PowerTech 4.5L &6.8L Diesel Engines - Level 12 Electronic Fuel System-Stanadyne DE10 Pump-CTM331

POWERTECH 4.5L & 6.
8L Diesel Engines Level 12 Electronic Fuel System With Stanadyne DE10 Pump
TECHNICAL MANUAL POWERTECH 4.5 L & 6.8 L Diesel EnginesLevel 12 Electronic Fuel System with DE10 Pump
03OCT05 (ENGLISH)
For complete service information also see: POWERTECH 4.5 L and 6.8 L Diesel EnginesBase Engine . . . . . . . . . . . . . . . . . CTM104 Alternators and Starter Motors . . . . . . . . . . . CTM77 OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems

LITHO IN U.S.A.
Introduction
Forward
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. This manual (CTM331) covers only Level 12 Electronic Fuel System with the Stanadyne DE10 injection pump. It is one of five volumes on 4.5 L and 6.8 L engines. The following four companion manuals cover the base engine, mechanical fuel system, level 4 electronic fuel system and level 1 electronic fuel system repair, operation and diagnostics: CTM104Base Engine CTM170Level 4 Electronic Fuel System with Bosch VP44 Pump CTM207Mechanical Fuel Systems CTM284Level 1 Electronic Fuel Systems with Delphi (Lucas) DP201 Pump Other manuals will be added in the future to provide additional information on electronic fuel systems as needed. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components. Information is organized in sections and groups for the various components requiring service instruction. Section 05 summarizes all applicable essential tools, service equipment and tools, other materials needed to do the job, and service parts kits. Section 06 summarizes all specifications, wear tolerances, and torque values. Before beginning diagnosis or repair on an engine, clean the engine. This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized. Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures. Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
OUO1080,00001FE 1916NOV011/1
CTM331 (03OCT05)
4.5 L & 6.8 L Level 12 Electronic Fuel System

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Introduction
POWERTECH 4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10 Pump
UN06NOV01
RG11931
Left Side of Engine
Right Side of Engine
POWERTECH is a registered trademark of Deere & Company
DPSG,OUO1004,129 1915MAY981/1
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Introduction
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Contents
01
SECTION 01General Information 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 2002 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual
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02
03
04
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INDX
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01
Section 01
General Information
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 Information Relative to Emissions Regulations . . . . . . . . . . . . . . . . . . . . . . . . .01-001-3 Engine Application Charts . . . . . . . . . . . . . . . .01-001-4 Group 002Fuels Lubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Testing Diesel Fuel . . . . . . . . . . . . . . . . . . . . .01-002-2 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-3
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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.
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
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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TS1356
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Safety
01 000 2
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.
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.
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 3
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
DX,AIR 1917FEB991/1
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.
DX,CLEAN 1904JUN901/1
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TS228
Safety
01 000 4
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 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. 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 not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.
UN23AUG88
DX,PAINT 1924JUL021/1
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 accidentally burst when heat goes beyond the immediate flame area.
DX,TORCH 1910DEC041/1
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Safety
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.
01 000 5
DX,LIGHT 1904JUN901/1
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
DX,SAFE,TOOLS 1910OCT971/1
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Safety
01 000 6
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.
DX,SERV 1917FEB991/1
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 only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
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Safety
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
01 000 7
DX,DRAIN 1903MAR931/1
Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
1907OCT88
DX,LIVE 1925SEP921/1
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01 000 8
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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 application code. For example:
4045TF275 Engine 4 ................................................................ 4.5 ............................................................. T ............................................................... F ............................................................... 275 ............................................................ Aspiration Code D ............................................................... T ............................................................... A ............................................................... H ............................................................... User Factory Code AP AT ............................................................. BE CQ ............................................................ DW ............................................................ E ............................................................... F ............................................................... FF ............................................................. FG ............................................................. FM ............................................................ H ............................................................... KV ............................................................. L ................................................................ LA ............................................................. LV ............................................................. N ............................................................... P ............................................................... PY ............................................................. RW ............................................................ T ............................................................... T8 ............................................................. TJ .............................................................. YC ............................................................. Z ............................................................... Application Code 001, etc. .................................................... Number of cylinders Liter displacement Aspiration code User code POWERTECH application code Naturally aspirated Turbocharged, no aftercooling Turbocharged and Air-to-Coolant Aftercooled Turbocharged and Air-to-Air Aftercooled Industries John Deere Mexica S. A de C. V. (Saltillo/Monterrey, Mexico Agritalia srl (Vittoria, Sicily, Italy) Bell Equipment Co. (Richards Bay, South Africa) John Deere Brazil (Horizontina, Brazil) John Deere Davenport Works (Davenport, Iowa) John Deere Ottumwa Works (Ottumwa, Iowa) OEM (Outside Equipment Manufacturers) Deere-Hitachi (Kernersville, North Carolina) Goldoni S.P.A. (Modena, Italy) Marine Engines John Deere Harvester Works (East Moline, Illinois) John Deere Commercial Worksite Products (Knoxville, Tennessee) John Deere Werke Mannheim (Germany) John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump) John Deere Commercial Products (Augusta, Georgia) John Deere Des Moines Works (Des Moines, Iowa) Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico) Larson & Toubro Ltd. (Pune, India) John Deere Waterloo Tractor Works (Waterloo, Iowa) John Deere Dubuque Works (Dubuque, Iowa) Cameco Industries (Thibodaux, Louisiana) John Deere Forestry (Timberjack) (Sweden/Finland/Canada) John Deere Jialian Harvester Co. Limited (China) John Deere WERKE Zweibrucken (Germany) See ENGINE APPLICATION CHARTS, later in this Group 01 001 1
POWERTECH is a registered trademark of Deere & Company
OUO1080,00001FA 1915NOV011/1
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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
CD4045T000000 CD .......................... Factory producing engine 4045T ..................... Engine model designation 000000 ................... Sequential serial number Factory Code (Engine Manufacturer) T0 ........................... Dubuque, Iowa CD .......................... Saran, France PE .......................... Torreon, Mexico J0 ........................... Rosario, Argentina Engine Model Designation 4045T ..................... Definition explained previously. See ENGINE MODEL DESIGNATION earlier in this group. Sequential Number 000000 ................... 6-digit sequential serial number
UN15NOV01
Engine Application Data (C) The second line of information on the serial number plate identifies the engine/machine or OEM relationship. See ENGINE APPLICATION CHARTS later in this group. Coefficient of Absorption (D) (Saran-Built Engines Only) The second line of information on the Saran serial number plate also contains the coefficient of absorption value for smoke emissions.
Dubuque Engine Serial Number Plate
Saran Engine Serial Number Plate

AEngine Serial Number Plate BEngine Serial Number CEngine Application Data DCoefficient of Absorption (Saran Engines Only)
Torreon Engine Serial Number Plate
OUO1080,00001FB 1915NOV011/1
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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.
UN03DEC01
01 001 3
NOTE: Before hot tank cleaning, ensure that option codes are recorded elsewhere.
OUO1080,000020E 1926NOV011/1
Information Relative to Emissions Regulations

Depending on the final destination, engines can meet the emissions regulations according to the US Environmental Protection Agency (EPA), California Air Resources Board (CARB) and for Europe, the Directive 97/68/EC relating the measures against the emissions of particles and gaseous pollutant from internal combustion engines. Such engines are called CERTIFIED and receive an emission label stuck on the engine. The regulations prohibit tampering with the emission-related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications. It is also illegal to install a part or component where the principle effect of that component is to bypass, defeat, or render inoperative any engine component or device which would affect the engines conformance to the emission regulations. To summarize, it is illegal to do anything except return the engine to its original published specifications. List of emission-related components: Fuel injection system Intake manifold Turbocharger Charge air cooling system Piston
OUO1080,0000035 1929AUG011/1
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Engine Application Charts

Machine Model Waterloo - Tractors 5425 Tractor 5525 Tractor 7220 Tractor 7320 Tractor 7420 Tractor 7520 Tractor 7815 Tractor Mannheim, Germany 6020SE Tractor (R2) 6120, 6120SE Tractor (R2) 6215 Advantage Tractor (NA) 6215 Classic Tractor (R2) 6220, 6220SE Tractor (R2) 6320SE Tractor (R2) 6415 Advantage Tractor (NA) 6420SE Tractor (R2) 6515 Classic Tractor (R2) 6520L Tractor (NA) 6520SE Tractor (R2) 6615 Advantage Tractor (NA) 6620SE Tractor 6715 Advantage Tractor (NA) Zweibrucken, Germany 3215 TeleHandler 3220 TeleHandler 3415 TeleHandler 3420 TeleHandler 3700 TeleHandler 3800 TeleHandler JOHN DEERE AGRICULTURAL EQUIPMENT Engine Model PE4045TLV53 PE4045TLV54 PE6068HRW59 PE6068HRW59 PE6068HRW60 PE6068HRW60 PE6068HRW63
CD4045TL270 CD4045TL271 CD4045TL272 CD4045TL272 CD4045TL272 CD4045HL270 CD4045HL272 CD4045HL271 CD6068HL270 CD4045HL273 CD6068TL270 CD6068TL271, CD6068HL271 6068HL272 CD6068TL273, CD6068HL273
CD4045HZ061, CD4045HZ060, CD4045HZ061, CD4045HZ060, CD4045TZ060 CD4045HZ060
CD4045HZ275 CD4045HZ275 CD4045HZ275 CD4045HZ275
Continued on next page
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JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT Engine Model PE4045DT058, T04045DT058 PE4045TT088, T04045TT088 PE4045TT089, T04045TT089 PE4045TT089, T04045TT089 PE6068TT057 PE4045TT084, T04045TT084 PE4045DT058, T04045DT058 PE4045TT085, T04045TT085 PE4045TT087, T04045TT087 PE4045TT086, T04045TT086 PE4045HT050 PE6068TT060 PE6068TT057 01 001 5
Application Dubuque 310G Backhoe Loader 310G Backhoe Loader (Alt Comp) 310SG Backhoe Loader 315SG Backhoe Loader 710G Backhoe 450H Crawler Dozer (Alt Comp) 450H Crawler Dozer (Nat Asp) 450H LGP Crawler Dozer 550H Crawler Dozer 550H LGP Crawler Dozer 650H Crawler Dozer 700H Crawler Dozer 710G Backhoe Loader Saltillo, Mexico 120C Excavator 160C LC Excavator Deere-Hitachi - Kernersville 200LC Excavator Forestry 810 Forwarder 543 DTT Feller Buncher Harvester 640 DTT Feller Buncher Harvester 1010 Forwarder 1110 Forwarder 1058 Forwarder 1410 Forwarder 1458 Forwarder 770 Harvester 770D Wheel Harvester 863 Harvester 1070 Harvester 1063 Harvester 548 Skidder 648DD/648TC Skidder
PE4045HP050 PE4045HP051
PE6068HT059
CD4045HTJ75 PE6068HDW62 PE6068HDW62 T04045HTJ76, CD4045HTJ76 CD6068HTJ75 T04045HTJ76 CD6068HTJ77 CD6068HTJ77 CD6068HTJ77 CD4045HTJ77 CD6068HTJ77 CD6068HTJ76 CD6068HTJ76 PE6068HDW59 PE6068HDW60
JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS) CD4045TF275 CD4045TFM75 Marine Engine PE4045HF275 CD4045TF275 PE4045TF275 CD6068HF275 PE6068HF275 CD6068TF275 PE6068TF275
OUO1089,0000205 1923SEP052/2
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Group 002
Fuels
Lubricants and Coolant
NOTE: 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
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.
OUOD002,0000171 1923SEP051/1
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Fuels
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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 1918DEC011/1
Testing Diesel Fuel

DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis verifies fuel type, cleanliness, water content, suitability for cold weather operation, and whether the fuel meets specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
DX,FUEL6 1914NOV051/1
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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 and Canada require sulfur content less than 0.05% (500 ppm). Diesel fuel in the European Union requires sulfur content less than 0.05% (500 ppm). 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 load level of 3100 gram as measured by the ASTM D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079. 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 3
OUOD002,0000179 1918DEC011/1
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Fuels
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Section 02
Repair and Adjustments

Contents
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Group 090Electronic Fuel System Repair and Adjustments Fuel SystemGeneral Information . . . . . . . . .02-090-1 Relieve Fuel System Pressure . . . . . . . . . . . .02-090-1 Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base . . .02-090-2 Fuel Pre-Filter/Water Bowl Assembly (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Final Fuel Filter Assembly . . . . . . . . . . . . . . . .02-090-6 Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl. . . . . . . . . . . . . . . . . .02-090-7 Remove Fuel Supply Pump. . . . . . . . . . . . . . .02-090-9 Install Fuel Supply Pump. . . . . . . . . . . . . . . .02-090-10 Injection Pump Static Timing . . . . . . . . . . . . .02-090-10 Remove Injection Pump . . . . . . . . . . . . . . . .02-090-11 Inspect Injection Pump Drive Gear ID and Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13 Install Injection Pump . . . . . . . . . . . . . . . . . .02-090-13 Remove Fuel Injection Nozzles . . . . . . . . . . .02-090-16 Clean Fuel Injection Nozzle Bore . . . . . . . . .02-090-18 Clean Fuel Injection Nozzles . . . . . . . . . . . . .02-090-18 Fuel Injection Nozzle Test . . . . . . . . . . . . . . .02-090-19 Disassemble Fuel Injection Nozzles . . . . . . .02-090-22 Adjust Fuel Injection Nozzle . . . . . . . . . . . . .02-090-23 Install Seals on Fuel Injection Nozzle . . . . . .02-090-24 Install Fuel Injection Nozzles . . . . . . . . . . . . .02-090-25 Bleed the Fuel System . . . . . . . . . . . . . . . . .02-090-26 Group 110Electrical Engine Control Repair and Adjustment Engine Control Unit (ECU) . . . . . . . . . . . . . . .02-110-1 Remove and Install Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . .02-110-2 Remove and Install Loss of Coolant Temperature Sensor . . . . . . . . . . . . . . . . . .02-110-2 Replace Crankshaft Position Sensor . . . . . . . .02-110-3 Remove and Install Oil Pressure Sensor . . . . .02-110-3 Remove and Install Manifold Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Remove and Install Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Remove and Install Fuel Heater . . . . . . . . . . .02-110-5 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-6 Use Electrical Insulating Compound . . . . . . . .02-110-6 Using High-Pressure Washer . . . . . . . . . . . . .02-110-7 Repair WEATHERPACK Connector . . . . . . .02-110-8 CTM331 (03OCT05)
Remove Blade Terminals from Connector Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11 Repair (Pull Type) METRI-PACK Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-12 Repair (Push Type) METRI-PACK Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-14 Repair DEUTSCH Connectors . . . . . . . . . .02-110-17 Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-20
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Contents
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CTM331 (03OCT05)
02-2

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Group 090
Electronic Fuel System Repair and Adjustments

Fuel SystemGeneral Information
Stanadyne DE10 pumps are static lock-pin timed during installation of the injection pump. The fuel supply pump is a separate component mounted on upper right-hand side of engine block and is actuated by a pin in block that rides on engine camshaft lobe. Engines may be equipped with an optional fuel pre-filter/water bowl. All engines are equipped with a round final fuel filter with water bowl. Hand primer on top of filter element is optional. All engines use Stanadyne Rate Shaping Nozzles (RSN). Field-installed options include fuel heater, water bowl and hand fuel primer.
02 090 1
OUO1089,00001F7 1906NOV011/1
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 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 this group.
High Pressure Fluids
RG,35,JW7625 1920NOV971/1
CTM331 (03OCT05)
02-090-1

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PN=29
X9811
UN23AUG88
Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base
Refer to operators manual for proper servicing and (hourly) replacement intervals. Engines are equipped with a final fuel filter/water bowl (A) and may have an optional pre-filter/water bowl. Final fuel filters/water bowls can be equipped with a transparent (see-through) water collection bowl and/or hand primer on machines equipped with only one filter.
AFinal Fuel Filter/Water Bowl
UN15NOV01
02 090 2
Final Fuel Filter
OUO1089,00001F6 1906NOV011/3
CTM331 (03OCT05)
02-090-2

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PN=30
RG11989

1. Thoroughly clean fuel filter/pre-filter assemblies and surrounding area to keep from getting dirt and debris into fuel system. 2. Connect a drain line to filter drain adapters and drain all fuel from system.
02 090 3
UN26NOV01
NOTE: The fuel filters are keyed to the filter header. If both pre-filter and final filter are removed, ensure that they are reinstalled in the correct headers.
3. Remove final fuel filter element and pre-filter/water bowl, if desired. See REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL, in this group.
Final Fuel Filter Base
NOTE: Pre-filter and final filter fuel lines may be connected to different filter inlet and outlet ports depending on engine application. Mark fuel line location to aid during assembly. Refer to markings on fuel filter base for fuel inlet/outlet ports, as they are different between the pre- and final filter bases.
4. Disconnect fuel lines from all ports. 5. Remove final fuel filter base (A). 6. If equipped, remove pre-filter base. 7. Replace parts as necessary. 8. Install mounting brackets and tighten to torque specifications provided below.
Specification Final Fuel Filter Bracket-to-Cylinder Head Torque ............................................................................. Final Fuel Filter Mounting Base-to-BracketTorque ................................................ Fuel Pre-Filter Bracket-to-Cylinder Head and AlternatorTorque ......................................... Fuel Pre-Filter/Water Bowl Mounting Base-to-Bracket Torque .............................................................................
AFinal Fuel Filter Base
73 Nm (54 lb-ft) 73 Nm (54 lb-ft) 73 Nm (54 lb-ft)
50 Nm (36 lb-ft)
OUO1089,00001F6 1906NOV012/3
CTM331 (03OCT05)
02-090-3

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PN=31
RG12021

9. Install pre-filter and final filter fuel filter/water bowl elements. See REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL, in this group.
02 090 4
10. Connect fuel lines to all ports. 11. Bleed the fuel system. See BLEED THE FUEL SYSTEM in this group.
OUO1089,00001F6 1906NOV013/3
CTM331 (03OCT05)
02-090-4

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PN=32
Fuel Pre-Filter/Water Bowl Assembly (Optional)

ADrain Adapter BPacking CCap Screw DWater Bowl ERetaining Ring FFilter Element GFilter Base with Seal Ring HVent Plug IPacking JPlug (2 used) KDiaphragm LSpring Seat MSpring NSpring Cover OPump Knob PRetaining Ring
02 090 5
Primary Filter/Water Bowl Assembly
RG,35,JW7623 1921JAN021/1
CTM331 (03OCT05)
02-090-5

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PN=33
RGT7751HS
UN19NOV97
RGT7751HR
UN19NOV97
Final Fuel Filter Assembly

1Retaining Ring 2O-Ring 3Stem 4O-Ring 5Retaining Ring 6Filter 7O-Ring 8O-Ring 9Drain Adapter 10Screw 11O-Ring 12Water Bowl 13Adapter 14O-Ring 15Fuel Heater (Optional) 16O-Ring 17Filter Base 18Primer Assembly (Optional) 19Cap
02 090 6
Final Fuel Filter
OUO1080,00001FC 1915NOV011/1
CTM331 (03OCT05)
02-090-6

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PN=34
RG12015
UN16NOV01
Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl

NOTE: Refer to operators manual for proper servicing and (hourly) replacement intervals. Final fuel filters can be equipped with a transparent (see-through) water bowl and/or hand primer on machines equipped with only one filter. Replacement of pre- and final fuel filter elements are similar. Differences will be noted. Make sure correct embossments on filter elements match the slots in the mounting header.
1. Thoroughly clean fuel filter/water bowl assembly and surrounding area, if not previously done. 2. Connect a drain line to filter drain adapters and drain all fuel from filters.
Final Fuel Filter Shown
ARetaining Ring BFilter Element
02 090 7
UN15NOV01
NOTE: Lifting up on retaining ring (A) as it is rotated helps to get it past raised locators.
3. Firmly grasp the retaining ring (A) and rotate it counterclockwise 1/4 turn. Remove ring with filter element (B). 4. Inspect filter mounting base for cleanliness. Clean as required. 5. Remove transparent (see-through) water bowl, if equipped. Drain and clean water bowl. Dry with compressed air. 6. Install transparent (see-through) water bowl, if equipped, onto new filter element. Make sure O-ring is properly installed in the top groove of bowl. 7. Thoroughly inspect filter base dust seal ring. Replace as needed.
OUO1089,00001F5 1906NOV011/2
CTM331 (03OCT05)
02-090-7

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PN=35
RG11990
Electronic Fuel System Repair and Adjustments NOTE: The fuel filters must be indexed properly and the key on canister must be oriented in slot of mounting base for correct installation.
02 090 8
8. Install 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 this group.
OUO1089,00001F5 1906NOV012/2
CTM331 (03OCT05)
02-090-8

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PN=36
Remove Fuel Supply Pump

IMPORTANT: A backup wrench must always be used when disconnecting fittings or fuel lines from supply pump to avoid damage to fittings. 1. Disconnect fuel inlet line (A) and outlet line (B) and cap connections on fuel supply pump and fuel lines to keep debris out of fuel system. 2. Remove cap screws (C) and remove fuel supply pump assembly from cylinder block.
02 090 9
UN15NOV01
NOTE: The fuel supply pump is driven by a push rod (D) that rides on an eccentric camshaft lobe. The cylinder head must be removed to remove this push rod.
3. Cover opening on cylinder block to prevent dirt from entering the engine.
Fuel Supply Pump Lines
ASupply Pump Inlet from Fuel Tank BSupply Pump Outlet to Final Fuel Filter CCap Screws DPush Rod
Remove Fuel Supply Pump
RG9051
UN16MAR98
4. Inspect face of pump lever for wear. If lever face is worn flat or concave, replace pump.
Fuel Supply Pump Push Rod
OUO1089,00001F8 1906NOV011/1
CTM331 (03OCT05)
02-090-9

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PN=37
RG12022
UN27NOV01
RG11991
Install Fuel Supply Pump

IMPORTANT: Apply LOCTITE 242 to threads of supply pump mounting cap screws (C) and fuel line fittings when reinstalling supply pump. DO NOT allow sealant to get into fuel system.
UN15NOV01
02 090 10
1. Install the fuel supply pump to cylinder block with pumping lever resting on top of push rod, using a new O-ring. Tighten cap screws (C) to specifications.
Specification Fuel Supply Pump Cap Screws Torque ............................................................................. 30 Nm (22 lb-ft)
IMPORTANT: ALWAYS use a backup wrench when installing fittings and/or fuel lines onto supply pump to avoid damage to fittings. 2. Connect supply pump inlet line (A) and outlet line (B) and tighten securely. 3. Bleed fuel system. See BLEED THE FUEL SYSTEM in this group.
Fuel Supply Pump Lines

ASupply Pump Inlet from Fuel Tank BSupply Pump Outlet to Final Fuel Filter CCap Screws
OUO1089,00001FA 1906NOV011/1
Injection Pump Static Timing

Static lock-pin timing is accomplished during installation of the injection pump. See INSTALL INJECTION PUMP later in this group.
OUO1089,00001FB 1906NOV011/1
CTM331 (03OCT05)
02-090-10

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RG11991
Remove Injection Pump

IMPORTANT: Never steam clean or pour cold water on a fuel injection pump while the pump is running or while it is warm. Doing so may cause seizure of internal rotating pump parts. 1. Clean the fuel injection pump, lines and area around the pump with cleaning solvent or a steam cleaner. 2. Rotate engine to TDC of number 1 cylinder compression stroke and install JDG1571 Timing Pin in flywheel. 3. Before removing injection pump from engine, install JDG1559 Injection Pump Timing Pin (A) into pump timing pin bore. 4. Remove injection pump drive gear cover (shown removed). Remove drive gear retaining nut and washer from end of pump shaft. Be careful not to let washer fall inside timing gear cover. 5. Attach JDG1560 Drive Gear Puller to injection pump drive gear (B) using two screws (C). 6. Evenly tighten the two screws (C) and snugly tighten center forcing screw (D) against end of pump shaft. 7. Tighten center forcing screw (D) until pump drive gear is free from tapered shaft. Remove JDG1560 Puller from drive gear.
AJDG1559 Timing Pin BInjection Pump Drive Gear CScrews (2 used) DCenter Forcing Screw
UN21JAN02 UN16NOV01
02 090 11
Stanadyne DE10 Fuel Injection Pump
JDG1559 Injection Pump Timing Pin
Injection Pump Drive Gear Removal
OUO1089,00001FE 1907NOV011/2
CTM331 (03OCT05)
02-090-11

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RG12000
UN21JAN02
RG12036
RG12002

8. Remove temperature sensor connector (A) and fuel control solenoid connector (B). IMPORTANT: ALWAYS use a backup wrench when loosening or tightening fuel delivery lines at fuel injection pump, so that the pump discharge fittings are not altered. This prevents possible internal pump damage.
UN16NOV01
02 090 12
9. Disconnect fuel supply line (D) and return line (C). 10. Remove clamp (E) retaining fuel delivery (pressure) lines (F). 11. Disconnect all fuel delivery lines (F) from injection pump and install protective caps. 12. Remove three injection pump mounting stud nuts (G). Remove injection pump from mounting studs. Place pump on a clean flat surface and inspect shaft OD and drive gear as outlined later in this group. See INSPECT INJECTION PUMP DRIVE GEAR ID AND SHAFT OD later in this group.
ATemperature Sensor Connector BFuel Control Solenoid Connector CFuel Return Line DFuel Supply Line EClamp FFuel Delivery Lines GNut (3 used)
Injector Pump Electrical Connector Removal
Disconnect Fuel Delivery Lines
OUO1089,00001FE 1907NOV012/2
CTM331 (03OCT05)
02-090-12

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RG12003
UN16NOV01
RG12001
Inspect Injection Pump Drive Gear ID and Shaft OD

IMPORTANT: Use a good light source to thoroughly inspect gear ID and shaft OD. 1. Inspect injection pump drive gear ID full 360 for metal transfer as a result of slippage on shaft. 2. Inspect injection pump drive shaft OD full 360 for presence of metal transfer from gear slippage. If there is clear evidence of metal transfer on pump shaft OD or in drive gear ID, injection pump and drive gear MUST BE replaced. IMPORTANT: When replacing injection pump drive gear or installing a new pump, the tapered surfaces of the pump drive shaft OD and drive gear ID MUST BE cleaned to remove protective coatings and oily residue. Use a suitable cleaner that does not leave a residue. Mating surfaces MUST BE ASSEMBLED DRY and LUBRICANTS MUST NOT BE USED.
02 090 13
OUO1089,00001FC 1906NOV011/1
Install Injection Pump

1. Before installing injection pump on engine, install JDG1559 Injection Pump Timing Pin (A) into pump timing pin bore. Install a small punch or screwdriver into hole in pump drive shaft (B) and turn shaft until timing pin drops into recess in injection pump drive shaft.
AJDG1559 Timing Pin BHole in Drive Shaft A
Install Timing Pin
OUO1089,0000204 1908NOV011/3
CTM331 (03OCT05)
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RG12019
UN19NOV01
Electronic Fuel System Repair and Adjustments NOTE: When rotating engine to TDC of compression stroke on number 1 cylinder, turn engine only in direction of rotation to prevent gear backlash. Backlash of gears is enough to throw the injection pump timing off by several degrees, resulting in poor engine performance.
2. Make sure that number 1 cylinder is locked at TDC of compression stroke and install JDG1571 Timing Pin in flywheel.
02 090 14
3. Install injection pump onto mounting studs and tighten three pump mounting stud nuts (A) to specification. Position drive gear while installing pump.
Specification Injection Pump Mounting Stud NutsTorque .................................................................. 25 Nm (19 lb-ft)
Injection Pump Mounting Stud Nuts
4. Install injection pump gear (D) on drive shaft. Install, but do not tighten, injection pump gear mounting nut (C).
NOTE: Hold the injection pump gear while applying torque to prevent the gear from rotating.
5. Rotate gear counterclockwise (viewed from front of engine) to remove any backlash, and tighten gear mounting nut to specification.
Injection Pump Timing Pin
Specification Injection Pump Gear Mounting NutTorque ................................................................ 195 Nm (145 lb-ft)
6. Install injection pump gear access plate and remove timing pin (B) from pump. Install plug in injection pump timing pin hole and tighten to specification.
Specification Injection Pump Timing Pin Plug Torque ........................................................................... 9.5 Nm (7.5 lb-ft)
UN16NOV01
7. Remove JDG1571 Timing Pin from flywheel.

Injection Pump Gear Installation
AInjection Pump Mounting Stud Nut (3 used) BJDG1559 Injection Pump Lock Timing Pin CGear Mounting Nut DPump Gear
OUO1089,0000204 1908NOV012/3
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02-090-14

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PN=42
RG12007
UN16NOV01
RG12004
NOTE: Retain JDG1559 Timing Pin (B) in pump during installation.
UN16NOV01

8. Connect injection pump fuel delivery (pressure) lines (F). Beginning with outlet (I) and continuing around the pump head in counterclockwise direction, attach lines in same order as engine firing (1-5-3-6-2-4 on 6-cylinder engines and 1-3-4-2 on 4-cylinder engines). IMPORTANT: ALWAYS use a backup wrench when loosening or tightening fuel delivery lines at fuel injection pump, so that the pump discharge fittings are not altered. This prevents possible internal pump damage. 9. Tighten fuel delivery lines at pump to specification.
Specification Injection Pump Fuel Delivery (Pressure) LinesTorque ............................................... 27 Nm (20 lb-ft)
02 090 15
Injector Pump Electrical Connectors
10. Install clamp (E). 11. Connect fuel supply line (D) and fuel return line (C). 12. Install temperature sensor connector (A) and fuel control solenoid connector (B). 13. Bleed air from fuel system as outlined in this group. See BLEED THE FUEL SYSTEM in this group. Start engine, run for several minutes and check entire fuel system for leaks.
ATemperature Sensor Connector BFuel Control Solenoid Connector CFuel Return Line DFuel Supply Line EClamp FFuel Delivery Lines GNut (3 used) HEngine Block Side IOutlet Connection to No. 1 Cylinder
Connect Fuel Delivery Lines
OUO1089,0000204 1908NOV013/3
CTM331 (03OCT05)
02-090-15

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RG12035
UN11JAN02
RG12003
UN16NOV01
RG12001
UN16NOV01
Remove Fuel Injection Nozzles

General Nozzle Service Precautions
02 090 16
Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage and getting debris in fuel system. 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.
Fuel Injection Nozzle
OUO1089,00001FF 1907NOV011/4
1. Loosen tube nuts (A) at each nozzle to remove leak-off lines and T-fittings as an assembly.
ATube Nuts
Fuel Leak-Off Lines
OUO1089,00001FF 1907NOV012/4
CTM331 (03OCT05)
02-090-16

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RG11994
UN21DEC05
RG11993
Before removal, thoroughly 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.
UN15NOV01

2. Disconnect fuel injection line from nozzle using a backup wrench on nozzle connection as shown. 3. Remove cap screw securing nozzle in cylinder head nozzle bore.
UN19NOV01
02 090 17
Fuel Injection Line at Nozzle
OUO1089,00001FF 1907NOV013/4
4. Pull injection nozzle out of cylinder head using JDG1515-1 Nozzle Puller (A). IMPORTANT: Do not use screwdrivers, pry bars, or similar tools for this as they might damage the injection nozzle beyond repair.
AJDG1515-1 Nozzle Puller
UN16NOV01
Injection Nozzle Puller Set
OUO1089,00001FF 1907NOV014/4
CTM331 (03OCT05)
02-090-17

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RG12018
RG11999
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 18
Clean Injection Nozzle Bore
RG,35,JW7596 1920NOV971/1
Clean Fuel Injection Nozzles

1. Remove carbon stop 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.
UN15NOV01
RG7743
Clean Fuel Injection Nozzle

ACarbon Stop Seal BUpper Sealing Washer
TEFLON is a registered trademark of the DuPont Co.
OUO1080,00001FD 1915NOV011/1
CTM331 (03OCT05)
02-090-18

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RG11995
Fuel Injection Nozzle Test

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 injury or gangrene may result.
High Pressure Fluid
Use only carefully filtered diesel fuel for testing the injection nozzles, since dirty fuel will severely damage the precision parts of a nozzle.
Fuel Injection Nozzle Test
Connect the nozzle to the tester so that the axis of the nozzle forms an angle of approximately 30 to the vertical and the spray of fuel is directed downwards. Check all connections for leaks. Close the gauge shut-off valve and flush (bleed) the nozzle by operating test pump rapidly.
1Nozzle Tester 2Pressure Line
OUO1089,0000200 1907NOV011/3
CTM331 (03OCT05)
02-090-19

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L30741
UN08AUG89
NOTE: Testing the performance of a nozzle while the engine is running is just a rough test. To obtain a true check of nozzle performance, use a nozzle tester JT25510 (1) and pressure line KJD10109 (2).
X9811
UN23AUG88
02 090 19

Spray Pattern Test Close gauge shut-off valve and operate the pump lever at 60 strokes per minute. If the fuel injection nozzle is working properly, the fuel should issue through all nozzle orifices in a fine, evenly shaped spray cone. This spray cone is inclined from the centerline of the nozzle body, but should be distributed. For a better check, place a piece of paper or cardboard at a suitable distance below the nozzle and check the appearance of the damp circular spots made by the fuel. Deviations from the regular spray pattern or angle may be due to the complete or partial clogging of a nozzle orifice. In this case the fuel issues in a jet rather than in a fine spray. Checking Valve Stem and Guide Wear Connect fuel injection nozzle to the nozzle tester with the tip raised a little higher than its opposite end. Cover the tip and pump the tester to a pressure of 10 300 kPa (103 bar) (1500 psi). Keep the pressure constant and observe how much fuel leaks out of the nozzle return end. After the first drop has formed, count the drops for 30 seconds and compare with specification.
Fuel Injection NozzleSpecification NozzleReturn Leakage at 10 300 kPa (103 bar) (1500 psi) ............. 1 to 14 drops (maximum) within 30 seconds
02 090 20
Checking Valve Seat Connect the nozzle to tester in horizontal position. Operate the pump lever rapidly to bleed the nozzle and allow the valve to seat. Dry the tip of the nozzle thoroughly. Now operate the pump lever slowly until the indicated pressure is approximately 2800 to 3500 kPa (28 to 35 bar) (400 to 500 psi) below opening pressure (see specification for opening pressure). Keep watching the nozzle. Under these conditions the fluid should not drip out of the nozzle tip. However some weeping or light moisture on the tip is considered acceptable. Work the pump lever quickly several times in succession to make the nozzle spray in the normal way. After the last stroke of the pump, observe again. If the nozzle is not quite leakproof, disassemble for servicing.
OUO1089,0000200 1907NOV012/3
CTM331 (03OCT05)
02-090-20

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Opening Pressure Test
NOTE: Absolute opening pressure is less important than equal opening pressure of all nozzles.
Close gauge shut-off valve and actuate the pump several times to allow the nozzle valve to seat properly. Open gauge shut-off valve. Pump the pressure up to the point where the pressure gauge needle falls rapidly. This point (take reading) is the nozzle valve opening pressure.
Fuel Injection NozzleSpecification Rate Shaping NozzleOpening Pressure for Setting (New or Reconditioned)............................................. 24 40024 900 kPa (244249 bar) (35403620 psi) Opening Pressure for Checking (New or Reconditioned).......................... 24 100 kPa (241 bar) (3500 psi) Min Opening Pressure for Setting (Used) ........................................................................ 23 00023 600 kPa (230236 bar) (33403420 psi) Opening Pressure for Checking (Used) ..................................................... 21 800 kPa (218 bar) (3170 psi) Min Rate Shaping NozzleOpening pressure difference between cylinders..................................................... 700 kPa (7 bar) (100 psi) Max 02 090 21
If spray pattern, leakage test, and valve wear test are good but the opening pressure test is unsatisfactory, adjust opening pressure.
OUO1089,0000200 1907NOV013/3
CTM331 (03OCT05)
02-090-21

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PN=49
Disassemble Fuel Injection Nozzles

NOTE: If all tests prove that the nozzle performs properly, no further service is necessary and the nozzle can be reinstalled. If an injection nozzle is not operating properly and must be disassembled for cleaning and/or reconditioning, see your Stanadyne dealer.
AT-Fitting BCap CO-Ring (2 used) DRetainer EProtection Cap FCarbon Stop Seal GSeal Washer HProtection Cap
UN15NOV01
02 090 22
RSN Nozzle Disassembly
OUO1089,0000201 1907NOV011/1
CTM331 (03OCT05)
02-090-22

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PN=50
RG11996
Adjust Fuel Injection Nozzle

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 injury or gangrene may result. 1. Unscrew spring chamber cap (C) using JDG1521 Spring Chamber Cap Wrench. 2. Loosen and remove lift adjusting screw lock nut (D). 3. Loosen pressure adjusting screw lock nut (E) using JDG1515-2 Special Wrench. 4. Connect nozzle to tester, then adjust opening pressure to specifications by turning the pressure adjusting screw (A). Use JDG1522 Pressure Adjusting Screw Tool. 5. Tighten pressure adjusting screw lock nut (E) to specification, then recheck opening pressure. 6. Carefully screw lift adjusting screw (B) until it bottoms on spring seat (F). 7. Unscrew lift adjusting screw with 7/8 turn. 8. Tighten lift adjusting screw lock nut (D) to specification.
UN15NOV01
RSN Nozzle Adjust

APressure Adjusting Screw BLift Adjusting Screw CSpring Chamber Cap DLift Adjusting Screw Lock Nut EPressure Adjusting Screw Lock Nut FSpring Seat
OUO1089,0000202 1907NOV011/2
CTM331 (03OCT05)
02-090-23

012506
PN=51
RG11997
X9811
UN23AUG88
02 090 23

9. Recheck opening pressure.
Fuel Injection NozzleSpecification Pressure Adjusting Screw Lock NutTorque ...................................................................... 10 Nm (7 lb-ft) Lift Adjusting Screw Lock Nut Torque .............................................................................. 5 Nm (3.5 lb-ft)
02 090 24
OUO1089,0000202 1907NOV012/2
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.
RG,35,JW7586 1920NOV971/1
CTM331 (03OCT05)
02-090-24

012506
PN=52
RG9096
UN27MAR98
Install Fuel Injection Nozzles

IMPORTANT: Before installing injection nozzles, make sure nozzles are clean and free from oil or grease.
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.
1. Remove plug (if installed previously) from nozzle bore in cylinder head and blow out bore with compressed air.
UN19NOV01
02 090 25
NOTE: Make sure that the sealing surface of the cylinder head (on which the seal washer will be resting) is smooth and free of damage or dirt. 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.
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 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)
Injection Nozzle in Cylinder Head
6. Install leak-off line assembly.

Specification Fuel Leak-Off Line Hex Nut Torque .............................................................................. 5 Nm (3.7 lb-ft) (44 lb-in.)
OUO1080,0000200 1916NOV011/2
CTM331 (03OCT05)
02-090-25

012506
PN=53
RG11998

7. Bleed air from loose injection line connection. Tighten connection using two wrenches to the following specifications.
02 090 26 Specification Fuel Injection Nozzle Delivery LineTorque ................................................................... 27 Nm (20 lb-ft)
See BLEED THE FUEL SYSTEM in this group.
Nozzle Fuel Pressure Line
OUO1080,0000200 1916NOV012/2
Bleed the Fuel System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. The fuel system may be bled at one of several locations. On some engine applications it may be necessary to consult your operators manual and choose the best location for your engine/machine application.
OUO1089,0000203 1907NOV011/5
CTM331 (03OCT05)
02-090-26

012506
PN=54
X9811
UN23AUG88
RG11999
UN19NOV01

1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base.
ABleed Vent Screw
UN25OCT01
02 090 27
Final Fuel Filter Bleed Vent Screw
OUO1089,0000203 1907NOV012/5
2. Operate fuel supply pump prime lever (B) or primer button on fuel filter base (if equipped). 3. Tighten bleed plug securely; continue operating primer until pumping action is not felt. 4. Start engine and check for leaks. If engine will not start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.
BPrimer Lever
UN25OCT01
Fuel Supply Pump Primer Lever
OUO1089,0000203 1907NOV013/5
CTM331 (03OCT05)
02-090-27

012506
PN=55
RG11806
RG11805

At Fuel Injection Pump 1. Loosen fuel return line (A) at fuel injection pump.
02 090 28
Specification Fuel Injection Pump Return LineTorque ................................................................... 27 Nm (20 lb-ft)
Fuel Injection Pump Return Line

AFuel Return Line
OUO1089,0000203 1907NOV014/5
At Fuel Injection Nozzles 1. Place throttle lever in half-throttle position. 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 over with starter motor for 15 seconds (but do not start engine) until fuel without any air bubbles flows out of loosened connection. Retighten connection to specifications.
Specification Fuel Injection Nozzle Delivery LinesTorque ................................................................. 27 Nm (20 lb-ft)
4. Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system. If engine still will not start, see your authorized servicing dealer or engine distributor.
OUO1089,0000203 1907NOV015/5
CTM331 (03OCT05)
02-090-28

012506
PN=56
RG11808
UN25OCT01
RG11807
3. As soon as fuel flow is free from air bubbles, tighten fuel return line to specifications. Primer lever is spring-loaded and will return to normal position.
UN25OCT01
2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped).
Group 110
Electrical Engine Control Repair and Adjustment

Engine Control Unit (ECU)
IMPORTANT: DO NOT pressure wash the Engine Control Unit (ECU). 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.
UN15NOV01
02 110 1
NOTE: For diagnosis and testing of the electronic engine control and sensors, refer to Group 150.
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.
OUO1080,0000201 1916NOV011/1
CTM331 (03OCT05)
02-110-1

012506
PN=57
RG12006
Remove and Install Engine Coolant Temperature Sensor

1. Disconnect engine coolant temperature sensor wiring connector and remove sensor. 2. Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in thermostat housing. Tighten to specifications.
Specification Engine Coolant Temperature SensorTorque .............................................................. 15 Nm (11 lb-ft)
02 110 2
3. Install sensor wiring connector.

Engine Coolant Temperature Sensor
AEngine Coolant Temperature Sensor
OUO1080,0000202 1916NOV011/1
Remove and Install Loss of Coolant Temperature Sensor

1. Disconnect loss of coolant temperature sensor wiring connector and remove sensor. 2. Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in the rear of the cylinder head. Tighten to specifications.
Specification Loss of Coolant Temperature SensorTorque .............................................................. 35 Nm (26 lb-ft)
UN26MAY00
Loss of Coolant Temperature (Rear of Cylinder Head)

ALoss of Coolant Temperature Sensor
RG40854,000014A 1911FEB021/1
CTM331 (03OCT05)
02-110-2

012506
RG10766
PN=58
RG12009
UN16NOV01
Replace Crankshaft Position Sensor

1. Disconnect sensor wiring connector. 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) 02 110 3
UN16NOV01

Crankshaft Position Sensor
ACrankshaft Position Sensor
OUO1080,0000203 1916NOV011/1
Remove and Install Oil Pressure Sensor

1. Disconnect oil pressure sensor wiring connector (shown disconnected) and remove sensor from cylinder block. 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)
UN02DEC99
Oil Pressure Sensor
LOCTITE is a registered trademark of Loctite Corp. TEFLON is a registered trademark of Du Pont Co.
OUO1080,0000204 1916NOV011/1
CTM331 (03OCT05)
02-110-3

012506
PN=59
RG10550
RG12011
Remove and Install Manifold Air Temperature Sensor

1. Disconnect air temperature sensor wiring connector and remove sensor (A) from air intake line. 2. Replace O-ring and install sensor in air intake line. Tighten sensor to specifications.
Specification Manifold Air Temperature SensorTorque ................................................................ 10 Nm (7 lb-ft)
UN16NOV01
02 110 4

Manifold Air Temperature Sensor
AManifold Air Temperature Sensor
OUO1080,00001F5 1909NOV011/1
Remove and Install Fuel Temperature Sensor

1. Disconnect fuel temperature sensor wiring connector and remove sensor (A) from fuel injection pump. 2. Replace O-ring and install sensor into fuel injection pump and tighten to specifications.
UN16NOV01
Specification Fuel Temperature Sensor Torque .............................................................. 1318 Nm (1013 lb-ft)

A Fuel Temperature Sensor
Fuel Temperature Sensor
OUO1080,00001F6 1912NOV011/1
CTM331 (03OCT05)
02-110-4

012506
PN=60
RG12014
RG12013
Remove and Install Fuel Heater

1. Disconnect fuel heater wiring connector and remove heater from filter base.
UN16NOV01
2. Replace O-ring and install fuel heater in primary fuel filter inlet port to specifications.
Specification Fuel HeaterTorque ........................................................... 9 Nm (7 lb-ft)
02 110 5
3. Install heater wiring connector.

Fuel Heater
OUO1080,00001F7 1912NOV011/1
CTM331 (03OCT05)
02-110-5

012506
PN=61
RG12016
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
CTM331 (03OCT05)
02-110-6

012506
PN=62
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.
Using High-Pressure Washer
RG,RG34710,1329 1923OCT971/1
CTM331 (03OCT05)
02-110-7

012506
PN=63
T6642EJ
UN18OCT88
02 110 7
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 8
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
CTM331 (03OCT05)
02-110-8

012506
PN=64
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
IMPORTANT: The seal must fit snug over the cable insulation without a gap between the cable seal and the insulation.
02 110 9
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
CTM331 (03OCT05)
02-110-9

012506
PN=65
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.
02 110 10
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
CTM331 (03OCT05)
02-110-10

012506
PN=66
TS0139
UN02DEC88
TS0130
UN23AUG88
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.
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
CTM331 (03OCT05)
02-110-11

012506
PN=67
RW4218
UN23AUG88
02 110 11
Repair (Pull Type) METRI-PACK Connectors

1. Disconnect the METRI-PACK connector (A) from the ECU.
UN13MAR02 RG12232A UN13MAR02 RG12231A
02 110 12
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.
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
METRI-PACK is a trademark of Delphi Packard Electric Systems

1
Included JT07195B Electrical Repair Kit

CTM331 (03OCT05)
02-110-12

012506
PN=68
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
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.
RG12233A
RG12234A
UN13MAR02
02 110 13
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
CTM331 (03OCT05)
02-110-13

012506
PN=69
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 14
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
CTM331 (03OCT05)
02-110-14

012506
PN=70
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.
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.
02 110 15
AG,OUOD008,299 1906MAR022/3
CTM331 (03OCT05)
02-110-15

012506
PN=71

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 16
AG,OUOD008,299 1906MAR023/3
CTM331 (03OCT05)
02-110-16

012506
PN=72
RW77140A
UN15MAR02
RW77138A
UN15MAR02
RW77139
Repair DEUTSCH Connectors

1. Disconnect the Deutsch connector. Remove the tie bands and tape.
UN07DEC98
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
02 110 17
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 1903NOV991/4
CTM331 (03OCT05)
02-110-17

012506
PN=73
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 18
Included in JDG359 Electrical Repair Kit

AG,OUOD008,304 1903NOV992/4
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 1903NOV993/4
CTM331 (03OCT05)
02-110-18

012506
PN=74
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 19
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 1903NOV994/4
CTM331 (03OCT05)
02-110-19

012506
PN=75
RW77141
UN07DEC98
20. Retape the wires and add the required tie bands to the harness.
TS0135
TS118
Repair AMP Connector
02 110 20
Using AMP Crimping Tool

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
CTM331 (03OCT05)
02-110-20

012506
PN=76
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.
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
02 110 21
DPSG,OUO1004,2867 1906MAR022/2
CTM331 (03OCT05)
02-110-21

012506
PN=77
T112335E
UN15MAR02
02 110 22
CTM331 (03OCT05)
02-110-22

012506
PN=78
Section 03
Theory of Operation
Contents
Page
Group 130Electronic Fuel System Operation About this Group . . . . . . . . . . . . . . . . . . . . . . .03-130-1 Fuel System Operation . . . . . . . . . . . . . . . . . .03-130-2 Fuel Supply Pump Operation . . . . . . . . . . . . .03-130-4 Final Fuel Filter Operation. . . . . . . . . . . . . . . .03-130-5 Fuel Injection Pump Operation . . . . . . . . . . . .03-130-6 Fuel Injection Nozzle Operation. . . . . . . . . . . .03-130-8 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 . . . . . . . . . . . .03-140-3 Electronic Control System Overview . . . . . . . .03-140-4 Measuring Temperature . . . . . . . . . . . . . . . . .03-140-5 Measuring Pressure . . . . . . . . . . . . . . . . . . . .03-140-7 Measuring Throttle Position . . . . . . . . . . . . . . .03-140-8 Measuring Engine Speed . . . . . . . . . . . . . . .03-140-11 Marine Throttle Control Options. . . . . . . . . . .03-140-12 Engine Synchronization Throttle Control . . . .03-140-13 Throttle Control Location Transfer . . . . . . . . .03-140-14 Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . .03-140-15 Water in Fuel (WIF) Sensor. . . . . . . . . . . . . .03-140-15 Engine Control Unit (ECU) . . . . . . . . . . . . . .03-140-17 Controller Area Network (CAN) . . . . . . . . . . .03-140-18 Cruise Control Operation. . . . . . . . . . . . . . . .03-140-19 Intake Air Heater Operation. . . . . . . . . . . . . .03-140-19 Engine Protection . . . . . . . . . . . . . . . . . . . . .03-140-20 Derate Programs. . . . . . . . . . . . . . . . . . . . . .03-140-20 Multiple Torque Curve Selection . . . . . . . . . .03-140-21 Governor Droop Mode Selection . . . . . . . . . .03-140-21 Engine Control Unit (ECU) Self-Diagnosis. . .03-140-22
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Contents
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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 Fuel Supply Pump Operation Final Fuel Filter Operation Fuel Injection Pump Operation Fuel Injection Nozzle Operation
03 130 1
RG40854,000001C 1903DEC011/1
CTM331 (03OCT05)
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012506
PN=81
Fuel System Operation
03 130 2
AFuel Tank BPrefilter CFuel Supply Pump DFinal Fuel Filter
EFuel Injection Pump FOverflow Valve GFuel Injection Nozzle
HFuel Leak-off Line ITank Pressure Fuel JSupply Pump Pressure Fuel
KInjection Pump Pressure Fuel
The fuel supply pump (C) draws fuel from the tank (A) by pressurizing the fuel. Once the fuel is pressurized in the fuel supply pump, it travels through the final fuel filter (D) to the fuel injection pump (E). On some
applications, fuel is routed through a prefilter (B) prior to the fuel supply pump. A water bowl can be included with either the prefilter or final fuel filters. Typically, the water bowl is located at the first filter in the system.
RG40854,000001D 1903DEC011/2
CTM331 (03OCT05)
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PN=82
RG11957
UN21DEC01

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 (G). If there is excess fuel in the injection pump, it is released through an overflow valve (F) and returned to tank through the fuel leak-off line (H). Once the pressure of the fuel inside the injection nozzle (G) overcomes the nozzle valve, fuel is forced
03 130 3
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 routed through the fuel return leak-off line and returns to the fuel tank. On some applications, the fuel goes through a fuel cooler before returning to the fuel tank.
RG40854,000001D 1903DEC012/2
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PN=83
Fuel Supply Pump Operation

The Sofabex fuel supply pump uses an eccentric lobe on the engine camshaft to operate the lever (G) on supply pump to pressurize fuel system. Fuel is drawn by the diaphragm-type pump from the fuel tank into the inlet side (D) of this pump. As the lever (G) rides on the high side of the camshaft lobe, the rod (F) pulls diaphragm (I) down. Suction pressure opens the inlet check valve (C) and fuel is drawn into the pump. As the camshaft lobe rotates to the low side, the return spring (E) forces the diaphragm (I) upward. The resulting fuel pressure closes the inlet check valve (C) and opens the outlet check valve (B), delivering fuel through the outlet (A) to the injection pump. A hand primer lever (H) is provided for manually forcing fuel through the system to bleed air from the fuel filter, lines, etc.
UN17APR98
03 130 4
AFuel Outlet BOutlet Check Valve CInlet Check Valve DFuel Inlet EReturn Spring FRod GLever HHand Primer Lever IDiaphragm
RG40854,0000110 1928SEP051/1
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PN=84
RG9119
Final Fuel Filter Operation

Fuel enters the filter at inlet (C), flows through filter element (D) and exits through outlet (B) to the fuel injection pump. The 5 micron filter element is housed in a sediment bowl attached to the base with a threaded retaining ring. Since water and contaminants settle at the bottom of the sediment bowl, a drain plug (E) is provided. On some options, a water bowl is attached to the bottom of the sediment bowl. Air in the system can be expelled through the air vent when bleed screw (A) is loosened. Optional priming pump (F) draws fuel from the fuel tank to fill the filter bowl when the filter element is changed. The priming pump also supplies fuel from the filter to the injection pump.
ABleed Screw BFuel Outlet CFuel Inlet DFilter Element EDrain Plug FPrimer Pump
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RG40854,0000111 1916JAN021/1
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RG9090
UN27MAR98
Fuel Injection Pump Operation
03 130 6
AFuel Inlet Fitting BHeavy Duty Driveshaft CTransfer Pump
DCam Ring EDischarge Fitting FFuel Control Solenoid
GPump Control Valve HDistributor Rotor IFuel Temperature Sensor
JFuel Return Fitting/Housing Pressure Regulator
NOTE: The above illustration has been reprinted with permission from Stanadyne Automotive Corporation.
The main components of the Stanadyne DE10 fuel injection pump are the driveshaft (B), the transfer pump (C), cam ring (D) and shoes, distributor rotor (H), pump control valve (G), and fuel control solenoid (F). The crankshaft of the engine drives the driveshaft of the pump using gears between the two components. The rotation of the driveshaft moves the transfer pump, cam shoes and rollers, and distributor shaft since all of these components are engaged. The fuel transfer pump (inside the injection pump) draws fuel from the final filter through the fuel inlet fitting (A). With each revolution, it pressurizes fuel between 01100 kPa (011 bar) (0160 psi) depending on the rotational speed of the pump. Once
the fuel has been pressurized by the transfer pump, it can travel to three locations: inside the plungers of the cam ring (D), into the injection pump housing cavities, and recirculated back to the fuel inlet passage. When the pump control valve is open, it allows the transfer pump pressurized fuel to enter the high pressure chamber. The Engine Control Unit (ECU) energizes the fuel control solenoid which causes the pump control valve to close. When the pump control valve is closed, the plungers in the high pressure chamber create injection pressure because they are forced inward by the rotation of the cam ring. High pressure fuel is forced through the discharge fittings to the injection nozzles. When the fuel control solenoid is de-energized, the pump control valve opens. The fuel in the high pressure chamber is spilled out of the high pressure chamber into the transfer pump fuel.
RG40854,0000112 1916JAN021/2
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PN=86
RG11958
UN20DEC01

Some of the transfer pump pressure fuel is released through a port that contains a vent wire into injection pump housing cavities. The purpose of housing pressure fuel is to keep the injection pump components cooled and lubricated. The amount of fuel that is released into the housing is determined by the size of the vent wire. The pressure of the housing is controlled by the fuel return fitting/pressure regulator (J). If the pressure exceeds the regulator, it will return fuel to the fuel tank. The ECU monitors the fuel temperature of the housing through a fuel temperature sensor (I). For more information on the fuel temperature sensor, see MEASURING TEMPERATURE in Group 140 of this Section. The remaining transfer pump pressure fuel travels through a transfer pump regulating valve. This allows for fuel to return to injection pump inlet pressure. It circulates the fuel back through the transfer pump.
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RG40854,0000112 1916JAN022/2
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PN=87
Fuel Injection Nozzle Operation

The nozzle spray tip (A) forms an integral unit with nozzle body (D) from which it cannot be separated. The injection nozzle is secured in the cylinder head by three superimposed spring clamps which press on a location clamp and a cap screw. The contact pressure is limited by a spacer ring. The nozzle is sealed in the cylinder head at its lower end with a carbon stop seal (B). The top end is sealed with seal washer (D). Clamp (P) ensures correct position of the complete fuel injection nozzle in the cylinder head. The leak-off line is connected by T-fitting (M), which is fitted on the nozzle body and secured a cap with O-ring seal (T). The fuel injection nozzle works basically in the same way as a normal spray type nozzle. Its opening pressure is adjusted by the pressure adjusting screw (O). The lift of nozzle valve (C) is adjusted by screw (K) located in pressure adjusting screw.
UN12FEB02
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The carbon stop seal (B) prevents carbon from collecting around nozzle in cylinder head. The fuel injection nozzles have four orifices.
ASpray tip BCarbon stop seal CNozzle valve DNozzle body ESeal washer FConnection for injection line GNozzle valve guide HUnion nut ISpring seat JAdjustable pressure spring KLift adjusting screw LLock nut for pressure adjusting screw MT-fitting NLock nut for lift adjusting screw OPressure adjusting screw PLocation clamp QNipple RFilter screen SFuel pressure line TCap
RG40854,0000020 1903DEC011/1
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RG11959
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 Measuring Temperature ECT (Engine Coolant Temperature) Sensor MAT (Manifold Air Temperature) Sensor Loss of Coolant Temperature Sensor Fuel Temperature Sensor Measuring Pressure Oil Pressure Sensor Measuring Throttle Position Measuring Engine Speed Crank Position Sensor Marine Throttle Control Options Engine Synchronization Throttle Control Throttle Control Location Control Pump Solenoid Water in Fuel (WIF) Sensor Engine Control Unit (ECU) Controller Area Network (CAN) Cruise Control Operation Intake Air Heater Operation Engine Protection Derate Programs Multiple Torque Curves Selection Governor Droop Mode Selection Engine Control Unit (ECU) Self Diagnosis
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RG40854,0000021 1904OCT051/1
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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. 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. 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. 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. 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
DTC 03 140 2
Digital ECT
ECU
FMI
J1587/J1708
MAT
PROM
PWM
RAM
SAE
Sensor SPN
VBAT VSW
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Engine Starting Mode When the key is turned to the ON position, a switched power voltage is sent to the Engine 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, the ECU monitors information from the various sensors, then determines the optimum amount of fuel to inject and the optimum injection timing in order to allow the engine to develop high power while maintaining low exhaust emission output. The ECU controls fuel delivery by energizing and de-engergizing the pump control valve solenoid. When the ECU energizes the solenoid, the pump control valve closes and injection begins. When the correct amount of fuel has been injected, the ECU de-energizes the solenoid, causing the pump control valve 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 move the pump control valve to the pressure position, which will allow injection pressure to be developed. The fuel is delivered to all of the cylinders. To provide cold temperature enrichment, the amount of fuel injected is based on the temperature measured by
03 140 3
RG40854,0000022 1903DEC011/1
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) Loss of Coolant Temperature Manifold Air Temperature (MAT) Oil Pressure Fuel Temperature Throttle Position Crankshaft Position Sensor
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Electronic Control System Overview
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AOil Pressure Sensor BPump Control Solenoid CEngine Control Unit (ECU)
DCrank Position Sensor EFuel Temperature Sensor FECT Sensor
GManifold Air Temperature (MAT) Sensor
HLoss of Coolant Temperature Sensor
NOTE: Some of the components shown are optional and not used on all applications.
The electronic control system serves as an engine governor by controlling the pump control valve through a solenoid so that fuel is delivered according to a given set of engine conditions, in precise amounts, and at a precise time in relation to piston position. In order
to achieve this, the engine control system performs the following functions: Constantly monitors engine operating conditions Delivery an optimum amount of fuel for operating conditions Provides multiple control modes Performs self-diagnosis
RG40854,0000024 1903DEC011/1
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Measuring Temperature
The Engine Coolant Temperature (ECT) sensor, Loss of Coolant Temperature sensor, Manifold Air Temperature (MAT) sensor, and Fuel Temperature 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
03 140 5
RG40854,0000025 1903DEC011/5
Engine Coolant Temperature (ECT) Sensor On most applications, the Engine Coolant Temperature (ECT) sensor is located in the thermostat housing (A). On other applications, it may be located at the rear of the cylinder head. 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.
UN29JAN02
AECT Sensor
RG40854,0000025 1903DEC012/5
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Loss of Coolant Temperature Sensor The Loss of Coolant Temperature sensor is located in the rear of the cylinder head (A) on some applications using this engine. The ECU monitors loss of 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.
ALoss of Coolant Temperature Sensor
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RG40854,0000025 1903DEC013/5
Manifold Air Temperature (MAT) Sensor The Manifold Air Temperature (MAT) sensor is located in the cross over tube (A) or in the intake manifold. The MAT sensor measures intake air temperature to help the ECU calculate the correct fueling and for cold starting. 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.
AMAT Sensor
RG10766
RG40854,0000025 1903DEC014/5
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RG11964
UN29JAN02

Fuel Temperature Sensor The fuel temperature sensor (A) is located on top of the injection pump. It measures the temperature of the fuel in the injection pump that is going through the overflow valve. The temperature is used to help the ECU to calculate the correct amount of fueling rENGINE PROTECTION or DERATE PROGRAMS laster in this Group.
AFuel Temperature Sensor
UN29JAN02
RG40854,0000025 1903DEC015/5
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.
RG40854,0000027 1903DEC011/2
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RG12827
UN30JAN03
RG11962
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PN=95

Oil Pressure Sensor The oil pressure sensor is an optional sensor located in the main engine galley (A). 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.
AOil Pressure Sensor 03 140 8
RG40854,0000027 1903DEC012/2
Measuring Throttle Position

The 4.5L & 6.8L engines have the option of operating with an analog throttle position sensor output signal, multi-state throttle, or a CAN throttle. On some applications, multiple throttles are used.
RG40854,0000031 1905DEC011/7
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 volts 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
RG40854,0000031 1905DEC012/7
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RG11820
UN15JAN03
RG11961
UN29JAN02
PN=96

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
RG12348
1906MAY02
03 140 9
RG40854,0000031 1905DEC013/7
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
RG40854,0000031 1905DEC014/7
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1926APR02
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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 application. 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.
03 140 10
Tri-State Throttle
RG40854,0000031 1905DEC015/7
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.
Ramp Throttle
RG40854,0000031 1905DEC016/7
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1926APR02
RG12285
1926APR02
PN=98

CAN Throttle CAN throttle is information sent to the ECU by another controller over the CAN bus of the desired throttle position.
1906MAY02 RG12349
CAN Throttle Schematic
03 140 11
RG40854,0000031 1905DEC017/7
Measuring Engine Speed

Crank Position Sensor The crank position sensor operates by detecting notches on their respective timing wheels. When a notch on the timing wheel is directly under the sensor, a voltage signal is induced. The ECU monitors this voltage signal to determine the position of the timing wheel. The sensor is located on the front of the crankshaft, behind the pressed-on crank gear. The crank position sensor (A) is located on the front of the crankshaft. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The ECU uses the crank position input to determine engine speed.
ACrank Position Sensor
RG40854,0000028 1903DEC011/1
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RG11965
UN29JAN02
PN=99
Marine Throttle Control Options
03 140 12
Dual Throttle Wiring Harness

AWheelhouse Throttle Input BWheelhouse Station Select Input CExternal Shutdown Connection DStarter Cutout Relay E23-Pin Connector F21-Pin Connector GAuxiliary Station Select Input HAuxiliary Station Select Adapter IAuxiliary Throttle Adapter JAuxiliary Throttle Input KEngine Synchronized Output LEngine Synchronized Input MBattery, Ground, Switched Power, and Start (to Instrument Panel) NCAN Connection (to Instrument Panel)
The 4.5 and 6.8 marine engines have two, dual-throttle options: 1. Dual throttles with transfer of control location, and 2. Engine synchronization control. To operate either option requires a variation of the marine transition harness (shown above). Which
harness variation depends on whether one or the other, or both options were purchased. Both options cannot be operated simultaneously. Descriptions of operation of each option follow.
DB92450,0000036 1928SEP051/1
CTM331 (03OCT05)
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RG14542
UN01NOV05
Engine Synchronization Throttle Control
03 140 13
Engine Synchronization Throttle Control Schematic
Two marine engines, having separate ECUs, are configured such that their speeds can be matched, one to the other. The ECU of either engine may be designated as lead ECU through the Trim Options page. IMPORTANT: Both ECUs must not be programmed to be lead, nor both ECUs programmed to be follower. Synchronized engine operation is enabled when the Synchronize Enable Switch of the Follower ECU (A) is closed. This provides the path for system voltage (switched) (A2) to command follower ECU to enable synchronized engine operation (C2). Once the operation is enabled, ECUs provide potential (G2) and ground (A2) for Synchronize Enable lights, which come on, and remain on. Follower engine ECU tachometer output is disabled. It no longer responds to its throttle. It continuously receives lead-engine (B) tachometer output (E3), which it uses to cause the follower engine to match the speed of the lead engine.
In order to achieve and maintain synchronous engine speed operation: Both engine speeds must be within 100 rpm, or less, of each other. Individual throttle command values must be within 5% of each other. Both engine speed signal values must be 975 rpm, or more. When attempting Synchronous engine operation, if one or more of the above conditions are not met, Synchronize Enable lights continuously flash on and off, until the failing condition(s) has (have) been corrected. Synchronize Enable lights test occurs at key ON lights briefly come on. For this test to happen, ignition key must have been OFF for at least thirty seconds, prior to turning it back on
DB92450,0000033 1928SEP051/1
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RG14460
UN28SEP05
PN=101
Throttle Control Location Transfer
Throttle Control Location Transfer Schematic
This feature allows throttle control from one of two locations, the wheelhouse or a second (auxiliary) station. When the ECU is initialized at key ON, throttle control defaults to the station selected via the trim options page during the last ECU programming. To change throttle control location during engine operation, the station select pushbutton switch at the requesting throttle is held engaged until that stations lamp is continuously lit, indicating that throttle control transfer has been successful. At this point, the switch can be released without interrupting throttle control at that station. In the case depicted in the above figure, Throttle Transfer Switch at the auxiliary throttle control station has been pushed ON. This connects Auxiliary Throttle Input (B3) to Auxiliary Throttle Transfer Switch Input (H1), informing ECU (A) of the transfer initiation. ECU provides Auxiliary Throttle Lamp Drive potential (G2) through the lamp to power ground (J2), causing it to light. ECU simultaneously stops Wheelhouse Throttle Lamp Drive potential (J1), causing the wheelhouse throttle control lamp to go out. Throttle control is now at the auxiliary location, and no longer at the wheelhouse location, from Wheelhouse Throttle Input (E1) to Wheelhouse Throttle Transfer Switch Input (H2).
For transfer of throttle control to be successful, the position of the requested throttle must be within 2% of the active throttle position. If the requesting throttle is not within the required 2%, upon initiation attempt of control transfer, the lamp flashes on and off. If the station select pushbutton switch is held engaged and the operator moves the requesting throttle to within the required 2%, transfer will occur, The lamp will go from flashing to solid, and the switch at the requesting throttle can be released. If the requesting throttle position is outside normal operating range (that is, out of normal signal range: 0-0.5 volts low and 4.5-5.0 volts high), its lamp momentarily lights, then shuts off and remains off. If the switch contacts of both throttles are simultaneously closed, the ECU selects the highest priority location, which has been designated during ECU programming. At key ON, a test of the lamps at both throttle stations will occur. Any lamp that does not come on during this test is bad, and should be replaced. For this test to happen, ignition key must have been OFF for at least thirty seconds. Normal throttle operating voltage is from 0.5 to 4.5 volts.
DB92450,0000034 1904OCT051/1
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RG14461
UN28SEP05
03 140 14
PN=102
Pump Solenoid
Located on the end of the injection pump, the pump solenoid (A) controls the movement of the pump control valve. This controls the quantity of fuel delivered to the engine. When the Engine Control Unit (ECU) supplies no current to the solenoid, the valve does not move. Thus, the injection pump delivers no fuel. When the ECU supplies current to the solenoid, the pump control valve closes off the high injection chamber, which allows the fuel in the chamber to reach injection pressure. The quantity of fuel is determined by various sensors in the control system and messages sent to the ECU.
RG11966
UN29JAN02
03 140 15
APump Solenoid Connector
RG40854,0000115 1924JAN021/1
Water in Fuel (WIF) Sensor

Two-Wire Sensor
RG41183,00000E0 1904OCT051/3
The water in fuel sensor consists of two electrodes (A) in the bottom of the bowl of the final fuel filter and a 200-kilohm resistor, in parallel with the electrodes. Diesel fuel is a very poor conductor of electricity, compared to water, and while only fuel is present in the bowl, virtually all current passes through the resistor. This causes ECU (E) to sense only a nominal, constant current demand. But when water (D) displaces fuel at the bottom of the bowl, Beyond the electrode insulators (B) resistance across the electrodes becomes significantly less than across the resistor, and additional current passes from D3, WIF signal supply, through the water across the electrodes (C) to F2, WIF circuit return. This causes ECU to detect a greater current demand, which derates or shuts down the engine. For more information on engine protection and derate programs, see ENGINE PROTECTION or DERATE PROGRAMS later in this Group.
Two-Wire WIF Sensor Schematic
RG41183,00000E0 1904OCT052/3
CTM331 (03OCT05)
03-140-15

012506
RG14498
UN28SEP05
PN=103

Three-Wire Sensor (Marine Only) With no water in the bowl at the bottom of the filter canister, the WIF circuit switch (internal to the ECU) pulls the circuit to +5 volts. When water is in the bowl, WIF sensor causes the WIF circuit to pull to ground, setting DTC 97.00, and engine operation to derate or shut down. For more information on engine protection and derate programs, see ENGINE PROTECTION or DERATE PROGRAMS later in this Group.
03 140 16
Three-Wire WIF Sensor Schematic
RG41183,00000E0 1904OCT053/3
CTM331 (03OCT05)
03-140-16

012506
RG14499
UN28SEP05
PN=104
A1 A2 A3
B1 B2 B3
C1 C2 C3 D1 D2 D3
E1 E2 E3
F1 F2 F3 G1 G2 G3
H1 H2 H3 J1 J2 J3 K1 K2 K3
03 140 17
ECU Connector
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 timing based on information from various sensors Limits maximum fuel for operation on multiple power curves Controls pump control valve solenoid for desired fuel delivery Provides all-speed governing Performs self diagnosis on the control system Stores trouble codes in memory
The ECU is composed of the following subsystems: Analog/Digital Converters This portion of the ECU converts the analog voltage signals from the various sensors into digital signals that the central processing unit can understand. 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 controls the pump control solenoid for desired fuel quantity and timing. It also controls the self diagnostic system.
RG40854,0000029 1903DEC011/2
CTM331 (03OCT05)
03-140-17

012506
RG11967
1919DEC01
PN=105

Memory The ECU contains 3 different types of memory: Random Access Memory - RAM The RAM is like the working desk top of the ECU. Data from the various sensors and the results of various calculations are temporarily stored in RAM. Information in RAM is lost when battery voltage to the ECU is removed. Read Only Memory - ROM 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 ROM contains programmed information. Information in ROM can only be read, not changed. ROM information is retained when battery voltage is removed.
03 140 18
RG40854,0000029 1903DEC012/2
Controller Area Network (CAN)

Controller Area Network (CAN) is used to allow communication between other controllers on the engine or vehicle and for connecting to diagnostic software. 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. This information includes part numbers, serial numbers, engine speed, fan speed, etc. The engine also uses CAN to talk to other vehicle controllers. Depending on the application, various information such as throttle position, derate requests, shutdown requests, and diagnostic trouble codes are communicated over this network. CAN also allows diagnostic software like and SERVICE ADVISOR to communicate with our engine controller. All of the information viewed through the software is transferred via the CAN Bus.
SERVICE ADVISOR is a trademark of Deere & Company
RG40854,000002A 1903DEC011/1
CTM331 (03OCT05)
03-140-18

012506
PN=106
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.
03 140 19
RG40854,000002B 1903DEC011/1
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.
RG40854,000002C 1903DEC011/1
CTM331 (03OCT05)
03-140-19

012506
PN=107
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. Shutdown Override Feature
03 140 20
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. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for engine protection features on different sensors on your application.
RG40854,000002D 1904DEC011/1
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 of this manual for sensor derate specifications on your application.
RG40854,000002F 1904DEC011/1
CTM331 (03OCT05)
03-140-20

012506
PN=108
Multiple Torque Curve Selection

The ECU has the ability to limit the maximum fuel quantity such that multiple torque curves can be individually selected while the engine is running. The 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 06, Group 210 of this manual and refer to the corresponding torque curve selection for your application.
03 140 21
RG40854,000002E 1904DEC011/1
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 06, Group 210 of this manual and refer to the corresponding governor droop mode for your application.
RG40854,0000030 1904DEC011/1
CTM331 (03OCT05)
03-140-21

012506
RG8552
1918SEP98
PN=109
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.
03 140 22
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.
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 12 Engine Control Unit (ECU), the ECU transmits SPN/FMI codes over the Controller Area Network (CAN). This allows for service tools such as SERVICE ADVISOR and the Diagnostic Gauge to display active and stored DTCs. When using SERVICE ADVISOR the codes will be displayed in a 000000.00 format. For example, SPN 110 FMI 3 will be displayed as 000110.03. OTHER CODES If codes are not displayed as SPN/FMI or as 2-digit codes, there may be another format that the application is using. For example on some applications, the code F455 is displayed for engine coolant temperature input voltage high. This may be seen on some applications within SERVICE ADVISOR. In this manual, it is necessary to convert this format of code into an SPN/FMI code to ensure that the correct diagnostic procedure is followed. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU WARNING LAMP
NOTE: If 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.
There are several different methods of displaying both stored and active DTCs from the ECU. SPN/FMI CODES
SERVICE ADVISOR is a trademark of Deere & Company SERVICE ADVISOR
RG,RG34710,1540 1930SEP971/2
CTM331 (03OCT05)
03-140-22

012506
PN=110

On some applications, there is a warning lamp that is used when a code becomes active. Typically, a solid light indicates that the ECU is taking extreme measures to protect the engine, and a blinking light indicates that the ECU has detected a fault and engine performance may be affected. Refer to Operators Manual for a given application for more detailed information. CLEARING STORED DTCS Stored DTCs can be cleared through 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.
RG,RG34710,1540 1930SEP972/2
03 140 23
CTM331 (03OCT05)
03-140-23

012506
PN=111
03 140 24
CTM331 (03OCT05)
03-140-24

012506
PN=112
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 . . . . . . .04-150-8 E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure. . . . . . . . . . . . . . . . . .04-150-8 E3 - Engine Does Not Develop Full Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-14 E3 - Engine Does Not Develop Full Power Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-14 E4 - Engine Emits Excessive White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-19 E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure . . . .04-150-19 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 E9 - Analog Throttle (B) Does Not Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-29 F1 - Fuel Supply System Check Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-29 F2 - Excessive Fuel Consumption . . . . . . . . .04-150-32 F3 - Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . .04-150-32 F5 - Fuel Injection Nozzle Check . . . . . . . . .04-150-33 D1 - ECU Does Not Communicate with the DST or SERVICE ADVISOR . . . . . . . .04-150-36 D1 - ECU Does Not Communicate With the DST orSERVICE ADVISOR . . . . . . .04-150-37 D1 - ECU Does Not Communicate with the DST or SERVICE ADVISOR Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-37 D2 - Diagnostic Gauge Does Not Communicate With ECU . . . . . . . . . . . . . .04-150-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-41 D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-41 A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-46 A1 - Intake Air Heater Check - Continued . . .04-150-47 CTM331 (03OCT05)
A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-48 A1 - Intake Air Heater Check Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-48 Check Fuel Supply Quality . . . . . . . . . . . . . .04-150-50 Test for Fuel Drain Back . . . . . . . . . . . . . . . .04-150-51 Test for Air in Fuel . . . . . . . . . . . . . . . . . . . .04-150-52 Check Fuel Supply Pressure . . . . . . . . . . . . .04-150-53 Bench Test Fuel Supply Pump . . . . . . . . . . .04-150-54 Bleed the Fuel System . . . . . . . . . . . . . . . . .04-150-56 Test for Cylinder Misfire (Engine Running) . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-59 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 Engine Configuration Data Parameters on Diagnostic Gauge . . . . . . . . . . . . . . . . . . .04-160-10 Viewing Active DTCs on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12 Viewing Stored DTCs on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12 Clearing Stored DTCs on Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13 Blinking DTCs . . . . . . . . . . . . . . . . . . . . . . . .04-160-14 Data Parameter Description . . . . . . . . . . . . .04-160-16 Engine Test Instructions - Excavator Torque Curve Change Test . . . . . . . . . . . .04-160-19 Reprogramming Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-19 Diagnostic Trouble Codes (DTCs) . . . . . . . . .04-160-20 Listing of Diagnostic Trouble Codes (DTCs) on ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22 Diagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-26 Intermittent Fault Diagnostics . . . . . . . . . . . .04-160-27 T1 - Multi-state Throttle Input High . . . . . . . .04-160-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-29 T1 - Multi-State Throttle Input High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-29 T2 - Multi-state Throttle Input Low. . . . . . . . .04-160-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
04
04-1

012506
PN=1
Contents
Page
Page
04
T2 - Multi-State Throttle Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-33 T3 - Analog Throttle (A) Input High . . . . . . . .04-160-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-37 T3 - Analog Throttle (A) Input High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-37 T4 - Analog Throttle (A) Input Low . . . . . . . .04-160-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-41 T4 - Analog Throttle (A) Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-41 T5 - Analog Throttle (B) Input High . . . . . . . .04-160-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-45 T5 - Analog Throttle (B) Input High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-45 T6 - Analog Throttle (B) Input Low . . . . . . . .04-160-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-49 T6 - Analog Throttle (B) Input Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-49 T7 - CAN Throttle Invalid. . . . . . . . . . . . . . . .04-160-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-53 T7 - CAN Throttle Invalid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-53 T11 - Excavator Throttle Reference Voltage High . . . . . . . . . . . . . . . . . . . . . . .04-160-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-57 T11 - Excavator Throttle Reference Voltage High Diagnostic Procedure . . . . . .04-160-57 T12 - Excavator Throttle Reference Voltage Low. . . . . . . . . . . . . . . . . . . . . . . .04-160-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-61 T12 - Excavator Throttle Reference Voltage Low Diagnostic Procedure . . . . . .04-160-61 T13 - Excavator Throttle Ground Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-65 T13 - Excavator Throttle Ground Voltage High Diagnostic Procedure . . . . . . . . . . . .04-160-65 T14 - Excavator Throttle Ground Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-69 T14 - Excavator Throttle Ground Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-69 T15 - Excavator Throttle Input Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-72 T15 - Excavator Throttle Input Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-73 T16 - Excavator Throttle Input Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-77 T16 - Excavator Throttle Input Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-77 T17 - Analog Throttle (C) Input High . . . . . . .04-160-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-81 CTM331 (03OCT05)
T17 - Analog Throttle (C) Input High Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-81 T18 - Analog Throttle (C) Input Low . . . . . . .04-160-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-85 T18 - Analog Throttle (C) Input Low Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-85 T19 - Throttle Not Calibrated Properly. . . . . .04-160-87 T20 - Throttle Input Voltage Below Lower Calibration Limit . . . . . . . . . . . . . . . . . . . . .04-160-88 T21 - Throttle Calibration Aborted . . . . . . . . .04-160-89 T22 - Analog Throttle (A) Input Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90 T23 - Multi-state Throttle Input Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91 000028.03 Throttle Voltage High . . . . . . .04-160-92 000028.04 Throttle Voltage Low . . . . . . . .04-160-92 000029.03 Throttle Voltage High . . . . . . .04-160-93 000029.04 Throttle Voltage Low . . . . . . . .04-160-94 000029.14 Throttle Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94 000084.31 Vehicle Speed Mismatch. . . . .04-160-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-97 000084.31 Vehicle Speed Mismatch Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-97 000091.03 Throttle Voltage High . . . . . . .04-160-99 000091.04 Throttle Voltage Low . . . . . . .04-160-100 000091.07 Throttle Calibration Invalid. . .04-160-100 000091.10 Throttle Voltage Low . . . . . . .04-160-101 000091.13 Throttle Calibration Aborted . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-101 000091.14 Throttle Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102 000097.00 Water in Fuel Continuously Detected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-104 Water in Fuel Continuously Detected Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-104 000097.03 Water in Fuel Signal Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-107 000097.03 Water In Fuel Signal Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-107 000097.04 Water in Fuel Signal Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-111 000097.04 Water In Fuel Signal Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-111 000097.16 Water in Fuel Detected . . . . .04-160-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-115 000097.16 Water In Fuel Detected Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-115
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000097.31 Water in Fuel Detected (750J Crawler Only). . . . . . . . . . . . . . . . . . . . . .04-160-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-117 Water in Fuel Detected (750J Crawler Only) Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-117 000100.01 Engine Oil Pressure Extremely Low . . . . . . . . . . . . . . . . . . . . .04-160-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-122 000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure . . . . . . . . . . . .04-160-122 000100.03 Engine Oil Pressure Input Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-125 000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure . . . . .04-160-125 000100.04 Engine Oil Pressure Input Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-130 000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure . . . . .04-160-130 000100.16 - Engine Oil Pressure High, Moderately Severe Level . . . . . . . . . . . . .04-160-134 000100.16 Engine Oil Pressure High, Moderately Severe Level Incorrect Reading Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-134 Electrical Test . . . . . . . . . . . . . . . . . . . . . . .04-160-135 000100.18 Engine Oil Pressure Moderately Low . . . . . . . . . . . . . . . . . . . .04-160-136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-137 000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure . . .04-160-137 000105.03 Manifold Air Temperature Input Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-139 000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure . . . . .04-160-139 000105.04 Manifold Air Temperature Input Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-143 000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure . . . . .04-160-143 000105.16 Manifold Air Temperature Moderately High. . . . . . . . . . . . . . . . . . . .04-160-146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-147 000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-147 000110.00 Engine Coolant Temperature Extremely High . . . . . . . . . . . . . . . . . . . .04-160-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-149 000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure . . .04-160-149 CTM331 (03OCT05)
000110.03 Engine Coolant Temperature Input Voltage High . . . . . . .04-160-150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-151 000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-151 000110.04 Engine Coolant Temperature Input Voltage Low . . . . . . . .04-160-154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-155 000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-155 000110.15 Engine Coolant Temperature High Least Severe . . . . . . .04-160-158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-159 000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-159 000110.16 Engine Coolant Temperature Moderately High. . . . . . . . . . . . . . . . . . . .04-160-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-161 000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-161 000111.00 Loss of Coolant Temperature Extremely High . . . . . . . . . . . . . . . . . . . .04-160-162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-163 000111.00 Loss of Coolant Temperature Extremely High Diagnostic Procedure . . .04-160-163 000111.03 Loss of Coolant Temperature Input Voltage High . . . . . . .04-160-166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-167 000111.03 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-167 000111.04 Loss of Coolant Temperature Input Voltage Low . . . . . . . .04-160-170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-171 000111.04 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-171 000158.17 ECU Power Down Error . . . .04-160-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-175 000158.17 ECU Power Down Error Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-175 000160.02 Wheel Speed Input Noise . . .04-160-178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-179 000160.02 Wheel Speed Input Noise Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-179
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000171.03 Ambient Air Temperature Input Voltage Out Of Range High (750J Crawlers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-182 000171.03 AAT Input Voltage Out Of Range High Diagnostic Procedure (750J Crawlers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-182 000171.04 Ambient Air Temperature Input Voltage Out Of Range Low (750J Crawlers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-186 000171.04 Ambient Air Temperature Input Voltage Out Of Range Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-186 000174.03 Fuel Temperature Input Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-189 000174.03 Fuel Temperature Input Voltage High Diagnostic Procedure . . . . .04-160-189 000174.04 Fuel Temperature Input Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-193 000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedure . . . . .04-160-193 000174.16 Fuel Temperature High Moderately Severe. . . . . . . . . . . . . . . . . .04-160-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-197 000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-197 000189.00 Engine Speed Derate . . . . . .04-160-199 000190.00 Engine Overspeed Extreme . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-200 000190.01 Engine Speed Below Normal Operational Range, Most Severe Level (OEM Marine Only) . . . . . . . . . . . . . . . . .04-160-201 000190.01 Engine Speed Below Normal Operational Range, Most Severe Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-202 000190.01 Engine Speed Below Normal Operational Range, Most Severe Level Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-202 000190.16 Engine Overspeed Moderate . . . . . . . . . . . . . . . . . . . . . . . . .04-160-204 000190.18 Engine Speed Below Normal Operational Range, Moderately Severe Level (OEM Marine Only) . . . . . . . . . . . .04-160-205 000523.09 Current Gear Selection Invalid or Not Received (J-series Loaders Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-206 000620.03 Sensor Supply Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-209 CTM331 (03OCT05)
000620.03 Sensor Supply Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-209 000620.04 Sensor Supply Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-213 000620.04 Sensor Supply Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-213 000629.13 ECU Error . . . . . . . . . . . . . . .04-160-216 000629.13 ECU Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-216 000637.02 Crank Position Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-219 000637.02 Crank Position Input Noise Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-219 000637.10 Crank Position Input Pattern Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-223 000637.10 Crank Position Input Pattern Error Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-223 000639.13 CAN Bus Error . . . . . . . . . . .04-160-226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-227 000639.13 CAN Bus Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-227 000644.02 External Speed Command Input (OEM, Marine Only) . . . . . . . . . . . .04-160-229 000729.03 Inlet Air Heater Signal High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-231 000729.03 Inlet Air Heater Signal High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-231 000729.05 Inlet Air Heater Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-235 000729.05 Inlet Air Heater Signal Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-235 000898.09 Vehicle Speed or Torque Message Invalid. . . . . . . . . . . . . . . . . . . .04-160-237 000970.31 Auxiliary Engine Shutdown Switch Active . . . . . . . . . . . . . . . . . . . . . .04-160-238 000971.31 External Engine Derate Switch Active . . . . . . . . . . . . . . . . . . . . . .04-160-239 001069.09 Tire Size Invalid . . . . . . . . . .04-160-240 001069.09 Tire Size Invalid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-241 001069.31 Tire Size Error. . . . . . . . . . . .04-160-244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-245 001069.31 Tire Size Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-245 001076.00 Pump Control Valve Closure Too Long . . . . . . . . . . . . . . . . . . . . . . . . .04-160-246
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-247 001076.00 Pump Control Valve Closure Too Long Diagnostic Procedure. . . . . . . .04-160-247 001076.01 Pump Control Valve Closure Too Short. . . . . . . . . . . . . . . . . . . . . . . . .04-160-250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-251 001076.01 Pump Control Valve Closure Too Short Diagnostic Procedure . . . . . . .04-160-251 001076.03 Pump Solenoid Current High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-255 001076.03 Pump Solenoid Current High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-255 001076.05 Pump Solenoid Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-259 001076.05 Pump Solenoid Circuit Open Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-259 001076.06 Pump Solenoid Circuit Severely Shorted . . . . . . . . . . . . . . . . . . .04-160-262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-263 001076.06 Pump Solenoid Circuit Severely Shorted Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-263 001076.07 Pump Control Valve Closure Not Detected . . . . . . . . . . . . . . . . . . . . . .04-160-266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-267 001076.07 Pump Control Valve Closure Not Detected Diagnostic Procedure . . . . .04-160-267 001076.10 Pump Solenoid Circuit Moderately Shorted . . . . . . . . . . . . . . . . .04-160-270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-271 001076.10 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-271 001076.13 Pump Current Decay Time Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-274 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-275 001076.13 Pump Current Decay Time Invalid Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-275 001079.03 Sensor Supply Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-278 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-279 001079.03 Sensor Supply Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-279 001079.04 Sensor Supply Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-283 001079.04 Sensor Supply Voltage Low Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-283 001109.31 Engine Protection Shutdown Warning . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-286 CTM331 (03OCT05)
001110.31 Engine Protection Shutdown . . . . . . . . . . . . . . . . . . . . . . . .04-160-287 001568.02 Torque Curve Selection Invalid or Missing (750J Crawler Only). . .04-160-288 001569.31 Fuel Derate . . . . . . . . . . . . . .04-160-290 002000.06 Internal ECU Failure . . . . . . .04-160-291 002000.13 Security Violation . . . . . . . . .04-160-292
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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: F1 - Fuel supply system check F2 - Excessive fuel consumption F3 - Fuel in oil F5 - Fuel injector nozzle check (D) Diagnosing Diagnostic Software Malfunctions: D1 - ECU does not communicate with the DST orSERVICE 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 Test for Fuel Drain Back Test for Air in Fuel Check Fuel Supply Pressure Bleed the Fuel System Test For Cylinder Misfire (Engine Running)
NOTE: Follow the diagnostic procedure of an active or stored DTC before pursuing any observable diagnostic procedure. 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 E9 - Analog Throttle (B) Does Not Respond (F) Diagnosing Fuel System Malfunctions:
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E1 - Engine Cranks/Wont Start
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, see E6 - ENGINE WILL NOT CRANK later in this Group.
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E1 - Engine Cranks/Wont Start Diagnostic Procedure

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1 E1 - Preliminary Check
Before using this diagnostic procedure: 1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY 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 DIAGNOSTIC PROCEDURE in this Group. 5. Verify that the unswitched voltage to the ECU remains above 6 volts during cranking.
No problems found: GO TO 2 Problem found: Repair and retest
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2 Active DTC Test 1. Connect the DST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU Communication Software Active DTC(s) present: Diagnose DTCs. If any of the DTCs have a SPN 637, diagnose them first. Cannot communicate with ECU: See D1 - ECU DOES NOT COMMUNICATE WITH the DST or SERVICE ADVISOR DIAGNOSTIC PROCEDURE later in this Group. No RPM reading shown during cranking: GO TO 4 04 150 3 No active DTCs present: GO TO 3
NOTE: In order for this step to be successfully performed on all HL and TL engines, the 4-way Hazard switch must be ON, prior to and during cranking.
4. Crank engine for 15 seconds, and verify that the DST or SERVICE ADVISOR shows an RPM reading while cranking. 5. Read DTCs using the DST orSERVICE ADVISOR.
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3 Crank Position Sensor Indicator Test
1. Start cranking engine 2. Using the DST or SERVICE ADVISOR, read the Crank Position Noise parameter while cranking.
Crank Position Noise above 0: GO TO 4 Crank Position Noise is 0: GO TO 5
NOTE: For an explanation of this parameter, see DATA PARAMETER DESCRIPTION in Group 160.
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4 Vehicle Wiring Inspection Check
Inspect the vehicle for possible failures that can cause any of the following conditions: 1. Bad electrical connections 2. Damaged engine speed sensor 3. EMI from improperly installed radio equipment, or other electronic devices
Problem found: Repair and retest. Engine starts, problem solved. Problem not found: GO TO 5
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5 Fuel Present at Injection Nozzles Check Perform following procedure to check for fuel at injection nozzle: Consistent and sequential squirts of fuel observed: GO TO 7 No fuel present at any pump discharge: GO TO 6 Squirts of fuel from only one discharge, or fuel only dribbles from one or more discharges:Damaged pump rotor. Replace pump. Note: Upon replacing pump, all injectors must be checked. REPLACE any faulty injectors to prevent damaging the new pump. GO TO 8
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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 all fuel line connections at pump end. 2. Crank engine while monitoring loosened connections for consistent, sequential squirts of fuel. 3. Retighten connection at nozzle to specification. 04 150 4 Specification Fuel Injection Nozzle Delivery Lines Torque ........................................................................................................ 27m (20 lb-ft)
6 Fuel Supply System Check
Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group.
Fuel supply system problem found: Repair problem and retest. Note: If system is equipped with a primary filter/hand pump assembly, ensure that there is no reverse flow due to umbrella valve displacement in the primer pump. (If there is, the injection pump has lost its prime: Test the pressure between the transfer pump and the DE10.) Engine starts, problem resolved. No fuel supply system problem found: GO TO 7 .
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7 Known, Good ECU Swap
If a known, good ECU is available, connect it to the system, and see if the engine will start.
Engine starts:Problem solved Engine doesnt start:GO TO 8

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8 Fuel Injection Nozzles Check Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group. Faulty fuel injection nozzles found: Repair or replace, and retest. Engine starts, problem resolved. No faulty fuel injection nozzles found:GO TO 9.
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9 Timing Wheel Check
Insert a screwdriver into the speed sensor hole, and verify that the timing wheel is not loose on the crankshaft.
Timing wheel loose on crankshaft:Replace timing wheel and retest. Engine starts. problem resolved. Timing wheel not loose on crankshaft:GO TO 10.
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10 Pump High Pressure Check
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 survgically removed within a few hours by a doctor familiar with this type of injury, or gangrene could result. Doctors unfamiliar with this type of injury may call the Deere and Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Using a spare injection line, connect a known, good nozzle to one of the pump discharges. Crank the engine, and verify that fuel is atomized from the nozzle tip.
No fuel passes from the nozzle tip:Replace the pump, and retest. Engine starts, problem resolved. Fuel is atomized from the nozzle tip:GO TO 11
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11 Intake and Exhaust Restrictions Test
Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
All components operating correctly: GO TO 12 Restrictions are found: Repair faulty component and retest. Engine starts, problem resolved.
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12 Compression Test Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual (CTM104). Compression pressure is within specification: GO TO 13 Compression pressure is not within specification: GO TO 16
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13 Piston Ring Check 04 150 6
NOTE: DO NOT use too much oil. DO NOT get oil on the valves.
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 of this manual. 2. Retest the compression pressure.
Compression pressure is within specification: GO TO 16 Compression pressure is not within specification: GO TO 14
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14 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 15 Valve lash on one or more valves out of specification: Adjust valve lash and retest. Engine starts, problem resolved.
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15 Valve Lift Check 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 16 Valve 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). Engine starts, problem resolved.
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16 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 pistons, rings, and/or cylinder liners or in the valve guides. Check the most likely items as needed. Oil control rings worn or broken Scored cylinder liners or pistons Piston ring grooves excessively worn Piston rings sticking in ring grooves Insufficient piston ring tension Piston ring gaps not staggered Cylinder liners glazed (insufficient load during engine break-in) Worn valve guides or stems Cylinder head may need reconditioning
Problem found with pistons, rings, and/or liners or valve guides: Repair problem as necessary.
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E2 - Engine Misfires/Runs Irregularly
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E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
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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 engine accessories, such as A/C, cycling on and off 5. Check for electromagnetic interference (EMI) from improperly installed radios, etc.
No problems found: GO TO 2 Problem found: Repair and retest. Engines runs normally, problem resolved.
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2 Active DTC Test
1. Connect the DST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU Communication Software 4. Ignition ON, engine idling 5. Read DTCs using the DST orSERVICE ADVISOR. 6. Verify ECU serial number, engine serial number, software version, and check pump serial number, if available. 7. Install updated software, if required.
No active DTCs: GO TO 3 . Active DTCs present: Diagnose DTCs. If any of the DTCs have a SPN 637, diagnose them first.
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3 Recreate Conditions 1. Operate engine under conditions where the miss/running complaint occurs. 2. With ignition ON and engine idling, read DTCs, using SA. 1. Not running rough:No problem found, verify complaint, and try to reproduce conditions of complaint. Running rough, with active DTCs present:Diagnose DTCs. If any active DTCs hav SPN 637, diagnose them first. Running rough with no active DTCs:GO TO 4
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4 Low Pressure Fuel System Check
1. Check low pressure fuel system performance per the Fuel Supply System Check Diagnostic Procedure. See F1 - FUEL SUPPLY SYSTEM CHECK in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Mechanical System Fuel Check (CTM207). 2. Inspect the fuel return line for restrictions, kinks, air ingestion (using a piece of clear line). Also, be sure to check any coolers for plugging.
Problems are found:Repair as necessary, and retest. Engine operates normally, problem resolved. No problems are found:GO TO 5 .
NOTE: If system is equipped with a primary filter/hand ;pump assembly, ensure that there is no reverse flow, due to umbrella valve displacement in the primer pump
3. Test the pressure between transfer pump and injection pump.
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5 High Pressure Fuel Line Check
Determine if fuel delivery lines are restricted: 1. Disconnect the suspected fuel delivery line on the injection nozzle end, and injection pump end. 2. Inspect for obvious signs of blockage, or bent, deformed, or pinched lines. 3. Force air through one end of the delivery line.
Lines not restricted:Air flows freely out other side of delivery line. GO TO 6 Lines are restricted:Air does not flow freely out other side of delivery line. Repair/replace lines and retest. Engine runs normally, problem resolved.
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6 Fuel Injection Nozzle Check 1. Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this group. Injection nozzles test OK:GO TO 7 Faulty injection nozzle(s) found.Repair/replace, and retest. Engine runs smoothly, problem resolved.
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 survgically removed within a few hours by a doctor familiar with this type of injury, or gangrene could result. Doctors unfamiliar with this type of injury may call the Deere and Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 2.To help identify which nozzle is bad, perform the following procedure to determine which injector makes the least difference when its line is cracked:1. Using two open-end wrenches,
loosen fuel line connection at the injection nozzles, one at a time.2. Listen to which nozzle makes less difference in engine smoothness. This is the bad nozzle.3. Retighten the connection at each nozzle to specification, before proceeding to the next nozzle.
Specification Fuel Line ConnectionTorque .............................................................. 27 Nm (20 ft-lb) 04 150 10

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7 Timing Wheel Check
Insert screwdriver into the speed sensor hole and determine whether or not the timing wheel is loose on the crankshaft. (The timing wheel is keyed to, and pressfit onto the crankshaft. It should not be loose, and should turn only when the crankshaft is turned.)
Timing wheel is not loose:GO TO 8 Timing wheel is loose:Replace wheel and retest. Engine runs normally, problem resolved.
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8 Check Wiring
1. Inspect the connections and wiring for problems, including a visual inspection of the wiring for corrosion. 2. Check connection between the harness and a sensor, or the harness and the ECU, using JT07328 Connector adapter Test Kit and inserting the male end of the corresponding test adapter into the female end of the ECU or sensor connector terminal.
Faulty wiring/connector pins not found:GO TO 9 . Faulty wiring/connector pins found:Repair and retest. Engine runs smoothly, problem resolved.
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9 Check ECU If available, substitute ECU with known, good, same-model ECU. Condition not resolved:Reinsert original ECU, and GO TO 10 . Condition resolved:Reinsert original ECU. Condition remains resolved:Connection problem, return to 8 . Original, fault returns:Replace ECU, Engine runs normally, problem resolved.
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10 Injection Pump Check
Note: Take DST or Service ADVISOR recordings while the engine is operating in its rough condition - also while it is running smoothly, if the condition is intermittent - in order that the recordings can be sent to a DTAC advisor, if requested. 1. If possible, do stall tests to check for overpower from the engine. 2. Do a detailed check of the electrical connections. 3. Inspect the pump solenoid cap contacts, and determine whether or not they are burned, or the contact studs are broken.
Electrical problems not found:Replace injector pump, and download payload designated for new pump. Electrical problems found:Repair and retest. Engine runs normally, problem resolved
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11 Head Gasket Failure Check
Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
No sign of head gasket failure: GO TO 12 Signs of head gasket failure found: Replace head gasket and retest. Engine runs normally, problem resolved.
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12 Compression Pressure Check Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). Compression pressure is within specification: GO TO 14 Compression pressure is not within specification: GO TO 13
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13 Piston Ring Check 04 150 12
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14 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 15 Valve lash on one or more valves out of specification: Adjust valve lash and retest. Engine runs normally, problem resolved.
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15 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5L & 6.8L Diesel Engines Base Engine Manual (CTM104). Lift on all valves within specification: GO TO 16 Valve 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). Retest. Engine runs normally, problem resolved. 04 150 13
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Problem found with pistons, rings, and/or liners or valve guides: Repair problem as necessary, and retest.
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E3 - Engine Does Not Develop Full Power
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E3 - Engine Does Not Develop Full Power Diagnostic Procedure
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Before using this diagnostic procedure, ensure that: There are no problems with transmission There are no engine mechanical problems There is not an excessive load on the engine There is no unbalanced ballast The air and fuel filters are not restricted or plugged Fuel quality is OK
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2 Active DTC Test
1. Connect the DST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU Communication Software 4. Ignition ON, engine OFF 5. Read DTCs using the DST orSERVICE ADVISOR.
No DTCs present: GO TO 3 DTCs present: Go to appropriate diagnostic procedure.
NOTE: On some DTCs, the ECU derates fuel in order to protect the engine.
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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 04 150 Group. 15
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4 Torque Curve Selection Check
The ECU on 4.5L & 6.8L diesel 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 on the DST or SERVICE ADVISOR.
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
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and refer to the corresponding torque curve for your application.
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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 using the DST or SERVICE ADVISOR.
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
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3. Compare governor selection to the appropriate governor mode chart. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and refer to the corresponding maximum speed and desired speed governor curves for your application.
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6 Throttle Test 1. Operate engine at full load rated speed. 2. Read the Percent Throttle parameter using the DST or SERVICE ADVISOR. 97% or above: GO TO 7 Below 97%: Refer to machine manual and perform the throttle calibration procedure; then retest.
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04 150 16
7 Turbocharger Boost Pressure Check
Check the Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE (TURBOCHARGER BOOST/POWER CHECK) in Section 04, Group 150 of 4.5 L & 6.8 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
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8 Fuel Supply System Check with Normal Boost Pressure
Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later 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.
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9 Compression Pressure Check
Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
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10 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 INSPECTION in Section 02, Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). None of the above problems found: GO TO 11 Problem found: Repair problem and retest.
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11 Fuel Supply System Check with Low Boost Pressure
Check the fuel supply system. F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE later in this Group.
Fuel supply system is OK: GO TO 12 Fuel supply system problem found: Repair fuel supply system problem and retest.
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12 Fuel Injection Nozzles Test
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group.
Injection nozzles test OK: Faulty injection pump OR Faulty ECU Faulty injection nozzle(s) found: Repair or replace faulty injection nozzles.
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13 Piston Ring Check
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14 Valve Lash Check 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 Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Valve clearance within specification: GO TO 15 Valve clearance out of specification: Adjust valves to specification and retest.
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15 Valve Lift Check 04 150 18
Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
Lift on all valves within specification: GO TO 16 Valve 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).
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E4 - Engine Emits Excessive White Exhaust Smoke
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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 4.5L/6.8L - L1 EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
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Before using this diagnostic procedure: Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY later in this Group. Ensure engine coolant temperature is not extremely low.

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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 CHECK FOR HEAD GASKET FAILURES in Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
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3 Compression Pressure Check
Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104).
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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 DIAGNOSTIC PROCEDURE later in this Group.
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04 150 20
5 Fuel Injection Nozzle Check
Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group.
Injection nozzles test good: Faulty injection pump Faulty injection nozzle(s) found: Repair or replace injection nozzles
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6 Piston Ring Check
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7 Valve Lash Check
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 Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Valve clearance within specification: GO TO 8 Valve clearance out of specification: Adjust valves to specification and retest.
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8 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). Lift on all valves within specification: GO TO 9 Valve 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).
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E5 - Engine Emits Excessive Black Or Gray Smoke
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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 4.5L/6.8L - L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Manual (CTM 104).
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Before using this diagnostic procedure, check the following: Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY later in this Group. Ensure engine is not excessively loaded Ensure air filter is not restricted or plugged
No problem found: GO TO 2 Problem found: Repair and retest.

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2 Torque Curve Check
NOTE: This check is only required for Excavators. For all other applications, GO TO 3 .
1. Connect the DST orSERVICE ADVISOR. 2. With the engine running, read the Torque Curve parameter using the DST or SERVICE ADVISOR.
Correct torque curve number displayed: GO TO 3 Incorrect torque curve number displayed: Adjust torque curve using the DST or SERVICE ADVISOR. See ENGINE TEST INSTRUCTIONS EXCAVATOR TORQUE CURVE CHANGE TEST in Section 4, Group 160 of this manual.
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. See EXCAVATORS - TORQUE CURVE SELECTION in Section 06, Group 210 of this manual.
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3 Air Intake and Exhaust Test Check for intake and exhaust restrictions and air leaks. See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS , TEST FOR INTAKE AIR LEAKS and CHECK FOR EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04, 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.
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4 Turbocharger Check
Check for turbocharger failure. See TURBOCHARGER INSPECTION in Section 02, Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
No turbocharger 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 fitting.
No restriction found: GO TO 7 Restriction found: Repair and retest.

1/1
CTM331 (03OCT05)
04-150-23

012506
PN=137

7 Fuel Injection Nozzle Check Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Group. Injection nozzles test good: Faulty injection pump Faulty injection nozzle(s) found: Repair or replace injection nozzles
1/1
04 150 24
CTM331 (03OCT05)
04-150-24

012506
PN=138
E6 - Engine Will Not Crank
Symptom
Problem
Solution
E6 - 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
RG40854,00000D8 1902JAN021/1
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 06, Group 200 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See E2 - ENGINE MISFIRES/RUNS IRREGULARLY DIAGNOSTIC PROCEDURE earlier in this Group.
Air leak on suction side of air intake system
Electronic control system problem or basic engine problem
RG40854,00000DA 1902JAN021/1
CTM331 (03OCT05)
04-150-25

012506
PN=139
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 06, Group 200 or CRANKSHAFT , MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS in Section 06, 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 02, 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 06, 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 02, 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 02, 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
RG40854,00000DB 1902JAN021/2
CTM331 (03OCT05)
04-150-26

012506
PN=140

Symptom Problem
Solution
Worn timing gears or excess back lash
Check timing gear back lash. See MEASURE TIMING GEAR BACKLASH in Section 02, 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 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). Inspect camshaft. See VISUALLY INSPECT CAMSHAFT in Section 02, 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 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See 4.5L/6.8L - L2 - ENGINE OIL PRESSURE LOW in Section 04, Group 150 of 4.5 & 6.8 L Diesel Engines Base Engine Manual (CTM 104). See TURBOCHARGER INSPECTION in Section 02, 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
RG40854,00000DB 1902JAN022/2
CTM331 (03OCT05)
04-150-27

012506
PN=141
E9 - 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
E9 - Analog Throttle (B) Does Not Respond
Active DTC Check
Read DTCs on the DST orSERVICE 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
RG40854,0000145 1923SEP051/1
CTM331 (03OCT05)
04-150-28

012506
PN=142
F1 - Fuel Supply System Check
RG40854,00000DD 1902JAN021/1
F1 - Fuel Supply System Check Diagnostic Procedure
1/1
1 F1 - Preliminary Check
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Section 03, Group 130 earlier in this manual.
Before using this diagnostic procedure: Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY after this Group. Inspect all fuel lines and fittings for ruptures or leaks. If fuel system has recently been opened, bleed fuel system. See BLEED THE FUEL SYSTEM later in this Group.
No problem found: GO TO 2 Problem found: Repair and retest.
04 150 29
1/1
2 Air In Fuel Check
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
No air found in fuel system: GO TO 3 Air found in fuel system: Bleed fuel system. See BLEED THE FUEL SYSTEM later in this Group.
1/1
3 Fuel Supply Pressure Check
Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this Group.
Pressure within specification: GO TO 7 Pressure is below specification: GO TO 4
1/1
CTM331 (03OCT05)
04-150-29

012506
PN=143

4 Fuel Filter Test
1. Replace final fuel filter and retest. 2. Replace prefilter (if equipped) and retest. 3. Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this Group.
Pressure within specification: Problem resolved Pressure below specification: GO TO 5
1/1
04 150 30
5 Fuel Supply Lines Check
Remove fuel supply lines and determine if there are any internal restrictions.
No restrictions found: GO TO 6 Restrictions found: Repair or replace components as needed.

1/1
6 Fuel Supply Pump Check
At this point, the most likely cause for low fuel pressure is a failure in the fuel supply pump. See BENCH TEST FUEL SUPPLY PUMP later in this Group.
1/1
7 Return Fuel Check
1. Disconnect fuel line from injection pump overflow valve. 2. Loosen overflow valve from injection pump. 3. Turn ignition switch to ON position. 4. Operate hand primer on fuel supply pump until fuel flows out the overflow valve fitting location. If fuel flow out the hole cannot be obtained, retighten all fittings.
Good fuel flow out of loose overflow valve: No fuel supply problem found. NOT good fuel flow or no flow out of loose overflow valve: GO TO 8
1/1
CTM331 (03OCT05)
04-150-30

012506
PN=144

8 Restricted Pre-Injection Fuel Line Check
This check will help determine if the pre-injection fuel line is restricted. Disconnect fuel line from the final filter to the injection pump. Force air through the fuel line.
No restrictions found: No fuel supply problems found. Return to diagnostic procedure earlier in this Group for: E1 - ENGINE CRANKS/WONT START DIAGNOSTIC PROCEDURE OR E3 - ENGINE DOES NOT DEVELOP FULL POWER DIAGNOSTIC PROCEDURE Restrictions found: Repair or replace components as needed. 04 150 31
1/1
CTM331 (03OCT05)
04-150-31

012506
PN=145
F2 - Excessive Fuel Consumption
Symptom
Problem
Solution
F2 - 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

04 150 32
Leaks in fuel supply system
RG40854,00000DE 1902JAN021/1
F3 - Fuel in Oil
Symptom
Problem
Solution
F3 - Fuel in Oil
Faulty injection pump front seal
Replace front seal.
RG40854,00000DF 1902JAN021/1
CTM331 (03OCT05)
04-150-32

012506
PN=146
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 of this manual. Removal - See REMOVE FUEL INJECTION NOZZLES in Section 02, Group 090 of this manual. Cleaning - See CLEAN FUEL INJECTION NOZZLES and CLEAN FUEL INJECTION NOZZLE BORE in Section 02, Group 090 of this manual.
Symptom Problem
Performance Tests - See FUEL INJECTION NOZZLE TEST in Section 02, Group 090 of this manual. Disassembly - See DISASSEMBLE FUEL INJECTION NOZZLES in Section 02, Group 090 of this manual. Adjusting - See ADJUST FUEL INJECTION NOZZLE in Section 02, Group 090 of this manual. Installing Seals - See INSTALL SEALS ON FUEL INJECTION NOZZLE in Section 02, Group 090 of this manual. Installation - See INSTALL FUEL INJECTION NOZZLES in Section 02, Group 090 of this manual.
Solution
04 150 33
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 FUEL INJECTION NOZZLE TEST 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. Replace injection nozzle
Broken spring Nozzle Will Not Open Plugged orifices Chipped orifices Bottomed lift screw Poor Spray Pattern Plugged orifices Chipped orifices Cracked nozzle tip Poor Atomization Plugged orifice Chipped orifice
RG40854,0000001 1906MAR021/2
CTM331 (03OCT05)
04-150-33

012506
PN=147

Symptom Problem
Solution
Cracked nozzle tip Seat Leakage Deposits in seat area Valve seat eroded or pitted
Replace injection nozzle. Clean seat. Lap valve to seat. Replace nozzle as necessary. Lap tip to seat. Replace nozzle as necessary. See FUEL INJECTION NOZZLE TEST in Section 02, Group 090 of this manual. Replace injection nozzle Replace injection nozzle Lap valve to guide. Replace nozzle as necessary. Clean Guide Area Clean nozzle. Lap valve to guide. Replace injection nozzle as necessary.
Tip seat pitted
Valve not free
04 150 34
Distorted body Cracked tip High Leak-Off Wear or scratched at guide
Low Leak-Off
Varnish on valve Insufficient clearance
RG40854,0000001 1906MAR022/2
CTM331 (03OCT05)
04-150-34

012506
PN=148
04 150 35
CTM331 (03OCT05)
04-150-35

012506
PN=149
D1 - ECU Does Not Communicate with the DST or SERVICE ADVISOR

CAN Low CAN High CAN Shield L2 L1
A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S C O N N E C T O R
1917NOV00 RG11336
012506
E F G
04 150 36
D C A J H B
D C E B Switched Voltage A Static Ground
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
L1 L2 L3 M1 M2 M3
Diagnostic Connector
N1 N2 N3 P1 P2 P3 R1 R2 R3
S1 S2 S3
B B A C C
T1 T2 T3
W1 W2 W3 X1 X2 X3
Y1 Y2 Y3
C CAN Terminator This diagnostic procedure should be used if communication between the DST orSERVICE ADVISOR and the Engine Control Unit (ECU) cannot
be established. For more information on CAN, see CONTROLLED AREA NETWORK (CAN) in Section 03, Group 130 earlier in this manual.
RG41221,00000F6 1908FEB031/1
CTM331 (03OCT05)
04-150-36

PN=150
D1 - ECU Does Not Communicate With the DST orSERVICE ADVISOR
RG40854,00000E9 1904JAN021/1
D1 - ECU Does Not Communicate with the DST or SERVICE ADVISOR Diagnostic Procedure
1/1
1 Connection Check
IMPORTANT: Do not force probes into connector terminals or damage will result. Use JT07328 Connector Adapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur.
No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s)
NOTE: For wiring and theory of operation, see D1 - ECU DOES NOT COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information
Perform a preliminary inspection of the ECU connector, the diagnostic connector, and all connections in between. Look for dirty, damaged, or poorly positioned terminals.
04 150 37
1/1
2 Intermittent Fault Test
NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information
1. Connect the DST or SERVICE ADVISOR. 2. Make sure all communication cables are properly connected 3. Ignition ON, engine OFF 4. Start the ECU Communication Software
DST or Service ADVISOR does not communicate with ECU: GO TO 3 The DST or Service ADVISOR communicates with ECU: 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 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
CTM331 (03OCT05)
04-150-37

012506
PN=151

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 A2 in the harness end of the ECU connector
10.0 V or above: Faulty ECU power fuse OR Faulty ECU power wiring OR Faulty ECU Below 10.0 V: Key-on signal wire open or shorted to ground OR Faulty ignition switch OR Faulty key-on power fuse
1/1
04 150 38
5 PDM Power Light Test
1. Ignition ON 2. Observe the power light on the Parallel Data Module (PDM)
Green power light ON: GO TO 8 Red power light or power light OFF: GO TO 6
1/1
6 Open in Diagnostic Ground Connector Wire Test
1. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector 3. Ignition ON 4. Using a multimeter, measure voltage between switched voltage terminal and ground terminal of the harness end of the diagnostic connector
Substantially less than battery voltage: GO TO 7 At or near battery voltage: Faulty diagnostic connector OR Faulty diagnostic cable OR Faulty Parallel Port Data Module (PDM)
1/1
7 Harness Power/Ground Wire Checks
1. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector 3. Probe the ground terminal in the harness side of the diagnostic connector with a test light connected to battery voltage.
Light ON: Faulty diagnostic connector OR Open or short in power wire Light OFF: Faulty diagnostic connector OR Open ground wire
1/1
CTM331 (03OCT05)
04-150-38

012506
PN=152

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 F1 in the ECU connector CAN high terminal C in the diagnostic connector and terminal G1 in the ECU connector
Both measurements 5 ohms or less: GO TO 9 One or more measurements greater than 5 ohms: Open in harness circuit
1/1
9 CAN Resistance Test
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
04 150 39
1/1
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
CTM331 (03OCT05)
04-150-39

012506
PN=153
D2 - Diagnostic Gauge Does Not Communicate With ECU
CAN Low CAN High CAN Shield
L2 L1
A1 A2 A3
B1 B2 B3
C1 C2 C3 D1 D2 D3
E1 E2 E3
F1 F2 F3 G1 G2 G3
E C U H A R N E S S C O N N E C T O R
A B C D
04 150 40
G F E
B G F E D
H1 H2 H3 J1 J2 J3 K1 K2 K3
Switched Voltage Static Ground
L1 L2 L3 M1 M2 M3
N1 N2 N3 P1 P2 P3
Diagnostic Gauge Connector B A A B B A C C C CAN Terminator
R1 R2 R3
S1 S2 S3 T1 T2 T3 W1 W2 W3 X1 X2 X3 Y1 Y2 Y3
NOTE: For more information on CAN, see CONTROLLED AREA NETWORK (CAN) in Section 03, Group 140 earlier in this manual.
Internal Diagnostic Gauge Errors The D2 - Diagnostic Gauge Does Not Communicate With ECU diagnostic procedure should be followed if
the diagnostic gauge shows the following error codes or it can not communicate with the ECU: EE-error ACP-Err/No Addr ACP-Err/Bus EP ACP-Err/Bus Error
RG41221,00000D4 1927MAR021/1
CTM331 (03OCT05)
04-150-40

012506
PN=154
RG11649
1923JAN01
D2 - Diagnostic Gauge Does Not Communicate With ECU
RG40854,0000147 1911FEB021/1
D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see D2 - DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information.
Perform a preliminary inspection of the ECU connector, the diagnostic gauge connector, and all connections in between. Look for dirty, damaged, or poorly positioned terminals.
04 150 41
1/1
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU supporting information.
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
CTM331 (03OCT05)
04-150-41

012506
PN=155

3 Sensor Voltage Test
1. Ignition OFF 2. Disconnect any of the following: Fuel temperature sensor MAT sensor ECT sensor 3. Ignition ON 4. Using a multimeter, measure the voltage between both terminals of the selected sensor harness connector.
4.5 V or above: GO TO 5 Below 4.5 V: GO TO 4
04 150 42
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 ground and terminal A2 in the harness end of the ECU connector.
10.0 V or above: Faulty ECU power fuse OR Faulty ECU power wiring OR Faulty ECU Below 10.0 V: Key-on signal wire open or short to ground OR Faulty ignition switch OR Faulty key-on power fuse
1/1
5 Diagnostic Gauge Power Test
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 Ground Connector Wire Test
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT COMMUNICATE WITH ECU DIAGNOSTIC PROCEDURE supporting information.
1. Ignition OFF 2. Disconnect the diagnostic cable from the diagnostic connector 3. Ignition ON 4. Using a multimeter, measure voltage between switched voltage terminal and ground terminal of the harness end of the diagnostic connector
Substantially less than battery voltage: GO TO 7 At or near battery voltage: Faulty diagnostic connector OR Faulty diagnostic cable OR Faulty Parallel Port Data Module (PDM)
1/1
CTM331 (03OCT05)
04-150-42

012506
PN=156

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 switched power wire. Light OFF: Open in diagnostic gauge connector ground wire.
1/1
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 F1 in the ECU connector. Terminal G in the diagnostic gauge connector and terminal G1 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 43
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
CTM331 (03OCT05)
04-150-43

012506
PN=157

10 CAN High and Low Voltage Test
1. Ignition OFF 2. Reconnect ECU connector 3. Ignition ON 4. Using a multimeter, measure voltage between a good chassis ground and: Terminal B in the diagnostic gauge connector Terminal G in the diagnostic gauge connector
Both 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
04 150 44
1/1
CTM331 (03OCT05)
04-150-44

012506
PN=158
04 150 45
CTM331 (03OCT05)
04-150-45

012506
PN=159
A1 - Intake Air Heater Check

Air Heater Indicator Light Switched Voltage G2
A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3
F1 F2 F3
Air Heater Relay Enable
K3
G1 G2 G3
H1 H2 H3 J1 J2 J3
K1 K2 K3
04 150 46
NOTE: Wiring schematic shows OEM engine applications only. For non-OEM engine wiring information, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this 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 that the ECU detects at key-on. The table on the corresponding page explains this relationship.
When the ECU sends battery voltage 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, 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.
RG40854,00000E6 1903JAN021/1
CTM331 (03OCT05)
04-150-46

012506
RG12049
E CC UO N HN AE RC NT EO SR S
1923JAN02
PN=160
A1 - Intake Air Heater Check - Continued

NOTE: The table below is for OEM applications ONLY. For specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Intake Air Heater Operating Conditions - OEM engines Intake Air Heater Operation - OEM Engines Fuel Temperature -5C (23F) -10C (14F) -15C (5F) -20C (-4F) -25C (-13F) and below Operation Time 5 seconds 15 seconds 20 seconds 30 seconds 30 seconds 04 150 47 Intake Air Heater Operating Conditions - 7020 Tractors engines Intake Air Heater Operation - 7020 Tractors Engines Fuel Temperature -1C (30F) -2C (28F) -3C (26F) -4C (25F) -5C (23F) -10C (14F) -15C (5F) -20C (-4F) and below Operation Time 2 seconds 4 seconds 6 seconds 8 seconds 10 seconds 15 seconds 20 seconds 30 seconds
Intake Air Heater Operating Conditions - Telehandler engines Intake Air Heater Operation - Telehandler Engines Fuel Temperature -1C (30F) -2C (28F) -3C (26F) -4C (25F) -5C (23F) -10C (14F) -15C (5F) -20C (-4F) and below Operation Time 2 seconds 4 seconds 6 seconds 8 seconds 10 seconds 15 seconds 20 seconds 30 seconds
Intake Air Heater Operating Conditions - 6020 Tractors engines Intake Air Heater Operation - 6020 Tractors Engines Fuel Temperature -1C (30F) -2C (28F) -3C (26F) -4C (25F) -5C (23F) -10C (14F) -15C (5F) -20C (-4F) and below Operation Time 2 seconds 4 seconds 6 seconds 8 seconds 10 seconds 15 seconds 20 seconds 30 seconds
RG40854,00000E7 1904JAN021/1
CTM331 (03OCT05)
04-150-47

012506
PN=161
A1 - Intake Air Heater Check
RG40854,00000EB 1904JAN021/1
A1 - Intake Air Heater Check Diagnostic Procedure
NOTE: The air heater indicator light is the same light that trouble codes are displayed on. If the light stays on past 25 seconds, check for trouble codes or a short to ground in the air heater indicator light wire.
1/1
1 Connection Check 04 150 48
NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER CHECK supporting information
Perform a preliminary inspection of the ECU connector, air heater relay connector, air heater connector, and all connections in between. Look for dirty, damaged, or poorly positioned terminals.
1/1
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 theDST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU Communication Software 4. Key ON, engine OFF 5. Read DTCs using the DST or SERVICE ADVISOR.
No active DTC(s) present: GO TO 4 Active DTC(s) present: Go to appropriate diagnostic procedure
1/1
CTM331 (03OCT05)
04-150-48

012506
PN=162

4 Fuel Temperature Check
NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKE AIR HEATER CHECK supporting information
1. Key ON, engine OFF 2. Read the Fuel Temperature parameter using the DST or SERVICE ADVISOR.
Below -5C (23F): GO TO 5 At or above -5C (23F): No air heater-related problem found
1/1
5 Voltage at Air Heater Check
NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKE AIR HEATER CHECK supporting information
1. Key OFF 2. Using a multimeter, measure the voltage between the air heater power stud and a good chassis ground while turning key ON (engine OFF)
At or near battery voltage: GO TO 6 No voltage detected: GO TO 7
NOTE: Voltage must be read as key is turned ON

04 150 49
1/1
6 Air Heater Check
1. Key OFF 2. Using a multimeter, measure the temperature of air heater housing 3. Key ON, engine OFF 4. Continue to monitor temperature of air heater housing
Temperature increases: No air heater related problem found Temperature does not increase Faulty air heater
1/1
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
1/1
CTM331 (03OCT05)
04-150-49

012506
PN=163
Check Fuel Supply Quality
04 150 50
The quality of diesel fuel affects engine performance. Check your operators manual for correct fuel specifications. Poor quality or contaminated fuel will make the engine hard to start, misfire, run rough or produce low power. If poor quality or contaminated fuel is suspected, perform the following: 1. Check prefilter (if equipped) and final fuel filter for serviceability. If filter is equipped with a water bowl, empty and clean water bowl. 2. Start engine and operate under load, observing engine performance.
3. Ignition OFF, engine off 4. Disconnect fuel line from inlet side of prefilter (if equipped) or inlet side of final filter on engines without prefilter. 5. Connect a hose to inlet port. 6. Submerge hose in a container of clean, good quality fuel meeting engine specifications. 7. Operate engine under load and observe performance. If performance improves, fuel is contaminated or not of the proper grade. Check fuel source.
RG40854,00000EC 1904JAN021/1
CTM331 (03OCT05)
04-150-50

012506
PN=164
RG11969
UN23JAN02
Test for Fuel Drain Back

Fuel draining back through the fuel system may cause hard starting. This procedure will determine if air is entering the system at connections and allowing fuel to siphon back to the fuel tank. 1. Disconnect fuel supply and return lines at fuel tank. IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including the fuel supply pump, fuel injection pump, fuel filters, and water bowl (if equipped). 3. Securely plug off the end of the fuel return pipe. CAUTION: Maximum air pressure should be 100 kPa (1 bar) (14.5 psi) when performing this test. 4. Using a low pressure air source, pressurize the fuel system at the fuel supply line. 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks.
04 150 51
NOTE: Connections may allow air to enter the system without allowing fuel to leak out.
6. If any leaks are found, take necessary steps to repair. 7. Reconnect supply and return lines and prime system. 8. Start engine and run for approximately 10 minutes. 9. Allow engine to sit overnight and try starting the following morning.
RG40854,00000EE 1904JAN021/1
CTM331 (03OCT05)
04-150-51

012506
PN=165
Test for Air in Fuel
04 150 52
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 hose from end of fuel leak-off line assembly. Connect a clear plastic hose to end of leak-off line assembly and place opposite end of hose in a suitable container filled with fuel as shown.
2. Operate engine and check for air bubbles in container. If bubbles are present, bleed the fuel system and repeat test. See BLEED THE FUEL SYSTEM later in this Group. 3. If bubbles are still present, check the following: Check for loose fuel fittings from the suction side of the fuel supply pump to the fuel tank to include all lines and filters. Check fuel tank suction tube (if equipped) and welded joints for cracks or holes. Perform any necessary repairs, bleed fuel system and repeat test.
RG40854,00000EF 1904JAN021/1
CTM331 (03OCT05)
04-150-52

012506
PN=166
RG11970
UN23JAN02
Check Fuel Supply Pressure

IMPORTANT: Before disconnecting any fuel line, completely clean any debris from around the fitting. DO NOT allow debris to enter fuel line. 1. Remove plug on final fuel filter base. 2. Install test equipment as shown. 3. Start engine. Fuel pump should maintain minimum positive pressure listed below. If pressure is low, replace filter element and recheck pressure.
Specification Fuel Supply PumpStatic Pressure ....................................................... 2530 kPa (0.250.30 bar) (3.54.5 psi) Fuel Supply PumpMinimum Static Pressure at 850 rpm Engine Speed .................................................. 15 kPa (0.15 bar) (2.0 psi) Fuel Supply PumpMinimum Positive Pressure at 2400 rpm Engine Speed ............................................... 2134 kPa (0.210.34 bar) (35 psi) Fuel Supply PumpMinimum Flow at 2400 rpm Engine Speed ............................. 1.5 L/min (0.42 gpm)
UN15JAN98 RG7946
04 150 53
RG40854,00000F9 1915JAN021/1
CTM331 (03OCT05)
04-150-53

012506
PN=167
Bench Test Fuel Supply Pump

The following bench tests can be performed on a supply pump installed on the engine when the pump is suspected to be defective. See CHECK FUEL SUPPLY PRESSURE in Section 04, Group 150. Perform the Vacuum/Pressure Test and Leakage Test, listed below. Replace the supply pump if either test shows the pump to be defective. There is no repair procedure. Vacuum/Pressure Test
Fuel Supply Pump with Metal Cover
04 150 54
NOTE: This test will give a good indication of condition of both the inlet and outlet valves, as well as the diaphragm. The numerical values obtained on both the vacuum and pressure sides are not important; rather it is the needle movement that is important (very slow for a good pump; very fast or not at all for a defective pump).
1. Remove inlet and outlet fittings. 2. Install vacuum/pressure gauge to inlet side of pump (C). 3. Move primer lever (D) all the way downward. Release lever and at the same time observe gauge: The gauge needle should read the same value each time, and then very slowly return to 0. This indicates that the inlet valve and diaphragm are in good condition. Proceed to next step. If the gauge needle does not move at all, or if the needle rapidly returns to 0, the pump is defective and must be replaced. 4. Remove vacuum/pressure gauge and install onto outlet side of pump (B). 5. Move primer lever all the way to upward position. Release lever and at same time observe gauge reading:
ALever BOutlet Side of Pump CInlet Side of Pump DPrimer Lever
RG40854,0000146 1911FEB021/3
CTM331 (03OCT05)
04-150-54

012506
PN=168
RG9052
UN16MAR98

The gauge needle should initially read 2841 kPa (0.280.41 bar) (46 psi), then return to 0 very slowly. This indicates that the outlet valve and diaphragm are in good condition. Supply pump is operating properly and should be reinstalled on engine.
Specification Fuel Supply PumpPressure ...................... 2841 kPa (0.280.41 bar) (46 psi)
If the gauge needle initially reads same value as above and then returns immediately back to 0, the pump is defective and must be replaced.
04 150 55
RG40854,0000146 1911FEB022/3
Leakage Test The leakage test should be performed if a supply pump is suspected of leaking fuel externally, or internally into the engine crankcase. 1. Install an air line on inlet side of pump (C) and apply 140 kPa (1.4 bar) (20 psi) pressure. 2. Hold finger over outlet side of pump (B) or install a plug. Submerge pump into a container of clean diesel fuel.
Fuel Supply Pump with Metal Cover
UN16MAR98
If air bubbles occur around banded connection holding the two halves of pump together (indicating leakage), replace pump. If the diaphragm is bad, there will be leakage through vent holes (if equipped) and around the rocker arm. Replace pump as necessary.
ALever BOutlet Side of Pump CInlet Side of Pump DPrimer Lever
RG40854,0000146 1911FEB023/3
CTM331 (03OCT05)
04-150-55

012506
PN=169
RG9052
Bleed the Fuel System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. The fuel system may be bled at one of several locations. On some engine applications it may be necessary to consult your operators manual and choose the best location for your engine/machine application.
04 150 56
RG40854,00000F0 1904OCT051/5
1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base.
ABleed Vent Screw
UN25OCT01
RG40854,00000F0 1904OCT052/5
CTM331 (03OCT05)
04-150-56

012506
PN=170
RG11805
X9811
UN23AUG88

2. Operate fuel supply pump prime lever (B) or primer button on fuel filter base (if equipped). 3. Tighten bleed plug securely; continue operating primer until pumping action is not felt. 4. Start engine and check for leaks. If engine will not start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.
BPrimer Lever
UN25OCT01 RG11806
04 150 57
RG40854,00000F0 1904OCT053/5
At Fuel Injection Pump IMPORTANT: Always use a backup wrench when loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage. 1. Loosen fuel return line (A) at fuel injection pump. 2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 3. As soon as fuel flow is free from air bubbles, tighten fuel return line to specifications. Primer lever is spring-loaded and will return to normal position.
Specification Fuel Injection Pump Return LineTorque ................................................................... 27 Nm (20 lb-ft)
AFuel Return Line
RG40854,00000F0 1904OCT054/5
CTM331 (03OCT05)
04-150-57

012506
PN=171
RG11807
UN25OCT01

At Fuel Injection Nozzles 1. Place throttle lever in half-throttle position. 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 over with starter motor 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)
04 150 58
4. Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system. If engine still will not start, see your authorized servicing dealer or engine distributor.
RG40854,00000F0 1904OCT055/5
CTM331 (03OCT05)
04-150-58

012506
PN=172
RG11808
UN25OCT01
Test for Cylinder Misfire (Engine Running)

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 59
5. Repeat test for each remaining cylinder. 6. Remove faulty injection nozzles and repair as required. See F5 - FUEL INJECTION NOZZLE CHECK earlier in this Group.
RG40854,00000F1 1904JAN021/1
CTM331 (03OCT05)
04-150-59

012506
PN=173
04 150 60
CTM331 (03OCT05)
04-150-60

012506
PN=174
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 06, 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
RG40854,00000FA 1915JAN021/1
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
RG40854,00000FB 1915JAN021/1
CTM331 (03OCT05)
04-160-1

012506
PN=175
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
RG40854,00000FC 1915JAN021/1
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
RG40854,00000FD 1915JAN021/6
CTM331 (03OCT05)
04-160-2

012506
PN=176
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.
RG40854,00000FD 1915JAN022/6 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.
RG40854,00000FD 1915JAN023/6 RG9893 UN06JAN99
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.
RG40854,00000FD 1915JAN024/6
CTM331 (03OCT05)
04-160-3

012506
PN=177
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.
RG40854,00000FD 1915JAN025/6 RG9895 UN06JAN99
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.
RG40854,00000FD 1915JAN026/6
CTM331 (03OCT05)
04-160-4

012506
RG9894
UN06JAN99
PN=178
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.
RG40854,00000FE 1915JAN021/4
CTM331 (03OCT05)
04-160-5

012506
PN=179

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.
RG40854,00000FE 1915JAN022/4
CTM331 (03OCT05)
04-160-6

012506
PN=180
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.
RG40854,00000FE 1915JAN023/4
CTM331 (03OCT05)
04-160-7

012506
PN=181

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
RG40854,00000FE 1915JAN024/4
CTM331 (03OCT05)
04-160-8

012506
PN=182
04 160 9
CTM331 (03OCT05)
04-160-9

012506
PN=183
Engine Configuration Data Parameters on Diagnostic Gauge

Accessing Engine Configuration Data Parameters:
1919JAN01
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 10
RG40854,00000FF 1915JAN021/2
CTM331 (03OCT05)
04-160-10

012506
PN=184
RG10031
UN28OCT99
RG11647

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. 04 160 11
Torque 1 Speed 2 Torque 2 Speed 3 Torque 3 Speed 4 Torque 4 Speed 5 Torque 5 Speed 6 Torque 6 Gov Gain Ref Torque
% RPM % RPM % RPM % RPM % RPM % % Nm (ft-lbs)
Speed 7
RPM
Time Limit Lo Limit Hi Limit Low Limit Hi Limit
sec RPM RPM % %
RG40854,00000FF 1915JAN022/2
CTM331 (03OCT05)
04-160-11

012506
PN=185
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 SrvcCode sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the SrvcCode sub-menu to view active DTCs by pressing either the right or the left touch switch until all codes are found. 4. In order to exit SrvcCode sub menu, simultaneously press the right and left touch switch
04 160 12
RG40854,0000100 1915JAN021/1
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 StorCode sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the StorCodesub-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 StorCodesub menu, simultaneously press the right and left touch switch
DPSG,OUOD007,2842 1921OCT991/1
CTM331 (03OCT05)
04-160-12

012506
PN=186
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 StorCode sub-menu by simultaneously pressing the right and the left touch switch. 3. Scroll through the StorCodesub-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 clear codes, simultaneously press the right and left switch for at least 8 seconds
ADiagnostic Gauge BTouch Switches CLights 04 160 13
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 StorCode sub menu, simultaneously press the right and left touch switch
RG40854,000006A 1923JAN011/1
CTM331 (03OCT05)
04-160-13

012506
PN=187
RG10031
UN28OCT99
Blinking DTCs
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: 5. 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. 6. Once complete, the above sequence will be repeated. 7. When complete, turn ignition OFF As an example, if an engine had an active DTC 18 and stored DTC 53, the flashing sequence would be: 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
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. Turn the ignition switch ON.
04 160 14
2. Hold Override Shutdown Switch for a few seconds 3. The Fault Lamp will begin to flash a code number. For example, flash three times...short pause...flash two times...long pause. This example is code 32. 4. 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.
RG40854,0000102 1915JAN021/1
CTM331 (03OCT05)
04-160-14

012506
PN=188
04 160 15
CTM331 (03OCT05)
04-160-15

012506
PN=189
Data Parameter Description

Following is a list of the data parameters that can be read on the DST orService ADVISOR. Included in the list below is a brief description of each parameter, the range of possible readings, and each parameters unit of measurement.
Parameter Air Heater Time Remaining Analog Throttle (A) Input Voltage (OEM) Analog Throttle (A) Input Voltage Analog Throttle (B) Input Voltage (OEM) 04 160 16 Analog Throttle (B) Input Voltage Analog Throttle (C) Input Voltage (OEM) Analog Throttle (C) Input Voltage Battery Voltage Crank Position Input Noise Indicator Units sec volts volts volts volts volts volts volts % Description Amount of time the air heater will continue to heat the air prior to starting. Voltage from analog throttle (A) position sensor (potentiometer) on OEM applications ONLY. Voltage from analog throttle (A) position sensor (potentiometer) on non-OEM applications. Voltage from analog throttle (B) position sensor (potentiometer) on OEM applications ONLY. Voltage from analog throttle (B) position sensor (potentiometer) on non-OEM applications. Voltage from analog throttle (C) position sensor (potentiometer) on OEM applications ONLY. Voltage from analog throttle (C) position sensor (potentiometer). Switched battery voltage may vary depending on application "0" reading means that there is NO noise. Between 0100, the noise on the crank sensor signal becomes progressively worse. When 100 is reached, a trouble code is thrown. The speed of the crank timing wheel. The mode selected is dependent on the application. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and refer to the corresponding desired speed governor curve for your application. 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
Crank Position Sensor Speed Desired Speed Governor Curve
rpm N/A
a
ECU Boot Block Part Number ECU Configuration File Part Number ECU EOL Data Part Number
a
N/Aa N/A
a
N/Aa
N/A = Not Applicable
Service ADVISOR is a trademark of Deere & Company
RG40854,0000103 1915JAN021/3
CTM331 (03OCT05)
04-160-16

012506
PN=190

Parameter ECU Part Number ECU Serial Number ECU Software Assembly Part Number ECU Software Part Number Engine Coolant Temperature Units N/A
a
Description Part number for the Engine Control Unit (ECU) hardware. 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.
N/Aa N/A
a
N/Aa C (F)
NOTE: If there is an active fault for the ECT circuit, the ECT will be displayed as NA
Engine Coolant Temperature Input Voltage Engine Hourmeter volts hr -minsec % N/Aa kPa (psi) N/Aa rpm N/Aa N/A
a
Engine Coolant Temperature sensor input voltage to the ECU Total hours the ECU has run on an engine.
Engine Load at Current Speed Engine Model Number Engine Oil Pressure Engine Serial Number Engine Speed Fuel Mode Fuel System Part Number Fuel System Serial Number Fuel Temperature
Percentage of load on the engine at a given speed. The model number for the engine. Engine Oil pressure value Serial number for the engine. The speed that the crank sensor detects the crank timing wheel to be moving at. This code explains the operation mode of the engine. 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. NOTE: If there is an active fault for the fuel temperature circuit, the fuel temperature will be displayed as NA Fuel temperature sensor input voltage to the ECU. 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 Temperature value. 04 160 17
N/Aa C (F) volts L (gal) C (F)
Fuel Temperature Input Voltage Fuel Usage Rate Manifold Air Temperature
NOTE: If there is an active fault for the MAT circuit, MAT will be displayed as NA
a
RG40854,0000103 1915JAN022/3
CTM331 (03OCT05)
04-160-17

012506
PN=191

Parameter Manifold Air Temperature Input Voltage Maximum Speed Governor Curve Units volts N/Aa Description Manifold Air Temperature sensor input voltage to the ECU. The mode selected is dependent on the application. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and refer to the corresponding maximum speed governor curve for your application. Oil pressure value.
Oil Pressure
kPa (psi)
NOTE: If there is an active fault for the oil pressure circuit, the oil pressure will be displayed as NA
Oil Pressure Input Voltage Option Assembly Part Number volts N/Aa Oil Pressure sensor input voltage to the ECU 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. Voltage that ECU supplies sensors on voltage supply #1 Type of throttle(s) active Percentage of throttle 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 06, Group 210 of this manual and refer to the corresponding torque curve for your application. 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.
Performance Option Part Number Sensor Supply Voltage 04 160 18 Throttle Type Throttle Position Torque Curve Number
N/Aa volts N/A % N/Aa

a
Vehicle Option Part Number Vehicle Serial Number

a
N/Aa N/Aa
RG40854,0000103 1915JAN023/3
CTM331 (03OCT05)
04-160-18

012506
PN=192
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 orSERVICE ADVISOR. Performing the Torque Curve High-altitude Adjustment 1. Ignition ON, engine off. 2. Select Excavator Torque Curve Change Test on the DST orSERVICE ADVISOR. 3. Select the option that corresponds to the desired operation. 1. Normal operation 2. Altitude derate
04 160 19
RG40854,0000171 1923SEP051/1
Reprogramming Engine Control Unit (ECU)

The ECU may be reprogrammed using the DST orSERVICE ADVISOR. Refer to the training material provided with your Service Advisor training course. All authorized Service Advisor users have received this training. Also, online training is available at John Deere University, which is an internet-based distance-learning application.
RG41221,0000092 1923SEP051/1
CTM331 (03OCT05)
04-160-19

012506
PN=193
Diagnostic Trouble Codes (DTCs)

There are several different methods of displaying both stored and active DTCs from the ECU. 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 12 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 orSERVICE ADVISOR and the Diagnostic Gauge to display active and stored DTCs. When using the DST orSERVICE 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 applications do not display engine codes as an SPN/FMI. In most of these cases, the code is displayed as a 2-digit code. An example of a 2-digit code is 18 for engine coolant temperature input voltage high. If used on an application with multiple controllers, ECU may be displayed in front of the numbers, such as ECU 018. A 2-digit code may be seen on the DST orSERVICE ADVISOR, the on-board display, or when the code is blinked for various reasons. In this manual, it will be necessary to convert these codes to the SPN/FMI code in order to follow the correct diagnostic procedure. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU in Group 160 of this manual. OTHER CODES If codes are not displayed as SPN/FMI or as 2-digit codes, there may be another format that the application is using. For example on some applications, the code F455 is displayed for engine coolant temperature input voltage high. This may be seen on some applications within the DST orSERVICE ADVISOR. In this manual, it is necessary to convert this format of code into an SPN/FMI code to ensure that the correct diagnostic procedure is followed. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU WARNING LAMP On some applications, there is a warning lamp that is used when a code becomes active. When a code is active, this lamp will either blink or stay on solid. Typically, a solid light indicates that the ECU is taking extreme measures to protect the engine, and a blinking light indicates that the ECU has detected a fault and engine performance may be affected. Refer to Operators Manual for a given application for more detailed information. CLEARING STORED DTCS Stored DTCs can be cleared through the OEM instrument panel, through the DST orSERVICE 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 20
SERVICE ADVISOR is a trademark of Deere & Company SERVICE ADVISOR
RG40854,0000104 1907SEP051/1
CTM331 (03OCT05)
04-160-20

012506
PN=194
04 160 21
CTM331 (03OCT05)
04-160-21

012506
PN=195
Listing of Diagnostic Trouble Codes (DTCs) on ECU

Ascending SPN/FMI Codes
DTCs Listing in Ascending SPN/FMI Codes SPN FMI Definition 000028 03 Throttle Voltage High 04 Throttle Voltage Low 000029 03 Throttle Voltage High 04 Throttle Voltage Low 14 Throttle Voltage Out of Range 000091 03 Throttle Voltage High 04 Throttle Voltage Low 07 Throttle Calibration Invalid 09 Accelerator Pedal Position CAN Message Missing, Late, or Invalid 10 Throttle Voltage Low 13 Throttle Calibration Aborted 14 Throttle Voltage Out of Range 000097 00 Water In Fuel, above Normal, Most Severe 03 Water in Fuel Signal Voltage High 04 Water in Fuel Signal Voltage Low 16 Water in Fuel Detected 31 Water In Fuel Detected, Condition Exists 000100 01 Engine Oil Pressure Extremely Low 03 Engine Oil Pressure Input Voltage High 04 Engine Oil Pressure Input Voltage Low 16 Engine Oil Pressure, Reading Incorrect 18 Engine Oil Pressure Moderately Low 000105 03 Manifold Air Temperature Input Voltage High 04 Manifold Air Temperature Input Voltage Low 16 Manifold Air Temperature Moderately High 000107 00 Air Filter Restricted 000110 00 Engine Coolant Temperature Extremely High 03 Engine Coolant Temperature Input Voltage High 04 Engine Coolant Temperature Input Voltage Low 15 Engine Coolant Temperature High Least Severe 16 Engine Coolant Temperature Moderately High 000111 00 Loss of Coolant Temperature Extremely High 03 Loss of Coolant Temperature Input Voltage High 04 Loss of Coolant Temperature Input Voltage Low 000158 17 ECU Power Down Error 000171 03 Ambient Air Temperature, Voltage OOR, High 04 Ambient Air Temperature, Voltage OOR, Low 000174 03 Fuel Temperature Input Voltage High 04 Fuel Temperature Input Voltage Low 16 Fuel Temperature High Moderately Severe 000189 00 Engine Speed Derate 000190 00 Engine Overspeed Extreme 01 Engine Speed, Below Normal, Most Severe 16 Engine Overspeed Moderate 000523 09 Current Gear Not Received or Invalid 18 Engine Speed, Below Normal, Moderately Severe 000620 03 Sensor Supply Voltage High
04 160 22
RG40854,0000106 1904OCT051/4
CTM331 (03OCT05)
04-160-22

012506
PN=196

04 04 13 02 08 10 01 02 10 13 02 03 05 09 31 31 00 01 03 05 06 07 10 13 03 04 31 31 04 31 06 13 Sensor Supply Voltage Low ECU Unswitched Power Missing ECU Error Engine Position Sensor Noise Detected Engine Position Sensor Signal Missing Engine Position Sensor Pattern Error Detected Timing (Crank) Sensor, Signal Pattern Error Crank Position Input Noise Crank Position Input Pattern Error CAN Bus Error External Speed Command Input, Data Erratic, Intermittent, or Incorrect Inlet Air Heater Signal High Inlet Air Heater Signal Low Vehicle Speed Invalid/Missing Auxiliary Engine Shutdown Switch Active External Engine Derate Switch Active Pump Control Valve Closure Too Long Pump Control Valve Closure Too Short Pump Solenoid Current High Pump Solenoid Circuit Open Pump Solenoid Circuit Severely Shorted Pump Control Valve Closure Not Detected Pump Solenoid Circuit Moderately Shorted Pump Current Decay Time Invalid Sensor Supply Voltage High Sensor Supply Voltage Low Engine Shutdown Warning Engine Shutdown Torque Curve Selection Input Voltage Low Fuel Derate Internal ECU Failure Security Violation
000627 000629 000636
000637
000639 000644 000729 000729 000898 000970 000971 001076
04 160 23
001079 001109 001110 001568 001569 002000
RG40854,0000106 1904OCT052/4
CTM331 (03OCT05)
04-160-23

012506
PN=197

Ascending 2-Digit/Other Codes
DTCs Listing in 2-Digit/Other Code 11 12 13 14 15 16 18 19 21 22 23 24 25 26 28 32 33 37 38 39 42 54 55 62 63 64 65 66 68 69 71 72 73 74 75 76 77 78 79 81 82 83 84 Ascending 2-Digit Codes SPN FMI 000091 000091 000028 000028 000029 000029 000110 000110 000620 001079 000620 001079 000100 000100 000105 000105 000629 N/Aa N/Aa 000174 000174 000637 000190 03 04 03 04 03 04 03 04 03 03 04 04 03 04 03 04 13 N/Aa N/Aa 03 04 02 10 00 16 17 13 15 16 18 01 16 31 00 00 01 05 06 07 10 03 13 06 16 31 31 17 31 Definition Throttle Voltage High Throttle Voltage Low Throttle Voltage High Throttle Voltage Low Throttle Voltage High Throttle Voltage Low Engine Coolant Temperature Input Voltage High Engine Coolant Temperature Input Voltage Low Sensor Supply Voltage High Sensor Supply Voltage High Sensor Supply Voltage Low Sensor Supply Voltage Low Engine Oil Pressure Input Voltage High Engine Oil Pressure Input Voltage Low Manifold Air Temperature Input Voltage High Manifold Air Temperature Input Voltage Low ECU Error When reading blink codes, signifies start of active fault codes. When reading blink codes, signifies start of previously active fault codes. Fuel Temperature Input Voltage High Fuel Temperature Input Voltage Low Crank Position Input Noise Crank Position Input Pattern Error Engine Overspeed Extreme Engine Overspeed Moderate ECU Power Down Error CAN Bus Error Engine Coolant Temperature High Least Severe Engine Coolant Temperature Moderately High Engine Oil Pressure Moderately Low Engine Oil Pressure Extremely Low Manifold Air Temperature Moderately High Fuel Derate Engine Coolant Temperature Extremely High Pump Control Valve Closure Too Long Pump Control Valve Closure Too Short Pump Solenoid Circuit Open Pump Solenoid Circuit Severely Shorted Pump Control Valve Closure Not Detected Pump Solenoid Circuit Moderately Shorted Pump Solenoid Current High Security Violation Internal ECU Error Fuel Temperature High Moderately Severe Engine Protection Shutdown Auxiliary Engine Shutdown Switch Active ECU Power Down Error External Engine Derate Switch Active
04 160 24
000158 000639 000110 000110 000100 000100 000105 001569 000110 001076 001076 001076 001076 001076 001076 001076 002000 002000 000174 001110 000970 000158 000971 a N/A = Not Applicable
RG40854,0000106 1904OCT053/4
CTM331 (03OCT05)
04-160-24

012506
PN=198

N/Aa 000029 000029 000029 000620 000620 000100 000105 000091 000091 000110 000091 000091 000174 000091 000091 000639 F445 000100 F446 000100 F450 000110 F455 000110 F457 000110 F460 000105 F465 000105 F49A 001076 F497 001076 F474 000174 F475 000174 001569 F478 001076 F48A 000637 F48b 000637 F490 001076 F491 001076 F492 001076 F493 001076 F494 001076 F495 001076 F49A 001076 F4A0 000111 F4A5 000111 F4A7 000111 F4E0 002000 F4E3 000629 F4EA 000158 F4Ed 002000 a N/A = Not Applicable 88 F400 F401 F402 F411 F414 F415 F418 F420 F421 F422 F423 F425 F474 F428 F42A N/Aa 03 04 14 04 03 04 16 04 10 16 09 03 16 07 14 13 03 01 04 03 00 04 03 10 13 16 03 31 13 10 02 06 01 03 07 00 05 10 04 03 00 06 13 17 13 When reading blink codes, signifies that no fault codes are in buffer. Multi-state Throttle Input High Multi-state Throttle Input Low Multi-state Throttle Input Voltage Out of Range Sensor Supply Voltage Low Sensor Supply Voltage High Engine Oil Pressure Input Voltage Low Manifold Air Temperatrue Moderately High Analog Throttle (A) Input Low Throttle Input Voltage Below Lower Calibration Engine Coolant Temperature Moderately High Throttle Calibration Aborted Analog Throttle (A) Input High Fuel Temperature High Moderately Severe Throttle Not Calibrated Properly Analog Throttle (A) Input Voltage Out of Range Skidders ONLY - CAN Bus Error Engine Oil Pressure Input Voltage High Engine Oil Pressure Extremely Low Engine Coolant Temperature Input Voltage Low Engine Coolant Temperature Input Voltage High Engine Coolant Temperature Extremely High Manifold Air Temperature Input Voltage Low Manifold Air Temperature Input Voltage High Pump Solenoid Circuit Moderately Shorted Pump Current Decay Time Invalid Fuel Temperature High Moderately Severe Fuel Temperature Input Voltage High Fuel Derate Pump Current Decay Time Invalid Crank Position Input Pattern Error Crank Position Input Noise Pump Solenoid Circuit Severely Shorted Pump Control Valve Closure Too Short Pump Solenoid Current High Pump Control Valve Closure Not Detected Pump Control Valve Closure Too Long Pump Solenoid Circuit Open Pump Solenoid Circuit Moderately Shorted Loss of Coolant Temperature Input Voltage Low Loss of Coolant Temperature Input Voltage High Loss of Coolant Temperature Extremely High Internal ECU Failure ECU Error ECU Power Down Error Security Violation
04 160 25
RG40854,0000106 1904OCT054/4
CTM331 (03OCT05)
04-160-25

012506
PN=199
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). If an SPN/FMI code is not used, convert the code to SPN/FMI. See LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU earlier in this Group. 3. Go to the diagnostic procedure that corresponds to the DTC(s) present. 5. After any repairs are made, recheck to make sure all DTCs have been eliminated.
NOTE: After using the DST orSERVICE 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 26
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.
RG40854,0000105 1923SEP051/1
CTM331 (03OCT05)
04-160-26

012506
PN=200
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. 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 orSERVICE 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.
04 160 27
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 DST orSERVICE ADVISOR can be used to help locate intermittent problems, as it includes a function called
RG40854,0000107 1923SEP051/1
CTM331 (03OCT05)
04-160-27

012506
PN=201
T1 - Multi-state Throttle Input High

Instrument Panel Connector
A1 A2 A3
X J B G W K L C A F V U T S
B1 B2 B3 C1 C2 C3
S Sensor Ground
D3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
M D E N P R
R High/Low Idle Input C1

S R
04 160 28 A B
C O N N E C T O R
A B
1924MAR03
Idle Switch Connector JOHN DEERE Instrument Panel Multi-state Throttle Switch Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. On some applications, there is a bump up and a bump down feature. This allows for high and low idle to be controlled. 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. 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.
RG40854,00000A2 1907DEC011/1
CTM331 (03OCT05)
04-160-28

012506
RG11976
PN=202
T1 - Multi-state Throttle Input High
RG40854,00000A1 1923SEP051/1
T1 - Multi-State Throttle Input High Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT HIGH supporting information.
Perform a preliminary inspection of the ECU connector and the multi-state throttle connector. Look for dirty, damaged, or poorly positioned terminals.
04 160 29
1/1
1. Connect to the DST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR 5. Make note of any DTCs, then clear all DTCs. 6. Ignition ON, engine OFF 7. Move the multi-state switch through all the positions. 8. Read DTCs using the DST orSERVICE ADVISOR.
000091.03 (Skidders: 000029.03) reoccurs: GO TO 3 000091.03 (Skidders: 000029.03) does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
NOTE: Skidder applications use a different SPN for multi-state throttle than other applications. SERVICE ADVISOR is a trademark of Deere & Company
1/1
CTM331 (03OCT05)
04-160-29

012506
PN=203

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. Read DTCs using the DST or SERVICE ADVISOR 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine OFF 7. Read DTCs using the DST or SERVICE ADVISOR.
000091.03 (Skidders: 000029.03) reoccurs: GO TO 4 000091.04 (Skidders: 000029.03) occurs: Faulty multi-state throttle switch connector OR Faulty multi-state throttle switch
NOTE: Skidder applications use a different SPN for multi-state throttle than other applications.
04 160 30
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 and a good chassis ground.
Between 4.0 V and 6.0 V: Open in multi-state switch ground circuit OR Faulty ECU connection OR Faulty ECU Below 4.0 V: Open in multi-state switch 5 V input circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-30

012506
PN=204
04 160 31
CTM331 (03OCT05)
04-160-31

012506
PN=205
T2 - Multi-state Throttle Input Low

A1 A2 A3
X J B G W K L C A F V U T S
B1 B2 B3 C1 C2 C3
S Sensor Ground
D3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
M D E N P R
R High/Low Idle Input C1

S R
04 160 32 A B
C O N N E C T O R
A B
1924MAR03
Idle Switch Connector JOHN DEERE Instrument Panel Multi-state Throttle Switch Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. On some applications, there is a bump up and a bump down feature. This allows for high and low idle to be controlled. 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. 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.
RG40854,00000A0 1907DEC011/1
CTM331 (03OCT05)
04-160-32

012506
RG11976
PN=206
T2 - Multi-state Throttle Input Low
RG40854,00000A3 1923SEP051/1
T2 - Multi-State Throttle Input Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT LOW supporting information.
Perform a preliminary inspection of the ECU connector and the multi-state throttle connector. Look for dirty, damaged, or poorly positioned terminals.
04 160 33
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR 5. Make note of any DTCs, then clear all DTCs. 6. Ignition ON, engine OFF 7. Move the multi-state switch through all the positions. 8. Read DTCs using the DST orSERVICE ADVISOR.
000091.04 (Skidders: 000029.04) reoccurs: GO TO 3 000091.04 (Skidders: 000029.04) does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
NOTE: Skidder applications use a different SPN for multi-state throttle than other applications. SERVICE ADVISOR is a trademark of Deere & Company
1/1
CTM331 (03OCT05)
04-160-33

012506
PN=207

3 Throttle Position Wiring Test
1. Ignition OFF 2. Disconnect multi-state throttle switch at two wire connector behind instrument panel. 3. Read DTCs using the DST or SERVICE ADVISOR. 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Read DTCs using the DST or SERVICE ADVISOR.
000091.04 (Skidders: 000029.04) reoccurs: Short to ground in multi-state input circuit OR Open in multi-state input circuit OR Faulty ECU 000091.03 (Skidders: 000029.03) occurs: Faulty multi-state throttle switch connector OR Faulty multi-state throttle switch.
NOTE: Skidder applications use a different SPN for multi-state throttle than other applications.
04 160 34
1/1
CTM331 (03OCT05)
04-160-34

012506
PN=208
04 160 35
CTM331 (03OCT05)
04-160-35

012506
PN=209
T3 - Analog Throttle (A) Input High

A1 A2 A3
J K L M N C
X B G W A F V E S U T R
B1 B2 B3 C1 C2 C3
C L
Sensor Return Sensor Input
D3 B3 E2
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
D P
M Sensor 5V
F1 F2 F3 G1 G2 G3 H1 H2 H3
CLM
04 160 36
J1 J2 J3 K1 K2 K3
C O N N E C T O R
Analog Throttle (A) Sensor Connector

1929MAR05
Analog Throttle (A) Sensor
A B C
A B C
JOHN DEERE Instrument Panel
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 voltage range may change per 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 high analog throttle (A) input voltage specification is 4.7 volts. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high 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.
RG40854,000009E 1907DEC011/1
CTM331 (03OCT05)
04-160-36

012506
PN=210
RG11974
T3 - Analog Throttle (A) Input High
RG40854,00000A4 1923SEP051/1
T3 - Analog Throttle (A) Input High Diagnostic Procedure
1/1
1 Connection Check
No faulty connection(s): GO TO 2 Faulty connection: Repair faulty connection(s)
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the analog (A) throttle connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
04 160 37
1/1
1. Connect to the DST or SERVICE ADVISOR . 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Analog Throttle (A) in the idle position. 5. Using the DST orSERVICE ADVISOR: For OEM applications, read Analog Throttle (A) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (A) Input Voltage
4.7 V or greater: GO TO 4 Below 4.7 V: GO TO 3
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is 4.7V. For the high voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-37

012506
PN=211

3 Throttle Travel Voltage Test
While slowly operating analog throttle (A) through its full travel, use the DST or SERVICE ADVISOR for the following: For OEM applications, read Analog Throttle (A) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (A) Input Voltage
Goes above 4.7 V: Faulty analog throttle (A) sensor connector OR Open in analog throttle (A) sensor ground circuit OR Faulty analog throttle (A) sensor Never goes above 4.7 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 38
1/1
1. Ignition OFF 2. Disconnect analog throttle (A) sensor connector behind instrument panel. 3. Ignition ON, Engine OFF 4. Using the DST orSERVICE ADVISOR: For OEM applications, read Analog Throttle (A) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (A) Input Voltage
0.3 V or less: GO TO 5 Above 0.3 V: Short to voltage in analog throttle (A) input circuit OR Faulty ECU
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of 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 in throttle (A) sensor harness 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
CTM331 (03OCT05)
04-160-38

012506
PN=212
04 160 39
CTM331 (03OCT05)
04-160-39

012506
PN=213
T4 - Analog Throttle (A) Input Low

A1 A2 A3
J K L M N C
X B G W A F V E S U T R
B1 B2 B3 C1 C2 C3
C L
Sensor Return Sensor Input
D3 B3 E2
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
D P
M Sensor 5V
F1 F2 F3 G1 G2 G3 H1 H2 H3
CLM
04 160 40
J1 J2 J3 K1 K2 K3
C O N N E C T O R
Analog Throttle (A) Sensor Connector

1929MAR05
Analog Throttle (A) Sensor
A B C
A B C
JOHN DEERE Instrument Panel
The analog throttle (A) input voltage goes 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 non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low 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.
RG40854,000009C 1907DEC011/1
CTM331 (03OCT05)
04-160-40

012506
PN=214
RG11974
T4 - Analog Throttle (A) Input Low
RG40854,00000A5 1923SEP051/1
T4 - Analog Throttle (A) Input Low Diagnostic Procedure
1/1
1 Connection Check
No faulty connection(s): GO TO 2 Faulty connection: Repair faulty connection.
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT LOW supporting information.
Perform a preliminary inspection of the ECU connector, the analog (A) throttle connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
04 160 41
1/1
1. Connect to the DST or SERVICE ADVISOR . 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Throttle (A) in the idle position. 5. Using the DST orSERVICE ADVISOR: For OEM applications, read Analog Throttle (A) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (A) Input Voltage
0.3 V or less: GO TO 4 Above 0.3 V: GO TO 3
1/1
CTM331 (03OCT05)
04-160-41

012506
PN=215

While slowly operating analog throttle (A) through its full travel, use the DST or SERVICE ADVISOR for the following: For OEM applications, read Analog Throttle (A) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (A) Input Voltage
Goes below 0.3 V: Faulty analog throttle (A) sensor connector OR Open in analog throttle (A) sensor ground circuit OR Faulty analog throttle (A) sensor Never goes above 0.3 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 42
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 in the harness side of the sensor connector. 4. Ignition ON, engine OFF 5. Using the DST or SERVICE ADVISOR: For OEM applications, read Analog Throttle (A) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (A) Input Voltage
Below 4.7 V: GO TO 5 4.7 V or greater: Faulty analog throttle (A) sensor connector OR Faulty analog throttle (A) sensor
1/1
CTM331 (03OCT05)
04-160-42

012506
PN=216

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 in the sensor harness connector.
Between 4.0 V and 6.0 V: Open in analog throttle (A) input circuit OR Short to ground in analog throttle (A) input circuit OR Faulty ECU connector OR Faulty ECU Below 4.0 V: Open in analog throttle (A) 5 V Supply circuit OR Short to ground in analog throttle (A) 5 V Supply circuit 04 OR 160 Faulty ECU connector 43 OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-43

012506
PN=217
T5 - Analog Throttle (B) Input High

Analog Throttle (B) Sensor Connector Sensor Return Analog Throttle (B) Sensor
A B C A B C
D3
A1 A2 A3
B1 B2 B3
Analog Throttle (B) Input F2 Sensor 5V E2
C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
Throttle Emulator A B
04 160 44
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 high analog throttle (B) input voltage specification is 4.7 volts. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high 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.
RG40854,000009A 1907DEC011/1
CTM331 (03OCT05)
04-160-44

012506
PN=218
RG11975
1914DEC01
C O N N E C T O R
T5 - Analog Throttle (B) Input High
RG40854,00000A6 1923SEP051/1
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.
Perform a preliminary inspection of the ECU connector, the analog (B) throttle connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
04 160 45
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Analog Throttle (B) in the idle position. 5. Using the DST orSERVICE ADVISOR: For OEM applications, read Analog Throttle (B) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is 4.7V. For the high voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-45

012506
PN=219

While slowly operating analog throttle (B) through its full travel, use the DST or SERVICE ADVISOR for the following: For OEM applications, read Analog Throttle (B) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (B) Input Voltage
Goes above 4.7 V: Faulty analog throttle (B) sensor connector OR Open in analog throttle (B) sensor ground circuit OR Faulty analog throttle (B) sensor Never goes above 4.7 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 46
1/1
1. Ignition OFF 2. Disconnect analog throttle (B) sensor connector behind instrument panel. 3. Ignition ON, Engine OFF 4. Using the DST or SERVICE ADVISOR: For OEM applications, read Analog Throttle (B) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (B) Input Voltage
0.3 V or less: GO TO 5 Above 0.3 V: Short to voltage in analog throttle (B) input circuit OR Faulty ECU
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of 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 in throttle (B) sensor harness connector.
Light ON: Faulty analog throttle (B) sensor connector OR Faulty analog throttle (B) sensor Light OFF: Open in analog throttle (B) ground circuit
1/1
CTM331 (03OCT05)
04-160-46

012506
PN=220
04 160 47
CTM331 (03OCT05)
04-160-47

012506
PN=221
T6 - Analog Throttle (B) Input Low

Analog Throttle (B) Sensor Connector Sensor Return Analog Throttle (B) Sensor
A B C A B C
D3
A1 A2 A3
B1 B2 B3
Analog Throttle (B) Input F2 Sensor 5V E2
C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
Throttle Emulator A B
04 160 48
The analog throttle (B) input voltage goes 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 (B) input voltage specification is 0.3 volts. For non-OEM 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.
RG40854,0000098 1907DEC011/1
CTM331 (03OCT05)
04-160-48

012506
PN=222
RG11975
1914DEC01
C O N N E C T O R
T6 - Analog Throttle (B) Input Low
RG40854,00000A7 1923SEP051/1
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.
Perform a preliminary inspection of the ECU connector, the analog (B) throttle connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
04 160 49
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Analog Throttle (B) in the idle position. 5. Using the DST orSERVICE ADVISOR: For OEM applications, read Analog Throttle (B) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (B) Input Voltage
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is 0.3V. For the low voltage specification on non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-49

012506
PN=223

While slowly operating analog throttle (B) through its full travel, use the DST or SERVICE ADVISOR for the following: For OEM applications, read Analog Throttle (B) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (B) Input Voltage
Goes below 0.3 V: Faulty analog throttle (B) sensor connector OR Open in analog throttle (B) sensor ground circuit OR Faulty analog throttle (B) sensor Never goes above 0.3 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group
04 160 50
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 in the harness side of the sensor connector. 4. Ignition ON, engine OFF 5. Using the DST or SERVICE ADVISOR: For OEM applications, read Analog Throttle (B) Input Voltage (OEM) For non-OEM applications, read Analog Throttle (B) Input Voltage
Below 4.7 V: GO TO 5 4.7 V or greater: Faulty analog throttle (B) sensor connector OR Faulty analog throttle (B) sensor
1/1
CTM331 (03OCT05)
04-160-50

012506
PN=224

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 in the sensor harness connector.
Between 4.0 V and 6.0 V: Open in analog throttle (B) input circuit OR Short to ground in analog throttle (B) input circuit OR Faulty ECU connector OR Faulty ECU Below 4.0 V: Open in analog throttle (B) 5 V Supply circuit OR Short to ground in analog throttle (B) 5 V Supply circuit 04 OR 160 Faulty ECU connector 51 OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-51

012506
PN=225
T7 - CAN Throttle Invalid

CAN Low CAN High CAN Shield F1 G1
A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
E F G
04 160 52
D C A J H B
D C E B A
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3
C O N N E C T O R
K1 K2 K3
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. 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.
RG40854,0000096 1907DEC011/1
CTM331 (03OCT05)
04-160-52

012506
PN=226
RG11972
1914DEC01
B B A C
T7 - CAN Throttle Invalid
RG40854,00000A8 1923SEP051/1
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.
Perform a preliminary inspection of the ECU connector and any connectors associated with the CAN throttle. Look for dirty, damaged, or poorly positioned terminals.
04 160 53
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs. 6. Ignition ON, engine running 7. Read DTCs using the DST orSERVICE ADVISOR.
000091.09 reoccurs: GO TO 3 000091.09 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-53

012506
PN=227

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 54
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 V and 3.5 V: Faulty ECU connector OR Other connector in the CAN system OR Faulty ECU. Either measurement less than 1.5 V or greater than 3.5 V: CAN wiring shorted to ground or voltage OR Another controller in the CAN system is faulty OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-54

012506
PN=228
04 160 55
CTM331 (03OCT05)
04-160-55

012506
PN=229
T11 - Excavator Throttle Reference Voltage High

A1 A2 A3
Throttle Reference To Pump and Valve Controller Throttle Input
F3 B3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
F1 F2 F3
Throttle Ground
C1
G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
04 160 56
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 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.
RG40854,0000094 1907DEC011/1
CTM331 (03OCT05)
04-160-56

012506
RG11977
1914DEC01
C O N N E C T O R
PN=230
T11 - Excavator Throttle Reference Voltage High
RG40854,00000A9 1923SEP051/1
T11 - Excavator Throttle Reference Voltage High Diagnostic Procedure
NOTE: This diagnostic 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.
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
04 160 57
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs using the DST orSERVICE ADVISOR.
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 does not 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.
6. Read DTCs using the DST orSERVICE ADVISOR. Ignition ON, engine OFF Ignition ON, engine running
1/1
CTM331 (03OCT05)
04-160-57

012506
PN=231

3 Throttle Reference Wire Test
1. Ignition OFF 2. Disconnect ECU connector. 3. Using a multimeter, measure voltage between terminal F3 in the harness end of the ECU connector and the ground stud of the Pump and Valve controller.
3.95 V or less: GO TO 4 Greater than 3.95 V: Short to power in throttle reference wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
4 Ground Test 04 160 58
There is a difference between grounds of the ECU and Pump and Valve controller. Check for loose ground connections at each controller.
1/1
CTM331 (03OCT05)
04-160-58

012506
PN=232
04 160 59
CTM331 (03OCT05)
04-160-59

012506
PN=233
T12 - Excavator Throttle Reference Voltage Low

A1 A2 A3
F3 B3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
F1 F2 F3
Throttle Ground
C1
G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
04 160 60
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.
RG40854,0000092 1907DEC011/1
CTM331 (03OCT05)
04-160-60

012506
RG11977
1914DEC01
C O N N E C T O R
PN=234
T12 - Excavator Throttle Reference Voltage Low
RG40854,0000091 1923SEP051/1
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 61
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs.
1/1
CTM331 (03OCT05)
04-160-61

012506
PN=235

3 Throttle Reference Wire Test
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure voltage between terminal F3 in the harness end of the ECU connector and the ground stud of the Pump and Valve controller.
3.55 V or greater: GO TO 4 Less than 3.55 V: Open in throttle reference wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
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
CTM331 (03OCT05)
04-160-62

012506
PN=236
04 160 63
CTM331 (03OCT05)
04-160-63

012506
PN=237
T13 - Excavator Throttle Ground Voltage High

A1 A2 A3
F3 B3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
F1 F2 F3
Throttle Ground
C1
G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
04 160 64
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.
RG40854,0000090 1907DEC011/1
CTM331 (03OCT05)
04-160-64

012506
RG11977
1914DEC01
C O N N E C T O R
PN=238
T13 - Excavator Throttle Ground Voltage High
RG40854,00000AA 1923SEP051/1
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 65
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs. 6. Read DTCs using the DST orSERVICE ADVISOR. Ignition ON, engine OFF Ignition ON, engine running
1/1
CTM331 (03OCT05)
04-160-65

012506
PN=239

3 Throttle Ground Wire Test
1. Ignition OFF 2. Disconnect ECU connector 3. Disconnect Pump and Valve controller connector. 4. Using a multimeter, measure resistance between terminal C1 in the harness end 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 66
1/1
4 Pump and Valve Controller Test
1. Ignition OFF 2. ECU connector still disconnected. 3. Using a multimeter, measure resistance between terminal C1 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
CTM331 (03OCT05)
04-160-66

012506
PN=240
04 160 67
CTM331 (03OCT05)
04-160-67

012506
PN=241
T14 - Excavator Throttle Ground Voltage Low

A1 A2 A3
F3 B3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
F1 F2 F3
Throttle Ground
C1
G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
04 160 68
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.
RG40854,000008E 1907DEC011/1
CTM331 (03OCT05)
04-160-68

012506
RG11977
1914DEC01
C O N N E C T O R
PN=242
T14 - Excavator Throttle Ground Voltage Low
RG40854,00000AB 1923SEP051/1
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.
04 160 69
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs. 6. Read DTCs using the DST orSERVICE ADVISOR. Ignition ON, engine OFF Ignition ON, engine running
1/1
CTM331 (03OCT05)
04-160-69

012506
PN=243

3 Throttle Ground Test
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminal C1 in the harness end of the ECU connector and the corresponding ground terminal of the Pump and Valve controller connector.
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
1/1
CTM331 (03OCT05)
04-160-70

012506
PN=244
04 160 71
CTM331 (03OCT05)
04-160-71

012506
PN=245
T15 - Excavator Throttle Input Voltage High

A1 A2 A3
F3 B3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
F1 F2 F3
Throttle Ground
C1
G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
04 160 72
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.
RG40854,0000089 1907DEC011/1
CTM331 (03OCT05)
04-160-72

012506
RG11977
1914DEC01
C O N N E C T O R
PN=246
T15 - Excavator Throttle Input Voltage High
RG40854,00000AC 1923SEP051/1
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.
04 160 73
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs.
1/1
CTM331 (03OCT05)
04-160-73

012506
PN=247

3 Throttle Signal Wire Test
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure voltage between terminal B3 in the harness end of the ECU connector and the ground pin of the Pump and Valve controller.
4.0 V or less: GO TO 4 Greater than 4.0 V: Short to power in throttle signal wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
1/1
CTM331 (03OCT05)
04-160-74

012506
PN=248
04 160 75
CTM331 (03OCT05)
04-160-75

012506
PN=249
T16 - Excavator Throttle Input Voltage Low

A1 A2 A3
F3 B3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
F1 F2 F3
Throttle Ground
C1
G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3
04 160 76
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.
RG40854,000008B 1907DEC011/1
CTM331 (03OCT05)
04-160-76

012506
RG11977
1914DEC01
C O N N E C T O R
PN=250
T16 - Excavator Throttle Input Voltage Low
RG40854,00000AD 1923SEP051/1
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 77
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs
1/1
CTM331 (03OCT05)
04-160-77

012506
PN=251

3 Throttle Signal Wire Test
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure voltage between terminal B3 in the harness end of the ECU connector and the ground pin of the Pump and Valve controller.
1.0 V or greater: GO TO 4 Less than 1.0 V: Open in throttle signal wire OR Faulty Pump and Valve controller connector OR Faulty Pump and Valve controller
1/1
1/1
CTM331 (03OCT05)
04-160-78

012506
PN=252
04 160 79
CTM331 (03OCT05)
04-160-79

012506
PN=253
T17 - Analog Throttle (C) Input High

Analog Throttle (C) Sensor Connector Sensor Ground A Analog Throttle (C) Sensor
B C D
Analog Throttle (C) Input 5V Supply E2 E1 D3

S3 T3 W3 X3 Y3
S2 T2 W2 X2 Y2
1922AUG02 RG12589
A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1
F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1
L3 M3 N3 P3 R3 L2 M2 N2 P2 R2 L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
04 160 80
ECU HARNESS CONNECTOR 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 for Tractor applications. 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 4.7 volts. The voltage is higher than what is physically possible for the cruise analog throttle 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 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.
RG40854,0000110 1912AUG021/1
CTM331 (03OCT05)
04-160-80

012506
PN=254
T17 - Analog Throttle (C) Input High
RG40854,0000111 1923SEP051/1
T17 - Analog Throttle (C) Input High Diagnostic Procedure
1/1
1 Connection Check
No faulty connections: GO TO 2 Faulty connections: Repair faulty connection(s).
NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT HIGH supporting information.
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 81
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Throttle (C) in the idle position 5. Read the analog throttle (C) voltage parameter on the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-81

012506
PN=255

Read the analog throttle (C) voltage parameter while slowly operating the analog throttle (C) through full travel
Goes above 4.7 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 4.7 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group
04 160 82
1/1
1. Ignition OFF 2. Disconnect analog throttle sensor connector 3. Ignition ON, engine OFF 4. Read the analog throttle (C) voltage parameter
0.3 V or less: GO TO 5 Above 0.3 V: Short to voltage in analog throttle input circuit OR Faulty ECU
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 harness 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
CTM331 (03OCT05)
04-160-82

012506
PN=256
04 160 83
CTM331 (03OCT05)
04-160-83

012506
PN=257
T18 - Analog Throttle (C) Input Low

Analog Throttle (C) Sensor Connector Sensor Ground A Analog Throttle (C) Sensor
B C D
Analog Throttle (C) Input 5V Supply E2 E1 D3

S3 T3 W3 X3 Y3
S2 T2 W2 X2 Y2
1922AUG02 RG12589
L3 M3 N3 P3 R3 L2 M2 N2 P2 R2 L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
04 160 84
ECU HARNESS CONNECTOR 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 for Tractor applications. 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 4.7 volts. The voltage is higher than what is physically possible for the cruise analog throttle 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 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.
RG40854,0000112 1912AUG021/1
CTM331 (03OCT05)
04-160-84

012506
PN=258
T18 - Analog Throttle (C) Input Low
RG40854,0000113 1923SEP051/1
T18 - Analog Throttle (C) Input Low Diagnostic Procedure
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT LOW supporting information.
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor connector looking for dirty, damaged, or poorly positioned terminals.
04 160 85
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Throttle (C) in the idle position 5. Read the analog throttle (C) voltage parameter
1/1
CTM331 (03OCT05)
04-160-85

012506
PN=259

Read the analog throttle (C) voltage parameter while slowly operating the analog throttle (C) through full travel
Goes below 0.3 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 0.3 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group
04 160 86
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 in the harness side of the sensor connector 4. Ignition ON, engine OFF 5. Read the analog throttle (C) voltage parameter
Below 4.7 V: GO TO 5 4.7 V or greater: Faulty analog throttle (C) sensor connector OR Faulty analog throttle sensor
1/1
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 in the sensor harness 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 Faulty ECU connection OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-86

012506
PN=260
T19 - Throttle Not Calibrated Properly
Throttle Calibration Throttle calibration is necessary to allow the ECU to learn the range of the throttle. It is done when a new ECU or a new throttle has been installed. This code will set if: The ECU detects an improper throttle calibration range. If this code sets, the following will occur: Throttle position will not match percent throttle.
If this code sets: Diagnose other DTCs first. If no other DTCs are found, perform throttle sensor diagnostics. For 310G Backhoe Loaders, see THROTTLE POSITION SENSOR TEST (S.N. XXXXXX ) in Section 9015, Group 120 of TM1885. For 310SG/315SG Backhoe Loaders, see THROTTLE POSITION SENSOR TEST (S.N. XXXXXX ) in Section 9015, Group 120 of TM1883.
04 160 87
RG40854,0000118 1928JAN021/1
CTM331 (03OCT05)
04-160-87

012506
PN=261
T20 - Throttle Input Voltage Below Lower Calibration Limit
Throttle Calibration Throttle calibration is necessary to allow the ECU to learn the range of the throttle. It is performed when a new ECU or a new throttle has been installed. This code will set if: The ECU detects a throttle input voltage lower than the defined low calibration limit.
04 160 88
If this code sets, the following will occur: Throttle position will not match percent throttle.
RG40854,000011F 1928JAN021/1
CTM331 (03OCT05)
04-160-88

012506
PN=262
T21 - Throttle Calibration Aborted
Throttle Calibration Throttle calibration is necessary to allow the ECU to learn the range of the throttle. It is done when a new ECU or a new throttle has been installed. This code will set if: Throttle calibration mode was enabled but was aborted before it was completed. If this code sets, the following will occur: Throttle position will not match percent throttle.
04 160 89
RG40854,000011E 1928JAN021/1
CTM331 (03OCT05)
04-160-89

012506
PN=263
T22 - Analog Throttle (A) Input Voltage Out of Range
Analog Throttle Sensor The analog throttle position sensor is a variable resistor (potentiometer) used to measure the position of the throttle. 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 voltage range may change per application.
04 160 90
For engine with multiple throttles, the ECU will not read the input of the faulty throttle, so the ECU run entirely off of the other throttle. If this code sets: Diagnose other DTCs first. If no other DTCs are found, perform throttle sensor diagnostics. For 310G Backhoe Loaders, see THROTTLE POSITION SENSOR TEST (S.N. XXXXXX ) in Section 9015, Group 120 of TM1885. For 310SG/315SG Backhoe Loaders, see THROTTLE POSITION SENSOR TEST (S.N. XXXXXX ) in Section 9015, Group 120 of TM1883. Check for other throttle DTCs. Diagnose those first. Return throttle to 0% throttle position Some applications require key OFF/restart cycle to clear the code.
This code will set if: The ECU detects a high or low out of range analog throttle (A) input voltage. If this code sets, the following will occur: For engines with only one throttle, the ECU will not read the input of the throttle and run the engine at low idle.
RG40854,000011D 1928JAN021/1
CTM331 (03OCT05)
04-160-90

012506
PN=264
T23 - Multi-state Throttle Input Voltage Out of Range
Multi-state Throttle Switch Multi-state throttle is composed of an idle switch that allows engine speed to be at high or low idle. On some applications, there is a bump up and a bump down feature. This allows for high and low idle to be controlled. 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 ECU detects a high or low out of range multi-state throttle input voltage. If this code sets, the following will occur: The engine will not run if this code is active. If this code sets: Check to see if DTC 000091.03 or 4 is active. Diagnose those first. Return throttle to 0% throttle position
04 160 91
RG40854,000011C 1928JAN021/1
CTM331 (03OCT05)
04-160-91

012506
PN=265
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.
Application Excavator OEM 04 160 92 Tractors Diagnostic Procedure T11 - Excavator Throttle Reference Voltage High T5 - Analog Throttle (B) Input High T17 - Analog Throttle (C) Input High
RG41221,00000CE 1922JAN031/1
000028.04 Throttle Voltage Low
Throttle voltage is below the specification.

Application Excavator Tractor Diagnostic Procedure T12 - Excavator Throttle Reference Voltage Low T18 - Analog Throttle (C) Input Low
RG41221,00000CF 1922JAN031/1
CTM331 (03OCT05)
04-160-92

012506
PN=266

Application Excavator Forwarder OEM Skidder Tractor Diagnostic Procedure T13 - Excavator Throttle Ground Voltage High T5 - Analog Throttle (B) Input High T3 - Analog Throttle (A) Input High T1 - Multi-state Throttle Input High T5 - Analog Throttle (B) Input High 04 160 93
RG41221,00000D0 1922JAN031/1
CTM331 (03OCT05)
04-160-93

012506
PN=267

Application Excavator Forwarder 04 160 94 OEM Skidder Tractor Diagnostic Procedure T14 - Excavator Throttle Ground Voltage Low T6 - Analog Throttle (B) Input Low T4 - Analog Throttle (A) Input Low T2 - Multi-state Throttle Input Low T6 - Analog Throttle (B) Input Low
RG41221,00000D1 1922JAN031/1
000029.14 Throttle Voltage Out of Range
Throttle voltage is out of range.

Application Skidder Diagnostic Procedure T23 - Multi-state Throttle Input Voltage Out of Range
RG41221,00000D2 1922JAN031/1
CTM331 (03OCT05)
04-160-94

012506
PN=268
04 160 95
CTM331 (03OCT05)
04-160-95

012506
PN=269
000084.31 Vehicle Speed Mismatch

To Wheel Speed Sensor 64 21L
BCU
BIF
C2
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
1922AUG02 RG12588
1 04 160 96
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows limited information. For further wiring information, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
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 000084.31 will set if: The wheel speed from the BCU (PWM signal) and the BIF (CAN) do not match at the ECU. If DTC 000084.31 sets, the following will occur: Engine performance may be affected slightly.
RG40854,0000114 1912AUG021/1
CTM331 (03OCT05)
04-160-96

012506
PN=270
000084.31 Vehicle Speed Mismatch
The wheel speed from the BCU (PWM signal) and the BIF (CAN) do not match at the ECU.
RG40854,0000115 1923SEP051/1
000084.31 Vehicle Speed Mismatch Diagnostic Procedure
NOTE: If DTC 001069.31 occurs with DTC 000084.31, diagnose DTC 001069.31 first.
04 160 97
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED MISMATCH supporting information.
Perform a preliminary inspection of ECU connectors, BIF, and BCU connectors looking for dirty, damaged, or poorly positioned terminals.

1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Make note of all DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Read DTCs using the DST orSERVICE ADVISOR.
000084.31 reoccurs: GO TO 3 000084.31 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
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
CTM331 (03OCT05)
04-160-97

012506
PN=271

4 BCU to BIF PWM Wire Check
1. Ignition OFF 2. Disconnect BCU connector and BIF connector. 3. Using multimeter, measure resistance between terminal 64 on the BCU connector and terminal 21L on the 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.
1/1
04 160 98
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 D2 of ECU connector and terminal 64 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
CTM331 (03OCT05)
04-160-98

012506
PN=272

Application Backhoe Crawler Excavator Forwarder OEM Skidder Telehandler Tractor Diagnostic Procedure T3 - Analog Throttle (A) Input High T3 - Analog Throttle (A) Input High 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 T3 - Analog Throttle (A) Input High 04 160 99
RG41221,00000D3 1922JAN031/1
CTM331 (03OCT05)
04-160-99

012506
PN=273

Application Backhoe Crawler 04 160 ,100 Excavator Forwarder OEM Skidder Telehandler Tractor Diagnostic Procedure T4 - Analog Throttle (A) Input Low T4 - Analog Throttle (A) Input Low 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 T4 - Analog Throttle (A) Input Low
RG41221,00000D4 1922JAN031/1
000091.07 Throttle Calibration Invalid
The ECU detects an improper throttle calibration range.

Application Crawler Diagnostic Procedure T19 - Throttle Not Calibrated Properly
RG41221,00000D5 1922JAN031/1
CTM331 (03OCT05)
04-160-100

012506
PN=274
The throttle voltage is below the defined low calibration limit.

Application Crawler Diagnostic Procedure T20 - Throttle Input Voltage Below Lower Calibration Limit 04 160 ,101
RG41221,00000D6 1922JAN031/1
000091.13 Throttle Calibration Aborted
Throttle calibration aborted before it was completed.

Application Crawler Diagnostic Procedure T21 - Throttle Calibration Aborted
RG41221,00000D7 1922JAN031/1
CTM331 (03OCT05)
04-160-101

012506
PN=275
000091.14 Throttle Voltage Out of Range
Throttle voltage is above or below the specification.

Application Backhoe Crawler 04 160 ,102 Skidder Diagnostic Procedure T22 - Analog Throttle (A) Input Voltage Out of Range T22 - Analog Throttle (A) Input Voltage Out of Range T22 - Analog Throttle (A) Input Voltage Out of Range
RG41221,00000D8 1922JAN031/1
000097.00 Water in Fuel Continuously Detected

NOTE: Wiring schematic shows OEM engine applications only. For wiring information on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 laber in this manual.
Water in Fuel (WIF) Sensor
DB92450,000001A 1904OCT051/3
CTM331 (03OCT05)
04-160-102

012506
PN=276

Two-Wire The water in fuel sensor consists of two electrodes (A) (in the bottom of the bowl of the final fuel filter) and a resistor (internal to the ECU (E)) in parallel with the electrodes. Diesel fuel is a very poor conductor of electricity, compared to water, and while only fuel is present in the bowl, WIF analog signal passes through the resistor. While in a no-WIF state, ECU senses only normal WIF analog signal (F2) demand. When water displaces fuel at the bottom of the bowl, above the level (D) of the WIF electrode insulation (B), current passes across WIF sensor electrodes (C), ECU senses a greater WIF analog signal demand (from across ECU contacts F2 and D3), and ECU causes either engine derate or shut down.
Two-Wire WIF Sensor Schematic
04 160 ,103
DB92450,000001A 1904OCT052/3
DTC 000097.00 will set it: water is present in the bottom of the bowl of the final fuel filter, up to the level of the uninsulated WIF sensor electrodes. If DTC 000097.00 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. - With Derate Feature: The engine is derated to 80% of total power. The rate at which the engine is derated varies between applications. - Other: Engine is shut down.
Three-Wire WIF Sensor Schematic

D3Signal Return E2Excitation Voltage F2WIF Signal Input J1ECU Harness Connector AECU BWIF Sensor Connector CWIF Sensor
DB92450,000001A 1904OCT053/3
CTM331 (03OCT05)
04-160-103

012506
RG14499
UN28SEP05
Three-Wire (OEM Marine Only) With no water in the bowl at the bottom of the filter canister, the WIF circuit switch (internal to the ECU) pulls the circuit to +5 volts. When water is in the bowl, WIF sensor causes the WIF circuit to pull to ground.
RG14498
UN28SEP05
PN=277
000097.00 Water in Fuel Continuously Detected Diagnostic Procedure
The WIF limit is above a predetermined quantity for an extended period of time..
DB92450,000001E 1905OCT051/1
Water in Fuel Continuously Detected Diagnostic Procedure

04 160 ,104
1/1
1 Connection Check
IMPORTANT: Do not force probes in to 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 connedtion(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 to the DST or SERVICE ADVISOR. 2. Ignition ON, entine 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 on the DST or SERVICE ADVISOR
000097.00 reoccurs:GO TO 3 000097.00 doesnt reoccur:Problem most likely caused by moisture build up over time. Monitor the seciment bowl for moisture periodically, drain as needed.
1/1
CTM331 (03OCT05)
04-160-104

012506
PN=278

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 buildup 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 ,105
CTM331 (03OCT05)
04-160-105

012506
PN=279
000097.03 Water in Fuel Signal Voltage High

Water in Fuel Sensors Water in Fuel Sensor Connector Water in Fuel Input
A B A B
Sensor Ground
D3
F2
1919DEC02 RG12775
04 160 ,106
ECU HARNESS CONNECTOR Water in Fuel (WIF) Sensor The water in fuel sensor consists of two electrodes in the bottom of the bowl of the final fuel filter and a 200-kilohm resistor, in parallel with the electrodes. Diesel fuel is a very poor conductor of electricity, compared to water, and while only fuel is present in the bowl, virtually all current passes through the resistor. This causes ECU to sense only a nominal, constant current demand. But when water displaces fuel at the bottom of the bowl, resistance across the electrodes becomes significantly less than across the resistor, and additional current passes through the water across the electrodes. This causes ECU to detect a greater current demand, which derates or shuts down the engine. DTC 000097.03 will set if:
The WIF input voltage exceeds the sensors high voltage specification. The voltage corresponds to an amount of water in fuel that is not possible. - For OEM applications, the high WIF input voltage specification is 5.0 volts. - For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for the high WIF input voltage specification. If DTC 000097.03 sets, the following will occur: ECUs WIF engine protection feature disabled. See ENGINE PROTECTION in Section 03, Group 140 earlier in this manual.
RG40854,0000002 1927JUL051/1
CTM331 (03OCT05)
04-160-106

012506
PN=280
000097.03 Water in Fuel Signal Voltage High
The WIF input voltage exceeds the sensors high voltage specification. The voltage corresponds to an amount of water in fuel that is not possible.
RG40854,0000003 1923SEP051/1
000097.03 Water In Fuel Signal Voltage High Diagnostic Procedure

04 160 ,107
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 000097.03 WATER IN FUEL SIGNAL VOLTAGE HIGH supporting information.
1/1
1. Connect to the DST or SERVICE ADVISOR. 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 the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-107

012506
PN=281

3 WIF Sensor Test
1. Ignition OFF 2. Disconnect WIF sensor connector. 3. Install a jumper wire between both terminals in the WIF sensor connector on the engine harness. 4. Make note of all DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Using the ECU diagnostic software, read DTCs
000097.03 reoccurs: GO TO 4 000097.04 occurs: Faulty WIF sensor connector OR Faulty WIF sensor
04 160 ,108
1/1
4 WIF Input Open Test
1. Ignition OFF 2. Remove jumper wire between both terminals. 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between WIF input terminal (terminal A) in the sensor connector on the engine harness and a good chassis ground.
4.0 - 6.0 volts: Open in WIF sensor ground circuit OR Faulty ECU connection OR Faulty ECU Below 4.0 volts: Open in WIF sensor input circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-108

012506
PN=282
04 160 ,109
CTM331 (03OCT05)
04-160-109

012506
PN=283
000097.04 Water in Fuel Signal Voltage Low

A B A B
Sensor Ground
D3
F2
1919DEC02 RG12775
04 160 ,110
ECU HARNESS CONNECTOR Water in Fuel (WIF) Sensor The water in fuel sensor consists of two electrodes in the bottom of the bowl of the final fuel filter and a 200-kilohm resistor, in parallel with the electrodes. Diesel fuel is a very poor conductor of electricity, compared to water, and while only fuel is present in the bowl, virtually all current passes through the resistor. This causes ECU to sense only a nominal, constant current demand. But when water displaces fuel at the bottom of the bowl, resistance across the electrodes becomes significantly less than across the resistor, and additional current passes through the water across the electrodes. This causes ECU to detect a greater current demand, which derates or shuts down the engine. DTC 000097.04 will set if:
The WIF input voltage drops below the sensors low voltage specification. The voltage corresponds to an amount of water in fuel that is not possible. For OEM applications, the low WIF input voltage specification is 0.5 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual for the low WIF input voltage specification. If DTC 000097.04 sets, the following will occur: ECUs WIF engine protection feature disabled.
RG40854,0000004 1904SEP021/1
CTM331 (03OCT05)
04-160-110

012506
PN=284
000097.04 Water in Fuel Signal Voltage Low
The WIF input voltage drops below the sensors low voltage specification. The voltage corresponds to an amount of water in fuel that is not possible.
RG40854,0000005 1923SEP051/1
000097.04 Water In Fuel Signal Voltage Low Diagnostic Procedure

04 160 ,111
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL SIGNAL VOLTAGE LOW supporting information.
1/1
1. Connect to the DST or SERVICE ADVISOR. 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 the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-111

012506
PN=285

3 WIF Sensor Test
1. Ignition OFF 2. Disconnect WIF sensor connector. 3. Make note of all DTCs, then clear all DTCs. 4. Ignition ON engine OFF 5. Using the ECU diagnostic software, read DTCs
000097.04 reoccurs: Short to ground in WIF sensor input circuit OR Faulty ECU 000097.03 occurs: Faulty WIF sensor
1/1
04 160 ,112
CTM331 (03OCT05)
04-160-112

012506
PN=286
04 160 ,113
CTM331 (03OCT05)
04-160-113

012506
PN=287
000097.16 Water in Fuel Detected

A B A B
Sensor Ground
D3
F2
1919DEC02 RG12775
04 160 ,114
ECU HARNESS CONNECTOR Water in Fuel (WIF) Sensor The water in fuel sensor consists of two electrodes in the bottom of the bowl of the final fuel filter and a 200-kilohm resistor, in parallel with the electrodes. Diesel fuel is a very poor conductor of electricity, compared to water, and while only fuel is present in the bowl, virtually all current passes through the resistor. This causes ECU to sense only a nominal, constant current demand. But when water displaces fuel at the bottom of the bowl, resistance across the electrodes becomes significantly less than across the resistor, and additional current passes through
the water across the electrodes. This causes ECU to detect a greater current demand, which derates or shuts down the engine. DTC 000097.16 will set if: The WIF is above a predetermined quantity at any given time. If DTC 000097.16 sets, the following will occur: Engine protection be enabled.
RG40854,0000006 1904SEP021/1
CTM331 (03OCT05)
04-160-114

012506
PN=288
000097.16 Water in Fuel Detected
The WIF is above a predetermined quantity at any given time.
RG40854,0000007 1923SEP051/1
000097.16 Water In Fuel Detected Diagnostic Procedure

04 160 ,115
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL DETECTED supporting information.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs. 5. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out. 6. Operate engine in normal use. 7. Read DTCs using the DST orSERVICE ADVISOR.
000097.16 reoccurs: GO TO 3 000097.16 does not reoccur: Problem is was most likely caused by moisture buildup over time. Monitor the sediment bowl for moisture periodically, drain as needed.
1/1
CTM331 (03OCT05)
04-160-115

012506
PN=289

3 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 ,116
000097.31 Water in Fuel Detected (750J Crawler Only)

Water in Fuel (WIF) Sensor The water in fuel sensor enables ECU (E) to detect water in fuel. When this happens, ECU either derates or shuts down the engine, depending on the option selected. For more WIF information, see Theory of Operation, Section 03, Group 140, earlier in this CTM. DTC 000097.31 will set it: Water has been detected in the separator bowl. If DTC 000097.31 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. - With Derate Feature: The engine is derated to 40% of total power, at the rate of 20 % per minute. Shutdown and override options are not available with this DTC.
Water In Fuel Sensor Schematic
DB92450,000001B 1904OCT051/1
CTM331 (03OCT05)
04-160-116

012506
RG14498
UN28SEP05
PN=290
000097.31 Water in Fuel Detected (750J Crawler Only)
The WIF is above a predetermined quantity at any given time.
DB92450,000001D 1923SEP051/1
Water in Fuel Detected (750J Crawler Only) Diagnostic Procedure

04 160 ,117
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see DTC 000097.31 WATER IN FUEL DETECTED (750J Crawler Only) supporting information.
1/1
1. Connect to the DST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU diagnostic software 4. Make note of all DTCs, then clear all DTCs. 5. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out. 6. Operate engine in normal use. 7. Read DTCs using the DST orSERVICE ADVISOR.
000097.31 reoccurs: GO TO 3 000097.31 does not reoccur: Problem is was most likely caused by moisture buildup over time. Monitor the sediment bowl for moisture periodically, drain as needed.
1/1
CTM331 (03OCT05)
04-160-117

012506
PN=291

3 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 ,118
CTM331 (03OCT05)
04-160-118

012506
PN=292
04 160 ,119
CTM331 (03OCT05)
04-160-119

012506
PN=293
000100.01 Engine Oil Pressure Extremely Low

Oil Pressure Sensor B C A
A C B B A C
Oil Pressure Sensor Connector B 5V Supply C Oil Pressure Input A Sensor Ground D3 F3 E2
1914DEC01 RG11978
012506
A3 B3 C3 D3 E3 A2 B2 C2 D2 E2
04 160 ,120
A1 B1 C1 D1 E1

A1 A2 A3
Oil Pressure Switch P Oil Pressure Input C1
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
NOTE: Wiring schematics show OEM engine applications for the oil pressure sensor and Telehandler applications for the oil pressure switch. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Oil Pressure Sensor or Switch 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 Section 03, Group 140 earlier in this manual.
The oil pressure switch is used to detect a loss of oil pressure. Oil pressure causes the contacts in the switch close when oil pressure drops below the minimum oil pressure threshold. The switch is open when the engine is not running and engine is running with sufficient oil pressure. DTC 000100.01 will set if: For engines with an oil pressure sensor, the ECU senses an extremely low oil pressure. For engines with an oil pressure switch, the ECU senses 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:
RG40854,0000088 1907DEC011/2
CTM331 (03OCT05)
04-160-120

PN=294
RG12045
C O N N E C T O R
1920DEC01

Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of 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 of this manual.
RG40854,0000088 1907DEC012/2
04 160 ,121
CTM331 (03OCT05)
04-160-121

012506
PN=295
000100.01 Engine Oil Pressure Extremely Low
For engines with an oil pressure sensor, the ECU senses an extremely low oil pressure. For engines with an oil pressure switch, the ECU
senses the oil pressure switch is open after the engine is above cranking RPM for several seconds.
RG40854,00000B2 1907SEP051/1
000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure

04 160 ,122
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW supporting information
Perform a preliminary inspection of the ECU connector, the oil pressure sensor, and any connectors in between them. Look 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 Section 04, 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 or switch circuits is OK. If oil pressure sensor or switch circuits are OK, replace oil pressure sensor or switch and retest. Oil pressure below specification: Low oil pressure problem. See 4.5L/6.8L - L2 ENGINE OIL PRESSURE LOW in Section 04, Group 150 of 4.5 L and 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
CTM331 (03OCT05)
04-160-122

012506
PN=296
04 160 ,123
CTM331 (03OCT05)
04-160-123

012506
PN=297
000100.03 Engine Oil Pressure Input Voltage High

A C B B A C
1914DEC01 RG11978
012506
A3 B3 C3 D3 E3 A2 B2 C2 D2 E2
04 160 ,124
A1 B1 C1 D1 E1
NOTE: Wiring schematic shows OEM engine applications only. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of 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 Section 03, 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 is higher than what is physically possible for oil pressure. For OEM applications, the high oil pressure input voltage specification is 4.5 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high oil pressure input voltage specification. If DTC 000100.03 sets, the following will occur: ECU uses a default oil pressure of 260 kPa (2.6 bar) (37.5 psi). ECUs low oil pressure engine protection feature disabled.
RG40854,0000086 1907DEC011/1
CTM331 (03OCT05)
04-160-124

PN=298
000100.03 Engine Oil Pressure Input Voltage High
The oil pressure input voltage exceeds the sensors high voltage specification. The voltage is higher than what is physically possible for oil pressure.
RG40854,00000B3 1919SEP051/1
000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure

04 160 ,125
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000100.03 ENGINE OIL PRESSURE INPUT VOLTAGE HIGH supporting information
Perform a preliminary inspection of the ECU connector, the oil pressure sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine running 7. Read Oil Pressure Input Voltage using the the DST orSERVICE ADVISOR.
4.5 V or greater: GO TO 3 Below 4.5 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
NOTE: For OEM applications, the high oil pressure input voltage specification is 4.5V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-125

012506
PN=299

3 Oil Pressure Input Shorted Test
1. Ignition OFF 2. Disconnect oil pressure sensor connector 3. Ignition ON, engine OFF 4. Read Oil Pressure Input Voltage using the DST or SERVICE ADVISOR.
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 other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
04 160 ,126
4 Oil Pressure Ground Circuit Open Test
Probe oil pressure sensor ground (Terminal A) in sensor harness connector 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
CTM331 (03OCT05)
04-160-126

012506
PN=300
04 160 ,127
CTM331 (03OCT05)
04-160-127

012506
PN=301
000100.04 Engine Oil Pressure Input Voltage Low

A C B B A C
1914DEC01 RG11978
012506
A3 B3 C3 D3 E3 A2 B2 C2 D2 E2
04 160 ,128
A1 B1 C1 D1 E1

A1 A2 A3
Oil Pressure Switch P Oil Pressure Input C1
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
NOTE: Wiring schematics show OEM engine applications for the oil pressure sensor and Telehandler applications for the oil pressure switch. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Oil Pressure Sensor or Switch 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 Section 03, Group 140 earlier in this manual.
The oil pressure switch is used to detect a loss of oil pressure. A lack of oil pressure causes the contacts in the switch close when oil pressure drops below the minimum oil pressure threshold. The switch is open when the engine is not running and engine is running with sufficient oil pressure. DTC 000100.04 will set if: For oil pressure sensors, the oil pressure input voltage drops below the sensors low voltage specification. The voltage is lower than what is physically possible for oil pressure. For OEM applications, the low oil pressure input voltage specification is 0.3 volts.
RG40854,0000084 1907DEC011/2
CTM331 (03OCT05)
04-160-128

PN=302
RG12045
C O N N E C T O R
1920DEC01

For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low oil pressure input voltage specification. For oil pressure switches, the oil pressure switch is closed when key is on and there is no engine speed. If DTC 000100.04 sets, the following will occur: ECU uses a default oil pressure of 260 kPa (2.6 bar) (37.5 psi). ECUs low oil pressure engine protection feature disabled.
RG40854,0000084 1907DEC012/2
04 160 ,129
CTM331 (03OCT05)
04-160-129

012506
PN=303
000100.04 Engine Oil Pressure Input Voltage Low
For oil pressure sensors, the oil pressure input voltage drops below the sensors low voltage specification.
For oil pressure switches, the oil pressure switch is closed when key is on and there is no engine speed.
RG40854,00000B4 1923SEP051/1
000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure

04 160 ,130
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
1/1
NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine running 7. Read DTCs using the the DST orSERVICE ADVISOR.
000100.04 reoccurs: GO TO 3 000100.04 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-130

012506
PN=304

3 Oil Pressure Sensor Check
NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE OIL PRESSURE INPUT VOLTAGE LOW supporting information.
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 Wiring Test
1. Ignition OFF 2. Disconnect oil pressure sensor connector 3. Install a jumper wire between oil pressure 5 V supply and oil pressure input in harness sensor connector 4. Read the Oil Pressure Input Voltage parameter using the DST or SERVICE ADVISOR.
Below 4.5 V: GO TO 5
04 160 4.5 V or greater: ,131 Faulty oil pressure sensor connector OR Faulty oil pressure sensor
NOTE: For OEM applications, the high oil pressure input voltage specification is 4.5V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
5 Oil Pressure Sensor 5 V Supply Test
1. Ignition OFF 2. Remove jumper wire 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between oil pressure 5 V supply terminal and a good chassis ground
Between 4.0 V and 6.0 V: Open in oil pressure input circuit OR Short to ground in oil pressure input circuit OR Faulty ECU connector OR Faulty ECU Below 4.0 V: Open in oil pressure 5 V supply circuit OR Short to ground in oil pressure 5 V supply circuit OR Faulty ECU connector OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-131

012506
PN=305

6 Oil Pressure Switch Short in Wire Check
1. Ignition OFF 2. Disconnect oil pressure switch connector and ECU connector 3. Using a multimeter, measure the resistance between terminal C1 in the ECU and: All other terminals in the ECU connector A good ground
All measurements greater than 2000 ohms: Faulty oil pressure switch OR Faulty ECU Any measurement less than 2000 ohms: Short in oil pressure input circuit
1/1
04 160 ,132
CTM331 (03OCT05)
04-160-132

012506
PN=306
04 160 ,133
CTM331 (03OCT05)
04-160-133

012506
PN=307
000100.16 - Engine Oil Pressure High, Moderately Severe Level

A C B B A C
1914DEC01 RG11978
012506
A3 B3 C3 D3 E3 A2 B2 C2 D2 E2
04 160 ,134
A1 B1 C1 D1 E1

Engine Oil Pressure Sensor Schematic
NOTE: Schematic shows OEM engine applications only. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of 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 Section 03, Group 140 earlier in this manual.
DTC 000100.16 will set if: With the ignition ON and zero engine speed, the ECU senses a moderately-severe, high-level oil pressure. If DTC 000100.16 sets, the following will occur: Engine protection is not enabled. With Shutdown Feature: No shutdown available for this code. With Derate Feature: No derate available for this code.
DB92450,0000015 1919JUL051/1
000100.16 Engine Oil Pressure High, Moderately Severe Level Incorrect Reading Diagnostic Procedure
The ECU detects moderately-severe, high-level oil pressure with ignition ON and zero engine speed, caused by open in sensor ground path.
DB92450,0000017 1922SEP051/1
CTM331 (03OCT05)
04-160-134

PN=308

Electrical Test
1/1
1 Connector Check
Inspect pin D3 of ECU connector J1 and pressure sensor connectors (male and female sides), pins C for bad connection, damaged pin, rust, or corrosion.
Open not found:GO TO 2 . Bad connections, damaged pins, and rust or corrosion found:Replace faulty element and retest.
04 160 ,135
1/1
2 Ground Wire Continuity Check
Open in wire:Remove and replace faulty wire, and retest. No open in wire:GO TO 3 .
NOTE: For wiring and theory of operation information, see DTC 000100.16 - ENGINE OIL PRESSURE HIGH, MODERATELY SEVERE LEVEL supporting information
1. Disconnect ECU connector J1 and EOP sensor connector 2. Using a multimeter, perform a continuity check of ground wire (A) from oil pressure sensor connector to ECU connector J1, pin D3
1/1
3 Pressure Sensor Continuity Check
Open in sensor:Remove and replace sensor, and retest.
NOTE: For wiring and theory of operation information, see DTC 000100.16 - ENGINE OIL PRESSURE HIGH, MODERATELY SEVERE LEVEL supporting information
1. Disconnect EOP sensor connector 2. Using a multimeter, perform a continuity check between pins A and B oil pressure sensor connector (sensor side).
1/1
CTM331 (03OCT05)
04-160-135

012506
PN=309
000100.18 Engine Oil Pressure Moderately Low

A C B B A C
1914DEC01 RG11978
012506
A3 B3 C3 D3 E3 A2 B2 C2 D2 E2
04 160 ,136
A1 B1 C1 D1 E1
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 Section 03, Group 140 earlier in this manual. DTC 000100.18 will set if:
For engines with an oil pressure sensor, the ECU senses a moderately low oil pressure. If DTC 000100.18 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. With Shutdown Feature: No shutdown available for this code. With Derate Feature: On OEM applications, the engine derates 40% per minute until the engine is running at 60% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
RG40854,0000082 1907DEC011/1
CTM331 (03OCT05)
04-160-136

PN=310
000100.18 Engine Oil Pressure Moderately Low
For engines with an oil pressure sensor, the ECU senses a moderately low oil pressure.
RG40854,00000B5 1907SEP051/1
000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure

04 160 ,137
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. CHECK ENGINE OIL PRESSURE in Section 04, 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 4.5L/6.8L - L2 ENGINE OIL PRESSURE LOW in Section 04, Group 150 of 4.5 L 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
CTM331 (03OCT05)
04-160-137

012506
PN=311
000105.03 Manifold Air Temperature Input Voltage High

MAT Sensor MAT Sensor Connector B A B A Sensor Ground MAT Input
D1
D3
1914DEC01 RG11979
04 160 ,138
MAT (Manifold Air Temperature) 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 is higher than what is physically possible for manifold air. 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 specification. If DTC 000105.03 sets, the following will occur: ECU uses a default MAT value of 60C (140F). ECUs high manifold air temperature engine protection feature disabled.
RG40854,0000080 1907DEC011/1
CTM331 (03OCT05)
04-160-138

012506
PN=312
000105.03 Manifold Air Temperature Input Voltage High
The manifold air temperature input voltage exceeds the sensors high voltage specification.
RG40854,00000B6 1923SEP051/1
000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure

04 160 ,139
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.
Perform a preliminary inspection of the ECU connector, the manifold air temperature sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Ignition ON, engine OFF 5. Read the Manifold Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
4.9 V or greater: GO TO 3 Below 4.9 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
NOTE: For OEM applications, the high manifold air temperature input voltage specification is 4.9V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-139

012506
PN=313

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 harness connector 4. Ignition ON, engine OFF 5. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Above 0.1 V: GO TO 4 0.1 V or below: Faulty MAT sensor connector OR Faulty MAT sensor
NOTE: For OEM applications, the low manifold air temperature input voltage specification is 0.1V. For the low voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04 160 ,140
1/1
4 MAT Sensor Open Ground Circuit Test
1. Ignition OFF 2. Remove jumper wire between both terminals. 3. Install jumper wire between MAT sensor harness connector input terminal and a good chassis ground. 4. Ignition ON, engine OFF 5. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Above 0.1 V: Open in MAT sensor input circuit OR Faulty ECU connection OR Faulty ECU 0.1 V or below: Open in MAT sensor ground circuit OR Faulty ECU connection OR Faulty ECU
NOTE: For OEM applications, the low manifold air temperature input voltage specification is 0.1V. For the low voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-140

012506
PN=314
04 160 ,141
CTM331 (03OCT05)
04-160-141

012506
PN=315
000105.04 Manifold Air Temperature Input Voltage Low

D1
D3
1914DEC01 RG11979
04 160 ,142
MAT (Manifold Air Temperature) 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 goes below the sensors low voltage specification. The voltage is lower than what is physically possible manifold air temperature to achieve. For OEM engine applications, the low manifold air temperature input voltage specification is 0.1 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low manifold temperature input voltage specification. If DTC 000105.04 sets, the following will occur: ECU uses a default MAT value of 60C (140F) to run engine. ECUs high manifold air temperature engine protection feature disabled.
RG40854,000007D 1907DEC011/1
CTM331 (03OCT05)
04-160-142

012506
PN=316
000105.04 Manifold Air Temperature Input Voltage Low
The manifold air temperature input voltage goes below the sensors low voltage specification.
RG40854,00000B7 1923SEP051/1
000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure

04 160 ,143
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. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Ignition ON, engine OFF 5. Read the Manifold Air Temperature Input Voltage parameter using SERVICE ADVISOR.
0.1 V or below: GO TO 3 Above 0.1 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
NOTE: For OEM engine applications, the low manifold air temperature input voltage specification is 0.1V. For the low voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-143

012506
PN=317

3 MAT Sensor Test
1. Ignition OFF 2. Disconnect MAT sensor connector. 3. Ignition ON, engine OFF 4. Read the Manifold Air Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
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
NOTE: For OEM engine applications, the high manifold air temperature input voltage specification is 4.9V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04 160 ,144
1/1
CTM331 (03OCT05)
04-160-144

012506
PN=318
04 160 ,145
CTM331 (03OCT05)
04-160-145

012506
PN=319
000105.16 Manifold Air Temperature Moderately High

D1
D3
1914DEC01 RG11979
04 160 ,146
MAT (Manifold Air Temperature) 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 MAT on OEM applications above 100C (212F) for H engines and 120C (248F) for T engines. For MAT specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC 000105.16 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. With Shutdown Feature: The ECU does not use shutdown feature with this code. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 80% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
RG40854,000007B 1907DEC011/1
CTM331 (03OCT05)
04-160-146

012506
PN=320
000105.16 Manifold Air Temperature Moderately High
The ECU senses MAT on OEM applications above specifications.
RG40854,00000B8 1918DEC011/1
000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure

04 160 ,147
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
CTM331 (03OCT05)
04-160-147

012506
PN=321
000110.00 Engine Coolant Temperature Extremely High

ECT Sensor t ECT Sensor Connector ECT Ground
B A B A
ECT Input B1
D3
1914DEC01 RG11980
04 160 ,148
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 Engine Control Unit (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 ECT on OEM applications above 118C (244F). For the most severe ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC 000110.00 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of 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 of this manual.
RG40854,0000071 1906DEC011/1
CTM331 (03OCT05)
04-160-148

012506
PN=322
000110.00 Engine Coolant Temperature Extremely High
The ECU senses ECT above specification.
RG40854,00000B9 1918DEC011/1
000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure

04 160 ,149
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH supporting information
Perform a preliminary inspection of the ECU connector, the Engine Coolant Temperature (ECT) connector, and any connectors in between them. Look 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, use a temperature gauge and verify that engine coolant temperature is above the most severe ECT specification.
NOTE: cations, the most severe ECT specification is 118C (244F). For the most severe ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
ECT 118C (244F) or above: Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). ECT significantly less than 118C (244F): Verify that ECT input and ground circuits are OK If both circuits are OK, replace ECT sensor and retest
1/1
CTM331 (03OCT05)
04-160-149

012506
PN=323
000110.03 Engine Coolant Temperature Input Voltage High

B A B A
ECT Input B1
D3
1914DEC01 RG11980
04 160 ,150
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 Engine Control Unit (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 ECT input voltage goes above the sensors high voltage specification. This voltage corresponds to a temperature that is lower than what is physically possible for engine coolant. For OEM engine applications, the high ECT input voltage specification is 4.9 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high ECT 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.
RG40854,0000072 1907DEC011/1
CTM331 (03OCT05)
04-160-150

012506
PN=324
000110.03 Engine Coolant Temperature Input Voltage High
The ECT input voltage goes above the sensors high voltage specification.
RG40854,00000BA 1923SEP051/1
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure

04 160 ,151
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
Perform a preliminary inspection of the ECU connector, the Engine Coolant Temperature (ECT) connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Ignition ON, engine running 5. Read the Engine Coolant Temperature Input Voltage parameter using SERVICE ADVISOR.
At or above 4.9 V: GO TO 3 Below 4.9 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
NOTE: On OEM applications, the high ECT input voltage specification is 4.9V. For high input voltage specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-151

012506
PN=325

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 harness connector 4. Ignition ON, engine OFF 5. Read the Engine Coolant Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Above 0.1 V: GO TO 4 At or below 0.1 V: Faulty ECT sensor connector OR Faulty ECT sensor
NOTE: On OEM applications, the low ECT input voltage specification is 0.1 volts and below. For ECT input voltage specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04 160 ,152
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 sensor harness connector input terminal and a good chassis ground 4. Ignition ON, engine OFF 5. Read the Engine Coolant Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Above 0.1 V: Open in ECT input sensor circuit OR Faulty ECU connection OR Faulty ECU 0.1 V or below: Open in ECT sensor ground circuit OR Faulty ECU connection OR Faulty ECU
NOTE: On OEM applications, the low ECT input voltage specification is 0.1 volts and below. For ECT input voltage specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-152

012506
PN=326
04 160 ,153
CTM331 (03OCT05)
04-160-153

012506
PN=327
000110.04 Engine Coolant Temperature Input Voltage Low

B A B A
ECT Input B1
D3
1914DEC01 RG11980
04 160 ,154
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 ECT input voltage goes below the sensors low voltage specification. This voltage corresponds to a temperature that is higher than what is physically possible for engine coolant. For OEM engine applications, the low ECT input voltage specification is 0.1 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high ECT 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.
RG40854,0000074 1907DEC011/1
CTM331 (03OCT05)
04-160-154

012506
PN=328
000110.04 Engine Coolant Temperature Input Voltage Low
The ECT input voltage goes below the sensors low voltage specification.
RG40854,00000BB 1923SEP051/1
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure

04 160 ,155
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
Perform a preliminary inspection of the ECU connector, the Engine Coolant Temperature (ECT) sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST orSERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Ignition ON, engine OFF 5. Read the Engine Coolant Temperature Input Voltage parameter using SERVICE ADVISOR.
0.1 V or below: GO TO 3 Above 0.1 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
NOTE: For OEM engine applications, the low ECT input voltage specification is 0.1V. For the low voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-155

012506
PN=329

3 Engine Coolant Temperature (ECT) Sensor Test
1. Ignition OFF 2. Disconnect ECT sensor connector 3. Ignition ON 4. Read the Engine Coolant Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Below 4.9 V: Short to ground in ECT sensor input circuit OR Faulty ECU 4.9 V or greater: Faulty ECT sensor
NOTE: For OEM engine applications, the high ECT input voltage specification is 4.9V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04 160 ,156
1/1
CTM331 (03OCT05)
04-160-156

012506
PN=330
04 160 ,157
CTM331 (03OCT05)
04-160-157

012506
PN=331
000110.15 Engine Coolant Temperature High Least Severe

B A B A
ECT Input B1
D3
1914DEC01 RG11980
04 160 ,158
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 000110.15 will set if:
The ECU senses ECT on OEM applications above 108C (226F). For the least severe ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC 000110.15 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. With Shutdown Feature: No shutdown available for this code. With Derate Feature: On OEM applications, the engine derates 2% per minute until the engine is running at 95% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
RG40854,0000076 1907DEC011/1
CTM331 (03OCT05)
04-160-158

012506
PN=332
000110.15 Engine Coolant Temperature High Least Severe
RG40854,00000BC 1907SEP051/1
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure

04 160 ,159
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 least severe ECT specification.
ECT above 108C (226F): Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). ECT significantly less than 108C (226F): Verify that ECT sensor input and ground circuits are OK. If ECT sensor circuits are OK, replace ECT sensor and retest
NOTE: On OEM applications, the least severe ECT specification is 108C (226F). For the least severe ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-159

012506
PN=333
000110.16 Engine Coolant Temperature Moderately High

B A B A
ECT Input B1
D3
1914DEC01 RG11980
04 160 ,160
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 ECT on OEM applications above 113C (235F). For the moderately ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC 000110.16 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. With Shutdown Feature: No shutdown available for this code. With Derate Feature: On OEM applications, the engine derates 40% per minute until the engine is running at 60% of full power. For non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
RG40854,0000079 1907DEC011/1
CTM331 (03OCT05)
04-160-160

012506
PN=334
000110.16 Engine Coolant Temperature Moderately High
RG40854,00000BD 1907SEP051/1
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure

04 160 ,161
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 113C (235F).
ECT above 113C (235F): Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). ECT significantly less than 113C (235F): Verify that ECT sensor input and ground circuits are OK. If ECT sensor circuits are OK, replace ECT sensor and retest
NOTE: On OEM applications, the moderately high ECT specification is 113C (235F). For the moderately high ECT specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-161

012506
PN=335
000111.00 Loss of Coolant Temperature Extremely High

Loss of Coolant Temperature Sensor t Loss of Coolant Temperature Sensor Connector Sensor Ground
B A B A
Input C1
D3
1924JAN02 RG11981
04 160 ,162
ECU HARNESS CONNECTOR Loss of Coolant Temperature Sensor The loss of coolant temperature sensor is a thermistor (temperature sensitive resistor) mounted in the rear of the cylinder head. It is used to measure the coolant temperature to detect whether there is a loss of coolant. The sensors variable resistance causes the input voltage to the ECU to vary. Higher coolant temperatures result in lower loss of coolant temperature input voltages to the ECU; lower temperatures result in higher voltages. For further loss of coolant temperature sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 earlier in this manual. DTC 000111.00 will set if:
The ECU senses a coolant temperature above 124C (255F). If DTC 000111.00 sets, the following will occur: The engine derates 20% per minute until the engine is running at 60% of full power. If the temperature goes below 124C (255F), the engine will regain power at 20% per minute.
RG40854,000006F 1906DEC011/1
CTM331 (03OCT05)
04-160-162

012506
PN=336
000111.00 Loss of Coolant Temperature Extremely High
The ECU senses a coolant temperature above specification.
RG40854,00000BE 1907SEP051/1
000111.00 Loss of Coolant Temperature Extremely High Diagnostic Procedure

04 160 ,163
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000111.00 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH supporting information
Perform a preliminary inspection of the ECU connector, the loss of coolant temperature sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
CTM331 (03OCT05)
04-160-163

012506
PN=337

2 Loss of Coolant Temperature Sensor and Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000111.00 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH supporting information
Under the conditions where DTC 000111.00 occurs, using a temperature gauge, verify that loss of coolant temperature is above 124C (255F).
Significantly less than 124C (255F): Verify that loss of coolant temperature sensor input and ground circuits are OK. If loss of coolant temperature sensor circuits are OK, replace loss of coolant temperature sensor and retest Temperature above 124C (255F): Engine overheating problem. See 4.5L/6.8L C1 - ENGINE COOLANT TEMPERATURE ABOVE NORMAL in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
04 160 ,164
1/1
CTM331 (03OCT05)
04-160-164

012506
PN=338
04 160 ,165
CTM331 (03OCT05)
04-160-165

012506
PN=339
000111.03 Loss of Coolant Temperature Input Voltage High

B A B A
Input C1
D3
1924JAN02 RG11981
04 160 ,166
The loss of coolant temperature input voltage exceeds 4.9 volts. This voltage corresponds to a temperature that is lower than what is physically possible for engine coolant. If DTC 000111.03 sets, the following will occur: ECUs high loss of coolant temperature engine protection feature disabled.
RG40854,00000C0 1919DEC011/1
CTM331 (03OCT05)
04-160-166

012506
PN=340
000111.03 Loss of Coolant Temperature Input Voltage High
The loss of coolant temperature input voltage exceeds 4.9 volts. This voltage corresponds to a temperature
that is lower than what is physically possible for engine coolant.
RG40854,00000C1 1923SEP051/1
000111.03 Loss of Coolant Temperature Input Voltage High Diagnostic Procedure

04 160 ,167
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000111.03 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine running 7. Read DTCs using the DST orSERVICE ADVISOR.
000111.03 reoccurs: GO TO 3 000111.03 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-167

012506
PN=341

3 Loss of Coolant Temperature Sensor and Connector Test
1. Ignition OFF 2. Disconnect loss of coolant temperature sensor connector 3. Install a jumper wire between both terminals in the loss of coolant temperature sensor harness connector 4. Ignition ON, engine OFF 5. Read DTCs using the DST or SERVICE ADVISOR.
000111.03 reoccurs: GO TO 4 000111.04 occurs: Faulty loss of coolant temperature sensor connector OR Faulty loss of coolant temperature sensor
1/1
04 160 ,168
4 Loss of Coolant Temperature Open Ground Test
1. Ignition OFF 2. Remove jumper wire between both terminals 3. Install jumper wire between loss of coolant temperature sensor harness connector input terminal and a good chassis ground 4. Ignition ON, engine OFF 5. Using a multimeter, measure voltage between loss of coolant temperature input (5V supply) terminal and a good chassis ground.
Between 4.0 V and 6.0 V: Open in loss of coolant temperature input sensor circuit OR Faulty ECU connection OR Faulty ECU Below 4.0 V: Open in loss of coolant temperature sensor ground circuit OR Faulty ECU connection OR Faulty ECU
1/1
CTM331 (03OCT05)
04-160-168

012506
PN=342
04 160 ,169
CTM331 (03OCT05)
04-160-169

012506
PN=343
000111.04 Loss of Coolant Temperature Input Voltage Low

B A B A
Input C1
D3
1924JAN02 RG11981
04 160 ,170
The loss of coolant temperature input voltage drops below 0.1 volts. This voltage corresponds to a temperature that is higher than what is physically possible for engine coolant. If DTC 000111.04 sets, the following will occur: ECUs high loss of coolant temperature engine protection feature disabled.
RG40854,0000069 1906DEC011/1
CTM331 (03OCT05)
04-160-170

012506
PN=344
000111.04 Loss of Coolant Temperature Input Voltage Low
The loss of coolant temperature input voltage drops below 0.1 volts. This voltage corresponds to a
temperature that is higher than what is physically possible for engine coolant.
RG40854,00000C2 1923SEP051/1
000111.04 Loss of Coolant Temperature Input Voltage Low Diagnostic Procedure

04 160 ,171
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000111.04 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1/1
NOTE: For wiring and theory of operation information, see DTC 000111.04 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine OFF 7. Read DTCs using the DST orSERVICE ADVISOR.
000111.04 reoccurs: GO TO 3 000111.04 does not reoccur: Problem is intermittent. If no other codes are present, INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-171

012506
PN=345

3 Loss of Coolant Temperature Sensor Test
NOTE: For wiring and theory of operation information, DTC 000111.04 LOSS OF COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information
1. Ignition OFF 2. Disconnect loss of coolant temperature sensor connector 3. Ignition ON 4. Read DTCs using the DST or SERVICE ADVISOR.
000111.04 reoccurs: Short to ground in loss of coolant temperature sensor input circuit OR Faulty ECU 000111.03 occurs: Faulty loss of coolant temperature sensor
1/1
04 160 ,172
CTM331 (03OCT05)
04-160-172

012506
PN=346
04 160 ,173
CTM331 (03OCT05)
04-160-173

012506
PN=347
000158.17 ECU Power Down Error

Battery Ignition Switch VSW 30 A VBAT K1
A2
1914DEC01 RG11982
04 160 ,174
DTC 000158.17 will set if:
ECU detects voltage is 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.
RG40854,0000066 1906DEC011/1
CTM331 (03OCT05)
04-160-174

012506
PN=348
000158.17 ECU Power Down Error
ECU detects voltage is on the switched voltage input wire to the ECU.
RG40854,0000109 1923SEP051/1
000158.17 ECU Power Down Error Diagnostic Procedure

04 160 ,175
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU POWER DOWN ERROR supporting information.
Perform a preliminary inspection of the ECU connector, ignition power circuit, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Cycle ignition OFF for 10 seconds, then back ON 7. Read DTCs using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-175

012506
PN=349

3 Wiring Test
1. Ignition OFF 2. Disconnect the ECU connector 3. Ignition ON, engine OFF 4. Using a multimeter, measure voltage between terminal A2 the ECU wiring harness connector and a good chassis ground.
Measurement above 3.0 V: Faulty ignition switch circuit OR ECU key-on power supply shorted to voltage OR Faulty ignition switch Measurement below 3.0 V: Faulty ECU connection OR Faulty ECU
04 160 ,176
1/1
CTM331 (03OCT05)
04-160-176

012506
PN=350
04 160 ,177
CTM331 (03OCT05)
04-160-177

012506
PN=351
000160.02 Wheel Speed Input Noise

To Wheel Speed Sensor 64 21L
BCU
BIF
C2
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
1922AUG02 RG12588
1 04 160 ,178
NOTE: Wiring schematic shows limited information. For further wiring information, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Wheel Speed Sensor 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. DTC 000160.02 will set if: The ECU detects noise on the wheel speed input. If DTC 000160.02 sets, the following will occur: Road speed limiting function is disabled.
RG40854,0000002CONV1 1912AUG021/1
CTM331 (03OCT05)
04-160-178

012506
PN=352
000160.02 Wheel Speed Input Noise
The ECU detects noise on the wheel speed input.
RG40854,0000003CONV1 1923SEP051/1
000160.02 Wheel Speed Input Noise Diagnostic Procedure

04 160 ,179
1/1
1 Connection Check
No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s).
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL SPEED INPUT NOISE supporting information.
Perform a preliminary inspection of the ECU connectors and BCU connectors looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Warm engine 3. Ignition ON, engine OFF 4. Start ECU communication software 5. Read DTCs using the DST orSERVICE ADVISOR. 6. Make note of all DTCs, then clear all DTCs 7. Ignition ON, engine running 8. Read DTCs
1/1
CTM331 (03OCT05)
04-160-179

012506
PN=353

3 Open Wheel Speed Input Check
1. Ignition OFF 2. Disconnect ECU connector and BCU connector 3. Using a multimeter, measure resistance between: Terminal D2 in the ECU connector and corresponding terminal on the BCU connector.
Measurement 5 ohms or less: GO TO 4 Measurement greater than 5 ohms: Open in wheel speed input wire
1/1
04 160 ,180
4 Short in Wheel Speed Input Check
1. Ignition OFF 2. Both ECU connectors and BCU connector still disconnected 3. Using a multimeter measure resistance between terminal D2 in the ECU connector on the engine harness and the following: A good chassis ground. All other terminals in both ECU connectors.
All measurements greater than 2000 ohms: GO TO 5 Any measurement less than 2000 ohms: Faulty wheel speed input wire
1/1
5 Noise Detection Test
1. 000160.02 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 cam sensor wiring
2. Other possible causes of 000160.02: Electromagnetic interference (EMI) from an incorrectly installed 2-way radio Interference from some radar source Possible burrs on the wheel speed timing gear notches, should be clean, square edges
1/1
CTM331 (03OCT05)
04-160-180

012506
PN=354
000171.03 Ambient Air Temperature Input Voltage Out Of Range High (750J Crawlers only)
UN28SEP05
Ambient Air Temperature Sensor Schematic
Ambient Air Temperature (AAT) Sensor The AAT sensor (C) is a thermistor (temperature sensitive resistor) mounted in the intake air duct. The AAT sensors variable resistance causes the input voltage to the ECU (A) to vary. Higher temperatures result in lower AAT input voltages to the ECU; lower temperatures result in higher voltages. The AAT sensor is used by the ECU to control the air heater in applications that use this optional feature.
DTC000171.03 will set if: The AAT input voltage exceeds the maximum threshold. This voltage corresponds to a temperature that is lower than what is physically possible for ambient air. If DTC 000171.03 sets, the following will occur: No engine protection measures, nor other reactions, accompany this DTC.
DB92450,000001F 1903AUG051/1
CTM331 (03OCT05)
04-160-181

012506
RG14504
04 160 ,181
PN=355
000171.03 Ambient Air Temperature Input Voltage Out Of Range High (750J Crawlers only)
The Ambient Air Temperature (AAT) input voltage goes above the sensors high voltage specification.
DB92450,0000020 1926SEP051/1
000171.03 AAT Input Voltage Out Of Range High Diagnostic Procedure (750J Crawlers only)
04 160 ,182
1/1
1 Connection Check
NOTE: For wiring, theory of operation, and sensor location information, see DTC 000171.03 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector, the AAT sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring, theory of operation, and sensor location information, see DTC 000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Make note of any DTCs, then clear all DTCs. 5. Ignition ON, engine cranking or running 6. Read the AAT Input Voltage parameter using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-182

012506
PN=356

3 AAT Voltage Supply Wiring Test 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. Continuity is present: GO TO 4 Continuity is not present: Isolate to open wire or place, and replace faulty item.
1. Ignition OFF 2. Disconnect AAT sensor connector 3. Using a multimeter, check for continuity between ECU, pin C1, and pin A of sensor connector.
1/1
4 AAT Voltage Return Wiring Test
Continuity is present: GO TO 5 Continuity is not present: Isolate to open wire or place, and replace faulty item.
1. Ignition OFF 2. Disconnect AAT sensor connector 3. Using a multimeter, check for continuity between ECU, pin D3, and pin B of sensor connector.
04 160 ,183
1/1
5 ECU Test
1. Engine OFF, Ignition ON. 2. . Clear DTC. 3. . Ignition OFF. 4. Reconnect sensor. 5. Substitute existing ECU with known, good, compatible ECU. 6. . Ignition ON, Engine ON.
DTC 000171.03 does not reoccur: Replace Sensor and use DST or Service ADVISOR to download payload.
1/1
CTM331 (03OCT05)
04-160-183

012506
PN=357

6 AAT Sensor Test 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. Continuity is present: GO TO 6 Continuity is not present: AAT sensor faulty. Replace sensor
1. Ignition OFF 2. Disconnect AAT sensor connector 3. Using a multimeter, check for continuity between pins A and B of sensor side of sensor connector.
1/1
7 ECU Test 04 160 ,184
DTC 000171.03 does not reoccur: Replace ECU and use DST or Service ADVISOR to download payload.
1/1
CTM331 (03OCT05)
04-160-184

012506
PN=358
000171.04 Ambient Air Temperature Input Voltage Out Of Range Low (750J Crawlers Only)
UN28SEP05
Ambient Air Temperature Sensor Schematic
Ambient Air Temperature (AAT) Sensor The AAT sensor (C) is a thermistor (temperature sensitive resistor) mounted in the intake air duct. The AAT sensors variable resistance causes the input voltage to the ECU (C) to vary. Higher temperatures result in lower AAT input voltages to the ECU; lower temperatures result in higher voltages. The AAT sensor is used by the ECU to control the air heater in applications that use this optional feature. For additional theory of operation of temperature sensors, see Measuring Temperature, in Section 03, Group 140 earlier in this CTM.
DTC000171.04 will set if: The AAT input voltage drops below the minimum threshold. This voltage corresponds to a temperature that is higher than what is physically possible for ambient air. If DTC 000171.04 sets, the following will occur: No engine protection measures, nor other reactions, accompany this DTC.
DB92450,0000021 1904OCT051/1
CTM331 (03OCT05)
04-160-185

012506
RG14504
04 160 ,185
PN=359
000171.04 Ambient Air Temperature Input Voltage Out Of Range Low (750J Crawlers Only)
The Ambient Air Temperature (AAT) input voltage drops below the sensors low voltage specification.
DB92450,0000022 1923SEP051/1
000171.04 Ambient Air Temperature Input Voltage Out Of Range Low Diagnostic Procedure
04 160 ,186
1/1
1 Connection Check
NOTE: For wiring, theory of operation, and sensor location information, see DTC 000171.04 AMBIENT AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector, the AAT sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring, theory of operation, and sensor location information, see DTC 000171.04 AMBIENT AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF. 3. Start the ECU communication software. 4. Make note of any DTCs, then clear all DTCs. 5. Ignition ON, engine cranking or running. 6. Read the Ambient Air Temperature Input Voltage parameter using the DST orSERVICE ADVISOR
1/1
CTM331 (03OCT05)
04-160-186

012506
PN=360

3 AAT Voltage Supply Wiring Test 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. Short found: Replace faulty item Short found: GO TO 4
NOTE: For wiring, theory of operation, and sensor location information, seeDTC 000171.04 AMBIENT AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF. 2. Disconnect ECU harness connector and AAT sensor connector. 3. Using a multimeter, check for short between pin C1 of ECU harness connector, and pin A of sensor connector.
1/1
4 AAT Sensor Test
short is present: AAT sensor faulty. Replace sensor Short is not present: GO TO 5
1. Ignition OFF 2. Disconnect AAT sensor connector 3. Using a multimeter, across pins A and B of sensor side of sensor connecter, check for short to pin A or sensor.
04 160 ,187
1/1
5 ECU Test
DTC 000171.03 does not reoccur: Replace ECU and use DST or Service ADVISOR to download payload.
1/1
CTM331 (03OCT05)
04-160-187

012506
PN=361
000174.03 Fuel Temperature Input Voltage High

Fuel Temp Sensor t Fuel Temp Connector B A B A
Sensor Ground Fuel Temp Input
C3
D3
1908JAN02 RG11988
04 160 ,188
Fuel Temperature Sensor The fuel temperature sensor is a thermistor (temperature sensitive resistor) located on the injection pump fuel outlet housing. The fuel temperature sensors variable resistance causes the input voltage to the ECU to vary. Higher fuel temperatures result in lower fuel temperature input voltages to the ECU; lower temperatures result in higher voltages. The ECU uses the fuel temperature sensor input to adjust the fuel delivery for the variations in fuel density caused by varying fuel temperatures. For more fuel temperature sensor information, see MEASURING TEMPERATURE in Section 03, Group 140 of this manual.
DTC 000174.03 will set if: The fuel temperature input voltage goes above the sensors high voltage specification. This voltage corresponds to a temperature that is lower than what is physically possible for fuel temperature. For OEM engine applications, the high fuel 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 fuel temperature input voltage specification. If DTC 000174.03 sets, the following will occur: The ECU will use a "limp-home" fuel temperature value of -20C (-4F) during cranking, and 40C (104F) during running. Engine power will be slightly derated.
RG40854,0000062 1907SEP051/1
CTM331 (03OCT05)
04-160-188

012506
PN=362
000174.03 Fuel Temperature Input Voltage High
The fuel temperature input voltage goes above the sensors high voltage specification.
RG40854,00000F3 1923SEP051/1
000174.03 Fuel Temperature Input Voltage High Diagnostic Procedure

04 160 ,189
1/1
1 Connection Check
Perform a preliminary inspection of the ECU connector, the fuel temperature sensor connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Ignition ON, engine running 5. Read the Fuel Temperature Input Voltage parameter using the DST orSERVICE ADVISOR.
4.9 V or greater: GO TO 3 Below 4.9 V: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
NOTE: On OEM applications, the high fuel temperature input voltage specification is 4.9 volts and above. For fuel temperature input voltage specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-189

012506
PN=363

3 Fuel Temperature Sensor and Connector Test
1. Ignition OFF 2. Disconnect fuel temperature sensor connector 3. Install a jumper wire between both terminals in the fuel temperature sensor harness connector 4. Ignition ON, engine OFF 5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Above 0.1 V: GO TO 4 At or below 0.1 V: Faulty fuel temperature sensor connector OR Faulty fuel temperature sensor
NOTE: On OEM applications, the low fuel temperature input voltage specification is 0.1 volts and below. For fuel temperature input voltage specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04 160 ,190
1/1
4 Fuel Temperature Open Ground Test
1. Ignition OFF 2. Remove jumper wire between both terminals 3. Install jumper wire between fuel temperature sensor harness connector input terminal and a good chassis ground 4. Ignition ON, engine OFF 5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Above 0.1 V: Open in fuel temperature input sensor circuit OR Faulty ECU connection OR Faulty ECU 0.1 V or below: Open in fuel temperature sensor ground circuit OR Faulty ECU connection OR Faulty ECU
NOTE: On OEM applications, the low fuel temperature input voltage specification is 0.1 volts and below. For fuel temperature input voltage specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-190

012506
PN=364
04 160 ,191
CTM331 (03OCT05)
04-160-191

012506
PN=365
000174.04 Fuel Temperature Input Voltage Low

C3
D3
1908JAN02 RG11988
04 160 ,192
DTC 000174.04 will set if: The fuel temperature input voltage goes above the sensors low voltage specification. This voltage corresponds to a temperature that is higher than what is physically possible for fuel temperature. For OEM engine applications, the low fuel temperature input voltage specification is 0.1 volts. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the low fuel temperature input voltage specification. If DTC 000174.04 sets, the following will occur: The ECU will use a "limp-home" fuel temperature value of -20C (-4F) during cranking, and 40C (104F) during running. Engine power will be slightly derated.
RG40854,0000064 1907SEP051/1
CTM331 (03OCT05)
04-160-192

012506
PN=366
000174.04 Fuel Temperature Input Voltage Low
The fuel temperature input voltage goes above the sensors low voltage specification.
RG40854,00000F2 1923SEP051/1
000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedure

04 160 ,193
1/1
1 Connection Check
NOTE: For wiring, theory of operation, and sensor location information, see DTC 000174.04 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information.
1/1
NOTE: For wiring, theory of operation, and sensor location information, see DTC 000174.04 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Ignition ON, engine OFF 5. Read the Fuel Temperature Input Voltage parameter using the DST orSERVICE ADVISOR
NOTE: For OEM engine applications, the low fuel temperature input voltage specification is 0.1V. For the low voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
1/1
CTM331 (03OCT05)
04-160-193

012506
PN=367

3 Fuel Temperature Sensor Test
NOTE: For wiring, theory of operation, and sensor location information, seeDTC 000174.04 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF 2. Disconnect fuel temperature sensor connector 3. Ignition ON 4. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE ADVISOR.
Below 4.9 V: Short to ground in fuel temperature sensor input circuit OR Faulty ECU 4.9 V or greater: Faulty fuel temperature sensor
NOTE: For OEM engine applications, the high fuel temperature input voltage specification is 4.9V. For the high voltage specification on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04 160 ,194
1/1
CTM331 (03OCT05)
04-160-194

012506
PN=368
04 160 ,195
CTM331 (03OCT05)
04-160-195

012506
PN=369
000174.16 Fuel Temperature High Moderately Severe

C3
D3
1908JAN02 RG11988
04 160 ,196
DTC 000174.16 will set if: The ECU senses fuel temperature on OEM applications above 120C (248F). For fuel temperature specifications on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. If DTC 000174.16 sets, the following will occur: Engine protection is enabled. See ENGINE PROTECTION in Section 03, Group 140 of this manual. With Shutdown Feature: No shutdown available for this code. With Derate Feature: On OEM applications, the engine derates 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 of this manual.
RG40854,0000061 1907SEP051/1
CTM331 (03OCT05)
04-160-196

012506
PN=370
000174.16 Fuel Temperature High Moderately Severe
The ECU senses fuel temperature above specifications.
RG40854,00000F5 1907SEP051/1
000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure

04 160 ,197
1/1
1 DTC 000174.16 Preliminary Check
Before using this diagnostic procedure: 1. Ensure that the fuel level in the fuel tank is not extremely low 2. Ensure that fuel cooler is clean

1/1
2 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL TEMPERATURE HIGH MODERATELY SEVERE supporting information
1/1
CTM331 (03OCT05)
04-160-197

012506
PN=371

3 Fuel Supply Pressure Check
Determine fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in Section 04, Group 150 of this manual.
Fuel pressure within specification: GO TO 4 Fuel pressure below specification: Determine cause of low fuel supply pressure. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC PROCEDURE in Section 04, Group 150 of this manual. Repair and retest.
04 160 ,198
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 fuel cooler OR Faulty injection pump Restriction found in either fuel return line: Determine the cause of restriction Repair and retest
1/1
CTM331 (03OCT05)
04-160-198

012506
PN=372
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 or code such as DTC 002000.13 that requires engine speed to be limited. DTC 000189.00 will set if: The ECU detects a condition that requires an engine speed derate.
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: Check for other stored or active DTCs that indicate the reason for the speed derate.
04 160 ,199
RG40854,0000001 1912AUG021/1
CTM331 (03OCT05)
04-160-199

012506
PN=373
000190.00 Engine Overspeed Extreme
Crank Position Sensor
Crank Sensor Connector Crank Position Return

B A B A
Crank Position Input
B2
D2
1923JAN02 RG11984
04 160 ,200
The ECU detects that engine speed exceeds 3400 rpm. NOTE: Wiring schematic shows OEM engine applications only. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Crank Position Sensor The crank 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 sensor inputs a square-pulse signal to the ECU. The ECU uses the crank position input signal 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 portion of the sensor input signal is used by the ECU to determine Top-Dead-Center (TDC) crankshaft position.
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 shuts fuel off until engine speed is below 2800 rpm. If DTC 000190.00 sets: With DTC 000190.00, there may or not be a problem with the electronic control system. Using the DST orSERVICE ADVISOR, monitor DTCs on the active code display parameter. To find DTC list, see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU earlier in this Group. If there are other codes, go to the appropriate diagnostic procedure. If there are no other stored or active DTCs, clear DTC 000190.00 and monitor codes to see if DTC 000190.00 reoccurs.
RG40854,0000148 1923SEP051/1
CTM331 (03OCT05)
04-160-200

012506
PN=374
000190.01 Engine Speed Below Normal Operational Range, Most Severe Level (OEM Marine Only)
UN28SEP05
04 160 ,201
Engine Crank Sensor Schematic
The ECU detects that engine speed is below the specified curve and time.
Crank Position Sensor The crank 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 sensor inputs a square-pulse signal to the ECU. The ECU uses the crank position input signal 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 portion of the sensor input signal is used by the ECU to determine Top-Dead-Center (TDC) crankshaft position. For this fault code (from the time ECU sets DTC 000190.18), ECU will count time incrementally for 120 minutes, while engine operates in this state, and then set DTC000190.01. If engine speed increases
and passes into normal operating speed, before ECU time has incremented to 120 minutes, for the time the engine operates in normal state, ECU will count time decrementally, until counted time is decremented back to zero, or engine speed again lapses back into moderately below normal speed. ECU then resumes counting time incrementally, not from zero, but from the time remainder at which ECU stopped counting decrementally. DTC000190.01 sets if: The ECU detects when the engine speed drops below normal idle into the most severe below-normal-idle range and remains in it for an accumulation of 120 minutes. If DTC 000190.01 sets, the following occurs: CAN white light comes on. Engine stalls out.
DB92450,0000026 1904AUG051/1
CTM331 (03OCT05)
04-160-201

012506
RG14505
PN=375
000190.01 Engine Speed Below Normal Operational Range, Most Severe Level
The ECU detects that engine speed is below the specified curve and time.
DB92450,0000027 1903AUG051/1
000190.01 Engine Speed Below Normal Operational Range, Most Severe Level Diagnostic Procedure
04 160 ,202
1/1
1 Fuel Lines and Fittings Check
Check fuel lines and fittings for damage.
Damaged fuel line or fitting found:Replace damaged part, bleed fuel system, and restart engine. Damaged fuel line or fitting not found:GO TO 2
1/1
2 Fuel Check, Low Pressure Side
1. Check final fuel filter for clogging. 2. Check prefilter for clogging.
Clogging found in one or both filters:Replace filters, clear contaminants from sediment bowl, remove contaminated fuel and clean any contaminant sediment from fuel tank. Fill fuel tank, and bleed fuel line through far side of final fuel filter, until bleeding fuel is clear. No clogging found in either filter:GO TO 3 .
1/1
CTM331 (03OCT05)
04-160-202

012506
PN=376

3 Transfer Pump Check IMPORTANT: A backup wrench must always be used when loosening and tightening fittings of fuel lines from and to supply pump to avoid damage to fittings. 1.At fuel line from transfer pump to final fuel filter, loosen tube nut fitting at fuel filter Tube NutTorqueallow fuel to be freely bled from it. end sufficiently to .................................................................................. 24 Nm (18 lb-ft) 2. Depending on type of transfer pump, electrically or manually operate pump. IMPORTANT: A backup wrench must always be used when loosening and tightening fittings of fuel lines from and to supply pump to avoid damage to fittings. 3.Check to see whether or not fuel is steadily bleeding out. Specification Tube NutTorque .................................................................................. 24 Nm (18 lb-ft) Bleed fuel system. Restart engine. 04 160 ,203
1/1
Fuel is steadily bleeding out:Close fitting, Tighten to specifications. Specification
Restart engine. Fuel is not bleeding out:Remove and replace pump. Tighten to specifications.
CTM331 (03OCT05)
04-160-203

012506
PN=377
000190.16 Engine Overspeed Moderate

B A B A
B2
D2
1923JAN02 RG11984
04 160 ,204
The ECU detects that engine speed is higher than 3000 rpm. NOTE: Wiring schematic shows OEM engine applications only. For wiring on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Crank Position Sensor The crank 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 sensor inputs a square-pulse signal to the ECU. The ECU uses the crank position input signal 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 portion of the sensor input signal is used by the ECU to determine Top-Dead-Center (TDC) crankshaft position.
DTC 000190.16 will set if: The ECU detects that engine speed is higher than 3000 rpm. If DTC 000190.16 sets, the following will occur: The ECU shuts fuel off until engine speed is below 2800 rpm. If DTC 000190.16 sets: With DTC 000190.16, there may or not be a problem with the electronic control system. Using the DST orSERVICE ADVISOR, monitor DTCs on the active code display parameter. To find DTC list, see LISTING OF DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU earlier in this Group. If there are other codes, go to the appropriate diagnostic procedure. If there are no other stored or active DTCs, clear DTC 000190.16 and monitor codes to see if DTC 000190.16 reoccurs.
RG40854,0000149 1923SEP051/1
CTM331 (03OCT05)
04-160-204

012506
PN=378
000190.18 Engine Speed Below Normal Operational Range, Moderately Severe Level (OEM Marine Only)

B A B A
B2
D2
1923JAN02
The ECU detects that engine speed is moderately below the specified curve and time.
Crank Position Sensor The crank 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 sensor inputs a square-pulse signal to the ECU. The ECU uses the crank position input signal 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 portion of the sensor input signal is used by the ECU to determine Top-Dead-Center (TDC) crankshaft position. For this trouble, ECU will count time incrementally for 30 minutes while engine operates in this state, and then set DTC000190.18. If engine speed increases and passes into normal operating speed,
before ECU time has incremented to 30 minutes, for the time the engine operates in normal state, ECU will count time decrementally, until counted time is decremented back to zero, or engine speed again lapses back into moderately below normal speed. ECU then resumes counting time incrementally, not from zero, but from the time remainder at which ECU stopped counting decrementally. DTC 000190.18 will set if: The ECU detects that engine speed has been operating moderately below the specified curve and time for 30 minutes. If DTC 000190.18 sets, the following will occur: The CAN white light comes on. If ECU determines that engine has operated continuously, or cumulatively, in this condition for 30 minutes.
DB92450,0000028 1904AUG051/1
CTM331 (03OCT05)
04-160-205

012506
RG11984
04 160 ,205
PN=379
000523.09 Current Gear Selection Invalid or Not Received (J-series Loaders Only)
ECU is receiving invalid selection information for current gear, or is receiving no information at all.
Gear Selection The Loader controller transmits the vehicle gear selection to the ECU over the CAN bus. The ECU uses this information to select the correct governor curve mode.
04 160 ,206
DTC 000523.09 will set if: The ECU does not receive vehicle gear selection information, or the information ECU receives is invalid. If DTC 000523.09 Sets: The ECU does not receive vehicle gear selection information, or it is invalid Transport curve cannot be selected. (Only one torque curve is used for this machine. No timers or derate torque curves are used. Using the DST or SERVICE ADVISOR, monitor DTCs on the active code display parameter. Check to see if any other controllers on the machine have any active or stored CAN or vehicle-related DTCs. If they do, go to the appropriate diagnostic procedure. If no other stored or active CAN or vehicle related DTCs are found, replace ECU and retest.
NOTE: For diagnostic troubleshooting procedure, refer to the Loader Vehicle Technical Manual.
DB92450,0000029 1905AUG051/1
CTM331 (03OCT05)
04-160-206

012506
PN=380
04 160 ,207
CTM331 (03OCT05)
04-160-207

012506
PN=381
000620.03 Sensor Supply Voltage High

A1 A2 A3
Analog Throttle (A) Sensor Analog Throttle (B) Sensor Oil Pressure Sensor E2
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
04 160 ,208
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.
RG40854,000005C 1906DEC011/1
CTM331 (03OCT05)
04-160-208

012506
RG11983
C O N N E C T O R
1924JAN02
PN=382
The ECU detects a voltage that is higher than 5.5 volts on the ECU 5 volt sensor supply circuit.
RG40854,00000F6 1923SEP051/1
000620.03 Sensor Supply Voltage High Diagnostic Procedure

04 160 ,209
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR SUPPLY VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connector. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine OFF 7. Read DTCs using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-209

012506
PN=383

3 Sensor Supply Wire Check for Short
1. Ignition OFF 2. Disconnect ECU connector 3. Using multimeter, measure resistance between terminal E2 in the harness end of the ECU connector and all other terminals in the harness end of the ECU connector.
Greater than 20,000 ohms: Faulty ECU connector OR Faulty ECU Less than 20,000 ohms: Short to voltage in sensor supply wire
1/1
04 160 ,210
CTM331 (03OCT05)
04-160-210

012506
PN=384
04 160 ,211
CTM331 (03OCT05)
04-160-211

012506
PN=385
000620.04 Sensor Supply Voltage Low

A1 A2 A3
Analog Throttle (A) Sensor Analog Throttle (B) Sensor Oil Pressure Sensor E2
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
04 160 ,212
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.
RG40854,000005E 1906DEC011/1
CTM331 (03OCT05)
04-160-212

012506
RG11983
C O N N E C T O R
1924JAN02
PN=386
The ECU detects a voltage that is lower than 4.44 volts on the ECU 5 volt sensor supply circuit.
RG40854,00000F7 1923SEP051/1
000620.04 Sensor Supply Voltage Low Diagnostic Procedure

04 160 ,213
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR SUPPLY VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connector. Look for dirty, damaged, or poorly positioned terminals.
1/1
2 Sensor Check
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition OFF 7. Disconnect all sensors that receive their 5V supply from terminal E2 of the ECU 8. Ignition ON, engine running 9. Read DTCs using the DST orSERVICE ADVISOR.
000620.04 reoccurs: GO TO 4 000620.04 does not reoccur: GO TO 3
1/1
CTM331 (03OCT05)
04-160-213

012506
PN=387

1. Ignition ON, engine OFF 2. While reconnecting each sensor one at a time, monitor DTCs using the DST or SERVICE ADVISOR.
000620.04 reoccurs: Faulty sensor Replace and retest 000620.04 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
04 160 ,214
4 Sensor Supply Short to Ground Check
1. Ignition OFF 2. Disconnect the ECU connector 3. Using a multimeter, measure resistance between terminal D3 in the harness end of the ECU connector and: A good chassis ground Terminal J2 in the harness end of the ECU connector
Greater than 20,000 ohms: Faulty ECU connector OR Faulty ECU Less than 20,000 ohms: Sensor 5 volt supply circuit shorted to ground
1/1
CTM331 (03OCT05)
04-160-214

012506
PN=388
04 160 ,215
CTM331 (03OCT05)
04-160-215

012506
PN=389
000629.13 ECU Error
The ECU detects an internal problem.

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.
RG40854,000003C 1923SEP051/1
000629.13 ECU Error Diagnostic Procedure

04 160 ,216
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 to the DST or SERVICE ADVISOR. 3. Ignition ON, engine OFF 4. Start the ECU communication software 5. Read DTCs using the DST orSERVICE ADVISOR. 6. Make note of any DTCs, then clear all DTCs 7. Ignition ON, engine running or cranking for 15 seconds 8. Read DTCs using the DST orSERVICE ADVISOR.
000629.13 reoccurs: Faulty ECU 000629.13 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-216

012506
PN=390
04 160 ,217
CTM331 (03OCT05)
04-160-217

012506
PN=391
000637.02 Crank Position Input Noise

Crank Position Sensor Crank Sensor Connector Crank Position Return
B A B A
B2
D2
1923JAN02 RG11984

04 160 ,218
Crank Position Sensor The crank 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 crank 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 000637.02 will set if: The ECU detects excessive noise (extra pulses) on the crank position input. If DTC 000637.02 sets, the following will occur: Engine probably will not run
RG40854,0000038 1906DEC011/1
CTM331 (03OCT05)
04-160-218

012506
PN=392
000637.02 Crank Position Input Noise
The ECU detects excessive noise (extra pulses) on the crank position input.
RG40854,00000F8 1923SEP051/1
000637.02 Crank Position Input Noise Diagnostic Procedure

04 160 ,219
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK POSITION INPUT NOISE supporting information.
Perform a preliminary inspection of the ECU connector, the crank position sensor connector, and any other connector. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of all DTCs, then clear all DTCs 6. Warm engine 7. Ignition ON, engine running 8. Read DTCs using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-219

012506
PN=393

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 crank sensor wiring Check wiring for proper pin location in the crank 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 ,220
1/1
CTM331 (03OCT05)
04-160-220

012506
PN=394
04 160 ,221
CTM331 (03OCT05)
04-160-221

012506
PN=395
000637.10 Crank Position Input Pattern Error

Crank Position Sensor Crank Sensor Connector Crank Position Return
B A B A
B2
D2
1923JAN02 RG11984

04 160 ,222
Crank Position Sensor The crank 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 crank 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 000637.10 will set if: The ECU detects an improper pattern on the crank position input. If DTC 000637.10 sets, the following will occur: Engine probably will not run.
RG40854,000003A 1906DEC011/1
CTM331 (03OCT05)
04-160-222

012506
PN=396
000637.10 Crank Position Input Pattern Error
The ECU detects an improper pattern on the crank position input.
RG40854,000010A 1923SEP051/1
000637.10 Crank Position Input Pattern Error Diagnostic Procedure

04 160 ,223
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK POSITION INPUT PATTERN ERROR supporting information.
Perform a preliminary inspection of the ECU connector, the crank position sensor connector, and any other connector. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of any DTCs, then clear all DTCs 6. Ignition ON, engine running 7. Read DTCs using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-223

012506
PN=397

3 Crank Position Sensor Test
1. Ignition OFF 2. Disconnect crank position sensor connector 3. Using a multimeter, measure resistance between both terminals of the crank position sensor.
Between 2500 and 3500 ohms: GO TO 4 Below 2500 ohms or above 3500 ohms: Faulty crank position sensor
1/1
04 160 ,224
4 Open in Crank Sensor Input and Return Check
1. Ignition OFF 2. Disconnect crank position sensor connector 3. Disconnect ECU connector 4. Using a multimeter, measure resistance between: Terminal A of the crank position sensor harness connector and terminal B2 in the harness end of the ECU connector Terminal B of the crank position sensor harness connector and terminal D2 in the harness end of the ECU connector
Both measurements 5 ohms or less: GO TO 5 Either measurement greater than 5 ohms: Open in crank position sensor input wire OR Open in crank position sensor return wire OR Terminals A and B in the crank position sensor harness connector possibly inverted
1/1
5 Crank Sensor Input Wiring Check
1. Ignition OFF 2. Crank position sensor connector and ECU connector still disconnected 3. Using a multimeter measure resistance between terminal B2 in the harness end of the ECU connector and the following: A good ground All other terminals in both ECU connectors
All measurements greater than 2000 ohms: GO TO 6 Any measurement less than 2000 ohms: Faulty crank position sensor input wiring harness
1/1
CTM331 (03OCT05)
04-160-224

012506
PN=398

6 Crank Sensor Return Wiring Check
1. Ignition OFF 2. Crank position sensor connector and ECU connector still disconnected 3. Using a multimeter measure resistance between terminal D2 in the harness end of the ECU connector and the following: A good ground All other terminals in both ECU connectors
All measurements greater than 2000 ohms: GO TO 7 Any measurement less than 2000 ohms: Faulty crank position sensor return wiring harness
1/1
7 Crank Sensor and Timing Wheel Check
1. Remove crank position sensor from injection pump 2. Remove crank position sensor 3. Inspect sensor for cracks, corrosion, or any foreign material on the end of the sensor 4. Inspect the crank timing wheel notches for burrs or chips
All components OK: GO TO 8 Fault found in a component: Repair or replace component as needed
04 160 ,225
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 crank position sensor connector OR Faulty ECU connector OR Faulty ECU One or more gears out of time: Make necessary adjustments to ensure correct timing. See INSTALL CAMSHAFT in Section 02, Group 050 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
1/1
CTM331 (03OCT05)
04-160-225

012506
PN=399
000639.13 CAN Bus Error

A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
E F G
04 160 ,226
D C A J H B
D C E B A
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3
C O N N E C T O R
K1 K2 K3
C C CAN Terminator
Controller Area Network (CAN) CAN is the network in which the individual controllers on a machine communicate with each other. The number of controllers communicating on CAN depends on the application. On some
applications, the ECU is the only controller on CAN; on other applications, there are many controllers on CAN. DTC 000639.13 will set if: The ECU detects a problem communicating on CAN. If DTC 000639.13 sets, the following will occur: Depending on the application, engine operation may or may not be affected.
RG40854,0000036 1906DEC011/1
CTM331 (03OCT05)
04-160-226

012506
PN=400
RG11972
1914DEC01
B B A C
000639.13 CAN Bus Error
The ECU detects a problem communicating on CAN.
RG40854,000010F 1923SEP051/1
000639.13 CAN Bus Error Diagnostic Procedure

04 160 ,227
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS ERROR supporting information
Perform a preliminary inspection of the ECU connector, the CAN connections, and any other connector. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start ECU communication software 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Make note of all DTCs, then clear all DTCs 6. Ignition ON 7. Read DTCs using the DST or SERVICE ADVISOR.
DTC 000639.13 reoccurs: GO TO 3 DTC 000639.13 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-227

012506
PN=401

3 Check Other Controllers For CAN Related DTCs
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 machine manual to diagnose and repair the cause of DTC, then determine if DTC 000639.13 reoccurs
1/1
4 CAN Resistance Test 04 160 ,228
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminals F1 and G1 in the harness end of the ECU connector
Between 55 ohms and 65 ohms: Faulty ECU connector OR Faulty ECU Less than 55 ohms or greater than 65 ohms: Open or short in CAN communication circuit
1/1
CTM331 (03OCT05)
04-160-228

012506
PN=402
000644.02 External Speed Command Input (OEM, Marine Only)

1905AUG05
ECU receives erratic or incorrect data from external source

CAN Communication CAN is the network in which the individual controllers on a machine communicate with each other. The number of controllers communicating on CAN depends on the application. On some applications, the ECU is the only controller on CAN; on other applications, there are many controllers on CAN. It is through CAN that external signals are communicated to ECU. In this case, it is either engine speed or engine torque requirements. DTC 00644.02 will set if: The ECU receives erratic or incorrect data through CAN from external source requiring either engine speed or torque. If DTC 00644.02 sets, the following will occur: CAN white light turns on.
CAN Communication Connection
RG14448
04 160 ,229
NOTE: When DTC 000644.02 sets, refer to the vehicle technical manual.
DB92450,000002A 1905AUG051/1
CTM331 (03OCT05)
04-160-229

012506
PN=403
000729.03 Inlet Air Heater Signal High

TO +12V
Air Heater Relay Enable 30 Air Heater Relay 87 85 K3 86
A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
04 160 ,230
E1 E2 E3
Air Heater Relay Return
H2 G3
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3
C O N N E C T O R
Heater Coil
K1 K2 K3
Switched Voltage 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.
RG40854,0000002CONV2 1912AUG021/1
CTM331 (03OCT05)
04-160-230

012506
RG12587
1922AUG02
Air Heater Indicator Lamp
PN=404
000729.03 Inlet Air Heater Signal High
The ECU is not sending current to the air heater relay, but detects 12 volts going to the heater coil.
RG40854,0000003CONV2 1912AUG021/1
000729.03 Inlet Air Heater Signal High Diagnostic Procedure

04 160 ,231
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000729.03 INLET AIR HEATER SIGNAL HIGH supporting information
Perform a preliminary inspection of the ECU connector, air heater relay, and the air heater. Look 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
CTM331 (03OCT05)
04-160-231

012506
PN=405

3 Air Heater Relay Return Wire Test
1. Ignition OFF 2. Disconnect the ECU connector 3. Using a multimeter, measure resistance between terminal H2 in the harness end of the ECU connector 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 ,232
1. Ignition OFF 2. ECU connector still disconnected 3. Using a multimeter, measure resistance between terminal K3 in the harness end of the ECU connector and terminal 86 on the air heater relay
Measurements 5 ohms or less: Faulty air heater relay Measurements greater than 5 ohms: Air heater relay enable wire shorted to power
1/1
CTM331 (03OCT05)
04-160-232

012506
PN=406
04 160 ,233
CTM331 (03OCT05)
04-160-233

012506
PN=407
000729.05 Inlet Air Heater Signal Low

TO +12V
Air Heater Relay Enable 30 Air Heater Relay 87 85 K3 86
A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
04 160 ,234
E1 E2 E3
Air Heater Relay Return
H2 G3
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3
C O N N E C T O R
Heater Coil
K1 K2 K3
Switched Voltage 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. 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.
RG40854,0000004 1912AUG021/1
CTM331 (03OCT05)
04-160-234

012506
RG12587
1922AUG02
Air Heater Indicator Lamp
PN=408
000729.05 Inlet Air Heater Signal Low
The ECU is sending current to the air heater relay, but does not detect 12 volts going to the heater coil.
RG40854,0000005 1923SEP051/1
000729.05 Inlet Air Heater Signal Low Diagnostic Procedure

04 160 ,235
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 000729.05 INLET AIR HEATER SIGNAL LOW supporting information
Perform a preliminary inspection of the ECU connector, air heater relay, and the air heater. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine running 6. Read DTCs using the DST orSERVICE ADVISOR.
000729.05 reoccurs: GO TO 3 000729.05 doesnt reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-235

012506
PN=409

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 ,236
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
CTM331 (03OCT05)
04-160-236

012506
PN=410
000898.09 Vehicle Speed or Torque Message Invalid
The ECU does not receive the engine speed or torque message over CAN or it is not valid.
CAN (Controller Area Network) Vehicle Speed or Torque Message The CAN (Controller Area Network) transmits the vehicles desired engine speed or torque to the ECU from another controller. DTC 000898.09 will set if: The ECU does not receive the engine speed or torque message over CAN or it is not valid. If DTC 000898.09 sets, the following will occur:
The ECU will default engine speed to low idle. If DTC 000898.09 sets: Connect to the DST or SERVICE ADVISOR. With ignition ON and engine OFF, start the ECU communication software Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. If DTC 000639.13 also occurs, see DTC 000639.13 CAN BUS ERROR DIAGNOSTIC PROCEDURE earlier in this Group. If no other stored or active CAN or vehicle related DTCs are found, replace the ECU and retest.
04 160 ,237
RG40854,0000114 1923SEP051/1
CTM331 (03OCT05)
04-160-237

012506
PN=411
000970.31 Auxiliary Engine Shutdown Switch Active
A1 A2 A3
B1 B2 B3
To External Shutdown Switch
Sensor Ground Switch Input
D3 A1
C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
04 160 ,238
The ECU does not read an input voltage on the auxiliary engine shutdown input wire.
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 on the auxiliary engine shutdown input wire. If DTC 000970.31 sets, the following will occur: The ECU will shut the engine down immediately.
Auxiliary Engine Shutdown Switch
RG40854,000003E 1906DEC011/1
CTM331 (03OCT05)
04-160-238

012506
RG12047
C O N N E C T O R
1924JAN02
PN=412
000971.31 External Engine Derate Switch Active
A1 A2 A3
B1 B2 B3
To External Derate Switch
Sensor Ground Input
D3 C2
C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
RG12046
C O N N E C T O R
1923JAN02
The ECU does not read an input voltage.

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:
04 160 ,239
External Fuel Derate Switch On OEM applications, the external derate switch is a normally open switch. When property being
On OEM applications, the ECU will derate the engine 2% per minute until the engine is running at 80% of full power. For derates on other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
RG40854,000003F 1906DEC011/1
CTM331 (03OCT05)
04-160-239

012506
PN=413
001069.09 Tire Size Invalid

A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
E F G
04 160 ,240
D C A J H B
D C E B A
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3
C O N N E C T O R
K1 K2 K3
C C CAN Terminator
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.
Tire Size Tire size is input into the vehicle for a given size of tire. DTC 001069.09 will set if:
The ECU either does not receive tire size information over CAN, or the information received is not valid. If DTC 001069.09 sets, the following will occur: ECU will assume the largest tire size Road speed limiting may occur at a speed that is less than the specified speed.
RG40854,0000006 1912AUG021/1
CTM331 (03OCT05)
04-160-240

012506
PN=414
RG11972
1914DEC01
B B A C
001069.09 Tire Size Invalid
The ECU either does not receive tire size information over CAN, or the information received is not valid.
RG40854,0000007 1923SEP051/1
001069.09 Tire Size Invalid Diagnostic Procedure

04 160 ,241
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID supporting information.
Perform a preliminary inspection of ECU connectors looking for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 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 the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-241

012506
PN=415

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 ,242
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 and 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
CTM331 (03OCT05)
04-160-242

012506
PN=416
04 160 ,243
CTM331 (03OCT05)
04-160-243

012506
PN=417
001069.31 Tire Size Error

A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
E F G
04 160 ,244
D C A J H B
D C E B A
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3
C O N N E C T O R
K1 K2 K3
C C CAN Terminator
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.
Tire Size Tire size is input into the vehicle for a given size of tire.
DTC 001069.31 will set if: Tire size has been incorrectly programmed into the vehicle. If DTC 001069.31 sets, the following will occur: ECU will assume the largest tire size Road speed limiting may occur at a speed that is less than the specified speed.
RG40854,0000008 1912AUG021/1
CTM331 (03OCT05)
04-160-244

012506
PN=418
RG11972
1914DEC01
B B A C
001069.31 Tire Size Error
Tire size has been incorrectly programmed into the vehicle.
RG40854,0000009 1923SEP051/1
001069.31 Tire Size Error Diagnostic Procedure

04 160 ,245
1/1
1 Connection Check
No faulty connection(s): GO TO 2 Faulty connection(s): Repair faulty connection(s).
NOTE: For wiring and theory of operation information, see DTC 001069.31 TIRE SIZE ERROR supporting information.
Perform a preliminary inspection of the ECU, BIF, and BCU connectors looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001069.31 TIRE SIZE ERROR supporting information.
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start ECU communication software. 4. Read DTCs using the DST orSERVICE ADVISOR. 5. Clear all DTCs 6. Engine running, vehicle under normal operating conditions. 7. Read DTCs using the DST or SERVICE ADVISOR.
001069.31 reoccurs: Reprogram tire size on vehicle. 001069.31 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-245

012506
PN=419
001076.00 Pump Control Valve Closure Too Long

Pump Solenoid
A1 A2 A3
Pump Solenoid Connector Pump Solenoid Return

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,246
Stanadyne DE10 Injection Pump The Stanadyne DE10 injection pump has an fuel control solenoid that is controlled by the Engine Control Unit (ECU). The ECU switches current on and off in order to charge the solenoid. When the current to the solenoid is increased, it moves a pump control valve into a position that allows for injection pressure to be developed. When the current to the solenoid is decreased, the pump control valve will return to a position that ends injection pressure. By controlling current to the solenoid, the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. For
more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.00 will set if: The ECU determines that the pump control valve takes too long to close. If DTC 001076.00 sets, the following will occur: Engine performance might be erratic. CAN Yellow Warning Lamp comes on.
RG40854,0000040 1904OCT051/1
CTM331 (03OCT05)
04-160-246

012506
RG11985
1920DEC01
Pump Solenoid Supply
C O N N E C T O R
PN=420
001076.00 Pump Control Valve Closure Too Long
The ECU determines that the pump control valve takes too long to close.
RG40854,0000124 1923SEP051/1
001076.00 Pump Control Valve Closure Too Long Diagnostic Procedure

04 160 ,247
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.00 PUMP CONTROL VALVE CLOSURE TOO LONG supporting information.
Perform a preliminary inspection of the ECU connector, the pump connector, and any other connector. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software. 4. Make note of any DTCs, then clear all DTCs. 5. Ignition ON, engine cranking or running 6. Read DTCs using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-247

012506
PN=421

3 ECU Test
Substitute existing ECU for Known Good One. Download Payload.
Problem Resolved: Replace original ECU. Problem Not Resolved: Replace pump.
1/1
04 160 ,248
CTM331 (03OCT05)
04-160-248

012506
PN=422
04 160 ,249
CTM331 (03OCT05)
04-160-249

012506
PN=423
001076.01 Pump Control Valve Closure Too Short

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,250
Stanadyne DE10 Injection Pump The Stanadyne DE10 injection pump has an fuel control solenoid that is controlled by the Engine Control Unit (ECU). The ECU switches current on and off in order to charge the solenoid. When the current to the solenoid is increased, it moves a pump control valve into a position that allows for injection pressure to be developed. When the current to the solenoid is decreased, the pump control valve will return to a position that ends injection pressure. By controlling current to the solenoid, the ECU has the ability to manage the
quantity and timing of fuel delivery to the engine. For more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.01 will set if: The ECU determines that the control valve closes too quickly. If DTC 001076.01 sets, the following will occur: Engine performance may be erratic.
RG40854,0000044 1906DEC011/1
CTM331 (03OCT05)
04-160-250

012506
RG11985
1920DEC01
C O N N E C T O R
PN=424
001076.01 Pump Control Valve Closure Too Short
The ECU determines that the control valve closes too quickly.
RG40854,0000125 1923SEP051/1
001076.01 Pump Control Valve Closure Too Short Diagnostic Procedure

04 160 ,251
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.01 PUMP CONTROL VALVE CLOSURE TOO SHORT supporting information.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Make note of any DTCs, then clear all DTCs 5. Ignition ON, engine cranking or running 6. Read DTCs using the DST orSERVICE ADVISOR.
1/1
CTM331 (03OCT05)
04-160-251

012506
PN=425

3 ECU Test
Substitute existing ECU for Known Good One. Download Payload.
Problem Resolved: Replace original ECU. Problem Not Resolved: Replace pump.
1/1
04 160 ,252
CTM331 (03OCT05)
04-160-252

012506
PN=426
04 160 ,253
CTM331 (03OCT05)
04-160-253

012506
PN=427
001076.03 Pump Solenoid Current High

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,254
Stanadyne DE10 Injection Pump The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). The ECU switches current on and off in order to charge the solenoid. When the current to the solenoid is increased, it moves a pump control valve into a position that allows for injection pressure to be developed. When the current to the solenoid is decreased, the pump control valve will return to a position that ends injection pressure. By controlling current to the solenoid, the ECU has the ability to manage the quantity and timing of fuel delivery to
the engine. For more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.03 will set if: The ECU determines that pump solenoid current is higher than normal. If DTC 001076.03 sets, the following will occur: Engine performance might be erratic. Red Stop lamp comes on.
RG40854,0000046 1904OCT051/1
CTM331 (03OCT05)
04-160-254

012506
RG11985
1920DEC01
C O N N E C T O R
PN=428
001076.03 Pump Solenoid Current High
The ECU determines that pump solenoid current is higher than normal.
RG40854,0000126 1919SEP051/1
001076.03 Pump Solenoid Current High Diagnostic Procedure

04 160 ,255
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.03 PUMP SOLENOID CURRENT HIGH supporting information.
1/1
1/1
CTM331 (03OCT05)
04-160-255

012506
PN=429

3 Pump Solenoid Return Wire Check
1. Ignition OFF 2. Disconnect pump solenoid connector and ECU connector 3. Using a multimeter, measure resistance between Terminal A3 and all other terminals in the ECU connector
Measurement greater than 20,000 ohms: GO TO 4 Measurement less than 20,000 ohms: Short to power in pump solenoid return wire
1/1
04 160 ,256
4 Pump Solenoid Supply Wire Check
1. Ignition OFF 2. Disconnect pump solenoid connector and ECU connector 3. Using a multimeter, measure resistance between Terminal K2 and all other terminals in the ECU connector
Measurement greater than 20,000 ohms: GO TO 5 Measurement less than 20,000 ohms: Short to power in pump solenoid supply wire
1/1
1. Remove and install new injection pump. See REMOVE INJECTION PUMP and INSTALL INJECTION PUMP in Section 02, Group 090 of this manual. 2. Ignition ON, engine running. 3. Read DTCs using the DST or SERVICE ADVISOR.
001076.03 reoccurs: Faulty ECU 001076.03 does not reoccur: Problem repaired
1/1
CTM331 (03OCT05)
04-160-256

012506
PN=430
04 160 ,257
CTM331 (03OCT05)
04-160-257

012506
PN=431
001076.05 Pump Solenoid Circuit Open

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,258
the engine. For more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.05 will set if: The ECU determines that pump solenoid circuit is open. If DTC 001076.05 sets, the following will occur: Engine does not run. Red stop lamp comes on.
RG40854,0000049 1904OCT051/1
CTM331 (03OCT05)
04-160-258

012506
RG11985
1920DEC01
C O N N E C T O R
PN=432
001076.05 Pump Solenoid Circuit Open
The ECU determines that pump solenoid circuit is open.
RG40854,000004C 1923SEP051/1
001076.05 Pump Solenoid Circuit Open Diagnostic Procedure

04 160 ,259
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.05 PUMP SOLENOID CIRCUIT OPEN supporting information.
1/1
1/1
CTM331 (03OCT05)
04-160-259

012506
PN=433

3 Pump Solenoid Supply Wire Check
1. Ignition OFF, engine OFF 2. Disconnect ECU connector 3. Disconnect pump solenoid supply wire from solenoid cap on pump. 4. Using a multimeter, measure resistance between terminal K2 of the ECU connector and solenoid-side of solenoid supply wire.
Multimeter reads infinite, or nominal, ohms: GO TO 4 Multimeter reads zero: Faulty solenoid supply wire
1/1
04 160 ,260
4 Pump Solenoid Return Wire Check
1. Ignition OFF 2. Disconnect ECU connector 3. Disconnect pump solenoid return wire from solenoid cap on pump. 4. Using a multimeter, measure resistance between terminal A3 of the ECU connector and solenoid-side of solenoid return wire.
Multimeter reads infinite, or nominal, ohms: GO TO 5 Multimeter reads zero: Faulty solenoid supply wire
1/1
5 Pump Solenoid Cap
1. Ignition OFF 2. Remove solenoid cap from fuel injection pump 3. Using a multimeter, measure resistance between both ends of each stud on the solenoid cap.
Multimeter reads infinite ohms: GO TO 6 Multimeter reads zero: Faulty stud in solenoid cap
1/1
6 ECU-Pump Check
1. Ignition OFF. 2. Substitute current ECU with known, good, equivalent ECU. 3. Download payload. 4. Ignition ON, attempt engine start.
Engine starts, DTC does not reset: Faulty ECU. Engine does not start: Faulty fuel injection pump.
1/1
CTM331 (03OCT05)
04-160-260

012506
PN=434
04 160 ,261
CTM331 (03OCT05)
04-160-261

012506
PN=435
001076.06 Pump Solenoid Circuit Severely Shorted

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,262
the engine. For more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.06 will set if: The ECU determines that pump solenoid circuit is shorted. If DTC 001076.06 sets, the following will occur: ECU will shut engine down immediately. Red stop lamp comes on.
RG40854,000004D 1904OCT051/1
CTM331 (03OCT05)
04-160-262

012506
RG11985
1920DEC01
C O N N E C T O R
PN=436
001076.06 Pump Solenoid Circuit Severely Shorted
The ECU determines that pump solenoid circuit is shorted.
RG40854,0000127 1923SEP051/1
001076.06 Pump Solenoid Circuit Severely Shorted Diagnostic Procedure

04 160 ,263
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.06 PUMP SOLENOID CIRCUIT SEVERELY SHORTED supporting information.
1/1
1/1
CTM331 (03OCT05)
04-160-263

012506
PN=437

3 Pump Solenoid Supply Circuit Check
1. Ignition OFF 2. Disconnect pump solenoid connector and ECU connector 3. Using a multimeter, measure resistance between terminal K2 of the harness side of the ECU connector and: A good ground All other terminals in the ECU connector
Measurement greater than 20,000 ohms: GO TO 4 Measurement less than 20,000 ohms: Pump solenoid supply wire shorted
1/1
04 160 ,264
4 Pump Solenoid Return Circuit Check
1. Ignition OFF 2. Disconnect pump solenoid connector and ECU connector 3. Using a multimeter, measure resistance between terminal A3 of the harness side of the ECU connector and: A good ground All other terminals in the ECU connector
Measurement greater than 20,000 ohms: GO TO 5 Measurement less than 20,000 ohms: Pump solenoid return wire shorted
1/1
1/1
CTM331 (03OCT05)
04-160-264

012506
PN=438
04 160 ,265
CTM331 (03OCT05)
04-160-265

012506
PN=439
001076.07 Pump Control Valve Closure Not Detected

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,266
the engine. For more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.07 will set if: The ECU determines that it can not detect the closure of the pump control valve. If DTC 001076.07 sets, the following will occur: Engine performance may be erratic. CAN yellow warning lamp comes on.
RG40854,000004F 1904OCT051/1
CTM331 (03OCT05)
04-160-266

012506
RG11985
1920DEC01
C O N N E C T O R
PN=440
001076.07 Pump Control Valve Closure Not Detected
The ECU determines that it can not detect the closure of the pump control valve.
RG40854,0000050 1923SEP051/1
001076.07 Pump Control Valve Closure Not Detected Diagnostic Procedure

04 160 ,267
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.07 PUMP CONTROL VALVE CLOSURE NOT DETECTED supporting information.
1/1
1/1
CTM331 (03OCT05)
04-160-267

012506
PN=441

1/1
04 160 ,268
CTM331 (03OCT05)
04-160-268

012506
PN=442
04 160 ,269
CTM331 (03OCT05)
04-160-269

012506
PN=443
001076.10 Pump Solenoid Circuit Moderately Shorted

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,270
Stanadyne DE10 Injection Pump The Stanadyne DE10 injection pump has an internal solenoid that is controlled by the Engine Control Unit (ECU). The ECU switches current on and off in order to charge the solenoid. When the current to the solenoid is increased, it moves a pump control valve into a position that allows for injection pressure to be developed. When the current to the solenoid is decreased, the pump control valve will return to a position that ends injection pressure. By controlling current to the solenoid, the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. For more operation information, see
FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.10 will set if: Pump solenoid circuit is moderately shorted to power. If DTC 001076.10 sets, the following will occur: ECU derates engine to 50% of full power immediately. Red stop light comes on.
RG40854,0000051 1904OCT051/1
CTM331 (03OCT05)
04-160-270

012506
RG11985
1920DEC01
C O N N E C T O R
PN=444
001076.10 Pump Solenoid Circuit Moderately Shorted
Pump solenoid circuit is moderately shorted to power.
RG41221,0000137 1923SEP051/1
001076.10 Pump Solenoid Circuit Moderately Shorted Diagnostic Procedure

04 160 ,271
1/1
1 Connection Check
NOTE: For wiring and theory of operation information, see DTC 001076.10 PUMP SOLENOID CIRCUIT MODERATELY SHORTED supporting information.
1/1
1/1
CTM331 (03OCT05)
04-160-271

012506
PN=445

1/1
04 160 ,272
1/1
1/1
CTM331 (03OCT05)
04-160-272

012506
PN=446
04 160 ,273
CTM331 (03OCT05)
04-160-273

012506
PN=447
001076.13 Pump Current Decay Time Invalid

Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
04 160 ,274
Stanadyne DE10 Injection Pump The Stanadyne DE10 injection pump has an internal, fuel control solenoid that is controlled by the Engine Control Unit (ECU). The ECU switches current on and off in order to charge the solenoid. When the current to the solenoid is increased, it moves a pump control valve into a position that allows for injection pressure to be developed. When the current to the solenoid is decreased, the pump control valve will return to a position that ends injection pressure. By controlling current to the solenoid, the ECU has the ability to manage the quantity and timing of fuel delivery to the engine. For
more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 001076.13 will set if: ECU detects high resistance in the pump solenoid. If DTC 001076.13 sets, the following will occur: ECU derates engine to 50% of full power immediately. Red stop lamp comes on.
RG41221,00000EE 1904OCT051/1
CTM331 (03OCT05)
04-160-274

012506
RG11985
1920DEC01
C O N N E C T O R
PN=448
001076.13 Pump Current Decay Time Invalid
ECU detects high resistance in the pump solenoid.
RG41221,00000EF 1904OCT051/1
001076.13 Pump Current Decay Time Invalid Diagnostic Procedure

04 160 ,275
1/1
1 Connection Check

1/1
NOTE: For wiring and theory of operation information, see DTC 001076.13 PUMP CURRENT DECAY TIME INVALID supporting information.
1/1
CTM331 (03OCT05)
04-160-275

012506
PN=449

1/1
04 160 ,276
1/1
1/1
CTM331 (03OCT05)
04-160-276

012506
PN=450
04 160 ,277
CTM331 (03OCT05)
04-160-277

012506
PN=451

Analog Throttle (A) Sensor Connector Analog Throttle (A) Sensor A B C A B C Sensor Return Sensor 5V D3 E2
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
Analog Throttle (A) Input B3
04 160 ,278
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 circuit. If DTC 001079.03 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply input voltage.
RG40854,0000052 1906DEC011/1
CTM331 (03OCT05)
04-160-278

012506
PN=452
RG12044
C O N N E C T O R
1923JAN02
The ECU detects a voltage that is higher than 5.5 volts on the ECU 5 volt sensor supply circuit.
RG40854,000010E 1923SEP051/1
001079.03 Sensor Supply Voltage High Diagnostic Procedure

04 160 ,279
1/1
1 Connection Check
Perform a preliminary inspection of the ECU connector, the analog throttle (A) connector, and any connectors in between. Look for dirty, damaged, or poorly positioned terminals.
1/1
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Make notes of any DTCs, then clear all DTCs 5. Ignition ON, engine OFF 6. Read DTCs using the DST orSERVICE ADVISOR.
001079.03 reoccur: GO TO 3 001079.03 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
CTM331 (03OCT05)
04-160-279

012506
PN=453

3 Sensor Supply Wire Check for Short
NOTE: For wiring and theory of operation information, DTC 001079.03 SENSOR SUPPLY VOLTAGE HIGH supporting information.
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance between terminal E2 the harness end of the ECU connector and all other terminals in the harness end of the ECU connector
Greater than 20,000 ohms: Faulty ECU connector OR Faulty ECU Less than 20,000 ohms: Short to voltage in sensor supply wire
1/1
04 160 ,280
CTM331 (03OCT05)
04-160-280

012506
PN=454
04 160 ,281
CTM331 (03OCT05)
04-160-281

012506
PN=455

Analog Throttle (A) Sensor Connector Analog Throttle (A) Sensor A B C A B C Sensor Return Sensor 5V D3 E2
F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 A1 A2 A3
B1 B2 B3 C1 C2 C3
D1 D2 D3 E1 E2 E3
E C U H A R N E S S
Analog Throttle (A) Input B3
04 160 ,282
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 001079.04 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 001079.04 sets, the following will occur: The ECU will use default values for the sensors that use sensor supply input voltage.
RG40854,0000054 1906DEC011/1
CTM331 (03OCT05)
04-160-282

012506
PN=456
RG12044
C O N N E C T O R
1923JAN02
The ECU detects a voltage that is lower than 4.44 volts on the ECU 5 volt sensor supply circuit.
RG40854,000010D 1923SEP051/1
001079.04 Sensor Supply Voltage Low Diagnostic Procedure

04 160 ,283
1/1
1 Connection Check
Perform a preliminary inspection of the ECU connector, the analog throttle (A) connector, and any connectors in between. Look for dirty, damaged, or poorly positioned terminals.
1/1
2 Sensor Check
1. Connect to the DST or SERVICE ADVISOR. 2. Ignition ON, engine OFF 3. Start the ECU communication software 4. Make note of any DTCs, then clear all DTCs 5. Ignition OFF 6. Disconnect all of the sensors that receive their 5 V supply from terminal E2 in the ECU connector. 7. Ignition ON, engine running 8. Read DTCs using the DST orSERVICE ADVISOR.
001079.04 reoccurs: GO TO 4 001079.04 does not reoccur: GO TO 3
1/1
CTM331 (03OCT05)
04-160-283

012506
PN=457

1. Ignition ON 2. While reconnecting each of the sensors one at a time, read DTCs using the DST or SERVICE ADVISOR.
001079.04 reoccurs: Sensor that reset the DTC is faulty Replace and retest 001079.04 does not reoccur: Problem is intermittent. If no other codes are present, see INTERMITTENT FAULT DIAGNOSTICS, earlier in this Group.
1/1
04 160 ,284
4 Sensor Supply Short to Ground Check
1. Ignition OFF 2. Disconnect ECU connector 3. Using a multimeter, measure resistance individually between terminal E2 in the harness end of the ECU connector and: A good chassis ground Terminal J2 in the harness end of the ECU connector Terminal D3 in the harness end of the ECU connector
Greater than 20,000 ohms: Faulty ECU connector OR Faulty ECU Less than 20,000 ohms: Sensor 5 volt supply circuit shorted to a ground
1/1
CTM331 (03OCT05)
04-160-284

012506
PN=458
04 160 ,285
CTM331 (03OCT05)
04-160-285

012506
PN=459
001109.31 Engine Protection Shutdown Warning
The ECU detects low oil pressure, high engine coolant temperature, high loss of coolant temperature, or high fuel temperature.
Engine Shutdown Warning: This code informs the operator that the ECU will shut the engine down because it has detected a condition such as low oil pressure, high engine coolant temperature, high loss of coolant temperature, low coolant level, high fuel temperature, or a faulty injection pump. 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: The The The The ECU ECU ECU ECU detects detects detects detects low oil pressure. a high engine coolant temperature. a high loss of coolant temperature. a high fuel temperature.
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 of the manual. If DTC 000110.00 is active, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. If DTC 000111.00 is active, see DTC 000111.00 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. If DTC 000174.16 is active, see DTC 000174.16 FUEL TEMPERATURE HIGH MODERATELY SEVERE DIAGNOSTIC PROCEDURE earlier in this Group of the manual.
04 160 ,286
If DTC 001109.31 sets, the following will occur:
RG40854,0000056 1906DEC011/1
CTM331 (03OCT05)
04-160-286

012506
PN=460
001110.31 Engine Protection Shutdown
The ECU detects low oil pressure, high engine coolant temperature, high loss of coolant temperature, or high fuel temperature.
Engine Protection Shutdown: This code informs the operator that the ECU shut the engine down because it has detected a condition such low oil pressure, high engine coolant temperature, high loss of coolant temperature, 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: The The The The ECU ECU ECU ECU detects detects detects detects low oil pressure. a high engine coolant temperature. a high loss of coolant temperature. a high fuel temperature.
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 of the manual. If DTC 000110.00 is active, see DTC 000110.00 ENGINE COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. If DTC 000111.00 is active, see DTC 000111.00 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. If DTC 000174.16 is active, see DTC 000174.16 FUEL TEMPERATURE HIGH MODERATELY SEVERE DIAGNOSTIC PROCEDURE earlier in this Group of the manual.
04 160 ,287
If DTC 001110.31 sets, the following will occur:
RG40854,0000057 1906DEC011/1
CTM331 (03OCT05)
04-160-287

012506
PN=461
001568.02 Torque Curve Selection Invalid or Missing (750J Crawler Only)

CAN (Controller Area Network) Torque Curve Selection The ECU (A) has the ability to operate the engine on multiple, different torque curves. Individual curves can be selected based on information sent to the ECU over CAN (Controller Area Network) (B) by another controller.
CAN Communication Box Schematic
DTC 001568.02 will set if: The ECU either receives no torque curve selection information, or receives torque curve information that is not valid over CAN. If DTC 001568.02 sets, the following will occur: ECU defaults to low power torque curve (TorqParm0). If DTC 000639.13 also sets CAN Bus Error is active, see DTC 000639.13 CAN BUS ERROR DIAGNOSTIC PROCEDURE earlier in this group. Check to see if any other controllers on the machine have any active or stored CAN-related DTCs. If they do, go to the appropriate diagnostic procedure. If no other stored or active CAN-related DTCs are found, replace the ECU and retest.
04 160 ,288
DB92450,0000032 1905OCT051/1
CTM331 (03OCT05)
04-160-288

012506
RG14511
UN28SEP05
PN=462
04 160 ,289
CTM331 (03OCT05)
04-160-289

012506
PN=463
001569.31 Fuel Derate
The ECU detects low oil pressure, high manifold air temperature, high engine coolant temperature, high loss of coolant temperature, or high fuel temperature.
Fuel Derate The fuel derate trouble code is set to indicate that the ECU has detected a condition such as low oil pressure, high manifold air temperature, high coolant temperature, high loss of coolant temperature, or high fuel temperature. If the ECU detects one of these conditions, it will begin to derate the amount of fuel delivered to the engine. DTC 001569.31 will set if: The The The The The ECU ECU ECU ECU ECU detects detects detects detects detects low oil pressure. high manifold air temperature. a high engine coolant temperature. a high loss of coolant temperature. a high fuel temperature.
04 160 ,290
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 DTC 001569.31 sets: If DTC 000100.01 or DTC 000100.18 is active, see one of the following procedures earlier in this Group of the manual:
DTC 000100.01 ENGINE OIL PRESSURE EXTREMELY LOW DIAGNOSTIC PROCEDURE DTC 000100.18 ENGINE OIL PRESSURE MODERATELY LOW DIAGNOSTIC PROCEDURE If DTC 000105.16 is active, see DTC 000105.16 MANIFOLD AIR TEMPERATURE MODERATELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. If DTC 000110.00, DTC 000110.15, or DTC 000110.16 is active, see one of the following procedures earlier in this Group of the manual: 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 000111.00 is active, see DTC 000111.00 LOSS OF COOLANT TEMPERATURE EXTREMELY HIGH DIAGNOSTIC PROCEDURE earlier in this Group of the manual. If DTC 000174.16 is active, see DTC 000174.16 FUEL TEMPERATURE HIGH MODERATELY SEVERE DIAGNOSTIC PROCEDURE earlier in this Group of the manual.
RG40854,0000058 1906DEC011/1
CTM331 (03OCT05)
04-160-290

012506
PN=464
002000.06 Internal ECU Failure
Pump Solenoid
A1 A2 A3

B A B A
B1 B2 B3 C1 C2 C3
D1 D2 D3
E C U H A R N E S S
A3 K2
E1 E2 E3
RG11985
1920DEC01
C O N N E C T O R
ECU has detected a short in the ECU that causes an extremely high current at the injection pump.
the engine. For more operation information, see FUEL INJECTION PUMP OPERATION in Section 03, Group 130 of this manual. DTC 002000.06 will set if: ECU has detected a short in the ECU that causes an extremely high current at the injection pump. If DTC 002000.06 sets, the following will occur: Engine shuts down immediately If DTC 002000.06 sets: Replace the ECU and retest.
04 160 ,291
RG40854,000005A 1906DEC011/1
CTM331 (03OCT05)
04-160-291

012506
PN=465
002000.13 Security Violation
The ECU determines that it, OR another controller on the machine is not the right controller for the 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 ,292
The ECU will allow the engine to start, but will only allow low idle engine speed. For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for the high oil pressure input voltage specification. 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 the particular machine. If DTC 002000.13 sets, the following will occur:
RG40854,000005B 1906DEC011/1
CTM331 (03OCT05)
04-160-292

012506
PN=466
Section 05
Tools and Other Materials

Contents
Page
Group 170Electronic Fuel/Control System Repair Tools and Other Materials 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 Control System Repair and Adjustment Essential Tools . . . . . . . . . . . . . . . . . . . . . .05-170-5 Control System Repair and Adjustment Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-10
05
Group 180Diagnostic Service Tools ic Fuel System Diagnostic Tools . . . . . . . . . . .05-180-1
CTM331 (03OCT05)
05-1

012506
PN=1
Contents
05
CTM331 (03OCT05)
05-2

012506
PN=2
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials

Fuel System Repair and Adjustment Essential Tools
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company

RG12017 UN16NOV01
OUO1080,000020F 1927NOV011/10
Injection Pump Drive Gear Puller . . . . . . . . . . JDG1560 Remove drive gear from tapered shaft of injection pump.
JDG1560
05 170 1
OUO1080,000020F 1927NOV012/10 RG12020 UN19NOV01
DE10 Injection Pump Timing Pin . . . . . . . . . . JDG1559 Used for static lock pin timing during installation of injection pump.
JDG1559
OUO1080,000020F 1927NOV013/10
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDG1571 Used to lock flywheel at No. 1 TDC for injection pump timing. This timing pin MUST be used on engine applications using the tapered-nose crankshaft due to the higher torque specification for damper retaining cap screw.
JDG1571
OUO1080,000020F 1927NOV014/10
CTM331 (03OCT05)
05-170-1

012506
PN=469
RG12031
UN20DEC01

RG11741 UN24MAY01
Injection Nozzle Puller . . . . . . . . . . . . . . . . JDG1515-1 Use with slide hammer to remove injection nozzles.
JDG1515-1
OUO1080,000020F 1927NOV015/10 RG5084 UN23AUG88
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . . JDE39 Clean injection nozzle bore in cylinder head.
JDE39
05 170 2
OUO1080,000020F 1927NOV016/10 RG11742 UN24MAY01
Spring Chamber Cap Wrench . . . . . . . . . . . . JDG1521 Used to remove the spring chamber cap on RSN nozzles.
JDG1521
OUO1080,000020F 1927NOV017/10 RG12023 UN27NOV01
Pressure Adjusting Screw Tool . . . . . . . . . . . JDG1522 Used to adjust opening pressure on RSN nozzles.
JDG1522
Continued on next page OUO1080,000020F 1927NOV018/10
CTM331 (03OCT05)
05-170-2

012506
PN=470

JDG15152 UN13JUN01
Pressure Adjusting Screw Lock Nut Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1515-2 Used to loosen or tighten lock nut of pressure adjusting screws.
OUO1080,000020F 1927NOV019/10
Nozzle Carbon Stop Seal Installer . . . . . JD258 (JD-258) Used to install carbon stop seal in injection nozzle groove.
UN22JUL92 RG6254
JD258 (JD-258)
05 170 3
OUO1080,000020F 1927NOV0110/10
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.
OUO1080,0000210 1927NOV011/3
CTM331 (03OCT05)
05-170-3

012506
PN=471

Injection Nozzle Tester (R. BOSCH) . . . . . . . . . JT25510 Check nozzle opening pressure.
JT25510
OUO1080,0000210 1927NOV012/3 CD30308 UN08MAR95
05 170 4
Fuel Pressure Line . . . . . . . . . . . . . . . . . . .KJD10109 To connect injection nozzle to BOSCH tester.

KJD10109
OUO1080,0000210 1927NOV013/3
Fuel System Repair and Adjustment Other Materials

Number Name Use
T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)
Thread Lock and Sealer (Medium Strength)
Apply to fuel supply pump mounting screws and fuel line fittings.
LOCTITE is a registered trademark of Loctite Corp.
OUO1080,0000211 1927NOV011/1
CTM331 (03OCT05)
05-170-4

012506
PN=472
CD30307
UN07MAR95
Control 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).

RW25539 UN28AUG96
RG40854,0000003CONV3 1912MAR021/17
Terminal Extraction Tool . . . . . . . . . . . . . . . . .JDG364 Used to extract WEATHER PACK terminals from electrical connectors.
05 170 5
RG40854,0000003CONV3 1912MAR022/17
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
RG40854,0000003CONV3 1912MAR023/17
METRI-PACK Crimping Tool . . . . . . . . . . . . . JDG865 Used to crimp METRI-PACK male and female terminals on 14-20 gauge wires.
UN07MAR02
METRI-PACK is a trademark of Packard Electric Inc.
RG40854,0000003CONV3 1912MAR024/17
CTM331 (03OCT05)
05-170-5

012506
RW25542A
RW25542A
PN=473

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.
RG40854,0000003CONV3 1912MAR025/17
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.
RG11679
UN05FEB01
05 170 6
RG40854,0000003CONV3 1912MAR026/17
Electricians Pliers . . . . . . . . . . . . . . . . . . . . . JDG145 Used to cut, strip, and splice wires.
RG40854,0000003CONV3 1912MAR027/17
CTM331 (03OCT05)
05-170-6

012506
RG11686
UN13FEB01
PN=474
RW25558
UN29AUG96

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.
RG40854,0000003CONV3 1912MAR028/17 RW25541 UN20AUG96
RW25558
UN29AUG96
METRI-PACK Extractor (Wide) . . . . . . . . . . . JDG776 Used to remove terminals from 56-Series, 280-Series, and 630-Series METRI-PACK connectors.
05 170 7

RW25541 UN20AUG96
RG40854,0000003CONV3 1912MAR029/17
METRI-PACK Extractor (Narrow) . . . . . . . . . . JDG777 Used to remove terminals from 150-Series METRI-PACK, SUMITOMO, and YAZAKI connectors.
RG40854,0000003CONV3 1912MAR0210/17
CTM331 (03OCT05)
05-170-7

012506
PN=475

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.

05 170 8
RG40854,0000003CONV3 1912MAR0211/17
1214 Gauge Extractor (Set of Two)1 . . . . . . . . JDG361 Used to remove terminals on 12-14 gauge wires in DEUTSCH connectors.
UN14OCT05
Deutsch Extraction Tool
Included in DEUTSCH Electrical Repair Kit - JDG359

RG40854,0000003CONV3 1912MAR0212/17
1618 Gauge Extractor (Set of Two)1 . . . . . . . . JDG362 Used to remove terminals on 16-18 gauge wires in DEUTSCH connectors.
UN14OCT05

Continued on next page RG40854,0000003CONV3 1912MAR0213/17
CTM331 (03OCT05)
05-170-8

012506
RG12278
RG12278
PN=476
RW25540

2024 Gauge Extractor (Set of Two)1 . . . . . . . JDG363 Used to remove terminals on 20-24 gauge wires in DEUTSCH connectors.
UN14OCT05

RG40854,0000003CONV3 1912MAR0214/17
Crimping Tool1 . . . . . . . . . . . . . . . . . . . . . . . JDG360 Used to crimp DEUTSCH closed barrel terminals on 12-24 gauge wires.
UN15MAR02
RG12278
05 170 9
RG40854,0000003CONV3 1912MAR0215/17 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
RG40854,0000003CONV3 1912MAR0216/17 RG10739 UN26MAY00
Crimping Pliers . . . . . . . . . . . . . . . . . . . . . .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

RG40854,0000003CONV3 1912MAR0217/17
CTM331 (03OCT05)
05-170-9

012506
RG12235
PN=477
Control System 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.

05 170 10
OUO1080,0000215 1927NOV011/1
CTM331 (03OCT05)
05-170-10

012506
PN=478
Group 180
Diagnostic Service Tools

ic Fuel System Diagnostic Tools
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the European Microfiche Tool Catalog (MTC) unless otherwise noted.
SERVICEGARD is a trademark of Deere & Company.
RG40854,0000002CONV3 1919JUL051/11
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
RG40854,0000002CONV3 1919JUL052/11
Universal Pressure Test Kit . . . . . . . . . . . . . . . JT05412 Used for testing engine oil pressure, intake manifold pressure (turbo boost), and fuel supply pump pressure.
JT05412
Continued on next page RG40854,0000002CONV3 1919JUL053/11
CTM331 (03OCT05)
05-180-1

012506
RG5162
UN14OCT05
RG8518
PN=479

ECU Communication Software Kit. . . . . . . . . . . JDIS122 Please refer to your John Deere Dealer website for information on obtaining the latest version of software.
UN17OCT05
JDIS122
RG40854,0000002CONV3 1919JUL054/11
05 180 2
NOTE: Available from John Deere Distribution Service Center (DSC). United States and Canadian Agricultural dealers DO NOT ORDER without first contacting your Branch or TAM.
RG40854,0000002CONV3 1919JUL055/11
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.
UN19OCT05
RG8554
RG40854,0000002CONV3 1919JUL056/11
CTM331 (03OCT05)
05-180-2

012506
PN=480
RG11747

Power Adapter . . . . . . . . . . . . . . . . . . . . . . DS10037 Used with ECU Communication Hardware Kit. The power adapter connects between the PDM and the 26-pin, MagiKey connector. It is used whenever power is lost to the PDM during cranking the engine for the compression test.
Power Adapter
RG40854,0000002CONV3 1919JUL057/11
RG12277
UN22APR02
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.
UN19OCT05
05 180 3
RG40854,0000002CONV3 1919JUL058/11
NOTE: Available from John Deere Distribution Service Center (DSC). United States and Canadian Agricultural dealers DO NOT ORDER without first contacting your Branch or TAM.
Continued on next page RG40854,0000002CONV3 1919JUL059/11
CTM331 (03OCT05)
05-180-3

012506
PN=481
RG11747

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
RG40854,0000002CONV3 1919JUL0510/11
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 4
UN26NOV97
JT07328
RG40854,0000002CONV3 1919JUL0511/11
CTM331 (03OCT05)
05-180-4

012506
RG8803
PN=482
RG11126
Section 06
Specifications
Contents
Page Page
Group 200Repair Specifications Unified Inch Bolt and Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1 Metric Bolt and Screw Torque Values . . . . . . .06-200-2 General OEM Engine Specifications . . . . . . . .06-200-3 Electronic Fuel System Repair and Adjustment Specifications . . . . . . . . . . . . . .06-200-4 Electronic Engine Control Repair and Adjustment Specifications . . . . . . . . . . . . . .06-200-6 Group 210Diagnostic Specifications Group 150/160 Electronic Fuel System Diagnostic Specifications . . . . . . . . . . . . . . .06-210-1 Application Specifications . . . . . . . . . . . . . . . .06-210-3 Backhoes - Sensor Specifications . . . . . . . . . .06-210-6 Backhoes - Torque Curve Selection . . . . . . . .06-210-7 Backhoes - Governor Mode Selection . . . . . . .06-210-7 Backhoes - ECU Terminal Identification . . . . .06-210-8 Crawlers - Sensor Specifications. . . . . . . . . .06-210-10 Crawlers - Torque Curve Selection . . . . . . . .06-210-12 Crawlers - Governor Mode Selection. . . . . . .06-210-12 Crawlers - ECU Terminal Identification . . . . .06-210-13 Excavators - Sensor Specifications . . . . . . . .06-210-14 Excavators - Torque Curve Selection . . . . . .06-210-15 Excavators - Governor Mode Selection . . . . .06-210-15 Excavators - ECU Terminal Identification . . .06-210-16 Forwarders - Sensor Specifications . . . . . . . .06-210-18 Forwarders - Torque Curve Selection . . . . . .06-210-20 Forwarders - Governor Mode Selection. . . . .06-210-20 Forwarders - ECU Terminal Identification . . .06-210-21 Harvesters - Sensor Specifications . . . . . . . .06-210-22 Harvesters - Torque Curve Selection . . . . . .06-210-23 Harvesters - Governor Mode Selection . . . . .06-210-23 Harvesters - ECU Terminal Identification. . . .06-210-24 OEM Engines - Sensor Specifications . . . . . .06-210-26 OEM Engines - Torque Curve Selection . . . .06-210-28 OEM Engines - Governor Mode Selection With OC03038 Software or Later . . . . . . . .06-210-29 OEM Engines - Governor Mode Selection With OC03033 Software or Earlier . . . . . . .06-210-30 OEM Engines - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-31 OEM Engines - Electronic Control System Wiring Diagram - Base ECUs . . . . . . . . . .06-210-32 OEM Engines - Electronic Control System Wiring Diagram - Extended ECUs (Early) . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-33 CTM331 (03OCT05)
OEM Engines - Electronic Control System Wiring Diagram - Extended ECUs (Later) . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-34 OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-35 Skidders - Sensor Specifications . . . . . . . . . .06-210-36 Skidders - Torque Curve Selection . . . . . . . .06-210-38 Skidders - Governor Mode Selection . . . . . . .06-210-38 Skidders - ECU Terminal Identification . . . . .06-210-39 Telehandlers - Sensor Specifications . . . . . .06-210-40 Telehandlers - Torque Curve Selection . . . . .06-210-42 Telehandlers - Governor Mode Selection . . .06-210-42 Telehandlers - ECU Terminal Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-43 Tractors - Sensor Specifications . . . . . . . . . .06-210-44 Tractors - Torque Curve Selection. . . . . . . . .06-210-46 Tractors - Governor Mode Selection . . . . . . .06-210-46 Tractors - ECU Terminal Identification. . . . . .06-210-47
06
06-1

012506
PN=1
Contents
06
CTM331 (03OCT05)
06-2

012506
PN=2
Group 200
Repair Specifications
Unified Inch Bolt and Screw Torque Values
TS1671 UN01MAY03
Bolt or Screw Size 1/4
SAE Grade 1 Lubricated Nm 3.7

b
SAE Grade 2a
c
SAE Grade 5, 5.1 or 5.2

c
SAE Grade 8 or 8.2 Lubricatedb Nm 13.5 Nm lb-in 120 lb-ft 20.5 Dryc Nm 17 Nm 35 lb-in 150 lb-ft 26
Dry Nm 4.7
Lubricated Nm 6
Dry Nm 7.5
Lubricated Nm 9.5
Dry Nm 12
lb-in 33
lb-in 42
lb-in 53
lb-in 66
lb-in 84
lb-in 106
5/16
7.7
68
9.8
86
12
106
15.5
137
19.5 Nm
172 lb-ft 26
25 Nm 44
221 lb-ft 32.5
28
3/8
13.5
120
17.5 Nm
155 lb-ft 20.5
22 Nm 35
194 lb-ft 26
27 Nm 44
240 lb-ft 32.5
35
49
36
63
46
7/16
22 Nm
194 lb-ft 25 35.5 49 88 140 210 300 420 550 730
28
56
41
70
52
80
59
100
74
1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
34 48 67 120 190 285 400 570 750 990
42 60 85 150 240 360 510 725 950 1250
31 45 63 110 175 265 375 535 700 930
53 76 105 190 190 285 400 570 750 990
39 56 77 140 140 210 300 420 550 730
67 95 135 240 240 360 510 725 950 1250
49 70 100 175 175 265 375 535 700 930
85 125 170 300 490 730 910 1280 1700 2250
63 92 125 220 360 540 670 945 1250 1650
110 155 215 380 615 920 1150 1630 2140 2850
80 115 160 280 455 680 850 1200 1580 2100
120 175 240 425 690 1030 1450 2050 2700 3600
88 130 175 315 510 760 1075 1500 2000 2650
155 220 305 540 870 1300 1850 2600 3400 4550
115 165 225 400 640 960 1350 1920 2500 3350 06 200 1
Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
a
Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.
b
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C zinc flake coating.
c
Dry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 1924APR031/1
CTM331 (03OCT05)
06-200-1

012506
PN=485
Metric Bolt and Screw Torque Values

UN01MAY03
4.8 4.8
8.8 8.8
9.8 9.8
10.9 10.9
12.9 12.9
12.9 12.9
Bolt or Screw Size M6
Class 4.8 Lubricateda Nm 4.7 lb-in 42 Dryb Nm 6 lb-in 53
Class 8.8 or 9.8 Lubricateda Nm 8.9 lb-in 79 Dryb Nm 11.3 lb-in 100
Class 10.9 Lubricateda Nm 13 Nm lb-in 115 lb-ft 23.5 Dryb Nm 16.5 Nm 40 lb-in 146 lb-ft 29.5
Class 12.9 Lubricateda Nm 15.5 Nm 37 lb-in 137 lb-ft 27.5 Dryb Nm 19.5 Nm 47 lb-in 172 lb-ft 35
M8
11.5
102
14.5 Nm
128 lb-ft 21
22 Nm 43
194 lb-ft 32
27.5 Nm 55
243 lb-ft 40
32
M10
23 Nm
204 lb-ft 29.5 46 74 100 140 195 245 360 490 665 850
29
63
46
80
59
75
55
95
70
M12 M14 M16 M18 M20 06 200 2 M22 M24 M27 M30 M33 M36
40 63 100 135 190 265 330 490 660 900 1150
50 80 125 170 245 330 425 625 850 1150 1450
37 59 92 125 180 245 315 460 625 850 1075
75 120 190 265 375 510 650 950 1290 1750 2250
55 88 140 195 275 375 480 700 950 1300 1650
95 150 240 330 475 650 820 1200 1630 2200 2850
70 110 175 245 350 480 600 885 1200 1625 2100
110 175 275 375 530 725 920 1350 1850 2500 3200
80 130 200 275 390 535 680 1000 1350 1850 2350
140 220 350 475 675 920 1150 1700 2300 3150 4050
105 165 255 350 500 680 850 1250 1700 2325 3000
130 205 320 440 625 850 1080 1580 2140 2900 3750
95 150 235 325 460 625 800 1160 1580 2150 2770
165 260 400 560 790 1080 1350 2000 2700 3700 4750
120 190 300 410 580 800 1000 1475 2000 2730 3500
Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.
a
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C zinc flake coating.
b
Dry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 1924APR031/1
CTM331 (03OCT05)
06-200-2

012506
PN=486
TS1670
General OEM Engine Specifications

ITEM 4045TF275 Number of Cylinders Bore Stroke Displacement Compression Ratio Max. Crank Pressure Governor Regulation (Industrial) Governor Regulation (Generator) Oil Pressure At Rated Speed, Full Load ( 15 psi) Oil Pressure At Low Idle (Minimum) Length Width Height Weight 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 4045HF275 4 106 mm (4.19 in.) 127 mm (5.0 in.) 4.5 L (276 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 860 mm (33.9 in.) 612 mm (24.1 in.) 994 mm (39.1 in.) 451 kg (993 lb) 6068TF275 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1119 mm (43.9 in.) 623 mm (24.5 in.) 1012 mm (39.9 in.) 587 kg (1290 lb) 6068HF275 6 106 mm (4.19 in.) 127 mm (5.0 in.) 6.8 L (414 cu in.) 17.0:1 0.5 kPa (2 H2O) 710 % 5% 345 kPa (50 psi) 105 kPa (15 psi) 1123 mm (44.2 in.) 623 mm (24.5 in.) 1015 mm (40.0 in.) 587 kg (1290 lb)
06 200 3
DPSG,OUO1004,102 1919NOV011/1
CTM331 (03OCT05)
06-200-3

012506
PN=487
Electronic Fuel System Repair and Adjustment Specifications

Item Measurement Specification
Final Fuel Filter Bracket-to-Cylinder Head Final Fuel Filter Mounting Base-to-Bracket Primary Fuel Filter Bracket-to-Cylinder Head and Alternator Primary Fuel Filter/Water Bowl Mounting Base-to-Bracket Fuel Supply Pump
Torque
73 Nm (54 lb-ft)
Torque
73 Nm (54 lb-ft)
Torque
73 Nm (54 lb-ft)
Torque
50 Nm (36 lb-ft)
Pressure
2841 kPa (0.280.41 bar) (46 psi) 30 Nm (22 lb-ft) 24 Nm (18 lb-ft) 25 Nm (19 lb-ft) 195 Nm (145 lb-ft) 27 Nm (20 lb-ft)
Fuel Supply Pump Cap Screws Fuel line tube nuts Injection Pump Mounting Stud Nuts
06 200 4
Torque Torque Torque Torque Torque
Injection Pump Gear Mounting Nut Injection Pump Fuel Delivery (Pressure) Lines Injection Pump Timing Pin Plug Fuel Injection Nozzle Nozzle
Torque
9.5 Nm (7.5 lb-ft)
Return Leakage at 10 300 kPa (103 bar) (1500 psi)
1 to 14 drops (maximum) within 30 seconds
OUO1080,0000212 1904AUG051/2
CTM331 (03OCT05)
06-200-4

012506
PN=488
Item
Measurement
Specification
Fuel Injection Nozzle Rate Shaping Nozzle Opening Pressure for Setting (New or Reconditioned) Opening Pressure for Checking (New or Reconditioned) Opening Pressure for Setting (Used) Opening Pressure for Checking (Used) Rate Shaping Nozzle Opening pressure difference between cylinders 24 40024 900 kPa (244249 bar) (35403620 psi) 24 100 kPa (241 bar) (3500 psi) Min 23 00023 600 kPa (230236 bar) (33403420 psi) 21 800 kPa (218 bar) (3170 psi) Min
700 kPa (7 bar) (100 psi) Max
Fuel Injection Nozzle Pressure Adjusting Screw Lock Nut Lift Adjusting Screw Lock Nut Torque 10 Nm (7 lb-ft)
Torque
5 Nm (3.5 lb-ft)
Fuel Injection Nozzle Hold-Down Clamp Cap Screws Fuel Leak-Off Line Hex Nut
Torque
40 Nm (30 lb-ft)
06 200 5
Torque
5 Nm (3.7 lb-ft) (44 lb-in.) 27 Nm (20 lb-ft) 27 Nm (20 lb-ft)
Fuel Injection Pump Return Line Fuel Injection Nozzle Delivery Lines
Torque Torque
OUO1080,0000212 1904AUG052/2
CTM331 (03OCT05)
06-200-5

012506
PN=489
Electronic Engine Control Repair and Adjustment Specifications

Coolant Temperature Sensor in Thermostat Housing Coolant Temperature Sensor in Cylinder Head Crankshaft Position Sensor Oil Pressure Sensor Manifold Air Temperature Sensor Fuel Temperature Sensor Fuel Heater
Torque
15 Nm (11 lb-ft)
Torque
35 Nm (26 lb-ft)
Torque Torque Torque Torque Torque
14 Nm (10 lb-ft) 15 Nm (11 lb-ft) 10 Nm (7 lb-ft) 1318 Nm (1013 lb-ft) 9 Nm (7 lb-ft)
06 200 6
OUO1080,0000216 1927NOV011/1
CTM331 (03OCT05)
06-200-6

012506
PN=490
Group 210
Diagnostic Specifications
Group 150/160 Electronic Fuel System Diagnostic Specifications
Fuel Supply Pump
Static Pressure
2530 kPa (0.250.30 bar) (3.54.5 psi) 15 kPa (0.15 bar) (2.0 psi)
Fuel Supply Pump
Minimum Static Pressure at 850 rpm Engine Speed Minimum Positive Pressure at 2400 rpm Engine Speed Minimum Flow at 2400 rpm Engine Speed
Fuel Supply Pump
2134 kPa (0.210.34 bar) (35 psi) 1.5 L/min (0.42 gpm)
Fuel Supply Pump
DPSG,OUO1004,2762 1917MAY001/1
06 210 1
CTM331 (03OCT05)
06-210-1

012506
PN=491
06 210 2
CTM331 (03OCT05)
06-210-2

012506
PN=492
Application Specifications
Below is an overview of the specfications listed for applications in the next few pages. Backhoes Sensor Specifications - See BACKHOES SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See BACKHOES TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See BACKHOES GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See BACKHOES ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. Crawlers Sensor Specifications - See CRAWLERS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See CRAWLERS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See CRAWLERS GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See CRAWLERS ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. Excavators Sensor Specifications - See EXCAVATORS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See EXCAVATORS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See EXCAVATORS GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See EXCAVATORS - ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. Forwarders Sensor Specifications - See FORWARDERS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See FORWARDERS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See FORWARDERS GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See FORWARDERS - ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. Harvesters Sensor Specifications - See HARVESTERS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See HARVESTERS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See HARVESTERS GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See HARVESTERS - ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. OEM Engines Sensor Specifications - See OEM ENGINES SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See OEM ENGINES TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See OEM ENGINES GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See OEM ENGINES - ECU TERMINAL IDENTIFICATION later in this Group. Electronic Control System Wiring Diagram for Base ECUs - See OEM ENGINES ELECTRONIC CONTROL SYSTEM WIRING DIAGRAM BASE ECUS later in this Group.
06 210 3
RG40854,0000128 1929JAN021/2
CTM331 (03OCT05)
06-210-3

012506
PN=493
Electronic Control System Wiring Diagram for Early Extended ECUs - See OEM ENGINES ELECTRONIC CONTROL SYSTEM WIRING DIAGRAM EXTENDED ECUS (EARLY) later in this Group. Electronic Control System Wiring Diagram for Later Extended ECUs - See OEM ENGINES ELECTRONIC CONTROL SYSTEM WIRING DIAGRAM EXTENDED ECUS (LATER) later in this Group. 4.5L & 6.8L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram - See OEM ENGINES - 4.5L & 6.8L OEM APPLICATION INSTRUMENT PANEL/ENGINE START COMPONENTS ELECTRICAL WIRING DIAGRAM later in this Group. Skidders Sensor Specifications - See SKIDDERS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See SKIDDERS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See SKIDDERS GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See SKIDDERS ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. Telehandlers Sensor Specifications - See TELEHANDLERS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See TELEHANDLERS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See TELEHANDLERS - GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See TELEHANDLERS - ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual. Tractors Sensor Specifications - See TRACTORS SENSOR SPECIFICATIONS later in this Group. Torque Curve Selection - See TRACTORS TORQUE CURVE SELECTION later in this Group. Governor Mode Selection - See TRACTORS GOVERNOR MODE SELECTION later in this Group. ECU Terminal Identification - See TRACTORS ECU TERMINAL IDENTIFICATION later in this Group. Vehicle Wiring - See Vehicle manual.
06 210 4
RG40854,0000128 1929JAN022/2
CTM331 (03OCT05)
06-210-4

012506
PN=494
06 210 5
CTM331 (03OCT05)
06-210-5

012506
PN=495
Backhoes - Sensor Specifications

The specifications shown below are voltage, pressure, and temperature parameters that the Engine Control Unit (ECU) uses to determine whether a Diagnostic Trouble Code (DTC) is set for a given sensor.
Sensor Specifications for Backhoes 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. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 20% per minute until engine runs at 80% of full power.
000091.04
Low Input Voltage
Below 0.3 Volts
Manifold Air Temperature (MAT)
000105.03 000105.04
High Input Voltage Low Input Voltage Most Severe Temperature
Above 4.9 Volts Below 0.1 Volts Exceeds 113C (235F)
Engine Coolant Temperature (ECT)
000110.00
000110.03 000110.04 06 210 6 Fuel Temperature 000174.03
High Input Voltage Low Input Voltage High Input Voltage
Exceeds 4.9 Volts Below 0.1 Volts Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Moderately High Temperature Security Violation
Exceeds 120C (248F)
Security Violation
002000.13
Security Violation
RG40854,000013A 1923APR021/1
CTM331 (03OCT05)
06-210-6

012506
PN=496
Backhoes - Torque Curve Selection

Torque Curve Selection for Backhoes Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal operation
RG40854,000013B 1930JAN021/1
Backhoes - Governor Mode Selection

Desired Speed Governor Selection for Backhoes Mode Selected on SERVICE ADVISOR 0 Conditions Normal droop
Max. Speed Governor Selection for Backhoes Mode Selected on SERVICE ADVISOR 9 Conditions: Normal droop 06 210 7
RG40854,000013E 1930JAN021/1
CTM331 (03OCT05)
06-210-7

012506
PN=497
Backhoes - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B3 B2 D2 A3 K2 C3 B1 D1
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa N/Aa Changes with each sensor Changes with each sensor B A B B A A A A
06 210 8
RG40854,000013F 1930JAN021/1
CTM331 (03OCT05)
06-210-8

012506
PN=498
06 210 9
CTM331 (03OCT05)
06-210-9

012506
PN=499
Crawlers - Sensor Specifications

RG40854,0000132 1923APR021/2
06 210 10
CTM331 (03OCT05)
06-210-10

012506
PN=500
Sensor Specifications for Crawlers 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 20% per minute until engine runs at 60% of full power. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. High MAT engine protection is disabled. High MAT engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 20% per minute until engine runs at 60% of full power. High loss of coolant temperature engine protection is disabled. High loss of coolant temperature engine protection is disabled. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power.
000091.04
Low Input Voltage
Below 0.3 Volts
Oil Pressure
000100.01
Extremely Low Pressure
Below an extremely low engine oil pressure. This pressure increases with engine speed. Above 4.5 Volts Below 0.3 Volts Above 4.9 Volts Below 0.1 Volts Exceeds 113C (235F)
000100.03 000100.04 Manifold Air Temperature (MAT) 000105.03 000105.04 Engine Coolant Temperature (ECT) 000110.00
High Input Voltage Low Input Voltage High Input Voltage Low Input Voltage Most Severe Temperature
000110.03 000110.04 Loss of Coolant Temperature 000111.00
High Input Voltage Low Input Voltage Extremely High Temperature High Input Voltage
Exceeds 4.9 Volts Below 0.1 Volts Exceeds 124C (255F)
06 210 11
000111.03
Exceeds 4.9 Volts
000111.04
Low Input Voltage
Below 0.05 Volts
Fuel Temperature
000174.03
High Input Voltage
Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Moderately High Temperature
Exceeds 120C (248F)
RG40854,0000132 1923APR022/2
CTM331 (03OCT05)
06-210-11

012506
PN=501
Crawlers - Torque Curve Selection

Torque Curve Selection for Crawlers Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal operation
RG40854,0000135 1930JAN021/1
Crawlers - Governor Mode Selection

Desired Speed Governor Selection for Crawlers Mode Selected on SERVICE ADVISOR 0 Conditions Normal droop
Max. Speed Governor Selection for Excavators Mode Selected on SERVICE ADVISOR 9 06 210 12 Conditions: Normal droop
RG40854,0000134 1930JAN021/1
CTM331 (03OCT05)
06-210-12

012506
PN=502
Crawlers - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input Loss of Coolant Temperature
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B3 B2 D2 A3 K2 C3 B1 D1 F3 C1
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa N/Aa Changes with each sensor Changes with each sensor B A B B A A A A B A
06 210 13
RG40854,0000137 1930JAN021/1
CTM331 (03OCT05)
06-210-13

012506
PN=503
Excavators - Sensor Specifications

Sensor Specifications for Excavators Sensor Manifold Air Temperature (MAT) SPN.FMI 000105.03 000105.04 000105.16 Measured Sensor Parameter High Input Voltage Low Input Voltage Moderately High Temperature Most Severe Temperature Out of Range Value Above 4.9 Volts Below 0.1 Volts Exceeds 88C (190F) Derate 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 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. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power.
000110.00
Exceeds 115C (239F)
000110.03 000110.04 000110.15
High Input Voltage Low Input Voltage Least Severe Temperature Moderately Severe Temperature High Input Voltage
06 210 14 Fuel Temperature
000110.16
Exceeds 113C (235F)
000174.03
Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Exceeds 120C (248F)
RG40854,000012E 1923APR021/1
CTM331 (03OCT05)
06-210-14

012506
PN=504
Excavators - Torque Curve Selection

Torque Curve Selection for Excavators Torque Curve # on SERVICE ADVISOR 1 2 Conditions for Torque Curve Normal operation Altitude Derate
RG40854,000012F 1930JAN021/1
Excavators - Governor Mode Selection

Desired Speed Governor Selection for Excavators Mode Selected on SERVICE ADVISOR 0 Conditions Normal droop 06 210 15
Max. Speed Governor Selection for Excavators Mode Selected on SERVICE ADVISOR 9 Conditions: Normal droop
RG40854,0000131 1930JAN021/1
CTM331 (03OCT05)
06-210-15

012506
PN=505
Excavators - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low Sensor Ground Throttle Reference Throttle Input Throttle Ground Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input
a
ECU Terminal # A2 K1 J2 G1 F1 D3 F3 B3 C1 B2 D2 A3 K2 C3 B1 D1
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor N/Aa N/Aa N/Aa A B B A A A A
06 210 16
RG40854,0000130 1930JAN021/1
CTM331 (03OCT05)
06-210-16

012506
PN=506
06 210 17
CTM331 (03OCT05)
06-210-17

012506
PN=507
Forwarders - Sensor Specifications

RG40854,0000158 1923APR021/3
06 210 18
CTM331 (03OCT05)
06-210-18

012506
PN=508
Sensor Specifications for Forwarders Sensor Analog Throttle (A) (1010 Forwarders ONLY) 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 20% per minute until engine runs at 60% of full power. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. 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 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. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled.
000091.04
Low Input Voltage
Below 0.3 Volts
Analog Throttle (B) (1010 Forwarders ONLY)
000029.03
High Input Voltage
Above 4.7 Volts
000029.04
Low Input Voltage
Below 0.3 Volts
Oil Pressure
000100.01
Pressure goes below an engine speed dependent value. Above 4.5 Volts Below 0.3 Volts Above 4.9 Volts Below 0.1 Volts Exceeds 88C (190F)
000100.03 000100.04 Manifold Air Temperature (MAT) 000105.03 000105.04 000105.16
High Input Voltage Low Input Voltage High Input Voltage Low Input Voltage Moderately High Temperature Most Severe Temperature
000110.00
Exceeds 115C (239F)
06 210 19
000110.03 000110.04 000110.16
High Input Voltage Low Input Voltage Moderately Severe Temperature High Input Voltage
Fuel Temperature
000174.03
Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
RG40854,0000158 1923APR022/3
CTM331 (03OCT05)
06-210-19

012506
PN=509
Sensor Specifications for Forwarders 000174.16 Moderately High Temperature Security Violation Exceeds 120C (248F) ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 500% per minute until engine runs at 50% of full power.
Security Violation
002000.13
Security Violation
RG40854,0000158 1923APR023/3
Forwarders - Torque Curve Selection

Torque Curve Selection for Forwarders Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal Operation
06 210 20
RG40854,0000159 1921FEB021/1
Forwarders - Governor Mode Selection

Desired Speed Governor Selection for Forwarders Mode Selected on SERVICE ADVISOR 0 Conditions Normal droop
Max. Speed Governor Selection for Forwarders Mode Selected on SERVICE ADVISOR 9 Conditions: Normal droop
RG40854,000015A 1921FEB021/1
CTM331 (03OCT05)
06-210-20

012506
PN=510
Forwarders - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input (1010 Forwarders ONLY) Analog Throttle (B) Input (1010 Forwarders ONLY) Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 F2 B2 D2 A3 K2 C3 B1 D1 F3
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B B A B B A A A A B
06 210 21
RG40854,000015B 1921FEB021/1
CTM331 (03OCT05)
06-210-21

012506
PN=511
Harvesters - Sensor Specifications

Sensor Specifications for Harvesters Sensor Oil Pressure SPN.FMI 000100.01 Measured Sensor Parameter Extremely Low Pressure Out of Range Value Pressure goes below an engine speed dependent value. Above 4.5 Volts Below 0.3 Volts Above 4.9 Volts Below 0.1 Volts Exceeds 88C (190F) Derate ECU derates engine 20% per minute until engine runs at 60% of full power. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. 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 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. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. ECU derates engine 500% per minute until engine runs at 50% of full power.
Engine Coolant Temperature (ECT) 06 210 22
000110.00
Exceeds 115C (239F)
000110.03 000110.04 000110.16
Fuel Temperature
000174.03
Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Moderately High Temperature Security Violation
Exceeds 120C (248F)
Security Violation
002000.13
Security Violation
RG40854,0000167 1923APR021/1
CTM331 (03OCT05)
06-210-22

012506
PN=512
Harvesters - Torque Curve Selection

Torque Curve Selection for Harvesters Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal operation
RG40854,0000166 1921FEB021/1
Harvesters - Governor Mode Selection

Desired Speed Governor Selection for Harvesters Mode Selected on SERVICE ADVISOR 0 Conditions Normal droop
Max. Speed Governor Selection for Harvesters Mode Selected on SERVICE ADVISOR 9 Conditions: Normal droop 06 210 23
RG40854,0000165 1921FEB021/1
CTM331 (03OCT05)
06-210-23

012506
PN=513
Harvesters - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B2 D2 A3 K2 C3 B1 D1 F3
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor A B B A A A A B
06 210 24
RG40854,0000164 1921FEB021/1
CTM331 (03OCT05)
06-210-24

012506
PN=514
06 210 25
CTM331 (03OCT05)
06-210-25

012506
PN=515
OEM Engines - Sensor Specifications

RG40854,0000129 1923APR021/3
06 210 26
CTM331 (03OCT05)
06-210-26

012506
PN=516
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. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. 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 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.
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
Oil Pressure
000100.00
Below an extremely low engine oil pressure. This pressure increases with engine speed. Above 4.5 Volts Below 0.3 Volts Below a moderately low engine oil pressure. This pressure increases with engine speed. Above 4.9 Volts Below 0.1 Volts H engines: Exceeds 100C (212F) T engines: Exceeds 120C (248F) Exceeds 118C (244F)
000100.03 000100.04 000100.18
High Input Voltage Low Input Voltage Moderately Low Pressure
000105.03 000105.04 000105.16
High Input Voltage Low Input Voltage Moderately High Temperature
06 210 27
000110.00
Most Severe Temperature
000110.03 000110.04 000110.15
High Input Voltage Low Input Voltage Least Severe Temperature Moderately Severe Temperature
000110.16
Exceeds 113C (235F)
RG40854,0000129 1923APR022/3
CTM331 (03OCT05)
06-210-27

012506
PN=517
Sensor Specifications for OEM Engines Fuel Temperature 000174.03 High Input Voltage Exceeds 4.9 Volts High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power.
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Exceeds 120C (248F)
RG40854,0000129 1923APR023/3
OEM Engines - Torque Curve Selection

Torque Curve Selection for OEM Engines Torque Curve # on SERVICE ADVISOR 06 210 28 1 Conditions for Torque Curve Normal Curve
RG40854,000012A 1929JAN021/1
CTM331 (03OCT05)
06-210-28

012506
PN=518
OEM Engines - Governor Mode Selection With OC03038 Software or Later

Desired Speed Governor Mode Selection 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
Desired Speed Governor Mode Selection for OEM Engines Governor Mode 9 10 11 12 15 Conditions Normal Droop - (Default Gainset) Isochronous Droop- (Default Gainset) Normal Droop - (Selectable Gainset) Isochronous Droop- (Selectable Gainset) Absolute Max speed (used for speed derates) 06 210 29
RG40854,000012B 1929JAN021/1
CTM331 (03OCT05)
06-210-29

012506
PN=519
OEM Engines - Governor Mode Selection With OC03033 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 Governor Selection for OEM Engines Mode Selected on SERVICE ADVISOR 0 10 Conditions Normal Droop Isochronous Droop
Max. Speed Governor Selection for OEM Engines Governor Mode 0 9 10 Conditions Normal Droop Gen Sets ONLY: Above 93%throttle at 1800 RPM Isochronous Droop
06 210 30
RG41183,00000DE 1921MAR031/1
CTM331 (03OCT05)
06-210-30

012506
PN=520
OEM Engines - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Analog Throttle (B) Input Multi-state Throttle Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input Auxiliary Engine Shutdown Switch Input External Engine Derate Switch Input
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 F2 C1 B2 D2 A3 K2 C3 B1 D1 F3 A1 C2
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B B B A B B A A A A B May change by application May change by application 06 210 31
RG40854,000012C 1929JAN021/1
CTM331 (03OCT05)
06-210-31

012506
PN=521
OEM Engines - Electronic Control System Wiring Diagram - Base ECUs

RG12882 1931MAR03 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V
914
911
911
B1
Oil Pressure Sensor Clean Side Increase A Pressure C
911
B2
Fuel Temp
B3
Coolant Temp
B4
MAT
B5
Engine Crank Sensor
Y1
Fuel Control Solenoid A
B t
B
914 Sensor Return
B t Twisted Pair B A
463 911 448 447 493 Inject Lo 491 Inject Hi
B
904 012 905 020 012
467
461
428
F3
C3
B1
D3
D1
E2 Excitation Voltage (+5V)
D2 B2 Sensor Return
K2
A3
A2 Switched Battery
A1 Engine Control Unit (ECU)

G2 B3 C1 G3 E3
474 918 947 473 439
John Deere Level 12 (12V or 24V) ECU Connector K3

429
J1
417
J1
418
K1
022
J2
050
CAN L CAN H F1 G1
904 905 020 012 905 904 012
012
012
062 050 B A
Spare - Sourcing Driver 2 (Early ECUs)
Override Shut DN/Blink Codes
SAE J1939/11 3-Way Deutsch Term A B

Fan Driver (Later ECUs)
Twisted Shielded Pair 904 905 020
85 87 87A
A B C
904 905 020

020
K1
Fuel Pump Supply Relay
F02
10A
Air Heated Wait Lamp
C
022 Unswitched Battery
86
30
High/Low Idle
020
050 System Ground
SAE J1939/11 3-Way Deutsch Connector Located Near ECU
Air Heater
072
X11
J H G F E D C B A
050
905
904
X10
R H
429
417
418
X9
Fuel Heater A 050
Diagnostic Connector 050 050
X7
050
SE2 SE2 SE2
050
UT
UT
UT
SE2
050
X3
SE3- Focus 12 (ECU)
SE4- Fuel Heater Option
RG41221,0000106 1931MAR031/1
CTM331 (03OCT05)
06-210-32

012506
Fault Lamp
Tachometer
SE2
PN=522
OEM Engines - Electronic Control System Wiring Diagram - Extended ECUs (Early)
914
911
012
914
911
911
B1
911
B2
Fuel Temp
B3
Coolant Temp
B4
MAT
B5
Engine Crank Sensor
Y1
B t
B
914 Sensor Return
B
904 012 905 020 012
911
012
914
467
461
428
F3
C3
B1
D3
D1
D2 B2 Sensor Return
K2
A3 = Options On 12V ECUs And Included On All 24V ECUs
A2 Switched Battery
A1
C2 J3 F2
Cruise CANC. RES./External Derate 981 954 913 911 012 914
John Deere Level 12 (12V or 24V) Engine Control Unit (ECU)
A
ECU Connector K3
429
A1
941
H3 H2 H1 E1 G2 B3 C1 G3 E3
936 955 923 915 474 918 947 473 439
J1
417
K1
022
J2
050
CAN L CAN H F1 G1
904 905 020 012 905 904 012
012
012
062 050 B A
936 Resume Coast/Bump DN

Secondary Analog Throttle
SAE J1939/11 3-Way Deutsch Term

Spare - Sourcing Driver 2
85 87 87A
955 Set Accel/Bump Up

A B C
A B C
904 905 020

020
K1
F02
10A
Cruise On/ISOC. GOV.
923 Cruse Brake/Bump Enable

External Shutdown
86
30
Resume Coast
Analog Throttle
911
012
914
High/Low Idle
Bump Enable
020
Bump DN
Set Accel
Bump Up
Air Heater
050
050 System Ground
072
X11
J H G F E D C B A
050
905
904
X10
X6
T A B C D E F G H J K L M N O P Q R S T U V W X
R H
429
417
X9
Fuel Heater A 050
Auxillary Connector 050 050 SE2 SE2 SE2 SE2 SE2 SE2 SE2 050
X7
050
X3
UT
UT
SE2
SE3- Focus 12 (ECU)
RG40854,0000121 1928JAN021/1
CTM331 (03OCT05)
06-210-33

012506
PN=523
Cruse Brake
Tachometer
Fault Lamp
SE2
OEM Engines - Electronic Control System Wiring Diagram - Extended ECUs (Later)
914
911
012
914
911
911
B1
911
B2
Fuel Temp
B3
Coolant Temp
B4
MAT
B5
Engine Crank Sensor
Y1
B t
B
914 Sensor Return
B
904 012 905 020 012
911
012
914
467
461
428
F3
C3
B1
D3
D1
D2 B2 Sensor Return
K2
A3 = Options On 12V ECUs And Included On All 24V ECUs
A2 Switched Battery
A1
C2 J3 F2
981 954 913 911 012 914
John Deere Level 12 (12V or 24V) Engine Control Unit (ECU)
A
ECU Connector K3
429
A1
941
H3 H2 H1 E1 G2 B3 C1 G3 E3
936 955 923 915 474 918 947 473 439
J1
418
K1
022
J2
050
CAN L CAN H F1 G1
904 905 020 012 905 904 012
012
012
062 050 B A
Cruise CANC. RES./External Derate
SAE J1939/11 3-Way Deutsch Term A B C

High/Low Idle 022 Unswitched Battery Tachometer Fault Lamp
85 87 87A
Secondary Analog Throttle
A B C
904 905 020

020
K1
F02
10A
Cruise On/ISOC. GOV.
External Shutdown
86
30
Analog Throttle
Bump Enable
020
Cruse Brake
Bump DN
Air Heater
Fan Drive
Bump Up
050
050 System Ground
072
X11
J H G F E D C B A
050
905
904
X10
X6
T A B C D E F G H J K L M N O P Q R S T U V W X
R H
429
418
X9
Fuel Heater A 050
Auxillary Connector 050 050 SE2 SE2 SE2 SE2 SE2 SE2 SE2 050
X7
UT
UT
SE2
050
X3
SE3- Focus 12 (ECU)
RG41221,0000105 1931MAR031/1
CTM331 (03OCT05)
06-210-34

012506
SE2
PN=524
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring Diagram
RG11987 1919DEC01 914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 Starter Relay Solenoid 002 BAT
412
914 Sensor Return 911 Sensor Excitation (+5V) 020 CAN Shield 904 CAN H 905 CAN L 012 IGN +12V OR +24V
X1
UT
002 BAT Ignition Switch

422 914 911 012 412 012
002 BAT
002 BAT
422
002
012
911
012
S1
X3
Instrument Panel Connector B S
A X02 A
Wiring Supplied With JD Alternator
012
X3
002 422
Accessory Off Run Start Run ST D
X3
Instrument Panel Connector V
904
U F
905 020
Back Light Options 24V Back Light Option 24V Regulator
24V
911
002
002
911
022
032 B BAT
IGN G
412 012
A 10A B
+12V
022
022
002
032
ACC J X03 PC GND
411
442
925
929
929
925
442
929
925
442
929
925
442
929
925
442
929
925
442
904
905
050
411
050
411
050
411
050
411
050
OUTPUT
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
Back Lighting
Back Lighting
Back Lighting
Back Lighting
+12V OR +24V
Back Lighting
BAT
936
409
955
923
2 Coil
High Idle
A B A B
A
947
390 Ohm
Low Idle
1300 Ohm
918
911
Back Lighting
Starter Relay 12V OR 24V
S IGN
050
411
Twisted Shielded Pair A

5A
020
Out Coil
KST
Off B
Bump Up Off Bump Down A
Idle Switch High Idle Low Idle A
Idle (CW) Full Throttle POT
A B C
All B
Off B
Off Override Shutdown
P1
C B A D F F
P2
D A B C F
P3
D A B C F
P4
D A B C F
P5
D A B C A H E
P6
D C G B F
012
A B C 12V Back Light Option
A B C A B C
Data +
Data + Data -
Data + Data -
Data + Data -
Data + Data -
915
474
SPG
SPG
SPG
SPG
SPG
050
050
002
022
442
050
Remote On/Off Plug

Bump Enable Bump Down
442 050 411

947 918 915 474
442 050 411
442 050 411
442 050 411
442 050 411
442 411
Bump Up
442
925
925
925
925
925
A B
020 905 904
032
B TVP (12V OR 24V)
ALT 12V
Start Motor 12V
SPG
S B
Data + Data -
Data -
N1
G1
M1
X5
929
929
929
929
929
12V
S4
Override Shutdown Momentary
GND
F1
Speed Select Momentary
Bump Enable Momentary Bump Enable Off Bump OFF Enable
Analog Throttle
Air Heater Wait Lamp
S2
S3
S5
Dimmer Option A B A B
X3
Instrument Panel E Connector
050 SPG 947 918 915 474
C B A C B A
SAE J1939/11 3-Way Deutsch Conn Back Light No Dimmer Back Light Dimmer High (CW) Low
050
050
002
X4
Single Point Ground 050
022
SAE J1939/11 3-Way Deutsch Term
SE4 UT SE1-Engine Start Components
SE3
SE3 SE3
SE3
SE3
SE3
SE3
SE3
050 SPG SE2-Control Panel
050 SPG
050 SPG
RG40854,0000122 1928JAN021/1
CTM331 (03OCT05)
06-210-35

012506
PN=525
Skidders - Sensor Specifications

RG40854,000016C 1923APR021/2
06 210 36
CTM331 (03OCT05)
06-210-36

012506
PN=526
Sensor Specifications for Skidders 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 20% per minute until engine runs at 60% of full power. Low oil pressure engine protection is disabled. Low oil pressure engine protection is disabled. 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 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. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power.
000091.04
Low Input Voltage
Below 0.3 Volts
Oil Pressure
000100.01
Pressure goes below an engine speed dependent value. Above 4.5 Volts Below 0.3 Volts Above 4.9 Volts Below 0.3 Volts Exceeds 88C (190F)
000110.00
Exceeds 115C (239F)
000110.03 000110.04 000110.16
06 210 37
Fuel Temperature
000174.03
Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Exceeds 120C (248F)
RG40854,000016C 1923APR022/2
CTM331 (03OCT05)
06-210-37

012506
PN=527
Skidders - Torque Curve Selection

Torque Curve Selection for Skidders Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal operation
RG40854,000016D 1921FEB021/1
Skidders - Governor Mode Selection

Desired Speed Governor Selection for Skidders Mode Selected on SERVICE ADVISOR 0 Conditions Normal droop
Max. Speed Governor Selection for Skidders Mode Selected on SERVICE ADVISOR 9 06 210 38 Conditions: Normal droop
RG40854,000016F 1921FEB021/1
CTM331 (03OCT05)
06-210-38

012506
PN=528
Skidders - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Multi-state Throttle Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 C1 B2 D2 A3 K2 C3 B1 D1 F3
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B B A B B A A A A B
06 210 39
RG40854,0000170 1921FEB021/1
CTM331 (03OCT05)
06-210-39

012506
PN=529
Telehandlers - Sensor Specifications

RG40854,0000140 1923APR021/2
06 210 40
CTM331 (03OCT05)
06-210-40

012506
PN=530
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. No derate
000091.04
Low Input Voltage
Below 0.3 Volts
Oil Pressure Switch
000100.01
Input circuit is grounded when engine is running at a minimum engine speed. Input circuit is grounded at key ON with no engine speed. Above 4.9 Volts Below 0.1 Volts Exceeds 88C (190F)
000100.04
Low Input Voltage
No derate.
000105.03 000105.04 000105.16
High Input Voltage Low Input Voltage Moderately High Temperature Most Severe Temperature
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. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU derates engine 20% per minute until engine runs at 80% of full power. ECU derates engine 40% per minute until engine runs at 60% of full power. High fuel temperature engine protection is disabled. High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power. 06 210 41
000110.00
Exceeds 120C (248F)
000110.03 000110.04 000110.15
000110.16
Exceeds 115C (239F)
Fuel Temperature
000174.03
Exceeds 4.9 Volts
000174.04
Low Input Voltage
Below 0.1 Volts
000174.16
Exceeds 120C (248F)
RG40854,0000140 1923APR022/2
CTM331 (03OCT05)
06-210-41

012506
PN=531
Telehandlers - Torque Curve Selection

Torque Curve Selection for Telehandlers Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal Operation
RG40854,0000141 1930JAN021/1
Telehandlers - Governor Mode Selection

Desired Speed Governor Selection for Telehandlers Mode Selected on SERVICE ADVISOR 0 Conditions Normal Droop
Max. Speed Governor Selection for Telehandlers Mode Selected on SERVICE ADVISOR 9 06 210 42 Conditions: Normal droop
RG40854,0000142 1930JAN021/1
CTM331 (03OCT05)
06-210-42

012506
PN=532
Telehandlers - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Oil Pressure Input
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 E1 B2 D2 A3 K2 C3 B1 D1 C1
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa NA Changes with each sensor Changes with each sensor B A B B A A A A Refer to vehicle manual for this.
06 210 43
RG40854,0000143 1930JAN021/1
CTM331 (03OCT05)
06-210-43

012506
PN=533
Tractors - Sensor Specifications

RG40854,0000014 1920AUG021/3
06 210 44
CTM331 (03OCT05)
06-210-44

012506
PN=534
Sensor Specifications for Tractors 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. If no other throttle is available, engine will run at idle speed. If no other throttle is available, engine will run at idle speed. Above 4.9 Volts Below 0.1 Volts Exceeds 100C (212F) 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 60% of full power. High ECT engine protection is disabled. High ECT engine protection is disabled. ECU does not derate engine. ECU derates engine 2% per minute until engine runs at 90% of full power. High fuel temperature engine protection is disabled. 06 210 45
000091.04
Low Input Voltage
Below 0.3 Volts
Analog Throttle (B)
000029.03
High Input Voltage
000029.04
Low Input Voltage
Analog Throttle (C)
000028.03
High Input Voltage
000028.04
Low Input Voltage
000105.03 000105.04 000105.16
High Input Voltage Low Input Voltage Moderately High Temperature Most Severe Temperature
000110.00
Exceeds 115C (239F)
000110.03 000110.04 000110.15 000110.16
Exceeds 4.9 Volts Below 0.1 Volts Exceeds 110C (230F) Exceeds 112C (234F)
Fuel Temperature
000174.03
Exceeds 4.9 Volts
RG40854,0000014 1920AUG022/3
CTM331 (03OCT05)
06-210-45

012506
PN=535
Sensor Specifications for Tractors 000174.04 Low Input Voltage Below 0.1 Volts High fuel temperature engine protection is disabled. ECU derates engine 2% per minute until engine runs at 80% of full power.
000174.16
Exceeds 120C (248F)
RG40854,0000014 1920AUG023/3
Tractors - Torque Curve Selection

Torque Curve Selection for Tractors Torque Curve # on SERVICE ADVISOR 1 Conditions for Torque Curve Normal Operation
06 210 46
RG40854,0000015 1920AUG021/1
Tractors - Governor Mode Selection

Desired Speed Governor Selection for Tractors Mode Selected on SERVICE ADVISOR 0 1 Conditions Normal Droop Droop used with field cruise
Max. Speed Governor Selection for Tractors Mode Selected on SERVICE ADVISOR 9 10 Conditions: Normal droop Droop used with field cruise
RG40854,0000016 1920AUG021/1
CTM331 (03OCT05)
06-210-46

012506
PN=536
Tractors - ECU Terminal Identification

ECU Terminal Function Switched Battery Unswitched Battery System Ground CAN High CAN Low 5V Sensor Supply Sensor Ground Analog Throttle (A) Input Analog Throttle (B) Input Analog Throttle (C) Input Crank Position Input Crank Position Return Pump Solenoid Return Pump Solenoid Supply Fuel Temperature Input Engine Coolant Temperature Input Manifold Air Temperature Input Wheel Speed Input Air Heater Return Air Heater Relay Enable Air Heater Light Indicator
a
ECU Terminal # A2 K1 J2 G1 F1 E2 D3 B3 F3 E1 B2 D2 A3 K2 C3 B1 D1 C2 H2 K3 G3
Sensor Connector Terminal # N/Aa N/Aa N/Aa N/Aa N/Aa Changes with each sensor Changes with each sensor B 4 C A B B A A A A Comes from BCU Air Heater Relay Air Heater Relay N/Aa 06 210 47
RG40854,0000017 1920AUG021/1
CTM331 (03OCT05)
06-210-47

012506
PN=537
06 210 48
CTM331 (03OCT05)
06-210-48

012506
PN=538
Index
Page Page
A
Air heater, intake Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-46 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 Air in fuel test . . . . . . . . . . . . . . . . . . . . . . .04-150-52 Air temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 Application specifications Backhoes . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Forwarders . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Harvesters . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 OEM engines . . . . . . . . . . . . . . . . . . . . . .06-210-3 Skidders . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Telehandlers . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Tractors . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3
Crank sensor Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-11 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Cruise control operation . . . . . . . . . . . . . . .03-140-19 Cylinder misfire test . . . . . . . . . . . . . . . . . .04-150-59
D
Data parameter description . . . . . . . . . . . .04-160-16 Derate programs Application specifications . . . . . . . . . . . . .06-210-3 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-20 Diagnostic Gauge Clearing stored codes . . . . . . . . . . . . . . .04-160-13 Diagnostics ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-40 ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-40 ACP-Err/No Addr . . . . . . . . . . . . . . . . .04-150-40 Does Not Communicate With ECU . . .04-150-40 EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-40 Engine configuration parameters. . . . . . .04-160-10 Viewing active codes . . . . . . . . . . . . . . .04-160-12 Viewing stored codes . . . . . . . . . . . . . . .04-160-12 Diagnostic Scan Tool (DST) Data parameter description . . . . . . . . . . .04-160-16 Tests Excavator torque curve change . . . . . .04-160-19 Diagnostic Trouble Codes SPN.FMI 000190.01 . . . . . . . . . . . . . . . . . . . . .04-160-202 Diagnostic Trouble Codes (DTCs) Active engine codes . . . . . . . . . . . . . . . .04-160-12 Active vs. inactive . . . . . . . . . . . . . . . . . .03-140-22 Blinking Codes . . . . . . . . . . . . . . . . . . . .04-160-14 Clearing engine codes . . . . . . . . . . . . . .04-160-13 Clearing stored codes . . . . . . . . . . . . . . .03-140-22 Diagnosing intermittent faults . . . . . . . . .04-160-27 Diagnostic procedure . . . . . . . . . . . . . . .04-160-26 Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22 SPN/FMI codes . . . . . . . . . . . . . . . . . .04-160-22 2-digit codes . . . . . . . . . . . . . . . . . . . .04-160-24 Other F4A0 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4A5 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4A7 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4EA . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4ED. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4E0 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F4E3 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F400 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F401 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
B
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Bleed fuel system . . . . . . . . . . . 02-090-26, 04-150-56
C
CAN definition of . . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-18 Check Fuel supply pressure. . . . . . . . . . . . . . . .04-150-53 Fuel supply quality . . . . . . . . . . . . . . . . .04-150-50 Circuit malfunctions Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-4 Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 Connectors, electrical AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20 DEUTSCH, repair . . . . . . . . . . . . . . . . . .02-110-17 General information. . . . . . . . . . . . . . . . . .02-110-6 METRI-PACK, pull type. . . . . . . . . . . . . .02-110-12 METRI-PACK, push type . . . . . . . . . . . .02-110-14 Remove blade terminals from connector body . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11 Controller Area Network (CAN), operation. . . . . . . . . . . . . . . . . . . . . . . . .03-140-18 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Coolant temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Remove and install . . . . . . . . . . . . . . . . . .02-110-2 CTM331 (03OCT05)
Indx 1
Index-1
PN=1
Index
Page
Page
Indx 2
F402 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F403 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F404 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F405 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F411 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F413 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F414 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F415 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F416 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F417 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F418 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F419 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F42A . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F420 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F421 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F422 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F423 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F424 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F425 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F426 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F428 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F429 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F430 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F432 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F436 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F439 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F440 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F445 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F446 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F450 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F455 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F457 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F459 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F460 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F461 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F462 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F463 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F464 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F465 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F470 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F474 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F475 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F476 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F477 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F478 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F48A . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F48B . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F49A . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F490 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F491 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F492 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F493 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 F494 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 CTM331 (03OCT05)
F495 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 SPN.FMI 000028.03 . . . . . . . . . . . . . . . . . . . . . .04-160-92 000028.04 . . . . . . . . . . . . . . . . . . . . . .04-160-92 000029.03 . . . . . . . . . . . . . . . . . . . . . .04-160-93 000029.04 . . . . . . . . . . . . . . . . . . . . . .04-160-94 000029.14 . . . . . . . . . . . . . . . . . . . . . .04-160-94 000084.31 . . . . . . . . . . . . . . . . . . . . . .04-160-96 000091.03 . . . . . . . . . . . . . . . . . . . . . .04-160-99 000091.04 . . . . . . . . . . . . . . . . . . . . .04-160-100 000091.07 . . . . . . . . . . . . . . . . . . . . .04-160-100 000091.10 . . . . . . . . . . . . . . . . . . . . .04-160-101 000091.13 . . . . . . . . . . . . . . . . . . . . .04-160-101 000091.14 . . . . . . . . . . . . . . . . . . . . .04-160-102 000097.03 . . . . . . . . . . . . . . . . . . . . .04-160-106 000097.04 . . . . . . . . . . . . . . . . . . . . .04-160-110 000097.16 . . . . . . . . . . . . . . . . . . . . .04-160-114 000100.01 . . . . . . . . . . . . . . . . . . . . .04-160-120 000100.03 . . . . . . . . . . . . . . . . . . . . .04-160-124 000100.04 . . . . . . . . . . . . . . . . . . . . .04-160-128 000100.16 . . . . . . . . . . . . . . . . . . . . .04-160-134 000100.18 . . . . . . . . . . . . . . . . . . . . .04-160-136 000105.03 . . . . . . . . . . . . . . . . . . . . .04-160-138 000105.04 . . . . . . . . . . . . . . . . . . . . .04-160-142 000105.16 . . . . . . . . . . . . . . . . . . . . .04-160-146 000110.00 . . . . . . . . . . . . . . . . . . . . .04-160-148 000110.03 . . . . . . . . . . . . . . . . . . . . .04-160-150 000110.04 . . . . . . . . . . . . . . . . . . . . .04-160-154 000110.15 . . . . . . . . . . . . . . . . . . . . .04-160-158 000110.16 . . . . . . . . . . . . . . . . . . . . .04-160-160 000111.00 . . . . . . . . . . . . . . . . . . . . .04-160-162 000111.03 . . . . . . . . . . . . . . . . . . . . .04-160-166 000111.04 . . . . . . . . . . . . . . . . . . . . .04-160-170 000158.17 . . . . . . . . . . . . . . . . . . . . .04-160-174 000160.02 . . . . . . . . . . . . . . . . . . . . .04-160-178 000174.03 . . . . . . . . . . . . . . . . . . . . .04-160-188 000174.04 . . . . . . . . . . . . . . . . . . . . .04-160-192 000174.16 . . . . . . . . . . . . . . . . . . . . .04-160-196 000189.00 . . . . . . . . . . . . . . . . . . . . .04-160-199 000190.00 . . . . . . . . . . . . . . . . . . . . .04-160-200 000190.16 . . . . . . . . . . . . . . . . . . . . .04-160-204 000620.03 . . . . . . . . . . . . . . . . . . . . .04-160-208 000620.04 . . . . . . . . . . . . . . . . . . . . .04-160-212 000629.13 . . . . . . . . . . . . . . . . . . . . .04-160-216 000637.02 . . . . . . . . . . . . . . . . . . . . .04-160-218 000637.10 . . . . . . . . . . . . . . . . . . . . .04-160-222 000639.13 . . . . . . . . . . . . . . . . . . . . .04-160-226 000729.03 . . . . . . . . . . . . . . . . . . . . .04-160-230 000729.05 . . . . . . . . . . . . . . . . . . . . .04-160-234 000898.09 . . . . . . . . . . . . . . . . . . . . .04-160-237 000970.31 . . . . . . . . . . . . . . . . . . . . .04-160-238 000971.31 . . . . . . . . . . . . . . . . . . . . .04-160-239 001069.09 . . . . . . . . . . . . . . . . . . . . .04-160-240 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
Index-2
PN=2
Index
Page
Page
001069.31 . . . . . . . . . . . . . . . . . . . . .04-160-244 001076.00 . . . . . . . . . . . . . . . . . . . . .04-160-246 001076.01 . . . . . . . . . . . . . . . . . . . . .04-160-250 001076.03 . . . . . . . . . . . . . . . . . . . . .04-160-254 001076.05 . . . . . . . . . . . . . . . . . . . . .04-160-258 001076.06 . . . . . . . . . . . . . . . . . . . . .04-160-262 001076.07 . . . . . . . . . . . . . . . . . . . . .04-160-266 001076.10 . . . . . . . . . . . . . . . . . . . . .04-160-270 001076.13 . . . . . . . . . . . . . . . . . . . . .04-160-274 001079.03 . . . . . . . . . . . . . . . . . . . . .04-160-278 001079.04 . . . . . . . . . . . . . . . . . . . . .04-160-282 001109.31 . . . . . . . . . . . . . . . . . . . . .04-160-286 001110.31 . . . . . . . . . . . . . . . . . . . . .04-160-287 001568.02 . . . . . . . . . . . . . . . . . . . . .04-160-288 001569.31 . . . . . . . . . . . . . . . . . . . . .04-160-290 002000.06 . . . . . . . . . . . . . . . . . . . . .04-160-291 002000.13 . . . . . . . . . . . . . . . . . . . . .04-160-292 Stored engine codes . . . . . . . . . . . . . . . .04-160-12 Warning light. . . . . . . . . . . . . . . . . . . . . .03-140-22 2-Digit codes DTC 11 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 12 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 13 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 14 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 15 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 16 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 18 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 19 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 21 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 22 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 23 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 24 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 25 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 26 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 28 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 32 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 33 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 37 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 38 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 39 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 42 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 54 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 55 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 62 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 63 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 64 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 65 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 66 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 68 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 69 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 71 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 72 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 73 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 CTM331 (03OCT05)
DTC 74 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 75 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 76 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 77 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 78 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 79 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 81 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 82 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 83 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 84 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 DTC 88 . . . . . . . . . . . . . . . . . . . . . . . .04-160-24 Diagnostics Air heater check . . . . . . . . . . . . . . . . . . .04-150-46 Communication Problem ECU Does Not Communicate With Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . .04-150-40 Fuel system Excessive fuel consumption. . . . . . . . .04-150-32 Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-32 Supply system check. . . . . . . . . . . . . .04-150-29 Observable Abnormal engine noise . . . . . . . . . . . .04-150-26 Analog Throttle (B) does not respond . . . . . . . . . . . . . . . . . . . . . .04-150-28 Engine cranks/wont start. . . . . . . . . . . .04-150-2 Engine does not develop full power . . .04-150-14 Engine emits excessive black or gray exhaust smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Engine emits excessive white exhaust smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-19 Engine idles poorly . . . . . . . . . . . . . . .04-150-25 Engine misfires/runs irregularly . . . . . . .04-150-8 Engine will not crank . . . . . . . . . . . . . .04-150-25 OEM wiring diagram Base ECU . . . . . . . . . . . . . . . . . . . . . .06-210-32 Extended ECU - Early . . . . . . . . . . . . .06-210-34 Extended ECU - Later . . . . . . . . . . . . .06-210-33 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Digital multimeter, how to use . . . . . . . . . . .04-160-2 DST Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 DTC Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Indx 3
E
ECU Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-17 Repair and adjustment . . . . . . . . . . . . . . .02-110-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
Index-3
PN=3
Index
Page
Page
Indx 4
Electrical circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-2 Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-1 Electrical connectors AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20 DEUTSCH . . . . . . . . . . . . . . . . . . . . . . .02-110-17 General information. . . . . . . . . . . . . . . . . .02-110-6 METRI-PACK . . . . . . . . . . . .02-110-12, 02-110-14 WEATHERPACK . . . . . . . . . . . . . . . . . . .02-110-8 Electrical insulating compound . . . . . . . . . . .02-110-6 Electronic control system Air heater operation . . . . . . . . . . . . . . . .03-140-19 Analog throttle operation . . . . . . . . . . . . . .03-140-8 CAN throttle operation. . . . . . . . . . . . . . . .03-140-8 Cruise control operation . . . . . . . . . . . . .03-140-19 Derating . . . . . . . . . . . . . . . . . . . . . . . . .03-140-20 Engine protection . . . . . . . . . . . . . . . . . .03-140-20 Excavator throttle operation . . . . . . . . . . .03-140-8 Governor modes . . . . . . . . . . . . . . . . . . .03-140-21 Measuring engine speed . . . . . . . . . . . . .03-140-11 Measuring pressure . . . . . . . . . . . . . . . . .03-140-7 Measuring temperature . . . . . . . . . . . . . . .03-140-5 Monitoring engine parameters. . . . . . . . . .03-140-3 Multi-state throttle operation . . . . . . . . . . .03-140-8 Operation, theory of . . . . . . . . . . . . . . . . .03-140-3 Overview. . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4 Pump solenoid . . . . . . . . . . . . . . . . . . . .03-140-15 Engine Application charts . . . . . . . . . . . . . . . . . . .01-001-4 Model designation . . . . . . . . . . . . . . . . . . .01-001-1 Serial number plate. . . . . . . . . . . . . . . . . .01-001-2 Engine configuration parameters . . . . . . . .04-160-10 Engine Control Unit Reprogramming . . . . . . . . . . . . . . . . . . .04-160-19 Engine Control Unit (ECU) Operation, theory of . . . . . . . . . . . . . . . .03-140-17 Repair and adjustment . . . . . . . . . . . . . . .02-110-1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . .03-140-22 Engine cranks/wont start . . . . . . . . . . . . . . .04-150-2 Engine does not develop full power . . . . . .04-150-14 Engine emits excessive black or gray exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Engine emits excessive white exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19 Engine idles poorly . . . . . . . . . . . . . . . . . . .04-150-25 Engine misfires/runs irregularly. . . . . . . . . . .04-150-8 Engine noise, abnormal . . . . . . . . . . . . . . .04-150-26 Engine Protection . . . . . . . . . . . . . . . . . . . .03-140-20 Engine will not crank . . . . . . . . . . . . . . . . .04-150-25 CTM331 (03OCT05)
F
FMI, definition of. . . . . . . . . . . . . . . . . . . . . .03-140-2 Fuel Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3 Fuel drain back test . . . . . . . . . . . . . . . . . .04-150-51 Fuel filter Exploded view (final). . . . . . . . . . . . . . . . .02-090-6 Exploded view (primary) . . . . . . . . . . . . . .02-090-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5 Remove and install . . . . . . . . . . . . . . . . . .02-090-2 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7 Fuel heater Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5 Fuel injection nozzles Adjustment . . . . . . . . . . . . . . . . . . . . . . .02-090-23 Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Diagnose malfunctions . . . . . . . . . . . . . .04-150-33 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25 Opening pressure test. . . . . . . . . . . . . . .02-090-21 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Seal installation. . . . . . . . . . . . . . . . . . . .02-090-24 Spray pattern test . . . . . . . . . . . . . . . . . .02-090-20 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-19 Valve seat checking . . . . . . . . . . . . . . . .02-090-20 Valve stem and guide wear checking . . .02-090-20 Fuel injection pump Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11 Static timing . . . . . . . . . . . . . . . . . . . . . .02-090-10 Fuel supply pump Bench test. . . . . . . . . . . . . . . . . . . . . . . .04-150-54 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9 Fuel system Air in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-52 Bleed . . . . . . . . . . . . . . . . . .02-090-26, 04-150-56 Cylinder misfire test . . . . . . . . . . . . . . . .04-150-59 Diagnostics Excessive fuel consumption. . . . . . . . .04-150-32 Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-32 Supply system check. . . . . . . . . . . . . .04-150-29 Fuel drain back test . . . . . . . . . . . . . . . .04-150-51 Fuel supply pressure check . . . . . . . . . .04-150-53 Fuel supply quality check . . . . . . . . . . . .04-150-50 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
Index-4
PN=4
Index
Page
Page
General information. . . . . . . . . . . . . . . . . .02-090-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2 Relieve pressure . . . . . . . . . . . . . . . . . . . .02-090-1 Supply pressure specifications . . . . . . . . .06-210-1 Fuel temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4
L
Loss of coolant temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Remove and install . . . . . . . . . . . . . . . . . .02-110-2 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
M G
Glossary of terms Electronic control system . . . . . . . . . . . . .03-140-2 Governor mode Application specifications . . . . . . . . . . . . .06-210-3 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-21 Manifold air temperature sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 MAT, definition of . . . . . . . . . . . . . . . . . . . . .03-140-2 Misfire test, cylinder Cylinder misfire . . . . . . . . . . . . . . . . . . . .04-150-59 Multimeter, how to use . . . . . . . . . . . . . . . . .04-160-2
H
Heater, air intake Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-46 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 High pressure washer, using with electrical components . . . . . . . . . . . . . . . . . . . . . . .02-110-7
O
Observable Diagnostics Diagnostic Gauge Does Not Communicate With ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-40 OEM Engines Specifications Governor Mode Selection . . . . . . . . . 06-210-29, 06-210-30 Oil pressure sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
I
Injection nozzles Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18 Diagnose malfunctions . . . . . . . . . . . . . .04-150-33 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16 Injection pump Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Solenoid operation . . . . . . . . . . . . . . . . .03-140-15 Instrument panel (OEM) Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-14 Clearing stored codes . . . . . . . . . . . . . . .04-160-13 Diagnostic Gauge Diagnostics . . . . . . . .04-150-40 Viewing active codes . . . . . . . . . . . . . . .04-160-12 Viewing stored codes . . . . . . . . . . . . . . .04-160-12 Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-35 Intake air heater Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-46 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 Intermittent fault, diagnosing. . . . . . . . . . . .04-160-27 CTM331 (03OCT05)
Indx 5
P
Programming ECU . . . . . . . . . . . . . . . . . . .04-160-19
R
Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-19
S
Sensor, operation Coolant temperature . . . . . . . . . . . . . . . . .03-140-5 Crank position. . . . . . . . . . . . . . . . . . . . .03-140-11 Fuel temperature. . . . . . . . . . . . . . . . . . . .03-140-7 Loss of coolant temperature . . . . . . . . . . .03-140-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
Index-5
PN=5
Index
Page
Page
Indx 6
Manifold air temperature . . . . . . . . . . . . . .03-140-6 Oil pressure . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Sensor, replace Coolant temperature . . . . . . . . . . . . . . . . .02-110-2 Crank position. . . . . . . . . . . . . . . . . . . . . .02-110-3 Fuel temperature. . . . . . . . . . . . . . . . . . . .02-110-4 Loss of coolant temperature . . . . . . . . . . .02-110-2 Manifold air temperature . . . . . . . . . . . . . .02-110-4 Oil pressure . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Sensors Water in Fuel Operation . . . . . . . . . . . . . . . . . . . . . .03-140-15 Serial number plate . . . . . . . . . . . . . . . . . . .01-001-2 Service ADVISOR Data parameter description . . . . . . . . . . .04-160-16 Tests Excavator torque curve change . . . . . .04-160-19 Specifications Backhoes ECU terminal identification. . . . . . . . . . .06-210-8 Governor mode selection. . . . . . . . . . . .06-210-7 Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-6 Torque curve selection . . . . . . . . . . . . .06-210-7 Crawlers ECU terminal identification. . . . . . . . . .06-210-13 Governor mode selection. . . . . . . . . . .06-210-12 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-10 Torque curve selection . . . . . . . . . . . .06-210-12 Excavators ECU terminal identification. . . . . . . . . .06-210-16 Governor mode selection. . . . . . . . . . .06-210-15 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-14 Torque curve selection . . . . . . . . . . . .06-210-15 Forwarders ECU terminal identification. . . . . . . . . .06-210-21 Governor mode selection. . . . . . . . . . .06-210-20 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-18 Torque curve selection . . . . . . . . . . . .06-210-20 Fuel supply pressure. . . . . . . . . . . . . . . . .06-210-1 General OEM engine specifications . . . . .06-200-3 Harvesters ECU terminal identification. . . . . . . . . .06-210-24 Governor mode selection. . . . . . . . . . .06-210-23 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-22 Torque curve selection . . . . . . . . . . . .06-210-23 OEM engines ECU terminal identification. . . . . . . . . .06-210-31 OEM Engines Governor Mode Selection . . . . . . . . . 06-210-29, 06-210-30 OEM engines Instrument panel wiring diagram . . . . .06-210-35 CTM331 (03OCT05)
OEM Engines Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-26 OEM engines Start components wiring diagram. . . . .06-210-35 OEM Engines Torque curve selection . . . . . . . . . . . .06-210-28 OEM engines Wiring diagram Base ECU . . . . . . . . . . . . . . . . . . . .06-210-32 Extended ECU - Early . . . . . . . . . . .06-210-34 Extended ECU - Later . . . . . . . . . . .06-210-33 Skidders ECU terminal identification. . . . . . . . . .06-210-39 Governor mode selection. . . . . . . . . . .06-210-38 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-36 Torque curve selection . . . . . . . . . . . .06-210-38 Telehandlers ECU terminal identification. . . . . . . . . .06-210-43 Governor mode selection. . . . . . . . . . .06-210-42 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-40 Torque curve selection . . .06-210-42, 06-210-46 Tractors ECU terminal identification. . . . . . . . . .06-210-47 Governor mode selection. . . . . . . . . . .06-210-46 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-44 Speed governing . . . . . . . . . . . . . . . . . . . .03-140-21 SPN, definition of . . . . . . . . . . . . . . . . . . . . .03-140-2 Start components Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-35
T
Test Air heater check . . . . . . . . . . . . . . . . . . .04-150-46 Air in fuel . . . . . . . . . . . . . . . . . . . . . . . .04-150-52 Cylinder misfire . . . . . . . . . . . . . . . . . . . .04-150-59 Excavator torque curve change. . . . . . . .04-160-19 Fuel drain back . . . . . . . . . . . . . . . . . . . .04-150-51 Fuel supply pressure. . . . . . . . . . . . . . . .04-150-53 Fuel supply quality check . . . . . . . . . . . .04-150-50 Fuel supply system check . . . . . . . . . . . .04-150-29 Throttle DTCs T01 - Multi-state throttle input high . . . . .04-160-28 T02 - Multi-state throttle input low . . . . . .04-160-32 T03 - Analog throttle (A) input high . . . . .04-160-36 T04 - Analog throttle (A) input low . . . . .04-160-40 T05 - Analog throttle (B) input high . . . . .04-160-44 T06 - Analog throttle (B) input low . . . . .04-160-48 T07 - CAN throttle invalid . . . . . . . . . . . .04-160-52 T11 - Excavator throttle reference voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-56 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
Index-6
PN=6
Index
Page
T12 - Excavator throttle reference voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-60 T13 - Excavator throttle ground voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-64 T14 - Excavator throttle ground voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-68 T15 - Excavator throttle input voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-72 T16 - Excavator throttle input voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-76 T17 - Analog throttle (C) input high . . . . .04-160-80 T18 - Analog throttle (C) input low . . . . .04-160-84 T19 - Throttle not calibrated properly . . .04-160-87 T20 - Throttle input voltage below lower calibration limit . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-88 T21 - Throttle calibration aborted . . . . . .04-160-89 T22 - Analog throttle (A) input voltage out of range. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90 T23 - Multi-state throttle input voltage out of range. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91 Throttle, operation Analog . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Excavator . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Multi-state . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Tools Electronic Fuel System Diagnostic . . . . . .05-180-1 Torque curve selection Application specifications . . . . . . . . . . . . .06-210-3 Excavator change test. . . . . . . . . . . . . . .04-160-19 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-21 Trouble codes Diagnostic procedure . . . . . . . . . . . . . . .04-160-26 Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22
Indx 7
W
Water in Fuel Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-15 Wiring diagram Instrument panel (OEM) . . . . . . . . . . . . .06-210-35 OEM engines Base ECU . . . . . . . . . . . . . . . . . . . . . .06-210-32 Extended ECU - Early . . . . . . . . . . . . .06-210-34 Extended ECU - Later . . . . . . . . . . . . .06-210-33
CTM331 (03OCT05)
Index-7

012506
PN=7
Index
Indx 8
CTM331 (03OCT05)
Index-8

012506
PN=8

PowerTech 4.5L &6.8L Diesel Engines - Level 12 Electronic Fuel System-Stanadyne DE10 Pump-CTM331

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PowerTech 4.5L &6.8L Diesel Engines - Level 12 Electronic Fuel System-Stanadyne DE10 Pump-CTM331

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PowerTech 4.5L &6.8L Diesel Engines - Level 12 Electronic Fuel System-Stanadyne DE10 Pump-CTM331

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Available Formats

POWERTECH 4.5L & 6.

John Deere Power Systems

4.5 L & 6.8 L Level 12 Electronic Fuel System

Left Side of Engine

Right Side of Engine

POWERTECH is a registered trademark of Deere & Company

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

Handle Starting Fluid Safely

Prepare for Emergencies

4.5 L & 6.8 L Level 12 Electronic Fuel System

Avoid High-Pressure Fluids

Wear Protective Clothing

4.5 L & 6.8 L Level 12 Electronic Fuel System

Service Machines Safely

Work In Ventilated Area

Work in Clean Area

4.5 L & 6.8 L Level 12 Electronic Fuel System

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

4.5 L & 6.8 L Level 12 Electronic Fuel System

Illuminate Work Area Safely

Construct Dealer-Made Tools Safely

4.5 L & 6.8 L Level 12 Electronic Fuel System

Practice Safe Maintenance

Use Proper Tools

4.5 L & 6.8 L Level 12 Electronic Fuel System

Dispose of Waste Properly

Live With Safety

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

POWERTECH is a registered trademark of Deere & Company

4.5 L & 6.8 L Level 12 Electronic Fuel System

Engine Serial Number Plate Information

Dubuque Engine Serial Number Plate

Saran Engine Serial Number Plate

Torreon Engine Serial Number Plate

4.5 L & 6.8 L Level 12 Electronic Fuel System

OEM Engine Option Code Label

Information Relative to Emissions Regulations

4.5 L & 6.8 L Level 12 Electronic Fuel System

Engine Application Charts

CD4045HZ061, CD4045HZ060, CD4045HZ061, CD4045HZ060, CD4045TZ060 CD4045HZ060

CD4045HZ275 CD4045HZ275 CD4045HZ275 CD4045HZ275

Continued on next page

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

Testing Diesel Fuel

DIESELSCAN is a trademark of Deere & Company

4.5 L & 6.8 L Level 12 Electronic Fuel System

Lubricity of Diesel Fuel

4.5 L & 6.8 L Level 12 Electronic Fuel System

4.5 L & 6.8 L Level 12 Electronic Fuel System

Repair and Adjustments