PDF Technical Manual John Deere Powertech Plus 4.5L 6.8L Diesel Engines - 15 MB
This technical manual focuses on the Level 14 Electronic Fuel System with Denso High-Pressure Common Rail (HPCR) for John Deere Powertech Plus 4.5L and 6.8L diesel engines.
It is an advanced guide for diagnosing and repairing complex fuel system issues.
The manual provides theory of operation, diagnostic trouble codes, and detailed testing procedures.
This is a must-have for technicians specializing in modern diesel engine electronics.
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--- Page 1 ---
PowerTech Plus 4.5L
and 6.8L Diesel Engines
Level 14 Electronic
Fuel System With
Denso HPCR
TECHNICAL MANUAL
PowerTech Plus 4.5 L and 6.8 L
Diesel Engines—Level 14
Electronic Fuel System with Denso
HPCR
04DEC08 (ENGLISH)
For complete service information also see:
PowerTech Plus 4.5 L and 6.8 L Diesel
Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104
Alternators and Starter Motors . . . . . . . . . . . CTM77
OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems
LITHO IN U.S.A.
TP-6456
--- Page 3 ---
Safety
01
000 Practice Safe Maintenance
10
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
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
CTM320 (04DEC08) 01-000-10 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=16
--- Page 4 ---
Fuels, Lubricants, and Coolant
01
• Possible compatibility issues with other materials IMPORTANT: Raw pressed vegetable oils are NOT 002
3
(including copper, lead, zinc, tin, brass, and bronze) acceptable for use as fuel in any
used in fuel systems and fuel handling equipment concentration in John Deere
• Possible reduction in water separator efficiency engines. Their use could cause
• Potential high acid levels within fuel system engine failure.
• Possible damage to paint if exposed to biodiesel
DX,FUEL7 –19–04OCT07–2/2
CTM320 (04DEC08) 01-002-3 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=31
--- Page 5 ---
Fuel System Identification
01
003 Low Pressure Fuel System Type 3
2
Option Codes:
3503, 3504, 3510, 3511
–UN–06JUN05
RG14264
Low Pressure Fuel System Type 3
JB81757,0000083 –19–01FEB08–1/1
High Pressure Fuel System Type 1
Option Codes:
169D, 167D, 16C7
Identify your fuel system components.
A—Lock Nut (3 used)
B—Two Pumping Elements
C—Suction Control Valve
–UN–31JAN08
RG16087
High Pressure Fuel Pump Type 1
PU00210,0000001 –19–01FEB08–1/1
CTM320 (04DEC08) 01-003-2 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=46
--- Page 6 ---
Electronic Fuel System Repair and Adjustments
NOTE: The proper installation is indicated when a "click"
is heard and a release of the retaining ring is felt.
A plug is provided with the new element for
plugging the used element.
02
090
11. Install water separator bowl on primary fuel filter and 11
tighten ring.
12. Turn fuel lubricating dosing element (C) using a
suitable filter or strap wrench to remove. Discard the
element.
NOTE: New fuel lubricating dosing element canister
should come around 3/4 full of lubricating additive.
Be sure that when removing cap, the canister is
held right side up so as not to spill the fluid.
13. Remove cap from new fuel lubricating dosing element
canister.
14. Wipe the sealing surfaces of the header with a clean
rag.
15. Install and tighten fuel lubricating dosing element by
hand until firmly against the header. Apply an extra
3/4 turn after gasket contact is made.
16. Reconnect water in fuel sensor wiring.
17. Open fuel shut-off valve, if equipped.
NOTE: The electric fuel transfer (lift) pump (E) and
constant air bleed (F) enables the fuel system to
self prime.
18. Key on for 30 seconds to prime fuel system, then
start engine and check for possible leaks.
PU00210,0000C39 –19–25AUG08–3/3
CTM320 (04DEC08) 02-090-11 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=61
--- Page 7 ---
Electronic Fuel System Repair and Adjustments
G I
F
H
02
090
26
A
B
C
–UN–18FEB08
D E
RG16067
High Pressure Fuel Pump Exploded View
A—High Pressure Fuel Pump D—Nut G—Fuel Leak-off Fitting I—Allen Screw
B—Adapter Plate E—O-ring H—Cap Screw (High Pressure
C—Drive Gear F—Fuel Supply Fitting Pump-to-Adapter Plate)
Disassemble and Reassemble High Pressure Fuel B) Reassembling
Pump
1. Install high pressure pump (A) on adapter plate (B)
A) Disassembling with a new O-ring (E). Tighten the two cap screws
(H) and one allen screw (I) to specification.
1. Remove nut (D). Use a vise with claws to block the
gear when removing gear. Specification
High Pressure Pump to Adapter
Plate—Torque .................................................... 35 N•m (26 lb.-force)
2. Remove gear (C) using JDG1560 tool.
2. Install gear (C) on pump shaft then tighten nut (D)
3. Remove the two cap screws (H) and one allen
to specification. Use a vise with claws to block the
screw (I) and separate high pressure pump (A) from
gear when tightening.
adapter plate (B).
Specification
4. Replace parts as necessary. High Pressure Pump Gear
Nut—Torque ...................................................... 68 N•m (50 lb.-force)
.
Continued on next page PU00210,0000C3B –19–22FEB08–2/4
CTM320 (04DEC08) 02-090-26 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=76
--- Page 8 ---
Electronic Fuel System Repair and Adjustments
Clean Electronic Injector (EI) Bore
1. Clean light deposits out of electronic injector bore 2. Work brush up and down several times to clean
using an electric drill and D17030BR Thread bore.
Cleaning brush.
02
090
41
RG40854,0000118 –19–22JAN07–1/1
Clean Electronic Injector (EI) Orifice
Electronic injector orifice cannot be cleaned. If orifice is
plugged, replace electronic injector.
RG40854,0000117 –19–22JAN07–1/1
Clean Electronic Injector (EI) Body
IMPORTANT: Never use a steel brush to clean 2. If necessary, use a brass wire brush to remove
electronic injectors. Steel brush may carbon deposits.
damage electronic injectors.
1. Clean new or used electronic injectors by washing
in diesel fuel.
RG40854,0000116 –19–22JAN07–1/1
Inspect Electronic Injector (EI) Body
1. Inspect electronic injector body to see that it is not 2. If electronic injector is scratched or scored, replace
scratched or scored. electronic injector.
RG40854,0000115 –19–22JAN07–1/1
CTM320 (04DEC08) 02-090-41 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=91
--- Page 9 ---
Electronic Air System Repair and Adjustment
Remove and Install Exhaust Gas
Recirculation (EGR) Cooler
1.
02
100 Remove the EGR exhaust tube. See REMOVE AND
–UN–24MAR05
4 INSTALL EGR EXHAUST TUBE earlier in this Group.
2. Remove the EGR coolant inlet tube. See REMOVE
AND INSTALL EGR COOLANT INLET TUBE earlier in
RG14099
this Group.
3. Loosen EGR cooler rear support bushing cap screw EGR Cooler Rear Support Bushing Cap Screw
(B).
4. Remove front EGR cooler cap screws (C).
5. Remove rear support bushing. Carefully remove the
EGR cooler (A) and coolant outlet tube (D) as an
assembly by sliding to the rear of the engine. If
–UN–24MAR05
required, coolant outlet tube can be removed from the
EGR cooler.
6. Inspect EGR cooler for damage and leaks.
RG14100
7. Install coolant outlet tube to EGR cooler, if removed.
EGR Cooler Front Cap Screws
Tighten cap screw to specifications.
Specification
EGR Cooler Outlet Tube Cap
Screw—Torque ................................................................ 35 N•m (25 lb-ft)
8. Install EGR cooler and outlet tube by carefully sliding
the assembly forward and inserting the coolant tube
–UN–24MAR05
into the thermostat housing (E).
9. Align the back of the EGR cooler and install the rear
support bushing with cap screw and tighten to RG14102
specifications.
Specification EGR Coolant Outlet Tube
Rear Support Bushing Cap
Screw—Torque ................................................................ 35 N•m (25 lb-ft)
A—EGR Cooler
B—Rear Support Bushing
C—Front Cap Screws
D—EGR Coolant Outlet Tube
E—Thermostat Housing
–UN–24MAR05
RG14101
EGR Coolant Outlet Tube
Continued on next page RG19661,000003F –19–03OCT07–1/2
CTM320 (04DEC08) 02-100-4 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=106
--- Page 10 ---
Electronic Air System Repair and Adjustment
3. Install VTG Lever nut (D) into hex pocket on VTG lever
(E) with rounded side of the nut facing outward. Hold
lock nut in place and insert 4mm allen wrench into
recessed hex area (F) located on the ball stud. Torque
ball stud to 8.5 N-m (75 lb-in).
02
100
4. Reconnect turbocharger wiring harness connector to 19
engine wiring harness.
SS01820,00003DD –19–16OCT08–2/2
CTM320 (04DEC08) 02-100-19 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=121
--- Page 11 ---
Electronic Engine Control Repair and Adjustment
Remove and Install Pump Position Sensor
NOTE: For an expanded component location drawing,
see COMPONENT LOCATION DIAGRAM 2 (4.5L
Engine) (D) or COMPONENT LOCATION
02
110 DIAGRAM 8 (6.8L Engine) (D) in Section 03,
14 Group 140 of this manual.
1. Disconnect pump position sensor wiring connector and
remove sensor.
2. Coat new sensor O-ring with TY6333 High
Temperature Grease and install sensor. Tighten to
specification.
3. Reconnect sensor wiring connection.
Specification
Pump Position Sensor—Torque ...................................... 15 N•m (11 lb-ft)
RG41183,00000E6 –19–04OCT07–1/1
Remove and Install Turbo Speed Sensor
NOTE: For an expanded component location drawing,
see COMPONENT LOCATION DIAGRAM 2 (4.5L
Engine) (A) or COMPONENT LOCATION
DIAGRAM 8 (6.8L Engine) (A) in Section 03,
Group 140 of this manual.
1. Disconnect turbo speed pressure sensor wiring
connector and remove sensor.
2. Install sensor. Tighten to specifications.
Specification
4.5L - Turbo Speed Sensor—
Torque ........................................................ 13.6 ± 0.6 N•m (10 ± 0.5 lb-ft)
Specification
6.8L - Turbo Speed Sensor—
Torque ............................................................. 12 ± 0.6 N•m (9 ± 0.4 lb-ft)
3. Install sensor wiring connector.
RG41183,00000E7 –19–04OCT07–1/1
CTM320 (04DEC08) 02-110-14 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=136
--- Page 12 ---
Electronic Engine Control Repair and Adjustment
02
110
29
–UN–23JAN08
RG16042
Diagram 5- Wire Harness, Left Side of Engine
O—Harness Bracket U—Cap Screw T04—Coolant Temperature X02—Pump Position Sensor
P—Flange nut P04—Oil Pressure Sensor Sensor Connector Connector
Q—Harness Clip Connector T05—Fuel Temperature Sensor Y01—Suction Control Valve
R—Harness Bracket P05—Fuel Rail Pressure Connector Connector
S—Nut Connector X01—Crank Position Sensor
T—Harness Clamp Connector
15. Disconnect connectors P04, P05, T04, and T05. other major electrical components. Secure
cable to prevent accidental shorts.
16. Disconnect connectors X01, X02, and Y01.
NOTE: Refer to the previous diagrams for reference
17. Remove Nut (S) and Cap Screw (U) from cable locations for the install procedure.
clamp (T).
1. Place harness over engine. Refer to ECU WIRING
18. Remove three harness clips (Q)) from harness HARNESS ROUTING FOR 6.8L ENGINE earlier in
brackets (O) and (R). this section of the manual for proper harness
placement.
19. Carefully remove harness from engine.
2. Connect three harness clips (Q) to harness
Install Engine Wire Harness brackets (O) and (R). See diagram 5.
NOTE: Disconnect cable from the negative battery
terminal before installing wire harness or any
Continued on next page DM59778,00000B4 –19–28JAN08–6/8
CTM320 (04DEC08) 02-110-29 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=151
--- Page 13 ---
Electronic Engine Control Repair and Adjustment
J
02
110
44
C
H I
E
D
F
16
18 20
AWG
D
G
–UN–01OCT08
RG14613A
A B
CINCH Crimper Elements
A—Crimper Side View E—Terminal Block (Open) H—Terminal Seated in Block J—Wire in Terminal (insulation
B—Crimper Front View F—1.5 mm Terminal Recess Recess end)
C—Wire-in-Terminal Blowup G—0.6 mm Terminal Recess I—Wire in Terminal (4.0 mm
D—Terminal Block (Closed) Insulation Stripped)
NOTE: The above figure is intended to only illustrate 12.
crimper and wire-loading elements. Its callouts
relate only to its own legend, and not to the
callouts in the procedural steps.
Continued on next page RG41183,00000E9 –19–01OCT08–12/17
CTM320 (04DEC08) 02-110-44 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=166
--- Page 14 ---
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
• Pre-filter Operation
• Fuel Transfer Pump Operation
• Electronic Fuel Transfer Pump Operation
• Final Fuel Filter Operation
• High Pressure Fuel Pump Operation 03
• High Pressure Common Rail (HPCR) 130
1
• Electronic Injector (EI) Operation
– EI - No Injection
– EI - Begin Injection
– EI - Ending Injection
RE38635,000014A –19–04AUG07–1/1
CTM320 (04DEC08) 03-130-1 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=181
--- Page 15 ---
Electronic Air System Operation
Electronic Air System Control Operation
A
B
E
C
D
F
03
135
G
2
H
I
J
K
I
L
–UN–30OCT07
H
L
E
M RG15604
A
A—Cooled charge air E—Fresh air in from filter H—Cooled exhaust gas K—EGR cooler
B—Charge air cooler F—Turbocharger turbine I—Compressed air L—Hot exhaust gas
C—VGT actuator G—EGR valve J—Air intake manifold M—Exhaust manifold
D—Turbocharger compressor
Air System with EGR cooler (B), which cools the compressed air (A), into the
air intake manifold (J), through ports in the head and
As the piston reaches the intake stroke it, sucks air (E) into the piston cylinder. On the exhaust stroke the
through the intake air filter, turbocharger compressor engine pushes exhaust gas (L) into the exhaust
(D), which compresses and heats the air (I), charge air manifold (M), then into two different directions:
Continued on next page DB92450,0000005 –19–30OCT07–1/4
CTM320 (04DEC08) 03-135-2 4.5 L and 6.8 L Level 14 Electronic Fuel System
120508
PN=196
--- Page 16 ---
Electronic Control System Operation
Component Location Diagram 1
03
140
7
–UN–27JUN07
RG15021
4.5L Engine
A—Suction Control Valve B—Fuel Temperature Sensor C—Oil Pressure Sensor D—ECU
NOTE: Some of the components shown are optional
and are NOT used on all applications.