . . . . . . . . . . . . . . . .04-160-54 Monitoring Parameters . . . . . . . . . . . . . . .03-140-4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-1 Reprogramming . . . . . . . . . . . . . . . . . . .04-160-28 Self-Diagnosis. . . . . . . . . . . . . . . . . . . . .03-140-26 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Index-4
PN=4
Index
Page
Page
Service Codes . . . . . . . . . . . . . . . . . . . .04-160-52 Terminal Indentification Application Specifications . . . . . . . . . . .06-210-2 Theory of Operation . . . . . . . . . . . . . . . .03-140-21 Trouble Codes . . . . . . . . . . . . . . . . . . . .04-160-52 Engine Coolant Temperature Sensor Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2 Measuring Temperature . . . . . . . . . . . . . .03-140-7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2 Engine Cranks/Wont Start . . . . . . . . . . . . . .04-150-2 Engine Does Not Develop Full Power. . . . .04-150-12 Engine General Specifications OEM Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-3 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-4 Engine Idles Poorly . . . . . . . . . . . . . . . . . .04-150-25 Engine Misfires/Runs Irregularly . . . . . . . . . .04-150-7 Engine Parameters. . . . . . . . . . . . . . . . . . . .03-140-4 Engine Protection . . . . . . . . . . . . . . . . . . . .03-140-24 Engine Shutdown Engine Protection . . . . . . . . . . . . . . . . . .03-140-24 Engine Speed Measuring . . . . . . . . . . . . . . . . . . . . . . . .03-140-16 Engine Test Instructions Compression Test . . . . . . . . . . . . . . . . . .04-160-24 Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-25 Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-22 Excavator Torque Curve Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-26 TractorTorque Curve Change Test . . . . .04-160-27 Engine Will Not Crank . . . . . . . . . . . . . . . .04-150-25 Enigne Emits Excessive Black or Gray Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Enigne Emits Excessive White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-18 Excavator Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 Excavator Torque Curve Change Test Engine Test Instructions . . . . . . . . . . . . .04-160-26 Excavators Application Specifications . . . . . . . . . . . . .06-210-2 Specifications ECU Terminal Identification . . . . . . . . .06-210-11 Governor Mode Selection . . . . . . . . . .06-210-10 Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-8 Torque Curve Selection . . . . . . . . . . . .06-210-10 Exhaust Smoke Black. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Gray . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 White . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-18 CTM170 (14MAY03)
F
Filter Element Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10 Final Fuel Filter Assembly Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9 Install Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Remove Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Replace Element. . . . . . . . . . . . . . . . . . .02-090-10 Theory of Operation Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7 Fly Bridge Panel Wiring Diagram Marine Engines . . . . . . . . . . . . . . . . . .06-210-20 Fuel Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-4 Diesel Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-5 Fuel Check Supply System Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-38 Fuel Derates. . . . . . . . . . . . . . . . . . . . . . . .03-140-24 Fuel Drain Back Test . . . . . . . . . . . . . . . . .04-150-68 Fuel Filter Assemblie Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9 Final Filter Install Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Operation Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7 Remove Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Replace Element . . . . . . . . . . . . . . . . .02-090-10 Primary Filter Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 Remove. . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 Theory of Operation Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Indx 5
Index-5
PN=5
Index
Page
Page
Indx 6
Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Fuel Injection Nozzles Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-38 Assemble . . . . . . . . . . . . . . . . . . . . . . . .02-090-37 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-24 Clean Body . . . . . . . . . . . . . . . . . . . . . . .02-090-33 Clean Bore . . . . . . . . . . . . . . . . . . . . . . .02-090-24 Diagnose Malfunctions . . . . . . . . . . . . . .04-150-46 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-30 Inspect Body . . . . . . . . . . . . . . . . . . . . . .02-090-33 Inspect Valve . . . . . . . . . . . . . . . . . . . . .02-090-34 Inspect Valve Adjusting Mechanism . . . .02-090-36 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-42 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22 Seals Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-090-41 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25 Theory of Operation . . . . . . . . . . . . . . . .03-130-10 Valve Clean. . . . . . . . . . . . . . . . . . . . . . . . . .02-090-34 Fuel Injection Pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-19 Overflow Valve Servicing . . . . . . . . . . . . . . . . . . . . . . .02-090-13 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Static Timing . . . . . . . . . . . . . . . . . . . . . .02-090-14 Theory of Operation . . . . . . . . . . . . . . . . .03-130-8 Fuel Pressure Relieve Pressure. . . . . . . . . . . . . . . . . . . .02-090-2 Fuel Pressure Sensor Measuring Pressure . . . . . . . . . . . . . . . .03-140-10 Fuel pressure sensor Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-10 Fuel Pressure Sensor Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Fuel Pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-19 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Theory of Operation . . . . . . . . . . . . . . . . .03-130-8 Fuel Supply Pressure . . . . . . . . . . . . . . . . .04-150-72 Fuel Supply Quality Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-65 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-67 Fuel Supply System Check Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-38 Fuel System Air in Fuel Test Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-69 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-71 Bleed the Fuel System . . . . . . . . . . . . . .04-150-73 CTM170 (14MAY03)
Fuel system Cylinder Misfire Test . . . . . . . . . . . . . . . .04-150-76 Fuel System Excessive Fuel Consumption . . . . . . . . .04-150-37 Fuel Drain Back Test . . . . . . . . . . . . . . .04-150-68 Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . . .04-150-37 Fuel Supply Pressure . . . . . . . . . . . . . . .04-150-72 General Information . . . . . . . . . . . . . . . . .02-090-1 Relieve Pressure. . . . . . . . . . . . . . . . . . . .02-090-2 Repair and Adjustment Other Material . . .05-170-4 Repair and Adjustment Service Eqipment . . . . . . . . . . . . . . . . . . . . . . . .05-170-3 Specifications . . . . . . . . . . . . . . . . . . . . . .06-200-6 Supply System Check Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-38 Theory of Operation Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-1 Fuel System Diagnostics Specifications . . . . . . . . . . . . . . . . . . . . . .06-210-1 Fuel Transfer Pump Install Filter Mount . . . . . . . . . . . . . . . . . . . . .02-090-11 Remote Mount. . . . . . . . . . . . . . . . . . .02-090-12 Remove Filter Mount . . . . . . . . . . . . . . . . . . . . .02-090-11 Remote Mount. . . . . . . . . . . . . . . . . . .02-090-12 Theory of Operation . . . . . . . . . . . . . . . .03-140-18
G
Glossary Electronic Control System . . . . . . . . . . . . .03-140-2 Governor Droop Mode Application Specifications . . . . . . . . . . . . .06-210-2 Governor Modes Theory of Operation . . . . . . . . . . . . . . . .03-140-25 Gray Exhaust Smoke . . . . . . . . . . . . . . . . .04-150-22
H
Harness Connectors General Information . . . . . . . . . . . . . . . . .02-110-6 Heater, Air Intake Diagnostic Check . . . . . . . . . . . . . . . . . .04-150-60 Theory of Operation . . . . . . . . . . . . . . . .03-140-23 High Pressure Washers Electrical Components . . . . . . . . . . . . . . .02-110-6 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Index-6
PN=6
Index
Page
Page
I
Idle Poor Idle . . . . . . . . . . . . . . . . . . . . . . . . .04-150-25 Inch Torque Values . . . . . . . . . . . . . . . . . . .06-200-1 Injection Nozzles Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-38 Assemble . . . . . . . . . . . . . . . . . . . . . . . .02-090-37 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-24 Clean Body . . . . . . . . . . . . . . . . . . . . . . .02-090-33 Clean Bore . . . . . . . . . . . . . . . . . . . . . . .02-090-24 Diagnose Malfunctions . . . . . . . . . . . . . .04-150-46 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-30 Inspect Body . . . . . . . . . . . . . . . . . . . . . .02-090-33 Inspect Valve . . . . . . . . . . . . . . . . . . . . .02-090-34 Inspect Valve Adjusting Mechanism . . . .02-090-36 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-42 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22 Seals Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-090-41 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25 Theory of Operation . . . . . . . . . . . . . . . .03-130-10 Valve Clean. . . . . . . . . . . . . . . . . . . . . . . . . .02-090-34 Injection Pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-19 Overflow Valve Servicing . . . . . . . . . . . . . . . . . . . . . . .02-090-13 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Static Timing . . . . . . . . . . . . . . . . . . . . . .02-090-14 Theory of Operation . . . . . . . . . . . . . . . . .03-130-8 Inspect Injection Nozzle Body . . . . . . . . . . . . . . .02-090-33 Injection Nozzle Valve. . . . . . . . . . . . . . .02-090-34 Adjusting Mechanism. . . . . . . . . . . . . .02-090-36 Install Engine Coolant Temperature Sensor . . . .02-110-2 Final Fuel Filter Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Fuel Injection Nozzle. . . . . . . . . . . . . . . .02-090-42 Fuel Injection Pump . . . . . . . . . . . . . . . .02-090-19 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . .02-090-19 Fuel Transfer Pump Filter Mount . . . . . . . . . . . . . . . . . . . . .02-090-11 Remote Mount. . . . . . . . . . . . . . . . . . .02-090-12 Injection Pump . . . . . . . . . . . . . . . . . . . .02-090-19 Oil Pressure Sensor . . . . . . . . . . . . . . . . .02-110-5 Primary Fuel Filter Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 CTM170 (14MAY03)
Instrument Panel Clearing Stored Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . .04-160-14 Diagnostic Gauge Engine Configuration Parameters . . . .04-160-11 Viewing Active Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Viewing Stored Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Wiring Diagram OEM Engines . . . . . . . . . . . . . . . . . . .06-210-30 Instrument panel (OEM) Diagnostic Gauge Diagnostics . . . . . . . .04-150-56 Insulating Compound . . . . . . . . . . . . . . . . . .02-110-6 Intake Air Heater Diagnostic Check . . . . . . . . . . . . . . . . . .04-150-60 Theory of Operation . . . . . . . . . . . . . . . .03-140-23 Intermittent Fault Diagnosing . . . . . . . . . . .04-160-57 Isochronous Governing. . . . . . . . . . . . . . . .03-140-25
L
Listing of DTCs. . . . . . . . . . . . . . . . . . . . . .04-160-52 Location of Sensors Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Low Power Engine Does Not Develop Full Power . . .04-150-12 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Indx 7
M
Manifold air temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-9 Manifold Air Temperature Sensor Measuring Temperature . . . . . . . . . . . . . .03-140-7 Marine Application Specifications . . . . . . . . . . . . .06-210-2 Specifications ECU Terminal Identification . . . . . . . . .06-210-16 Governor Mode Selection . . . . . . . . . .06-210-15 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-12 Torque Curve Selection . . . . . . . . . . . .06-210-15 Marine Engines Specifications Fly Bridge Panel Wiring Diagram. . . . .06-210-20 Wheel House Panel Wiring Diagram . . . . . . . . . . . . . . . . . . . . . .06-210-19 Wiring Diagram . . . . . . . . . . . . . . . . . .06-210-18 Measuring Engine Speed . . . . . . . . . . . . . .03-140-16 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Index-7
PN=7
Index
Page
Page
Measuring Pressure . . . . . . . . . . . . . . . . . .03-140-10 Measuring Temperature . . . . . . . . . . . . . . . .03-140-7 Measuring Throttle Position . . . . . . . . . . . .03-140-12 Meter How to Use. . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Metri-Pack Pull Type Connectors Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11 Metri-Pack Push Type Connectors Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-13 Metric Torque Values . . . . . . . . . . . . . . . . . .06-200-2 Misfires Engine Runs Irregularly. . . . . . . . . . . . . . .04-150-7 Model Number . . . . . . . . . . . . . . . . . . . . . . .01-001-1 Multi-State Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 Multimeter How to Use. . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Multiple Torque Curve Selection Theory of Operation . . . . . . . . . . . . . . . .03-140-25
N
Noise Abnormal . . . . . . . . . . . . . . . . . . . . . . . .04-150-26 Nozzles Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-38 Assemble . . . . . . . . . . . . . . . . . . . . . . . .02-090-37 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-24 Clean Body . . . . . . . . . . . . . . . . . . . . . . .02-090-33 Clean Bore . . . . . . . . . . . . . . . . . . . . . . .02-090-24 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-30 Inspect Body . . . . . . . . . . . . . . . . . . . . . .02-090-33 Inspect Valve . . . . . . . . . . . . . . . . . . . . .02-090-34 Inspect Valve Adjusting Mechanism . . . .02-090-36 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-42 Seals . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-41 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25 Theory of Operation . . . . . . . . . . . . . . . .03-130-10 Valve Clean. . . . . . . . . . . . . . . . . . . . . . . . . .02-090-34
Indx 8
ECU Does Not Communicate With DST. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-50 ECU Does Not Communicate With Service ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-50 Engine Cranks/Wont Start . . . . . . . . . . . .04-150-2 Engine Does Not Develop Full Power . . .04-150-12 Engine Emits Excessive Black or Gray Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Engine Emits Excessive White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . .04-150-18 Engine Idles Poorly . . . . . . . . . . . . . . . . .04-150-25 Engine Misfire/Runs Irregularly . . . . . . . . .04-150-7 Engine Will Not Crank. . . . . . . . . . . . . . .04-150-25 Excessive Fuel Consumption . . . . . . . . .04-150-37 Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . . .04-150-37 Fuel Supply System Check Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-38 OEM Engine General Specifications Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-3 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-4 OEM Engines Application Specifications . . . . . . . . . . . . .06-210-2 Specifications Governor Mode Selection . . . . . . . . . .06-210-25 Governor Mode Selection With OC03034 Software or Earlier . . . . . . . . . . . . . .06-210-25 Instrument Panel Wiring Diagram . . . .06-210-30 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-21 Torque Curve Selection . . . . . . . . . . . .06-210-24 Wiring Diagram . . . . . . . . . . . . . . . . . .06-210-28 Oil Pressure Sensor Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Measuring Pressure . . . . . . . . . . . . . . . .03-140-10 Oil pressure sensor Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-11 Oil Pressure Sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Option Code Label . . . . . . . . . . . . . . . . . . . .01-001-3 Overflow Valve Servicing . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13
P O
Observable Diagnostics Abnormal Engine Noise . . . . . . . . . . . . .04-150-26 Analog Throttle B . . . . . . . . . . . . . . . . . .04-150-28 Diagnostic Gauge Does Not Communicate With ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-56 CTM170 (14MAY03) Power Engine Does Not Develop Full Power . . .04-150-12 Pre Filter Theory of Operation Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Index-8
PN=8
Index
Page
Page
Pressure Measuring . . . . . . . . . . . . . . . . . . . . . . . .03-140-10 Pressure Sensors . . . . . . . . . . . . . . . . . . . .03-140-10 Primary Fuel Filter Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 Theory of Operation Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Programming ECU . . . . . . . . . . . . . . . . . . .04-160-28 Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-34 Downloading Payload Files Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-29 Service ADVISOR . . . . . . . . . . . . . . . .04-160-39 Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-47 Pulse-Width-Modulated Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 Pump Static Timing . . . . . . . . . . . . . . . . . . . . . .02-090-14 Pump Control Unit . . . . . . . . . . . . . . . . . . .03-140-20 Pump Position Sensor Measuring Speed . . . . . . . . . . . . . . . . . .03-140-16 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4
Replace Crank Position Sensor . . . . . . . . . . . . . . .02-110-4 Final Filter Element . . . . . . . . . . . . . . . . .02-090-10 Fuel Pressure Sensor . . . . . . . . . . . . . . . .02-110-3 Pump Position Sensor. . . . . . . . . . . . . . . .02-110-4 Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-28 Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-34 Downloading Payload Files Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-29 Service ADVISOR . . . . . . . . . . . . . . . .04-160-39 Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-47
S
Schematic Marine Engines . . . . . . . . . . . . . . . . . . . .06-210-18 Fly Bridge Panel . . . . . . . . . . . . . . . . .06-210-20 Wheel House Panel. . . . . . . . . . . . . . .06-210-19 OEM Engines . . . . . . . . . . . . . . . . . . . . .06-210-28 Instrument Panel . . . . . . . . . . . . . . . . .06-210-30 Seals, Install Fuel Injection Nozzle. . . . . . . . . . . . . . . .02-090-41 Sensor, operation Coolant temperature . . . . . . . . . . . . . . . . .03-140-8 Fuel pressure . . . . . . . . . . . . . . . . . . . . .03-140-10 Manifold air temperature . . . . . . . . . . . . . .03-140-9 Oil pressure . . . . . . . . . . . . . . . . . . . . . .03-140-11 Sensor, Operation Water in Fuel . . . . . . . . . . . . . . . . . . . . .03-140-19 Sensors Crank Position Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Engine Coolant Temperature Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2 Remove. . . . . . . . . . . . . . . . . . . . . . . . .02-110-2 Fuel Pressure Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Location Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Oil Pressure Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Remove. . . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Pressure . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10 Pump Position Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-16 Temperature . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12 Timing. . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-16 Serial Number Plate . . . . . . . . . . . . . . . . . . .01-001-2 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
R
Ramp Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 Relieve Fuel System Pressure . . . . . . . . . . .02-090-2 Remove Blade Terminals . . . . . . . . . . . . . . . . . . .02-110-10 Engine Coolant Temperature Sensor . . . .02-110-2 Final Fuel Filter Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Fuel Injection Nozzles . . . . . . . . . . . . . . .02-090-22 Fuel Injection Pump . . . . . . . . . . . . . . . .02-090-16 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Fuel Transfer Pump Filter Mount . . . . . . . . . . . . . . . . . . . . .02-090-11 Remote Mount. . . . . . . . . . . . . . . . . . .02-090-12 Injection Nozzles. . . . . . . . . . . . . . . . . . .02-090-22 Injection Pump . . . . . . . . . . . . . . . . . . . .02-090-16 Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22 Oil Pressure Sensor . . . . . . . . . . . . . . . . .02-110-5 Primary Fuel Filter Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 Repair Fuel Injection Pump . . . . . . . . . . . . . . . .02-090-18 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Injection Pump . . . . . . . . . . . . . . . . . . . .02-090-18 CTM170 (14MAY03)
Indx 9
Index-9
PN=9
Index
Page
Page
Indx 10
Service ADVISOR Conecting to . . . . . . . . . . . . . . . . . . . . . . .04-160-9 Data Parameter Description . . . . . . . . . .04-160-18 Downloading Payload Files . . . . . . . . . . .04-160-39 ECU Does Not Communicate With DST Service ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-50 Reprogramming ECU . . . . . . . . . . . . . . .04-160-47 Tests Compression Test . . . . . . . . . . . . . . . .04-160-24 Cylinder Cutout Test . . . . . . . . . . . . . .04-160-25 Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22 Excavator Torque Curve Change Test . . . . . . . . . . . . . . . . . . . . . . . . .04-160-26 TractorTorque Curve Change Test . . .04-160-27 Service Codes Active Engine Service Codes, Viewing . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Active vs. Inactive . . . . . . . . . . . . . . . . . .03-140-26 Clearing Stored Codes . . . . . . . . . . . . . .03-140-26 Diagnostic Procedure . . . . . . . . . . . . . . .04-160-56 Display Format . . . . . . . . . . . . . . . . . . . .03-140-26 List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-52 SPN/FMI . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 Stored Engine Service Codes, Viewing . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Theory of Operation . . . . . . . . . . . . . . . .04-160-51 Warning Light . . . . . . . . . . . . . . . . . . . . .03-140-26 2-Digit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 3-Digit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 Service Tool Connecting to . . . . . . . . . . . . . . . . . . . . . .04-160-9 Data Parameter Description . . . . . . . . . .04-160-18 ECU Does Not Communicate Service ADVISOR . . . . . . . . . . . . . . . .04-150-50 With DST. . . . . . . . . . . . . . . . . . . . . . .04-150-50 Software Files Reprogramming ECU Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-29 Service ADVISOR . . . . . . . . . . . . . . . .04-160-39 Specifications Combines ECU Terminal Identification . . . . . . . . . 06-210-7, 06-210-11 Governor Mode Selection . . . . . . . . . . .06-210-6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Torque Curve Selection . . . . . . . . . . . . .06-210-5 ECU Terminal Identification. . . . . . . . . . .06-210-26 Electronic Engine Control Repair and Adjustment . . . . . . . . . . . . . . . . . . . . . .06-200-8 Excavators Governor Mode Selection . . . . . . . . . .06-210-10 Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-8 Torque Curve Selection . . . . . . . . . . . .06-210-10 CTM170 (14MAY03)
Fuel System . . . . . . . . . . . . . . . . . . . . . . .06-200-6 Fuel System Diagnostics. . . . . . . . . . . . . .06-210-1 General OEM Engines Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-3 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-4 Marine ECU Terminal Identification . . . . . . . . .06-210-16 Governor Mode Selection . . . . . . . . . .06-210-15 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-12 Torque Curve Selection . . . . . . . . . . . .06-210-15 OEM Engines Governor Mode Selection . . . . . . . . . .06-210-25 Governor Mode Selection With OC03034 Software or Earlier . . . . . . . . . . . . . .06-210-25 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-21 Torque Curve Selection . . . . . . . . . . . .06-210-24 Telehandlers ECU Terminal Identification . . . . . . . . .06-210-35 Governor Mode Selection . . . . . . . . . .06-210-34 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-32 Torque Curve Selection . . . . . . . . . . . .06-210-34 Torque Values Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1 Metric . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2 Tractors 6010 Series ECU Terminal Identification . . . . . . .06-210-40 Governor Mode Selection. . . . . . . . .06-210-39 Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-36 Torque Curve Selection . . . . . . . . . .06-210-39 6020 Series ECU Terminal Identification . . . . . . .06-210-46 Governor Mode Selection. . . . . . . . .06-210-45 Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-42 Torque Curve Selection . . . . . . . . . .06-210-44 7020 Series ECU Terminal Identification . . . . . . .06-210-52 Governor Mode Selection. . . . . . . . .06-210-51 Sensor . . . . . . . . . . . . . . . . . . . . . . .06-210-48 Torque Curve Selection . . . . . . . . . .06-210-50 Speed Governing . . . . . . . . . . . . . . . . . . . .03-140-25 Speed Sensors. . . . . . . . . . . . . . . . . . . . . .03-140-16 SPN/FMI Listing of Codes . . . . . . . . . . . . . . . . . . .04-160-52 Starting Engine Cranks/Wont Start . . . . . . . . . . . .04-150-2 Static Timing Injection Pump . . . . . . . . . . . . . . . . . . . .02-090-14 Stored Diagnostic Trouble Codes View on Diagnostic Gauge . . . . . . . . . . .04-160-13 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Index-10
PN=10
Index
Page
Page
T
Telehandler Application Specifications . . . . . . . . . . . . .06-210-2 Telehandlers Specifications ECU Terminal Identification . . . . . . . . .06-210-35 Governor Mode Selection . . . . . . . . . .06-210-34 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-32 Torque Curve Selection . . . . . . . . . . . .06-210-34 Temperature Measuring . . . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Temperature Sensors . . . . . . . . . . . . . . . . . .03-140-7 Terminology Electronic Control System . . . . . . . . . . . . .03-140-2 Test Air in Fuel Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-69 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-71 Bleed the Fuel System . . . . . . . . . . . . . .04-150-73 Compression Test . . . . . . . . . . . . . . . . . .04-160-24 Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-25 Cylinder Misfire . . . . . . . . . . . . . . . . . . . .04-150-76 Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-22 Excavator Torque Curve Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-26 Fuel Drain Back . . . . . . . . . . . . . . . . . . .04-150-68 Fuel Supply Pressure . . . . . . . . . . . . . . .04-150-72 Injection Nozzles. . . . . . . . . . . . . . . . . . .02-090-25 TractorTorque Curve Change Test . . . . .04-160-27 Theory of Operation Cruise Control. . . . . . . . . . . . . . . . . . . . .03-140-23 Electronic Control System . . . . . . . . . . . . .03-140-3 Engine Control Unit. . . . . . . . . . . . . . . . .03-140-21 Final Fuel Filter Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7 Fuel Injection Nozzles . . . . . . . . . . . . . . .03-130-10 Fuel Injection Pump . . . . . . . . . . . . . . . . .03-130-8 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . .03-130-8 Fuel System Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4 Governor Droop Mode Selection . . . . . . .03-140-25 Injection Nozzles. . . . . . . . . . . . . . . . . . .03-130-10 Injection Pump . . . . . . . . . . . . . . . . . . . . .03-130-8 Intake Air Heater. . . . . . . . . . . . . . . . . . .03-140-23 Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . .03-130-10 Primary Fuel Filter Tier 1. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Tier 2. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Torque Curve Selection . . . . . . . . . . . . .03-140-25 CTM170 (14MAY03)
Throttle Diagnostic Trouble Codes T01 - Multi-state Throttle Input High . . . .04-160-58 T02 - Multi-state Throttle Input Low. . . . .04-160-62 T03 - Analog Throttle (A) Input High . . . .04-160-66 T04 - Analog Throttle (A) Input Low . . . .04-160-70 T05 - Analog Throttle (B) Input High . . . .04-160-74 T06 - Analog Throttle (B) Input Low . . . .04-160-78 T07 - CAN Throttle Invalid . . . . . . . . . . .04-160-82 T11 - Excavator Throttle Reference Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-86 T12 - Excavator Throttle Reference Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90 T13 - Excavator Throttle Ground Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94 T14 - Excavator Throttle Ground Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-98 T15 - Excavator Throttle Input Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102 T16 - Excavator Throttle Input Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-106 T17 - Analog Throttle (C) Input High . . .04-160-110 T18 - Analog Throttle (C) Input Low . . .04-160-114 Throttle Position Measuring . . . . . . . . . . . . . . . . . . . . . . . .03-140-12 Throttle Sensors . . . . . . . . . . . . . . . . . . . . .03-140-12 Tier 1 vs. Tier 2 . . . . . . . . . . . . . . . . . . . . . .01-001-5 Timing Injection Pump . . . . . . . . . . . . . . . . . . . .02-090-14 Timing Sensors . . . . . . . . . . . . . . . . . . . . .03-140-16 Tools Control System Repair and Adjustment Other Material . . . . . . . . . . . . . . . . . . . . . .05-170-10 Electronic Engine Control Repair . . . . . . .05-170-4 Electronic Fuel System Diagnostic . . . . . .05-180-1 Electronic Fuel System Repair . . . . . . . . .05-170-1 Fuel System Repair and Adjustment . . . . . . . . . . . . .05-170-3 Repair and Adjustment Other Material . . . . . . . . . . . . . . . . . . . . . . .05-170-4 Torque curve Selection Application Specifications . . . . . . . . . . . . .06-210-2 Torque Curve Selection Theory of Operation . . . . . . . . . . . . . . . .03-140-25 Torque Values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2 Tractors 6010 Series Application Specifications . . . . . . . . . . .06-210-2 Specifications ECU Terminal Identification . . . . . . .06-210-40 Governor Mode Selection. . . . . . . . .06-210-39 4.5 L & 6.8 L Level 4 Electronic Fuel System
051403
Indx 11
Index-11
PN=11
Index
Page
Page
Indx 12
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-36 Torque Curve Selection . . . . . . . . . .06-210-39 6020 Series Application Specifications . . . . . . . . . . .06-210-2 Specifications ECU Terminal Identification . . . . . . .06-210-46 Governor Mode Selection. . . . . . . . .06-210-45 Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-42 Torque Curve Selection . . . . . . . . . .06-210-44 7020 Series Application Specifications . . . . . . . . . . .06-210-2 Specifications ECU Terminal Identification . . . . . . .06-210-52 Governor Mode Selection. . . . . . . . .06-210-51 Sensor . . . . . . . . . . . . . . . . . . . . . . .06-210-48 Torque Curve Selection . . . . . . . . . .06-210-50 TractorTorque Curve Change Test Engine Test Instructions . . . . . . . . . . . . .04-160-27 Tri-State Throttle Measuring Throttle Position. . . . . . . . . . .03-140-12 Trouble Codes Active Engine Service Codes, Viewing . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Active vs. Inactive . . . . . . . . . . . . . . . . . .03-140-26 Clearing Stored Codes . . . . . . . . . . . . . .03-140-26 Diagnostic Procedure . . . . . . . . . . . . . . .04-160-56 Display Format . . . . . . . . . . . . . . . . . . . .03-140-26 List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-52 Trouble codes Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-52 Trouble Codes SPN/FMI . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 Stored Engine Service Codes, Viewing . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Theory of Operation . . . . . . . . . . . . . . . .04-160-51 Warning Light . . . . . . . . . . . . . . . . . . . . .03-140-26 2-Digit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51 3-Digit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-51
Wheel House Panel Wiring Diagram Marine Engines . . . . . . . . . . . . . . . . . .06-210-19 White Exhaust Smoke . . . . . . . . . . . . . . . .04-150-18 Wiring Diagram Marine Engines . . . . . . . . . . . . . . . . . . . .06-210-18 Fly Bridge Panel . . . . . . . . . . . . . . . . .06-210-20 Starting Circuit. . . . . . . . . .06-210-19, 06-210-20 Wheel House Panel. . . . . . . . . . . . . . .06-210-19 OEM Engines . . . . . . . . . . . . . . . . . . . . .06-210-28 Instrument Panel . . . . . . . . . . . . . . . . .06-210-30 Starting Circuit. . . . . . . . . . . . . . . . . . .06-210-30
V
Volt Meter How to Use. . . . . . . . . . . . . . . . . . . . . . . .04-160-2
W
Water in Fuel Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 Weatherpack Connectors Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7 CTM170 (14MAY03)
Index-12

051403
PN=12

Service Manual 6068 May 03

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COMPONENT TECHNICAL MANUAL

John Deere Power Systems

4.5 L & 6.8 L Level 4 Electronic Fuel System

4.5 L & 6.8 L Level 4 Electronic Fuel System

4.5 L & 6.8 L Level 4 Electronic Fuel System

4.5 L & 6.8 L Level 4 Electronic Fuel System

4.5 L & 6.8 L Level 4 Electronic Fuel System

Handle Starting Fluid Safely

Service Cooling System Safely

4.5 L & 6.8 L Level 4 Electronic Fuel System

Prevent Battery Explosions

Prepare for Emergencies

4.5 L & 6.8 L Level 4 Electronic Fuel System

Handling Batteries Safely

4.5 L & 6.8 L Level 4 Electronic Fuel System

Avoid High-Pressure Fluids

Wear Protective Clothing

4.5 L & 6.8 L Level 4 Electronic Fuel System

Service Machines Safely

Work In Ventilated Area

Engine Exhaust Fumes

4.5 L & 6.8 L Level 4 Electronic Fuel System

Work in Clean Area

Clean Work Area

Remove Paint Before Welding or Heating

4.5 L & 6.8 L Level 4 Electronic Fuel System

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Illuminate Work Area Safely

Use Proper Lifting Equipment

4.5 L & 6.8 L Level 4 Electronic Fuel System

Construct Dealer-Made Tools Safely

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

4.5 L & 6.8 L Level 4 Electronic Fuel System

Use Proper Tools

Use only service parts meeting John Deere specifications.

Dispose of Waste Properly

4.5 L & 6.8 L Level 4 Electronic Fuel System

Live With Safety

4.5 L & 6.8 L Level 4 Electronic Fuel System

POWERTECH is a registered trademark of Deere & Company

4.5 L & 6.8 L Level 4 Electronic Fuel System

Engine Serial Number Plate Information

Engine Application Data (C)

Saran Engine Serial Number Plate

Torreon Engine Serial Number Plate

4.5 L & 6.8 L Level 4 Electronic Fuel System

OEM Engine Option Code Label

4.5 L & 6.8 L Level 4 Electronic Fuel System

Engine Application Chart

CD6068HZ060 CD6068HZ060 CD4045HZ050

Machine Model OEM OEM Marine Marine Marine

4.5 L & 6.8 L Level 4 Electronic Fuel System

Tier 1 vs. Tier 2

Tier 1 - Final Fuel Filter

Tier 2 - Primary Fuel Filter

4.5 L & 6.8 L Level 4 Electronic Fuel System

4.5 L & 6.8 L Level 4 Electronic Fuel System

Diesel Fuel - Tier 1