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Page 1: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Service Manual

John Deere Tier II Engine

Troubleshooting

31200371

Original

February 2, 2007

Page 2: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007
Page 3: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

EFFECTIVITY PAGE

31

February 2, 2007 - A - Original Issue Of Manual

200371 John Deere Engine i

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EFFECTIVITY PAGE

-ii

John Deere Engine 31200371
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SECTION CONTENTS

Section Subject Page

Section 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

Section 2General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 Basic Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22.2 Pre-Troubleshooting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22.3 Electronic Control System Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32.4 Electronic Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.5 Monitoring Engine Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.6 Electronic Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.7 ECU Connector Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52.8 OEM Trim Option Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

Section 3Function Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23.2 Retrieving Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33.3 Engine Derate Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53.4 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63.5 ECU Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.123.6 CAN Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.143.7 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

Section 4Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

John Deere Engine i

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Section Subject Page

ii John Deere Engine

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1.1John Deere Engine

Section 1Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

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Safety Practices

1.1 INTRODUCTION

This manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.

Read, 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. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate 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. All 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 Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.

1.2 DISCLAIMER

All 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.

1.3 OPERATION & SAFETY MANUAL

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.

An 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.

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.2 John Deere Engine

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Safety Practices

1.5 SAFETY INFORMATION

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.

1.5.1 Safety Alert System and Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional 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.

For all safety messages, carefully read, understand and follow the instructions before proceeding.

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: 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.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

LIFTING OF EQUIPMENT: Before 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.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

DANGER

WARNING

1.3John Deere Engine

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Safety Practices

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: 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.

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER 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.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel 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.

Relieve 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. Before 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. Capture fluid in an

appropriate container and dispose of in accordance with prevailing environmental regulations.

RADIATOR CAP: Always wear steam-resistant, heat protective gloves when opening the radiator cap. Cover the cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: 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.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: 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.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7 SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

1.4 John Deere Engine

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Section 2General Troubleshooting

Contents

PARAGRAPH TITLE PAGE

2.1 Basic Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22.2 Pre-Troubleshooting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22.3 Electronic Control System Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32.4 Electronic Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.5 Monitoring Engine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.6 Electronic Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.7 ECU Connector Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52.8 OEM Trim Option Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.1John Deere Engine

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General Troubleshooting

2.1 BASIC ENGINE CHECKS

If the engine will not run or is running erratically, the fault may not be related to the electronic system. Ensure that the following points are checked before ECU troubleshooting.

• Travel Select Lever is in the (N) NEUTRAL position

• Park brake is set

• Throttle pedal has free range of motion without interuption

• Sufficient fuel in the fuel tank for engine operation

• Fuel quality is of an acceptable rating

• Battery power and ground connections are secure

• Fuel 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

2.2 PRE-TROUBLESHOOTING CHECKS

The following is a basic checklist of items to check when troubleshooting engine ECU issues on John Deere engines. Some of the reported issues have been engine shutdown, erratic running, and erratic throttle position. This list is not for actual ECU troubleshooting, but rather external factors that may affect ECU operation. Check fault codes prior to checking the following items. Refer to Section 3.2, “Retrieving Fault Codes,” for more information on fault codes. Some of the items below may not show a fault code.

• Check the female sockets in the engine harness plug that attaches to the engine’s ECU. 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.

• Check bolt used to retain harness connector to ECU. If loose, it needs to be tightened. Check operation after tightening bolt. Loctite® 242 should be applied to threads if bolt is loose.

• Verify brass insert in ECU 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 ECU is suspect. Contact your local John Deere service dealer with full details.

• Verify ground cable attachment on engine and frame. Check that bolts are tight; verify ground is clean and bare for contact between ground connection and frame. ECU primary supply ground wire must be properly secured in the wedge connector.

• Verify positive cables are clean and tight. Primary ECU power supply at the battery post is tight within the wedge connection, that the fuse is supplied and working properly.

• Check 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 ECU.

• Crank position sensor that is not giving consistent readings can cause hard starting, shutdown, erratic throttle issues. This is a John Deere isssue. Just be aware of the effect this sensor can have.

Check critical connectors for signs of looseness, corrosion, damage, etc. The following connectors are critical:

• ECU Connector

• Crank position sensor at front of engine

• Fuel pump solenoid connector

• Cam position sensor on block

• ECU 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:

1. Check all fuel and air filters, water ingression into this system will promote fault codes. Daily draining of the fuel/water separator is recommended.

2. Check the condition of the fuel lines from the tank to the engine.

3. Check the fuel tank cap vent.

4. Check all engine fault codes and record them. Refer to Section 3.2, “Retrieving Fault Codes.”

5. Check all wiring and socket conditions. A check for ground and positive voltage supply at the John Deere, 9 pin connector is also recommended. This would also detect a harness issue on the JLG side.

6. After all JLG/Gradall supplied items have been inspected, repaired, corrected and/or replaced, then the John Deere Dealer should be called to install the latest version of ECU software. Refer to Section 2.8, “OEM Trim Option Settings.”. The John Deere Dealer will need to file a DETAC case and request, the “OEM Trim Options” payload replacement software.

7. If the problem comes back, then the ECU will have to be replaced with a new one that has been updated.

2.2 John Deere Engine

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General Troubleshooting

2.3 ELECTRONIC CONTROL SYSTEM TERMINOLOGY

Term Definition

Actuator A device controlled by the (ECU) to perform a certain function.

Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt signals.

Boost Air charge pressure in the intake manifold.

CAN Controller Area Network. The electronic pathway network on vehicles that allows communication between controllers.

DTC Diagnostic Trouble Code. A code which is stored in the ECU’s memory when the ECU detects a problem in the electronic control system.

DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTC’s and run special tests. The DST consists of a Windows (‘95, ‘98, 2000) or NT compatible computer and a hardware kit available from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The software is available to download from your John Deere home page.

Digital A signal which consists of only two-volt levels - usually 0 volts and +5 volts.

ECT Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant.

ECU Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine.

FMI 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).

J1587-J1708 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.

MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold.

PDM Parallel Data Module. Device used as part of the DST that allows communication with the ECU.

PROM Programmable, Read-Only Memory. The computer chip which contains the calibration information for the engine control system.

PWM Pulse Width Modulation. A digital signal (not analog) which consists of a pulse generated at a fixed frequency. When an actuator is controlled by a PWM signal, the on time of the signal is increased or decreased (modulated) to increase or decrease the output of the actuator.

RAM Random Access Memory. The portion of computer memory within the ECU which changes as the engine is running and is stored while the engine is off.

SAE Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance and energy resource conservation.

Sensor Device used by the ECU to monitor various engine parameters.

SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to the SAE J1939 Standard. The SPN identifies the system of component that has the failure. The second half of the code is the Failure Mode Identifier (FMI).

VBAT Battery voltage or unswitched voltage.

VSW Switch voltage

2.3John Deere Engine

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General Troubleshooting

2.4 ELECTRONIC CONTROL SYSTEM OPERATION

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.

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 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-energizing 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.

2.5 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

2.6 ELECTRONIC CONTROL SYSTEM OVERVIEW

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

• Delivers an optimum amount of fuel for operating conditions

• Provides multiple control modes

• Performs self-diagnosis

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.

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.

2.4 John Deere Engine

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General Troubleshooting

2.7 ECU CONNECTOR LEGEND

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Pin Wire Designation

A1 941 (Brn, 16)

A2 012B (Red, 16)

A3 493 (Org, 16)

B1 461, (Brn, 18)

B2 447 (Purple, 18)

B3 918 (Gray, 16)

C1 947 (Purple, 18)

C2

C3 428 (Gray, 18)

D1 463 (Org, 18)

D2 448 (Gray, 18)

D3 914E (Yllw, 16)

E1 915 (Dk Grn, 16)

E2 911E (Brn, 16)

E3

F1 905E (Dk Grn, 18)

F2

F3 467 (Pur, 16)

G1 904E (Yllw, 18)

G2

G3 473 (Org, 16) Eng Over ride Light

H1

H2

H3

J1

J2 050G (Blk, 16) > 050F > Btry Neg

J3

K1 022C (Red, 16 >002B >Fuse > 002A > Btry Pos

K2 491 (Brn, 16)

K3

2.5John Deere Engine

Page 16: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

General Troubleshooting

2.8 OEM TRIM OPTION SETTINGS

Note: The following setting can only be accessed by John Deere service personnel.

Digital Throttle

Enable - OFF

3 - state Throttle - selected

Primary Analog Throttle

Enable - ON

Self Calibration Enable - ON

Secondary Analog Throttle

Enable - OFF

Throttle Adjustments - No Change

Throttle Out of Range Recovery - Resume Recovery

Min Throttle Offset - 0 rpm

Maximum Throttle Offset - 0 rpm

Throttle Rate - Standard (Maximum)

Ramp Rate - 1.6%

Combination Throttle - No Change

Enable OFF

Master Input - Primary Analog selected

2nd Input - Secondary Analog selected, Input Type - Accelerator

3rd Input - Digital selected, Type - Accelerator

Torque Speed Control - No Change

Enable TSC Source 1 - OFF

Enable TSC Source 2 - OFF

Source Address 1 - 3

Source Address 2 - 4

Governor

Single Governor - Selected

Harness Selectable Governor - OFF

RPM of Droop - 150

Standard Derates and Standard Shutdowns

Enable Derates - Selected

Standard Shutdowns

Oil Pressure, Coolant and Fuel temperature Shutdown - Enable

Shutdown Timer - 30 seconds

External Derate

Enable - OFF

External Derate Input - Normally Open Switch

External Derate Rate - 20% Derate over 10 minutes

External Shutdown

Enable - OFF

External Shutdown Input - Normally Open Switch

External Shutdown Timer - Immediate

Override External Shutdown at Engine Start - OFF

Override External Shutdown Time - 30 seconds

Oil Pressure Sensor - Enable

Cruise Control - No Change

Enable - OFF

On/Off Input - Normally Open Switch

Accel Input - Normally Open Switch

Decel Input - Normally Open Switch

Brake Input - Normally Closed Switch

Turnaround Input - Normally Open Switch

Tachometer Output - Enable

Low Idle Warm-Up - OFF

CAN Wait-to-Start Message - Enable

Governor Gains

Low Speed Governor Gain - Use Default Governor Gain

All Speed Governor Gain - Use Default Governor Gain

Selected Alternate Gain - Alternate Gain #1

Gain Adjustment Percentage - 100

2.6 John Deere Engine

Page 17: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

3.1John Deere Engine

Section 3Function Troubleshooting

Contents

PARAGRAPH TITLE PAGE

3.1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23.2 Retrieving Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33.3 Engine Derate Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53.4 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3.4.1 Engine Cranks, Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63.4.2 Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83.4.3 Engine Over Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.93.4.4 Engine Misfires/Runs Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

3.5 ECU Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.123.5.1 ECU Switched Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.123.5.2 ECU Power Down Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

3.6 CAN Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.143.7 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.7.1 Manifold Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.153.7.2 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.173.7.3 Analog Throttle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.193.7.4 Crank Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.213.7.5 Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.223.7.6 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.233.7.7 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.243.7.8 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.253.7.9 Loss of Engine Coolant Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

Page 18: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.1 TROUBLESHOOTING PROCEDURE

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.

Oil Pressure Sensor

Pump Control Solenoid

Electronic Control Unit (ECU)

Crank Position Sensor

Fuel Temperature Sensor

ECT Sensor

Manifold Air Temperature (MAT)

Sensor

Loss of Coolant Sensor

3.2 John Deere Engine

Page 19: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.2 RETRIEVING FAULT CODES

1. 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) NEUTRAL and engage the park brake.

2. Turn the ignition switch to “ON”.

3. Push down and hold the reset button on the dash for 3-5 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 32. If there are no “active” codes, the system will flash code 88. The system will then

flash code 33 if there are any “stored” fault codes. If there are no “stored” codes, the system will flash code 88.

4. Once the code is retrieved, turn the ignition OFF.

Note: When the engine sensor inputs exceed normal operating ranges, the ECU will derate the amount of fuel that is delivered to the engine. A 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.

Fault Codes SPN Codes FMI Codes Definition

11 N/A N/A Analog Throttle (A) Input High

12 N/A N/A Analog Throttle (B) Input High

18 110 3 Engine Coolant Temperature Input Voltage High

19 110 4 Engine Coolant Temperature Input Voltage Low

21 620 3 Sensor Supply Voltage High

1079 3 Sensor Supply Voltage High

22 620 4 Sensor Supply Voltage Low

1079 4 Sensor Supply Voltage Low

23 100 3 Engine Oil Pressure Input Voltage High

24 100 4 Engine Oil Pressure Input Voltage Low

25 105 3 Manifold Air Temperature Input Voltage High

26 105 4 Manifold Air Temperature Input Voltage Low

28 629 13 ECU Error

32 N/A N/A Signifies Start of Active Fault Codes

33 N/A N/A Signifies Start of Previously Active Fault Codes

37 174 3 Fuel Temperature Input Voltage High

38 174 4 Fuel Temperature Input Voltage Low

39 637 2 Crank Position Input Noise

10 Crank Position Input Pattern Error

42 190 0 Engine Overspeed Extreme

16 Engine Overspeed Moderate

54 158 17 ECU Power Down Error

55 639 13 CAN Error

62 110 15 Engine Coolant Temperature High Least Service

63 110 16 Engine Coolant Temperature High Moderately Service

64 100 18 Engine Oil Pressure Moderately Low

65 100 1 Engine Oil Pressure Extremely Low

3.3John Deere Engine

Page 20: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

66 105 16 Manifold Air Temperature Moderately High

68 1569 31 Fuel Derate

69 110 0 Engine Coolant Temperature High Most Severe

71 1076 0 Pump Control Valve Closure Too Long

72 1076 1 Pump Control Valve Closure Too Short

73 1076 5 Pump Solenoid Circuit Open

74 1076 6 Pump Solenoid Circuit Severely Shorted

75 1076 7 Pump Control Valve Closure Not Detected

76 1076 10 Pump Solenoid Circuit Moderately Shorted

77 1076 3 Pump Solenoid Current High

78 200 13 Security Violation

79 2000 6 Internal ECU Error

81 174 16 Fuel Temperature Moderately High

82 1110 31 Engine Protection Shutdown

83 970 31 Auxiliary Engine Shutdown Switch ActiveNote: If 5VDC is detected on circuit K2 there is a short in the system. If 5VDC is not

detected, John Deere assistance is required. JLG does not currently use this shutdown.

84 158 17 ECU Power Down Error

971 31 External Derate Switch Active

88 N/A N/A Signifies No Fault Codes Are In Buffer

3.4 John Deere Engine

Page 21: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.3 ENGINE DERATE CHART

Sensor Measured Sensor Parameter

Out of Range Value Derate

Analog Throttle (A) High Input Voltage Above 4.7 Volts If no other throttle is available, engine will run at idle speed

Low Input Voltage Below 0.3 Volts If no other throttle is available, engine will run at idle speed

Oil Pressure Switch Low Input Voltage Input circuit is grounded at key ON with no engine

speed

No derate

Extremely Low Pressure

Input circuit is grounded when engine is running at a

minimum engine speed

No derate

Manifold Air Temperature (MAT)

High Input Voltage Above 4.9 Volts High MAT engine protection is disabled

Low Input Voltage Below 0.1 Volts High MAT engine protection is disabled

Engine Coolant Temperature

High Input Voltage Exceeds 4.9 Volts High ECT engine protection is disabled

Low Input Voltage Below 0.1 Volts High ECT engine protection is disabled

Most Severe Temperature

Exceeds 244°F (118°C) ECU derates engine 20% per minute until engine runs at 40% of full power

Moderately Severe Temperature

Exceeds 235°F (113°C) ECU derates engine 2% per minute until engine runs at 80% of full power

Fuel Temperature High Input Voltage Above 4.9 Volts High fuel temperature engine protection is disabled

Low Input Voltage Below 0.1 Volts High fuel temperature engine protection is disabled

Moderately High Temperature

Exceeds 248°F (120°C) ECU derates engine 2% per minute until engine runs at 80% of full power

3.5John Deere Engine

Page 22: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.4 ENGINE TROUBLESHOOTING

3.4.1 Engine Cranks, Will Not Start

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Loosen one fuel line connection on the injection nozzles, crank engine over while monitoring the loose connection for consistent supply of fuel. Be 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 20 lb-ft after testing.

3. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.”

4. Check the ECU Power Wiring

a. Ignition OFFb. Disconnect ECU connector.c. Backprobe wire K1 and wire J2 and check for 12 VDC.

• If the required voltage is found, test the A2 circuit

• If voltage is not found, there is an open in the ECU Power wiring

d. Backprobe wire A2 and wire J2 and check for 12 VDC with the ignition ON.

• If the required voltage is found, test the Engine Cranking Speed

• If the required voltage is not found, there is an open in the ECU Power wiring

5. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire K1 on the ECU connector and check

for continuity with pin K1 on the harness end of the connector.

• If continuity is found, repeat this step for the A2 and J2 circuits of the ECU connector.

• If continuity is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

Note: If proper voltage is not found on the A2 circuit, the problem may exist earlier in the circuit. Refer to Section 4.1, “Wiring Schematics” for schematic information on a specific machine.

6. Test the Engine Cranking Speed

IMPORTANT: Cranking speed specifications are for OEM engines only.Make sure that batteries are fully charged before performing this test.

a. Disable the fuel supply system at the injection pump so fuel delivery is in the OFF position.

b. If not using the machine tachometer, install a photo tach or TIME TRAC®.

c. Crank engine for 15 seconds and record engine speed.

d. Compare recorded engine speed to the following chart:

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3.6 John Deere Engine

Page 23: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

Cranking speed should meet or exceed specified engine rpm for a given ambient air temperature. For example, at 29°C (85°F) ambient air temperature, cranking speed should be at least 200 rpm.

If cranking speed is below specifications, check the following:

• Starting system problems (low battery, loose or defective wiring, defective starter, etc.)

• Excessive engine loads (thick hydraulic oil, thick engine oil, etc.).

7. Test the Engine Compression Pressure.

IMPORTANT: Compression pressures are affected by the cranking speed of the engine. Before beginning test, ensure that batteries are fully charged and injection nozzle area is thoroughly cleaned.

Note: Engines equipped with Level 4 Electronic Fuel Systems with VP44 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 10 - 15 seconds with starter motor (minimum cranking speed - 150 rpm cold/200 rpm hot).

c. Test the remaining cylinders.d. Compare readings from all cylinders. Compression

pressure is set to be 2379-2792 kPa (24-28 bar)(345-405 psi). The maximum difference between cylinders should be no more than 350 kPa (3.5 bar)(50 psi).

Note: Pressure given was taken at 183 m (600 ft) above sea level. A 3.6 percent reduction in gauge pressure will result for each additional 300 m (1000 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. Do not use too much oil. Do not get oil on the valves.

f. Test compression pressure again.

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. Recondition cylinder head as required.

g. Measure compression pressure in all remaining cylinders and compare readings. Recondition cylinders and valves as required.

8. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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3.7John Deere Engine

Page 24: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.4.2 Engine Will Not Crank

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Check the ECU Power Wiring

a. Ignition OFFb. Disconnect ECU connector.c. Backprobe wire K1 and wire J2 and check for 12 VDC.

• If the required voltage is found, test the A2 circuit

• If voltage is not found, there is an open in the ECU Power wiring

d. Backprobe wire A2 and wire J2 and check for 12 VDC with the ignition ON.

• If the required voltage is found, test the Engine Cranking Speed

• If the required voltage is not found, there is an open in the ECU Power wiring

3. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire K1 on the ECU connector and check

for continuity with pin K1 on the harness end of the connector.

• If continuity is found, repeat this step for the A2 and J2 circuits of the ECU connector.

• If continuity is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

Note: If proper voltage is not found on the A2 circuit, the problem may exist earlier in the circuit. Refer to Section 4.1, “Wiring Schematics” for schematic information on a specific machine.

4. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.”

5. Check the starter circuit. If the starter solenoid operates, replace the starter motor.

Note: Remove starter motor providing engine compression is preventing turning over of assembly. To check, place proper size socket over crank dampner pulley and rotate engine.

6. During starter replacement, turn the engine over by hand to check for possible starter ring gear damage, chipped or damaged teeth.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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3.8 John Deere Engine

Page 25: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.4.3 Engine Over Speed

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).

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A fault code will result if the ECU detects that engine speed exceeds 3400 rpm. The ECU will shut fuel off until engine speed is below 2800 rpm.

3. Inspect the Crank Position sensor and Timing Wheel

a. Remove 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.

4. Test the Crank Position sensor.

a. Ignition OFFb. Disconnect crank position sensor connectorc. Measure resistance between both terminals of the

crank position sensor.

• If voltage is between 2500 and 3500 ohms, proceed to next step.

• If voltage is below 2500 ohms or above 3500 ohms, repair or replace the sensor.

5. Test Crank Position sensor connector

a. Ignition OFFb. Crank position sensor connector still disconnected

c. Backprobe Terminal A and test for continuity between Pin A on the same side of the connector.

• 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

6. Check Crank Position sensor Input and Return Wiring

a. Ignition OFFb. Crank Position sensor connector still disconnectedc. Disconnect ECU connectord. Backprobe wire B2 on the ECU connector and test for

continuity between Terminal A of the Crank Position sensor connector.

• If continuity is found, check the sensor return wire

• If continuity is not found, there is an open in the sensor input wiring OR a faulty ECU connector.

e. Backprobe wire D2 on the ECU connector and test for continuity between Terminal B of the ECT sensor connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the sensor return wiring OR a faulty ECU connector.

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3.9John Deere Engine

Page 26: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

7. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire B2 on the ECU connector and check

for continuity with pin B2 on the harness end of the connector.

• If continuity is found, repeat this step for the D2 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

8. Check Gear Timing

a. Ignition OFFb. Remove timing coverc. Check 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 Deere service distributor.

3.10 John Deere Engine

Page 27: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.4.4 Engine Misfires/Runs Irregularly

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Check for air intake system leaks, air in the fuel system.

• If air intake leak is found, investigate entry of dirt.

• Sample oil

• Refer to John Deere engine service manual.

3. Recover any DTC’s from the Engine Shutdown Override System. Refer to Section 3.2, “Retrieving Fault Codes.”

4. Check 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.

5. Check for proper engine RPM’s. The engine should run smoothly at low idle.

6. Check that the transmission and hydraulic systems do not have problems preventing full high idle operation.

7. Check that all system pressures are adjusted properly.

8. Insure that the throttle linkage and/or analog pedal are functioning properly.

9. Bring engine to operating temperature, determine the color of smoke from the exhaust system.

• Heavy white smoke - make sure engine is up to operating temperature. Fuel quality is good, min of CETANE 45.

• Heavy gray or black smoke - check fuel quality, CETANE of 45, make sure engine is up to operating temperature, engine is not under excessive load and that air filters are not restricted. Ensure the turbo is operating correctly (on equipped machines).

• Small amounts or no exhaust smoke - Contact John Deere if misfiring.

10. With engine running at a moderate engine rpm, loosen the injector fuel supply hard lines one at a time. A drop in the engine rpm would indicate the cylinder is OK. If there is no change in engine rpm, contact your local John Deere service distributor.

11. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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3.11John Deere Engine

Page 28: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.5 ECU TROUBLESHOOTING

3.5.1 ECU Switched Power

This error occurs when the ECU does not detect battery voltage. In this scenario, the engine will not start or run.

1. Check the ECU Power Wiring

a. Ignition OFFb. Disconnect ECU connector.c. Backprobe wire K1 and wire J2 and check for 12 VDC.

• If the required voltage is found, test the A2 circuit

• If voltage is not found, there is an open in the ECU Power wiring

d. Backprobe wire A2 and wire J2 and check for 12 VDC with the ignition ON.

• If the required voltage is found, test the Engine Cranking Speed

• If the required voltage is not found, there is an open in the ECU Power wiring

2. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire K1 on the ECU connector and check

for continuity with pin K1 on the harness end of the connector.

• If continuity is found, repeat this step for the A2 and J2 circuits of the ECU connector.

• If continuity is not found, there is a faulty ECU connector.

If proper voltage is not found on the A2 circuit, the problem may exist earlier in the circuit. Refer to Section 4.1, “Wiring Schematics” for schematic information on a specific machine.

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3.12 John Deere Engine

Page 29: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.5.2 ECU Power Down Error

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A fault code will result if the ECU detects voltage is on the switched voltage input wire to the ECU.

3. Check the ECU Power Wiring

a. Ignition OFFb. Disconnect ECU connector.c. Backprobe wire K1 and wire J2 and check for 12 VDC.

• If the required voltage is found, test the A2 circuit

• If voltage is not found, there is an open in the ECU Power wiring

d. Backprobe wire A2 and wire J2 and check for 12 VDC with the ignition ON.

• If the required voltage is found, test the Engine Cranking Speed

• If the required voltage is not found, there is an open in the ECU Power wiring

4. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire K1 on the ECU connector and check

for continuity with pin K1 on the harness end of the connector.

• If continuity is found, repeat this step for the A2 and J2 circuits of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

5. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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3.13John Deere Engine

Page 30: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.6 CAN TROUBLESHOOTING

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.

If a problem is found to be within the CAN throttle system, contact your local John Deere service distributor.

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3.14 John Deere Engine

Page 31: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7 ELECTRICAL TROUBLESHOOTING

3.7.1 Manifold Air Temperature Sensor

The Manifold Air Temperature (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 sensor’s 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.

Note: For OEM applications, the high manifold air temperature input voltage specification is 4.9 volts. Low manifold air temperature voltage specification is 0.1 volts.

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

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A fault code will result if the manifold air temperature input voltage exceeds or goes below the sensor’s voltage specification.

3. Check the MAT sensor

a. Ignition OFFb. Disconnect MAT sensor connectorc. Measure resistance between both terminals of the

MAT sensor

• If measurement is between 2500 and 3500 ohms, proceed to next step.

• If measurement is below 2500 ohms or above 3500 ohms, repair or replace the sensor.

4. Test MAT sensor connector

a. Ignition OFFb. MAT connector still disconnectedc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• 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

5. Check MAT Sensor Input and Return Wiring

a. Ignition OFFb. MAT connector still disconnectedc. Disconnect ECU connectord. Backprobe wire D1 on the ECU connector and test for

continuity between Terminal A of the MAT sensor connector.

• If continuity is found, check the sensor return wire

• If continuity is not found, there is an open in the sensor input wiring OR a faulty ECU connector.

e. Backprobe wire D3 on the ECU connector and test for continuity between Terminal B of the MAT sensor connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the sensor return wiring OR a faulty ECU connector.

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3.15John Deere Engine

Page 32: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

6. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire D1 on the ECU connector and check

for continuity with pin D1 on the harness end of the connector.

• If continuity is found, repeat this step for the D3 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

3.16 John Deere Engine

Page 33: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.2 Fuel Temperature Sensor

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 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.

Note: For OEM engine applications, the high fuel temperature input voltage specification is 4.9 volts. Low manifold air temperature voltage specification is 0.1 volts. The ECU will use a “limp-home” fuel temperature value of -20° C (-4° F) during cranking, and 40° C (104° F) during running.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A 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.

3. Check the Fuel Temperature sensor

a. Ignition OFFb. Disconnect Fuel Temperature sensor connectorc. Measure resistance between both terminals of the

Fuel Temperature sensor

• If measurement is between 2500 and 3500 ohms, proceed to next step.

• If measurement is below 2500 ohms or above 3500 ohms, repair or replace the sensor.

4. Test Fuel Temperature sensor connector

a. Ignition OFFb. Fuel Temperature connector still disconnectedc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• 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

5. Check Fuel Temperature sensor Input and Return Wiring

a. Ignition OFFb. Fuel Temperature connector still disconnectedc. Disconnect ECU connectord. Backprobe wire C3 on the ECU connector and test for

continuity between Terminal A of the Fuel Temperature sensor connector.

• If continuity is found, check the sensor return wire

• If continuity is not found, there is an open in the sensor input wiring OR a faulty ECU connector.

e. Backprobe wire D3 on the ECU connector and test for continuity between Terminal B of the Fuel Temperature sensor connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the sensor return wiring OR a faulty ECU connector.

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Page 34: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

6. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire C3 on the ECU connector and check

for continuity with pin C3 on the harness end of the connector.

• If continuity is found, repeat this step for the D3 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

3.18 John Deere Engine

Page 35: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.3 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 the throttle position. Analog throttle voltage at low idle will be approximately 0.500-1.0 VDC to 4.0-4.80 VDC at high idle. The ECU has the ability to learn different voltages for low and high idle, so the voltage range may change slightly between applications.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.”

3. Check the Sensor Wiring

a. Ignition OFFb. Disconnect the ECU connectorc. Backprobe wire E2 on the ECU connector and check

for continuity with Terminal D on the sensor side of the connector.

• If continuity is found, proceed to step D.

• If continuity is not found, there is an open in the sensor supply circuit OR a faulty sensor connector OR a faulty ECU connector

d. Backprobe wire E1 on the ECU connector and check for continuity with Terminal C on the sensor side of the connector.

• If continuity is found, proceed to step E.

• If continuity is not found, there is an open in the sensor supply circuit OR a faulty sensor connector OR a faulty ECU connector

e. Backprobe wire D3 on the ECU connector and check for continuity with Terminal A on the sensor side of the connector.

• If continuity is found, repair or replace the Analog Throttle sensor

• If continuity is not found, there is an open in the sensor supply circuit OR a faulty sensor connector OR a faulty ECU connector

4. Check the Sensor Connector

a. Ignition OFFb. Disconnect the sensor connectorc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• 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

5. Check the Sensor Input and Return Wiring

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire E2 on the ECU connector and test for

continuity between Terminal D of the sensor connector.

• If continuity is found, check the Analog Throttle Input to ECU wiring

• If continuity is not found, there is an open in the sensor supply wiring OR a faulty ECU connector

d. Backprobe wire E1 on the ECU connector and test for continuity between Terminal C of the sensor connector.

• If continuity is found, check the sensor ground wiring

• If continuity is not found, there is an open in the sensor Input to ECU wiring OR a faulty ECU connector

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3.19John Deere Engine

Page 36: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

e. Backprobe wire D3 on the ECU connector and test for continuity between Terminal A of the sensor connector.

• If continuity is found, check the ECU connector

• If continuity is not found, there is an open in the sensor ground wiring OR a faulty ECU connector

6. Check the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire E2 on the ECU connector and check

for continuity with pin E2 on the harness end of the connector

• If continuity is found, repeat this step for the E1 and D3 circuits of the ECU connector

• If continuity is not found, there is a faulty ECU connector

• If continuity is found on all circuits, proceed to next step

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

3.20 John Deere Engine

Page 37: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.4 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.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A fault code will result if the ECU detects that engine speed exceeds 3400 rpm. The ECU will shut fuel off until engine speed is below 2800 rpm.

3. Test the Crank Position sensor.

a. Ignition OFFb. Disconnect crank position sensor connectorc. Measure resistance between both terminals of the

crank position sensor.

• If voltage is between 2500 and 3500 ohms, proceed to next step.

• If voltage is below 2500 ohms or above 3500 ohms, repair or replace the sensor.

4. Test Crank Position sensor connector

a. Ignition OFFb. Crank position sensor connector still disconnectedc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• 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

5. Check Crank Position sensor Input and Return Wiring

a. Ignition OFFb. Crank Position sensor connector still disconnectedc. Disconnect ECU connectord. Backprobe wire B2 on the ECU connector and test for

continuity between Terminal A of the Crank Position sensor connector.

• If continuity is found, check the sensor return wire

• If continuity is not found, there is an open in the sensor input wiring OR a faulty ECU connector.

e. Backprobe wire D2 on the ECU connector and test for continuity between Terminal B of the ECT sensor connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the sensor return wiring OR a faulty ECU connector.

6. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire B2 on the ECU connector and check

for continuity with pin B2 on the harness end of the connector.

• If continuity is found, repeat this step for the D2 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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Page 38: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.5 Pump Solenoid

The stanadyne DE10 injection pump has an internal solenoid that is controlled by the ECU. The ECU switches current on and off in order to change 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 quality of the timing of fuel delivery to the engine.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.”

3. Check the Pump Solenoid

a. Ignition OFFb. Disconnect Pump Solenoid connectorc. Measure resistance between both terminals of the

Pump Solenoid

• If measurement is between 2500 and 3500 ohms, proceed to next step.

• If measurement is below 2500 ohms or above 3500 ohms, repair or replace the solenoid.

4. Test Pump Solenoid connector

a. Ignition OFFb. Pump Solenoid connector still disconnectedc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• 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

5. Check Pump Solenoid Input and Return Wiring

a. Ignition OFFb. Pump Solenoid connector still disconnectedc. Disconnect ECU connectord. Backprobe wire K2 on the ECU connector and test for

continuity between Terminal A of the Pump Solenoid connector.

• If continuity is found, check the solenoid return wire

• If continuity is not found, there is an open in the solenoid input wiring OR a faulty ECU connector.

e. Backprobe wire A3 on the ECU connector and test for continuity between Terminal B of the Pump Solenoid connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the solenoid return wiring OR a faulty ECU connector.

6. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire K2 on the ECU connector and check

for continuity with pin K2 on the harness end of the connector.

• If continuity is found, repeat this step for the A3 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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Page 39: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.6 Oil Pressure Sender

The oil pressure sender is a pressure transducer connected to the main oil galley. As engine oil pressure increases, the oil pressure sender input voltage increases. The ECU monitors oil pressure in order to protect the engine in case of a low oil pressure condition.

Note: ECU uses a default oil pressure of 260 kPa (2.6 bar) (37.5 psi). For OEM applications, the high oil pressure input voltage is 4.9 volts. The low oil pressure input voltage specification is 0.3 volts.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A fault code will result if:

• The oil pressure input voltage exceeds or drops below the sender’s voltage specification.

• ECU’s low oil pressure engine protection feature disabled.

3. Check the Sender Wiring

a. Ignition OFFb. Disconnect the ECU connectorc. Backprobe wire D3 on the ECU connector and check

for continuity between Terminal A on the Oil Pressure Sender

• If continuity is found, check the Sender Input Wiring

• If continuity is not found, there is an open in the circuit wiring OR a faulty ECU connector

d. Backprobe wire F3 on the ECU connector and check for continuity between Terminal C on the Oil Pressure Sender

• If continuity is found, check Sender Input Wiring

• If continuity is not found, there is an open in the circuit wiring OR a faulty ECU connector

e. Backprobe wire E2 on the ECU connector and check for continuity between Terminal B on the Oil Pressure Sender

• If continuity is found, repair or replace the Oil Pressure Sender

• If continuity is not found, there is an open in the Supply Wiring

4. Check the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire D3 on the ECU connector and check

for continuity with pin D3 on the harness end of the connector

• If continuity is found, repeat this step for the F3 and E2 circuits of the ECU connector.

• If continuity is not found, there is a faulty ECU connector

• If continuity is found on all circuits, proceed to next step

5. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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Page 40: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.7 Oil Pressure Switch

The oil pressure switch is used to detect a loss of oil pressure. A lack of oil pressure causes the contacts in the switch to 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.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.”

3. Check the Oil Pressure Switch Input and Ground Wiring

a. Ignition OFFb. Disconnect ECU connectorc. Backprobe wire C1 on the ECU connector and test for

continuity between the input wire at the Oil Pressure Switch.

• If continuity is found, check the Oil Pressure Switch Ground Wiring

• If continuity is not found, there is an open in the Input Wiring OR a faulty ECU connector.

d. Probe the Oil Pressure Switch Ground wire and test for continuity between the switch ground chassis connection.

• If continuity is found, repair or replace the Oil Pressure Switch.

• If continuity is not found, there is an open in the Ground Wiring circuit.

4. Check the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire C1 on the ECU connector and check

for continuity with pin C1 on the harness end of the connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is a faulty ECU connector.

5. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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3.24 John Deere Engine

Page 41: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.8 Coolant Temperature Sensor

The engine coolant temperature (ECT) 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 ECT’s 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.

The ECU senses ECT on OEM applications about 118° C (244° F).

Note: This engine is equipped with Engine protection with different features:

• 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% full power.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.”

3. Check the ECT Sensor

a. Ignition OFFb. Disconnect ECT sensor connectorc. Measure resistance between both terminals of the

ECT sensor

• If measurement is between 2500 and 3500 ohms, proceed to next step.

• If measurement is below 2500 ohms or above 3500 ohms, repair or replace the sensor.

4. Test ECT sensor connector

a. Ignition OFFb. ECT connector still disconnectedc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• 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

5. Check ECT Sensor Input and Return Wiring

a. Ignition OFFb. ECT connector still disconnectedc. Disconnect ECU connectord. Backprobe wire B1 on the ECU connector and test for

continuity between Terminal A of the ECT sensor connector.

• If continuity is found, check the sensor return wire

• If continuity is not found, there is an open in the sensor input wiring OR a faulty ECU connector.

e. Backprobe wire D3 on the ECU connector and test for continuity between Terminal B of the ECT sensor connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the sensor return wiring OR a faulty ECU connector.

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3.25John Deere Engine

Page 42: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

6. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire B1 on the ECU connector and check

for continuity with pin B1 on the harness end of the connector.

• If continuity is found, repeat this step for the D3 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

3.26 John Deere Engine

Page 43: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

3.7.9 Loss of Engine Coolant 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 and to detect whether there is a loss of coolant. The sensor’s 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.

1. Refer to Section 2, “General Troubleshooting” for initial checks before moving on to the following steps.

2. Recover any fault codes. Refer to Section 3.2, “Retrieving Fault Codes.” A fault code will result if 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.

3. Check the Loss of Coolant Sensor

a. Ignition OFFb. Disconnect Loss of Coolant sensor connectorc. Measure resistance between both terminals of the

Loss of Coolant sensor

• If measurement is between 2500 and 3500 ohms, proceed to next step.

• If measurement is below 2500 ohms or above 3500 ohms, repair or replace the sensor.

4. Test Loss of Coolant Temperature sensor connector

a. Ignition OFFb. Loss of Coolant sensor connector still disconnectedc. Backprobe Terminal A and test for continuity between

Pin A on the same side of the connector.

• If continuity is found, repeat step for the other terminals of the connector

• If continuity is not found, repair or replace the connector

5. If continuity is found on all terminals and both sides of the connector, proceed to next stepCheck Loss of Coolant Temperature Sensor Input and Return Wiring

a. Ignition OFFb. Loss of Coolant sensor connector still disconnectedc. Disconnect ECU connectord. Backprobe wire C1 on the ECU connector and test for

continuity between Terminal A of the Loss of Coolant Temperature sensor connector.

• If continuity is found, check the sensor return wire

• If continuity is not found, there is an open in the sensor input wiring OR a faulty ECU connector.

e. Backprobe wire D3 on the ECU connector and test for continuity between Terminal B of the Loss of Coolant Temperature sensor connector.

• If continuity is found, proceed to next step.

• If continuity is not found, there is an open in the sensor return wiring OR a faulty ECU connector.

6. Test the ECU connector

a. Ignition OFFb. ECU connector still disconnectedc. Backprobe wire C1 on the ECU connector and check

for continuity with pin C1 on the harness end of the connector.

• If continuity is found, repeat this step for the D3 circuit of the ECU connector.

• If continuty is not found, there is a faulty ECU connector.

• If continuity is found on all circuits, proceed to next step.

7. If all checks are completed and the engine still does not operate properly, contact your local John Deere service distributor.

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3.27John Deere Engine

Page 44: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Function Troubleshooting

This Page Intentionally Left Blank

3.28 John Deere Engine

Page 45: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Section 4Electrical Wiring

Contents

PARAGRAPH TITLE PAGE

4.1 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24.1.1 Models 534D-9 Tier II & 534D-10 Tier II . . . . . . . . . . . . . . . . . . . . . . . . 4.24.1.2 Model 544D Tier II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44.1.3 Models G10-55A & G12-55A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.64.1.4 Model 1044C-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

4.1John Deere Engine

Page 46: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Electrical Wiring

4.1 WIRING SCHEMATICS 4.1.1 Models 534D-9 Tier II & 534D-10 Tier II

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534D-10 Tier II:Before S/N 0160013979

4.2 John Deere Engine

Page 47: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Electrical Wiring

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534D-10 Tier II:S/N 0160013979 & After

4.3John Deere Engine

Page 48: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Electrical Wiring

4.1.2 Model 544D Tier II

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Page 52: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

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Page 53: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

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4.9John Deere Engine

Page 54: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

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Page 62: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

Electrical Wiring

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4.18 John Deere Engine

Page 63: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007
Page 64: John Deere Tier II Engine Troubleshooting - JLG Industries Manuals... · Service Manual John Deere Tier II Engine Troubleshooting 31200371 Original February 2, 2007

JLG Worldwide Locations

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Customer Support Toll Free: (877) 554-5438

Fax: (717) 485-6417

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 265 811 111Fax: (61) 265 810 122

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPhone: (55) 193 295 0407Fax: (55) 193 295 1025

JLG Industries (UK)Unit 4 & 5Bentley AvenueM24 2GP MiddletonStockportEnglandPhone: (44) 161 654 1000Fax: (44) 161 654 1003

JLG EQSZ.I. De Beaulieu47400 FuilletFrancePhone: (33) 553 848 584Fax: (33) 553 848 588

JLG Deutschland GmbHMax Planckstrasse 21D-27721 Ritterhude/lhlpohlBei BremenGermanyPhone: (49) 421 693 500Fax: (49) 421 693 5035

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N.T.Hong KongPhone: (852) 2639 5783Fax: (852) 2639 5797

JLG Industries (Italia)Via Po. 2220010 Pregnana Milanese - MIItalyPhone: (39) 029 359 5210Fax: (39) 029 359 5845

JLG Europe B.V.Polaris Avenue 632132 JH HoofddorpThe NetherlandsPhone: (31) 235 655 665Fax: (31) 235 572 493

JLG PolskaUI. Krolewska00-060 WarsawaPolandPhone: (48) 914 320 245Fax: (48) 914 358 200

JLG Industries (Scotland)Wright Business Centre1 Lonmay RoadQueenslie, Glasgow G33 4ELScotlandPhone: (44) 141 781 6700Fax: (44) 141 773 1907

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755Castellbisbal, BarcelonaSpainPhone: (34) 937 724 700Fax: (34) 937 711 762

JLG Industries (Sweden)Enkopingsvagen 150Box 704SE - 17527 JarfallaSwedenPhone: (46) 850 659 500Fax: (46) 850 659 534