Service Manual. John Deere Tier II Engine Troubleshooting. Original February 2, 2007

Transcription

1 Service Manual John eere Tier II ngine Troubleshooting 00 Original ebruary, 00

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3 TIVITY PG ebruary, Original Issue Of Manual 00 John eere ngine i

4 TIVITY PG -ii John eere ngine 00

5 STION ONTNTS Section Subject Page Section Safety Practices Introduction isclaimer Operation & Safety Manual o Not Operate Tags Safety Information Safety Instructions Safety ecals Section General Troubleshooting asic ngine hecks Pre-Troubleshooting hecks lectronic ontrol System Terminology lectronic ontrol System Operation Monitoring ngine Parameters lectronic ontrol System Overview U onnector Legend OM Trim Option Settings Section unction Troubleshooting Troubleshooting Procedure etrieving ault odes ngine erate hart ngine Troubleshooting U Troubleshooting N Troubleshooting lectrical Troubleshooting Section lectrical Wiring Wiring Schematics John eere ngine i

6 Section Subject Page ii John eere ngine

7 Section Safety Practices ontents PGPH TITL PG. Introduction isclaimer Operation & Safety Manual o Not Operate Tags Safety Information Safety lert System and Signal Words Safety Instructions Personal Hazards quipment Hazards General Hazards Operational Hazards Safety ecals John eere ngine.

8 Safety Practices. INTOUTION This manual provides general directions for accomplishing service and repair procedures. ollowing the procedures in this manual will help assure safety and equipment reliability. ead, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local JLG distributor. Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. or optimal safety, encourage everyone to think, and to act, safely. ppropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. ll references to the right side, left side, front and rear are given from the operator s seat looking in a forward direction. Supplementary information is available from JLG in the form of Service ulletins, Service ampaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.. ISLIM ll information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.. OPTION & STY MNUL The mechanic must not operate the machine until the Operation & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. n Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult the local JLG distributor before proceeding.. O NOT OPT TGS Place o Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. emove key and disconnect battery leads.. John eere ngine

9 Safety Practices. STY INOMTION To avoid possible death or injury, carefully read, understand and comply with all safety messages. In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety... Safety lert System and Signal Words NG NG indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WNING WNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.. STY INSTUTIONS ollowing are general safety statements to consider before performing maintenance procedures on the telehandler. dditional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs. or all safety messages, carefully read, understand and follow the instructions before proceeding... Personal Hazards PSONL STY G: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat. LITING: NV lift a heavy object without the help of at least one assistant or a suitable sling and hoist... quipment Hazards LITING O QUIPMNT: efore using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached. NV stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip. O NOT use a hoist, jack or jack stands only to support equipment. lways support equipment with the proper capacity blocks or stands properly rated for the load. HN TOOLS: lways use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended. John eere ngine.

10 Safety Practices.. General Hazards SOLVNTS: Only use approved solvents that are known to be safe for use. HOUSKPING: Keep the work area and operator s cab clean, and remove all hazards (debris, oil, tools, etc.). IST I: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a irst id Kit, and know how to use it. LNLINSS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service. When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off. heck and obey all ederal, State and/or Local regulations regarding waste storage, disposal and recycling... Operational Hazards NGIN: Stop the engine before performing any service unless specifically instructed otherwise. VNTILTION: void prolonged engine operation in enclosed areas without adequate ventilation. SOT SUS N SLOPS: NV work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service. LUI TMPTU: NV work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. llow systems to cool before proceeding. LUI PSSU: efore loosening any hydraulic or diesel fuel component, hose or tube, turn the engine O. Wear heavy, protective gloves and eye protection. NV check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. iesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury. elieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. efore starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. apture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations. ITO P: lways wear steam-resistant, heat protective gloves when opening the radiator cap. over the cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure. LUI LMILTITY: O NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials. NV drain or store fluids in an open container. ngine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion. O NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion. PSSU TSTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result. LVING MHIN: Lower the forks or attachment to the ground before leaving the machine. TIS: lways keep tires inflated to the proper pressure to help prevent tipover. O NOT over-inflate tires. NV use mismatched tire types, sizes or ply ratings. lways use matched sets according to machine specifications. MJO OMPONNTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine. TTY: O NOT charge a frozen battery.harging a frozen battery may cause it to explode. llow the battery to thaw before jump-starting or connecting a battery charger.. STY LS heck that all safety decals are present and readable on the machine. efer to the Operation & Safety Manual supplied with machine for information.. John eere ngine

11 Section General Troubleshooting ontents PGPH TITL PG. asic ngine hecks Pre-Troubleshooting hecks lectronic ontrol System Terminology lectronic ontrol System Operation Monitoring ngine Parameters lectronic ontrol System Overview U onnector Legend OM Trim Option Settings John eere ngine.

12 General Troubleshooting. SI NGIN HKS If the engine will not run or is running erratically, the fault may not be related to the electronic system. nsure that the following points are checked before U troubleshooting. Travel Select Lever is in the (N) NUTL position Park brake is set Throttle pedal has free range of motion without interuption Sufficient fuel in the fuel tank for engine operation uel quality is of an acceptable rating attery power and ground connections are secure uel tank vent hose is clear of obstructions No restrictions in the exhaust or intake system No broken fins on turbo equipped models No restrictions in fuel filters No water in the fuel system. P-TOULSHOOTING HKS The following is a basic checklist of items to check when troubleshooting engine U issues on John eere engines. Some of the reported issues have been engine shutdown, erratic running, and erratic throttle position. This list is not for actual U troubleshooting, but rather external factors that may affect U operation. heck fault codes prior to checking the following items. efer to Section., etrieving ault odes, for more information on fault codes. Some of the items below may not show a fault code. heck the female sockets in the engine harness plug that attaches to the engine s U. Use the proper tension gauge or a male pin to ensure that the female socket is in good condition. If it is not, the socket will have to be replaced. Usage of dielectric grease on all connections is required. heck bolt used to retain harness connector to U. If loose, it needs to be tightened. heck operation after tightening bolt. Loctite should be applied to threads if bolt is loose. Verify brass insert in U is not loose. In addition, it may be possible in some situations that the brass insert may not allow full seating of the connector bolt. If the connector bolt is tight, and you are able to wiggle the connector, the brass insert in the U is suspect. ontact your local John eere service dealer with full details. Verify ground cable attachment on engine and frame. heck that bolts are tight; verify ground is clean and bare for contact between ground connection and frame. U primary supply ground wire must be properly secured in the wedge Verify positive cables are clean and tight. Primary U power supply at the battery post is tight within the wedge connection, that the fuse is supplied and working properly. heck the overall condition of the engine harness including heat related damage and routing. Harness tie off locations should leave a small amount of slack to the individual sensors or U. rank position sensor that is not giving consistent readings can cause hard starting, shutdown, erratic throttle issues. This is a John eere isssue. Just be aware of the effect this sensor can have. heck critical connectors for signs of looseness, corrosion, damage, etc. The following connectors are critical: U onnector rank position sensor at front of engine uel pump solenoid connector am position sensor on block U water temperature sensor on thermostat housing (not to be confused with the JLG/Gradall installed water temperature sensor) The order in which the steps should be taken are as follows:. heck all fuel and air filters, water ingression into this system will promote fault codes. aily draining of the fuel/ water separator is recommended.. heck the condition of the fuel lines from the tank to the engine.. heck the fuel tank cap vent.. heck all engine fault codes and record them. efer to Section., etrieving ault odes.. heck all wiring and socket conditions. check for ground and positive voltage supply at the John eere, 9 pin connector is also recommended. This would also detect a harness issue on the JLG side.. fter all JLG/Gradall supplied items have been inspected, repaired, corrected and/or replaced, then the John eere ealer should be called to install the latest version of U software. efer to Section.8, OM Trim Option Settings.. The John eere ealer will need to file a T case and request, the OM Trim Options payload replacement software.. If the problem comes back, then the U will have to be replaced with a new one that has been updated.. John eere ngine

13 General Troubleshooting. LTONI ONTOL SYSTM TMINOLOGY Term ctuator nalog oost N T ST igital T U MI J-J08 MT PM POM PWM M S Sensor SPN VT VSW John eere ngine efinition device controlled by the (U) to perform a certain function. Signal which has a continuous range of possible voltages. Usually 0 to volt or 0 to volt signals. ir charge pressure in the intake manifold. ontroller rea Network. The electronic pathway network on vehicles that allows communication between controllers. iagnostic Trouble ode. code which is stored in the U s memory when the U detects a problem in the electronic control system. iagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check T s and run special tests. The ST consists of a Windows ( 9, 98, 000) or NT compatible computer and a hardware kit available from John eere istribution Service enter (S): JIS - U ommunication Hardware Kit. The software is available to download from your John eere home page. signal which consists of only two-volt levels - usually 0 volts and + volts. ngine oolant Temperature (sensor). Measures the temperature of the engine coolant. ngine ontrol Unit. The computer which controls the fuel, air, and ignition systems on the engine. ailure Mode Identifier. The second part of a two-part code that identifies control system trouble codes according to the S J99 standard. The MI identifies the type of failure that has occurred. The first half of the code is the Suspect Parameter Number (SPN). The Society of utomotive ngineers (S) standard for the electronic components of heavy duty vehicles. J is the software standard. J08 is the hardware standard. Manifold ir Temperature (sensor). Measures the temperature of the air in the intake manifold. Parallel ata Module. evice used as part of the ST that allows communication with the U. Programmable, ead-only Memory. The computer chip which contains the calibration information for the engine control system. Pulse Width Modulation. 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. andom ccess Memory. The portion of computer memory within the U which changes as the engine is running and is stored while the engine is off. Society of utomotive ngineers. Working with society to promote vehicle safety and maintenance and energy resource conservation. evice used by the U 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 S J99 Standard. The SPN identifies the system of component that has the failure. The second half of the code is the ailure Mode Identifier (MI). attery voltage or unswitched voltage. Switch voltage.

14 General Troubleshooting. LTONI ONTOL SYSTM OPTION ngine Starting Mode When the key is turned to the ON position, a switched power voltage is sent to the ngine ontrol Unit (U). This energizes the U and allows it to boot-up and ready itself for engine start. Note: If a wiring problem prevents the key ON signal from getting to the U, the engine will not start. s soon as the U 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 the ngine oolant Temperature (T) sensor. t this point, the engine will start and the U will go into the running mode. ngine unning Mode In the running mode, the U 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 U controls fuel delivery by energizing and de-energizing the pump control valve solenoid. When the U energizes the solenoid, the pump control valve closes and injection begins. When the correct amount of fuel has been injected, the U de-energizes the solenoid, causing the pump control valve to open, and fuel injection to stop.. LTONI ONTOL SYSTM OVVIW 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: onstantly monitors engine operating conditions elivers an optimum amount of fuel for operating conditions Provides multiple control modes Performs self-diagnosis onnection heck IMPOTNT: o not force probes into connector terminals or damage will result. Use JT08 onnector dapter Test Kit to make measurements in connectors. This will ensure that terminal damage does not occur. Perform a preliminary inspection of the U connector, the ngine oolant Temperature (T) connector, and any connectors in between them. Look for dirty, damaged, or poorly positioned terminals.. MONITOING NGIN PMTS 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 U: ngine oolant Temperature (T) Loss of oolant Temperature Manifold ir Temperature (MT) Oil Pressure uel Temperature Throttle Position rankshaft Position Sensor. John eere ngine

15 General Troubleshooting. U ONNTO LGN G H J G H J G H J K K K MN00 Pin Wire esignation 9 (rn, ) 0 (ed, ) 9 (Org, ), (rn, 8) (Purple, 8) 98 (Gray, ) 9 (Purple, 8) 8 (Gray, 8) (Org, 8) 8 (Gray, 8) 9 (Yllw, ) 9 (k Grn, ) 9 (rn, ) 90 (k Grn, 8) (Pur, ) G 90 (Yllw, 8) G G (Org, ) ng Over ride Light H H H J J 00G (lk, ) > 00 > try Neg J K 0 (ed, >00 >use > 00 > try Pos K 9 (rn, ) K John eere ngine.

16 General Troubleshooting.8 OM TIM OPTION STTINGS Note: The following setting can only be accessed by John eere service personnel. igital Throttle nable - O - state Throttle - selected Primary nalog Throttle nable - ON Self alibration nable - ON Secondary nalog Throttle nable - O Throttle djustments - No hange Throttle Out of ange ecovery - esume ecovery Min Throttle Offset - 0 rpm Maximum Throttle Offset - 0 rpm Throttle ate - Standard (Maximum) amp ate -.% ombination Throttle - No hange nable O Master Input - Primary nalog selected nd Input - Secondary nalog selected, Input Type - ccelerator rd Input - igital selected, Type - ccelerator Torque Speed ontrol - No hange nable TS Source - O nable TS Source - O Source ddress - Source ddress - Governor Single Governor - Selected Harness Selectable Governor - O PM of roop - 0 Standard erates and Standard Shutdowns nable erates - Selected Standard Shutdowns Oil Pressure, oolant and uel temperature Shutdown - nable Shutdown Timer - 0 seconds xternal erate nable - O xternal erate Input - Normally Open Switch xternal erate ate - 0% erate over 0 minutes xternal Shutdown nable - O xternal Shutdown Input - Normally Open Switch xternal Shutdown Timer - Immediate Override xternal Shutdown at ngine Start - O Override xternal Shutdown Time - 0 seconds Oil Pressure Sensor - nable ruise ontrol - No hange nable - O On/Off Input - Normally Open Switch ccel Input - Normally Open Switch ecel Input - Normally Open Switch rake Input - Normally losed Switch Turnaround Input - Normally Open Switch Tachometer Output - nable Low Idle Warm-Up - O N Wait-to-Start Message - nable Governor Gains Low Speed Governor Gain - Use efault Governor Gain ll Speed Governor Gain - Use efault Governor Gain Selected lternate Gain - lternate Gain # Gain djustment Percentage John eere ngine

17 Section unction Troubleshooting ontents PGPH TITL PG. Troubleshooting Procedure etrieving ault odes ngine erate hart ngine Troubleshooting ngine ranks, Will Not Start ngine Will Not rank ngine Over Speed ngine Misfires/uns Irregularly U Troubleshooting U Switched Power U Power own rror N Troubleshooting lectrical Troubleshooting Manifold ir Temperature Sensor uel Temperature Sensor nalog Throttle Sensor rank Position Sensor Pump Solenoid Oil Pressure Sender Oil Pressure Switch oolant Temperature Sensor Loss of ngine oolant Sensor John eere ngine.

18 unction Troubleshooting. TOULSHOOTING POU The procedures outlined in this section should be completed in succession as listed. Once the step is completed, retest for correction of the problem. If the problem is not corrected, move onto the next step. Manifold ir Temperature (MT) Sensor T Sensor uel Temperature Sensor Loss of oolant Sensor rank Position Sensor lectronic ontrol Unit (U) Pump ontrol Solenoid Oil Pressure Sensor. John eere ngine

19 unction Troubleshooting. TIVING ULT OS. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NUTL and engage the park brake.. Turn the ignition switch to ON.. Push down and hold the reset button on the dash for - seconds. The fault lamp will begin to flash a code number. The light will flash the first digit then pause for a short time and then flash the second digit. If there are active codes, the system will first flash code. If there are no active codes, the system will flash code 88. The system will then flash code if there are any stored fault codes. If there are no stored codes, the system will flash code 88.. Once the code is retrieved, turn the ignition O. Note: When the engine sensor inputs exceed normal operating ranges, the U will derate the amount of fuel that is delivered to the engine. fault code will always accompany a fuel derate. If the engine is running at a much lower rate, check the fault codes first to see if the engine is experiencing an internal problem. ault odes SPN odes MI odes efinition N/ N/ nalog Throttle () Input High N/ N/ nalog Throttle () Input High 8 0 ngine oolant Temperature Input Voltage High 9 0 ngine oolant Temperature Input Voltage Low 0 Sensor Supply Voltage High 09 Sensor Supply Voltage High 0 Sensor Supply Voltage Low 09 Sensor Supply Voltage Low 00 ngine Oil Pressure Input Voltage High 00 ngine Oil Pressure Input Voltage Low 0 Manifold ir Temperature Input Voltage High 0 Manifold ir Temperature Input Voltage Low 8 9 U rror N/ N/ Signifies Start of ctive ault odes N/ N/ Signifies Start of Previously ctive ault odes uel Temperature Input Voltage High 8 uel Temperature Input Voltage Low 9 rank Position Input Noise 0 rank Position Input Pattern rror 90 0 ngine Overspeed xtreme ngine Overspeed Moderate 8 U Power own rror 9 N rror 0 ngine oolant Temperature High Least Service 0 ngine oolant Temperature High Moderately Service 00 8 ngine Oil Pressure Moderately Low 00 ngine Oil Pressure xtremely Low John eere ngine.

20 unction Troubleshooting 0 Manifold ir Temperature Moderately High 8 9 uel erate ngine oolant Temperature High Most Severe 0 0 Pump ontrol Valve losure Too Long 0 Pump ontrol Valve losure Too Short 0 Pump Solenoid ircuit Open 0 Pump Solenoid ircuit Severely Shorted 0 Pump ontrol Valve losure Not etected 0 0 Pump Solenoid ircuit Moderately Shorted 0 Pump Solenoid urrent High 8 00 Security Violation Internal U rror 8 uel Temperature Moderately High 8 0 ngine Protection Shutdown 8 90 uxiliary ngine Shutdown Switch ctive Note: If V is detected on circuit K there is a short in the system. If V is not detected, John eere assistance is required. JLG does not currently use this shutdown. 8 8 U Power own rror 9 xternal erate Switch ctive 88 N/ N/ Signifies No ault odes re In uffer. John eere ngine

21 unction Troubleshooting. NGIN T HT Sensor Measured Sensor Parameter Out of ange Value erate nalog Throttle () High Input Voltage bove. Volts If no other throttle is available, engine will run at idle speed Low Input Voltage elow 0. Volts If no other throttle is available, engine will run at idle speed Oil Pressure Switch Low Input Voltage Input circuit is grounded at key ON with no engine speed Manifold ir Temperature (MT) ngine oolant Temperature xtremely Low Pressure Input circuit is grounded when engine is running at a minimum engine speed No derate No derate High Input Voltage bove.9 Volts High MT engine protection is disabled Low Input Voltage elow 0. Volts High MT engine protection is disabled High Input Voltage xceeds.9 Volts High T engine protection is disabled Low Input Voltage elow 0. Volts High T engine protection is disabled Most Severe Temperature Moderately Severe Temperature xceeds (8 ) xceeds ( ) U derates engine 0% per minute until engine runs at 0% of full power U derates engine % per minute until engine runs at 80% of full power uel Temperature High Input Voltage bove.9 Volts High fuel temperature engine protection is disabled Low Input Voltage elow 0. Volts High fuel temperature engine protection is disabled Moderately High Temperature xceeds 8 (0 ) U derates engine % per minute until engine runs at 80% of full power John eere ngine.

22 unction Troubleshooting. NGIN TOULSHOOTING.. ngine ranks, Will Not Start TTY IGNITION SWITH VSW 0 VT V K 0, 0, J 00G, LK G H J G H J G H J K K K MN000. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. Loosen one fuel line connection on the injection nozzles, crank engine over while monitoring the loose connection for consistent supply of fuel. e sure no air is coming out of the connection. If air is present, bleed the entire fuel system as required starting at the lift pump and the fuel/ water separator moving to the injection pump, followed by the injectors. Torque fuel lines to 0 lb-ft after testing.. ecover any fault codes. efer to Section., etrieving ault odes.. heck the U Power Wiring b. isconnect U c. ackprobe wire K and wire J and check for V. If the required voltage is found, test the circuit If voltage is not found, there is an open in the U Power wiring d. ackprobe wire and wire J and check for V with the ignition ON. If the required voltage is found, test the ngine ranking Speed If the required voltage is not found, there is an open in the U Power wiring. Test the U connector b. U connector still disconnected c. ackprobe wire K on the U connector and check U HNSS ONNTO for continuity with pin K on the harness end of the If continuity is found, repeat this step for the and J circuits of the U If continuity is not found, there is a faulty U If continuity is found on all circuits, proceed to next step. Note: If proper voltage is not found on the circuit, the problem may exist earlier in the circuit. efer to Section., Wiring Schematics for schematic information on a specific machine.. Test the ngine ranking Speed IMPOTNT: ranking speed specifications are for OM engines only. Make sure that batteries are fully charged before performing this test. a. isable the fuel supply system at the injection pump so fuel delivery is in the O position. b. If not using the machine tachometer, install a photo tach or TIM T. c. rank engine for seconds and record engine speed. d. ompare recorded engine speed to the following chart:. John eere ngine

23 unction Troubleshooting MINIMUM 0 NKING SP (PM) 0 0 If pressure is high, worn or stuck rings are indicated, replace piston rings or install new piston and liner set as needed. If pressure is low, valves could be worn or sticking. econdition cylinder head as required. g. Measure compression pressure in all remaining cylinders and compare readings. econdition cylinders and valves as required. 8. If all checks are completed and the engine still does not operate properly, contact your local John eere service distributor MINT I TMPTU MN00 ranking speed should meet or exceed specified engine rpm for a given ambient air temperature. or example, at 9 ( ) ambient air temperature, cranking speed should be at least 00 rpm. If cranking speed is below specifications, check the following: Starting system problems (low battery, loose or defective wiring, defective starter, etc.) xcessive engine loads (thick hydraulic oil, thick engine oil, etc.).. Test the ngine ompression Pressure. IMPOTNT: ompression pressures are affected by the cranking speed of the engine. efore beginning test, ensure that batteries are fully charged and injection nozzle area is thoroughly cleaned. Note: ngines equipped with Level lectronic uel Systems with VP Pump provide the ability to perform an electronic compression test. a. Install a test gauge adapter to an engine cylinder injector nozzle. b. Move throttle lever to STOP position. Turn crankshaft for 0 - seconds with starter motor (minimum cranking speed - 0 rpm cold/00 rpm hot). c. Test the remaining cylinders. d. ompare readings from all cylinders. ompression pressure is set to be 9-9 kpa (-8 bar)(-0 psi). The maximum difference between cylinders should be no more than 0 kpa (. bar)(0 psi). Note: Pressure given was taken at 8 m (00 ft) above sea level.. percent reduction in gauge pressure will result for each additional 00 m (000 ft) rise in altitude. e. If pressure is much lower than shown, remove gauge and apply oil to ring area of piston through injection nozzle or glow plug bore. o not use too much oil. o not get oil on the valves. f. Test compression pressure again. John eere ngine.

24 unction Troubleshooting.. ngine Will Not rank TTY IGNITION SWITH VSW 0 VT V K 0, 0, J 00G, LK G H J G H J G H J K K K MN000. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. heck the U Power Wiring b. isconnect U c. ackprobe wire K and wire J and check for V. If the required voltage is found, test the circuit If voltage is not found, there is an open in the U Power wiring d. ackprobe wire and wire J and check for V with the ignition ON. If the required voltage is found, test the ngine ranking Speed If the required voltage is not found, there is an open in the U Power wiring. Test the U connector b. U connector still disconnected c. ackprobe wire K on the U connector and check for continuity with pin K on the harness end of the If continuity is found, repeat this step for the and J circuits of the U If continuity is not found, there is a faulty U If continuity is found on all circuits, proceed to next step. Note: If proper voltage is not found on the circuit, the problem may exist earlier in the circuit. efer to Section., Wiring Schematics for schematic information on a specific machine. U HNSS ONNTO. ecover any fault codes. efer to Section., etrieving ault odes.. heck the starter circuit. If the starter solenoid operates, replace the starter motor. Note: emove starter motor providing engine compression is preventing turning over of assembly. To check, place proper size socket over crank dampner pulley and rotate engine.. uring starter replacement, turn the engine over by hand to check for possible starter ring gear damage, chipped or damaged teeth.. If all checks are completed and the engine still does not operate properly, contact your local John eere service distributor..8 John eere ngine

25 unction Troubleshooting.. ngine Over Speed rank Position Sensor rank Sensor onnector rank Position eturn rank Position Input, PUPL 8, GY G H J G H J G H J K K K 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 U 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 evenly spaced teeth and missing teeth. The missing teeth help the U to determine Top-ead-enter (T).. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. ecover any fault codes. efer to Section., etrieving ault odes. fault code will result if the U detects that engine speed exceeds 00 rpm. The U will shut fuel off until engine speed is below 800 rpm.. Inspect the rank Position sensor and Timing Wheel a. emove crank position sensor from injection pump. b. Inspect sensor for cracks, corrosion, or any foreign material on the end of the sensor. c. Inspect the crank timing wheel notches for burrs or chips. If a fault is found in a part, repair or replace the part.. Test the rank Position sensor. b. isconnect crank position sensor connector c. Measure resistance between both terminals of the crank position sensor. If voltage is between 00 and 00 ohms, proceed to next step. If voltage is below 00 ohms or above 00 ohms, repair or replace the sensor.. Test rank Position sensor connector b. rank position sensor connector still disconnected John eere ngine MN000 U HNSS ONNTO c. ackprobe Terminal and test for continuity between Pin on the same side of the If continuity is found, repeat step for the other terminals of the connector If continuity is not found, repair or replace the connector If continuity is found on all terminals and both sides of the connector, proceed to next step. heck rank Position sensor Input and eturn Wiring b. rank Position sensor connector still disconnected c. isconnect U connector d. ackprobe wire on the U connector and test for continuity between Terminal of the rank Position sensor If continuity is found, check the sensor return wire If continuity is not found, there is an open in the sensor input wiring O a faulty U e. ackprobe wire on the U connector and test for continuity between Terminal of the T sensor If continuity is found, proceed to next step. If continuity is not found, there is an open in the sensor return wiring O a faulty U.9

26 unction Troubleshooting. Test the U connector b. U connector still disconnected c. ackprobe wire on the U connector and check for continuity with pin on the harness end of the If continuity is found, repeat this step for the circuit of the U If continuty is not found, there is a faulty U If continuity is found on all circuits, proceed to next step. 8. heck Gear Timing b. emove timing cover c. heck timing between camshaft, crankshaft, and injection pump gears. If all gears are in time, proceed to next step. If one or more gears are out of time, make the necessary adjustments to ensure correct timing. 9. If all checks are completed and the engine still does not operate properly, contact your local John eere service distributor..0 John eere ngine

27 unction Troubleshooting.. ngine Misfires/uns Irregularly 0. With engine running at a moderate engine rpm, loosen the injector fuel supply hard lines one at a time. drop in the engine rpm would indicate the cylinder is OK. If there is no change in engine rpm, contact your local John eere service distributor.. If all checks are completed and the engine still does not operate properly, contact your local John eere service distributor. MY00. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. heck for air intake system leaks, air in the fuel system. If air intake leak is found, investigate entry of dirt. Sample oil efer to John eere engine service manual.. ecover any T s from the ngine Shutdown Override System. efer to Section., etrieving ault odes.. heck the individual engine cylinders for misfire by loosening one injector nozzle at a time to determine which cylinder is affected. Once the cylinder is located, check for an adequate fuel supply. If there is blockage in the hard line, disconnect both ends and blow pressurized air through the line.. heck for proper engine PM s. The engine should run smoothly at low idle.. heck that the transmission and hydraulic systems do not have problems preventing full high idle operation.. heck that all system pressures are adjusted properly. 8. Insure that the throttle linkage and/or analog pedal are functioning properly. 9. ring engine to operating temperature, determine the color of smoke from the exhaust system. Heavy white smoke - make sure engine is up to operating temperature. uel quality is good, min of TN. Heavy gray or black smoke - check fuel quality, TN of, make sure engine is up to operating temperature, engine is not under excessive load and that air filters are not restricted. nsure the turbo is operating correctly (on equipped machines). Small amounts or no exhaust smoke - ontact John eere if misfiring. John eere ngine.

28 unction Troubleshooting. U TOULSHOOTING.. U Switched Power TTY IGNITION SWITH VSW 0 VT V K 0, 0, J 00G, LK G H J G H J G H J K K K MN000 This error occurs when the U does not detect battery voltage. In this scenario, the engine will not start or run.. heck the U Power Wiring b. isconnect U c. ackprobe wire K and wire J and check for V. If the required voltage is found, test the circuit If voltage is not found, there is an open in the U Power wiring d. ackprobe wire and wire J and check for V with the ignition ON. If the required voltage is found, test the ngine ranking Speed If the required voltage is not found, there is an open in the U Power wiring. Test the U connector b. U connector still disconnected c. ackprobe wire K on the U connector and check for continuity with pin K on the harness end of the If continuity is found, repeat this step for the and J circuits of the U If continuity is not found, there is a faulty U U HNSS ONNTO If proper voltage is not found on the circuit, the problem may exist earlier in the circuit. efer to Section., Wiring Schematics for schematic information on a specific machine.. John eere ngine

29 unction Troubleshooting.. U Power own rror TTY IGNITION SWITH VSW 0 VT V K 0, 0, J 00G, LK G H J G H J G H J K K K. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. ecover any fault codes. efer to Section., etrieving ault odes. fault code will result if the U detects voltage is on the switched voltage input wire to the U.. heck the U Power Wiring b. isconnect U c. ackprobe wire K and wire J and check for V. If the required voltage is found, test the circuit If voltage is not found, there is an open in the U Power wiring d. ackprobe wire and wire J and check for V with the ignition ON. If the required voltage is found, test the ngine ranking Speed If the required voltage is not found, there is an open in the U Power wiring. Test the U connector b. U connector still disconnected c. ackprobe wire K on the U connector and check for continuity with pin K on the harness end of the If continuity is found, repeat this step for the and J circuits of the U If continuty is not found, there is a faulty U If continuity is found on all circuits, proceed to next step. John eere ngine MN000 U HNSS ONNTO. If all checks are completed and the engine still does not operate properly, contact your local John eere service distributor..

30 unction Troubleshooting. N TOULSHOOTING N Low N High N Shield 90, ark Green 90, Yellow G GGG H HH J J J K K K U HNSS ONNTO G H J SWITH VOLTG STTI GOUN IGNOSTI ONNTO MN000 N (ontroller rea Network) throttle is information sent to the U by another controller over N of the desired throttle position. This code will set if: The U either does not receive throttle information over N, or the information received is not valid. If this code sets, the following will occur: If more than one throttle is available, the U will ignore the input from the N throttle, and will use the input values from another throttle. If the N throttle is the only throttle or all additional throttles are also faulted, the U will use a default limp-home throttle value that will only allow idle engine speed. If a problem is found to be within the N throttle system, contact your local John eere service distributor.. John eere ngine

31 unction Troubleshooting. LTIL TOULSHOOTING.. Manifold ir Temperature Sensor MT Sensor t MT Sensor onnector Sensor Ground MT Input, Orange 9, Yellow G H J G H J G H J K K K MN000 The Manifold ir Temperature (MT) sensor is a thermistor (temperature sensitive resistor) mounted in the intake manifold. The MT sensor is used to measure the temperature of the intake air. The MT sensor s variable resistance causes the input voltage to the U to vary. Higher intake air temperatures result in lower MT input voltages to the U; lower temperatures result in higher voltages. Note: or OM applications, the high manifold air temperature input voltage specification is.9 volts. Low manifold air temperature voltage specification is 0. volts. heck the following items that can cause high intake air temperatures: xcessively high ambient air temperature estricted, dirty, or damaged charge air cooler Loose cooling fan belt Malfunctioning cooling fan estricted or damaged intake air piping amaged cooling fan shroud. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. ecover any fault codes. efer to Section., etrieving ault odes. fault code will result if the manifold air temperature input voltage exceeds or goes below the sensor s voltage specification.. heck the MT sensor b. isconnect MT sensor connector c. Measure resistance between both terminals of the MT sensor U HNSS ONNTO If measurement is between 00 and 00 ohms, proceed to next step. If measurement is below 00 ohms or above 00 ohms, repair or replace the sensor.. Test MT sensor connector b. MT connector still disconnected c. ackprobe Terminal and test for continuity between Pin on the same side of the If continuity is found, repeat step for the other terminals of the connector If continuity is not found, repair or replace the connector If continuity is found on all terminals and both sides of the connector, proceed to next step. heck MT Sensor Input and eturn Wiring b. MT connector still disconnected c. isconnect U connector d. ackprobe wire on the U connector and test for continuity between Terminal of the MT sensor If continuity is found, check the sensor return wire If continuity is not found, there is an open in the sensor input wiring O a faulty U e. ackprobe wire on the U connector and test for continuity between Terminal of the MT sensor If continuity is found, proceed to next step. If continuity is not found, there is an open in the sensor return wiring O a faulty U John eere ngine.

32 unction Troubleshooting. Test the U connector b. U connector still disconnected c. ackprobe wire on the U connector and check for continuity with pin on the harness end of the If continuity is found, repeat this step for the circuit of the U If continuty is not found, there is a faulty U If continuity is found on all circuits, proceed to next step.. If all checks are completed and the engine still does not operate properly, contact your local John eere service distributor.. John eere ngine

33 unction Troubleshooting.. uel Temperature Sensor uel Temp Sensor t uel Temp onnector Sensor Ground uel Temp Input 8, Gray 9, Yellow G H J G H J G H J K K K MN0090 The fuel temperature sensor is a thermistor (temperature sensitive resistor) located on the injection pump fuel outlet housing. The fuel temperature sensor s variable resistance causes the input voltage to the U to vary. Higher fuel temperatures result in lower fuel temperature input voltages to the U; lower temperatures result in higher voltages. The U uses the fuel temperature sensor input to adjust the fuel delivery for the variations in fuel density caused by varying fuel temperatures. Note: or OM engine applications, the high fuel temperature input voltage specification is.9 volts. Low manifold air temperature voltage specification is 0. volts. The U will use a limp-home fuel temperature value of -0 (- ) during cranking, and 0 (0 ) during running.. efer to Section, General Troubleshooting for initial checks before moving on to the following steps.. ecover any fault codes. efer to Section., etrieving ault odes. fault code will result if the fuel temperature input voltage goes above the sensor s high voltage specification. This voltage corresponds to a temperature that is lower than what is physically possible for fuel temperature.. heck the uel Temperature sensor b. isconnect uel Temperature sensor connector c. Measure resistance between both terminals of the uel Temperature sensor If measurement is between 00 and 00 ohms, proceed to next step. If measurement is below 00 ohms or above 00 ohms, repair or replace the sensor. U HNSS ONNTO. Test uel Temperature sensor connector b. uel Temperature connector still disconnected c. ackprobe Terminal and test for continuity between Pin on the same side of the If continuity is found, repeat step for the other terminals of the connector If continuity is not found, repair or replace the connector If continuity is found on all terminals and both sides of the connector, proceed to next step. heck uel Temperature sensor Input and eturn Wiring b. uel Temperature connector still disconnected c. isconnect U connector d. ackprobe wire on the U connector and test for continuity between Terminal of the uel Temperature sensor If continuity is found, check the sensor return wire If continuity is not found, there is an open in the sensor input wiring O a faulty U e. ackprobe wire on the U connector and test for continuity between Terminal of the uel Temperature sensor If continuity is found, proceed to next step. If continuity is not found, there is an open in the sensor return wiring O a faulty U John eere ngine.