John Deere POWERTECH® 4.5L & 6.8L Diesel Engines Level 1 Electronic Fuel Systems with Delphi (Lucas) DP201 Pump Component Technical Manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices. This manual contains high quality images, circuit diagrams, instructions to help you to maintenance, troubleshoot, diagnose, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

CTM284 English - John Deere POWERTECH® 4.5L & 6.8L Diesel Engines Level 1 Electronic Fuel Systems with Delphi (Lucas) DP201 Pump Component Technical Manual.pdf
ctm285 Spanish - Motores diésel POWERTECH® de 4,5 l y 6,8 l Sistemas de combustible electrónicos nivel 1 con bomba Delphi (Lucas) DP201
ctm286 French - Moteurs diesel POWERTECH® 4,5 l et 6,8 l Circuits d'alimentation électroniques niveau 1 avec pompe Delphi (Lucas) DP201
ctm287 German - POWERTECH® 4,5-l- u. 6,8-l- Dieselmotoren mit elektronischen Kraftstoffsystemen der Stufe 1 mit Delphi- (Lucas-) Pumpe DP201
ctm288 Italian - Motori diesel POWERTECH® da 4,5 l e 6,8 l Sistemi di iniezione elettronica livello 1 con pompa Delphi (Lucas) DP201

TABLE OF CONTENTS
Section 01: General................10
  Group 000: Safety................10
    Handle Fluids Safely — Avoid Fires................12
    Handle Starting Fluid Safely................13
    Service Cooling System Safely................14
    Prevent Battery Explosions................15
    Prepare for Emergencies................16
    Handling Batteries Safely................17
    Avoid High-Pressure Fluids................20
    Wear Protective Clothing................21
    Service Machines Safely................22
    Work In Ventilated Area................23
    Work in Clean Area................24
    Remove Paint Before Welding or Heating................25
    Avoid Heating Near Pressurized Fluid Lines................26
    Illuminate Work Area Safely................27
    Use Proper Lifting Equipment................28
    Construct Dealer-Made Tools Safely................29
    Practice Safe Maintenance................30
    Use Proper Tools................31
    Dispose of Waste Properly................32
    Live With Safety................33
  Group 001: Engine Identification................10
    Engine Model Designation................36
    Engine Serial Number Plate Information................38
    Engine Application Chart................41
  Group 002: Fuels................10
    Lubricants and Coolant................43
    Diesel Fuel................44
    Diesel Fuel Additive Products................45
    Bio-Diesel Fuel................46
    Lubricity of Diesel Fuel................47
Section 02: Repair and Adjustments................48
  Group 090: Electronic Fuel System Repair and Adjustments................48
    Fuel System — General Information................51
    Relieve Fuel System Pressure................52
    Remove and Install Final Fuel Filter/Water Separator Base................53
    Final Fuel Filter Assembly................55
    Replace Final Fuel Filter/Water Separator................57
    Remove Fuel Injection Pump................59
    Repair Fuel Injection Pump................63
    Install Fuel Injection Pump................64
    Fuel Injection Pump Timing................68
    Remove Fuel Injection Nozzles................69
    Clean Fuel Injection Nozzle Bore................71
    Clean Fuel Injection Nozzles................72
    Diagnose Fuel Injection Nozzle Malfunction................73
    Test Fuel Injection Nozzles................75
    Disassemble Fuel Injection Nozzles................80
    Inspect and Clean Fuel Injection Nozzle Body................84
    Inspect and Clean Valve and Valve Seat................86
    Inspect Valve Adjusting Mechanism................88
    Assemble Fuel Injection Nozzles................89
    Adjust Fuel Injection Nozzles................90
    Install Seals on Fuel Injection Nozzle................95
    Install Fuel Injection Nozzles................96
  Group 110: Electrical Engine Control Repair and Adjustment................48
    Engine Control Unit (ECU)................140
    Remove and Install Engine Coolant Temperature Sensor................100
    Replace Engine Speed Sensor................101
    Connectors................102
    Use Electrical Insulating Compound................103
    Using High-Pressure Washer................104
    Repair Weather Pack ™ Connector................105
    Remove Connector Body from Blade Terminals................108
    Repair (Pull Type) Metri-Pack ® Connectors................109
    Repair (Push Type) Metri-Pack ® Connectors................111
    Repair Deutsch ® Connectors................114
    Repair ECU Connector................117
    Repair Fuel Injection Pump Connector................118
Section 03: Theory of Operation................120
  Group 130: Electronic Fuel System Operation................123
    About this Group................122
    Fuel System Operation................123
    Fuel Transfer Pump Operation................124
    Final Fuel Filter/Water Separator Operation................125
    Fuel Injection Pump Operation................127
    Fuel Injection Nozzle Operation................129
  Group 140: Electrical Control System Operation................120
    Electronic Control System Overview................132
    Electronic Control System Terminology................133
    Electronic Control System Operation................135
    Monitoring Engine Parameters................136
    Measuring Temperature................137
    Measuring Throttle Position................138
    Measuring Engine Speed................139
    Engine Control Unit (ECU)................140
    Controller Area Network (CAN)................142
    Cruise Control Operation................143
    Governor Droop Mode Selection................441
    Engine Control Unit (ECU) Self-Diagnosis................145
Section 04: Diagnostics................146
  Group 150: Observable Diagnostics and Tests................146
    About this Group of the Manual................224
    E1 - Engine Cranks/Won't Start................146
    E2 - Engine Misfires/Runs Irregularly................146
    E3 - Engine Does Not Develop Full Power................146
    E4 - Engine Emits Excessive White Exhaust Smoke................146
    E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke................146
    E6 - Engine Will Not Crank................146
    E7 - Engine Idles Poorly................146
    E8 - Abnormal Engine Noise................146
    F1 - Fuel Supply System Check................184
    F1 - Fuel Supply System Check................184
    F2 - Excessive Fuel Consumption................146
    F3 - Fuel in Oil................146
    F4 - Excessive Fuel Filter Replacement................190
    D1 - ECU Does Not Communicate With DST or Service ADVISOR ™................193
    D1 - ECU Does Not Communicate With DST or Service ADVISOR ™................193
    Using TIME TRAC ® as a Tachometer................198
    Check and Adjust Injection Pump Dynamic Timing................199
    Check Cold Start Switch Operation................206
    Check Cold Start Advance System Operation................207
    Check Light Load Advance Operation................209
    Test Fuel Shut-Off Solenoid................210
    Check Fuel Transfer Pump................211
    Check Fuel Supply Quality................212
    Test for Fuel Drain Back................214
    Test for Air in Fuel................215
    Check Fuel Supply Pressure................217
    Bleed the Fuel System................218
    Test for Cylinder Misfire (Engine Running)................221
    Test Fuel Injection Nozzles (Engine Running)................222
  Group 160: Trouble Code Diagnostics and Tests................146
    About this Group of the Manual................224
    Electrical Concepts................225
    Using a Digital Multimeter................226
    Electrical Circuit Malfunctions................227
    Troubleshooting Circuit Malfunctions................230
    Connecting to Diagnostic Scan Tool (DST) or Service ADVISOR ™................234
    Data Parameter Description................236
    Engine Control Unit (ECU) — Level Identification................239
    Engine Control Unit (ECU) — Donating this Engines’ ECU to be Used Elsewhere................240
    Engine Control Unit (ECU) — Replacing Current ECU with Another ECU................242
    Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU................244
    Engine Control Unit (ECU) — Reprogramming Current ECU................246
    Engine Control Unit (ECU) — Reprogramming Instructions................248
    Software and Hardware Verification................250
    Diagnostic Trouble Codes (DTCs)................253
    Listing of Diagnostic Trouble Codes (DTCs) on ECU................254
    Diagnostic Procedure................256
    Intermittent Fault Diagnostics................257
    000028.03 — Analog Throttle (C) Input High................258
    000028.03 - Analog Throttle (C) Input High................147
    000028.04 — Analog Throttle (C) Input Low................263
    000028.04 - Analog Throttle (C) Input Low................147
    000029.03 — Analog Throttle (B) Input High................268
    000029.03 - Analog Throttle (B) Input High................147
    000029.04 — Analog Throttle (B) Input Low................274
    000029.04 - Analog Throttle (B) Input Low................147
    000091.03 — Analog Throttle (A) Input High................280
    000091.03 - Analog Throttle (A) Input High................147
    000091.04 — Analog Throttle (A) Input Low................286
    000091.04 - Analog Throttle (A) Input Low................147
    000091.07 - Throttle Not Calibrated Properly................147
    000091.13 - Throttle Calibration Aborted................147
    000110.03 — Engine Coolant Temperature Input Voltage High................294
    000110.03 - Engine Coolant Temperature Input Voltage High................148
    000110.04 — Engine Coolant Temperature Input Voltage Low................298
    000110.04 - Engine Coolant Temperature Input Voltage Low................148
    000190.00 - Engine Overspeed................148
    000190.02 — Engine Speed Input Noise................303
    000190.02 - Engine Speed Input Noise................148
    000629.04 — ECU Unswitched Power Missing................308
    000629.04 - ECU Unswitched Power Missing................148
    000639.13 — CAN Error................311
    000639.13 - CAN Error - Continued................148
    000810.02 — Calculated Vehicle Speed Input Signal Noise................315
    000810.02 - Calculated Vehicle Speed Input Signal Noise................148
    000931.02 — Pump Current Instability................318
    000931.02 - Pump Current Instability................148
    000931.03 — Pump Current Feedback Input Voltage High................324
    000931.03 - Pump Current Feedback Input Voltage High................148
    000931.04 — Pump Current Feedback Input Voltage Low................327
    000931.04 - Pump Current Feedback Input Voltage Low................148
    000931.15 — Pump Current Measurement Error (Engine OFF)................330
    000931.15 - Pump Current Measurement Error (Engine OFF)................148
    000931.31 — Pump Current Not Controllable................334
    000931.31 - Pump Current Not Controllable................148
    001041.02 — Start Signal Missing................340
    001041.02 - Start Signal Missing................148
    001041.03 — Start Signal Always Active................344
    001041.03 - Start Signal Always Active................148
    001069.02 — Tire Size Error................348
    001069.02 - Tire Size Error................148
    001079.03 — Sensor Supply Voltage High................351
    001079.03 - Sensor Supply Voltage High................148
    001079.04 — Sensor Supply Voltage Low................355
    001079.04 - Sensor Supply Voltage Low................148
    002000.13 - Security Violation................149
Section 05: Tools and Other Materials................360
  Group 170: Electronic Fuel/Control System Repair Tools and Other Materials................360
    Fuel System Repair and Adjustment Essential Tools................363
    Fuel System Repair and Adjustment Service Equipment and Tools................365
    Fuel System Repair and Adjustment Other Materials................366
    Control System Repair and Adjustment Essential Tools................367
    Control Repair and Adjustment Other Materials................370
  Group 180: Diagnostic Service Tools................360
    Engine Diagnostics and Testing Procedure Tools................374
Section 06: Specifications................377
  Group 200: Repair Specifications................377
    Electronic Fuel System Repair and Adjustment Specifications................380
    Electrical Engine Control Repair and Adjustment Specifications................382
  Group 210: Diagnostic Specifications................377
    Fuel Injection Pump Specifications (Agricultural Applications)................401
    Fuel Injection Pump Specifications (OEM)................419
    Fuel System Diagnostic Specifications................439
    Torque Curve Selection................440
    Governor Droop Mode Selection................441
    Electronic Control System Wiring Diagram for 6010 Series Tractors................442
    Electronic Control System Wiring Diagram for 6020 and 7020 Series Tractors................443

John Deere POWERTECH® 4.5L & 6.8L Diesel Engines Level 1 Electronic Fuel Systems with Delphi (Lucas) DP201 Pump Component Technical Manual (CTM284)