John Deere 4TNV94FHT Diesel Engines (Final Tier 4 Platform) Component Technical Manual CTM136419 PDF

Introduction
Foreword
Identification Views
4TNV94FHT Engine—Final Tier 4
Related Manuals
Tool Manual
Application List Manual
Training Information
Definition of Terms
Trademarks
Contents
General Information
Safety
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Avoid Hot Exhaust
Avoid Static Electricity Risk When Refueling
Construct Dealer-Made Tools Safely
Decommissioning—Proper Recycling and Disposal of Fluids and Components
Exhaust Filter Cleaning
Follow Safety Instructions
Handle Fluids Safely—Avoid Fires
Handling Batteries Safely
Illuminate Work Area Safely
Install All Guards
Live With Safety
Practice Safe Maintenance
Precautions for Welding
Prepare for Emergencies
Prevent Acid Burns
Prevent Battery Explosions
Prevent Machine Runaway
Protect Against High Pressure Spray
Protect Against Noise
Recognize Safety Information
Remove Paint Before Welding or Heating
Replace Safety Signs
Service Cooling System Safely
Service Machines Safely
Stay Clear of Rotating Drivelines
Support Machine Properly
Understand Signal Words
Use Proper Lifting Equipment
Use Proper Tools
Wait Before Opening High-Pressure Fuel System
Wear Protective Clothing
Work in Clean Area
Work In Ventilated Area
Engine Identification Information
Engine Serial Number Plate Information
Engine Serial Number (D)
Engine Model Number (E)
Information Relative to Emissions Regulations
Emissions Control System Certification Label
Fuels, Lubricants, and Coolants
Diesel Exhaust Fluid (DEF)—Use in Selective Catalytic Reduction (SCR) Equipped Engines
Storing Diesel Exhaust Fluid (DEF)
Refilling Diesel Exhaust Fluid (DEF) Tank
Testing Diesel Exhaust Fluid (DEF)
Disposal of Diesel Exhaust Fluid (DEF)
Diesel Fuel
Required Fuel Properties
E-Diesel fuel
Sulfur content for Interim Tier 4, Final Tier 4, Stage III B, and Stage IV Engines
Sulfur Content for Tier 3 and Stage III A Engines
Sulfur Content for Tier 2 and Stage II Engines
Sulfur Content for Other Engines
Diesel Fuel Additive Products
Handling and Storing Diesel Fuel
Lubricity of Diesel Fuel
Testing Diesel Fuel
Biodiesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Oil
John Deere Break-In™ Plus Engine Oil
Engine Oil and Filter Service Intervals
Oil Filters
Grease
Lubricant Storage
Mixing of Lubricants
Alternative and Synthetic Lubricants
Oilscan™ and CoolScan™
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
Additional Recommended Coolants
Other Coolants
Water Quality
Coolant Drain Intervals
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Testing Diesel Engine Coolant
Coolant Test Strips
When Using John Deere COOL-GARD II
When Using Nitrite-Containing Coolants
Coolant Analysis
Drain Intervals for Diesel Engine Coolant
John Deere COOL-GARD™ II Coolant Extender
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender
Repair and Adjustments
Engine Rebuild
Check and Service Cooling System
Check Air Intake System
Check Electrical System
Check Exhaust System
Clean Engine
Disconnect Turbocharger Oil Inlet Line
Engine Assembly Sequence
Engine Break-In
Engine Break-In Guidelines
Engine Break-In Procedure
Engine Disassembly Sequence
Engine Repair Stand
General Tune-Up Recommendations
Install Engine Adapter on Repair Stand
Install Lift Straps
Install Front Lift Strap
Install Rear Lift Strap
Lifting Procedure
Overhaul Guidelines
Safety Precautions
Cylinder Head and Valves Repair and Adjustment
Closed Crankcase Ventilation System—Installation
Closed Crankcase Ventilation System—Removal
Cylinder Block Top Deck—Cleaning and Inspection
Cylinder Head—Cleaning and Inspection
Cylinder Head—Flatness Check
Cylinder Head—Installation
Cylinder Head—Removal
Cylinder Head Gasket—Inspection
Glow Plug—Installation
Glow Plug—Removal
Glow Plug Bore—Cleaning and Inspection
Push Rod—Cleaning and Inspection
Push Rod—Installation
Push Rod—Removal
Rocker Arm Cover—Inspection
Rocker Arm Cover—Installation
Rocker Arm Cover—Removal
Rocker Arm Cover Spacer—Installation
Rocker Arm Cover Spacer—Removal
Rocker Arm Shaft Assembly—Assemble
Rocker Arm Shaft Assembly—Inspection
Rocker Arm Shaft Assembly—Installation
Rocker Arm Shaft Assembly—Removal
Rocker Arm Shaft Assembly—Tear Down
Valve—Cleaning and Inspection
Valve—Clearance Adjustment
Valve—Grinding
Valve—Measurement
Valve—Recess Measurement
Valve Assembly—Installation
Valve Assembly—Removal
Valve Bridge, Valve Keepers, and Valve Spring Retainer—Inspection and Measurement
Valve Guide—Cleaning and Measurement
Valve Guide—Installation
Valve Guide—Removal
Valve Seat—Cleaning and Inspection
Valve Seat—Grinding
Valve Spring—Inspection and Measurement
Cylinder Block, Pistons, and Connecting Rods Repair and Adjustment
Connecting Rod—Center-to-Center Bore Measurement
Connecting Rod and Cap—Inspection
Connecting Rod Bearing—Inspection and Measurement
Connecting Rod Bearing—Inspection and Measurement (Rod and Crankshaft in Engine)
Connecting Rod Cap Screw—Torque Procedure
Cylinder Block—Cleaning and Inspection
Cylinder Block—Honing and Boring
Piston—Cleaning
Piston—Inspection
Piston and Connecting Rod Assembly—Assemble
Piston and Connecting Rod Assembly—Installation
Piston and Connecting Rod Assembly—Removal
Piston and Connecting Rod Assembly—Tear Down
Piston Cooling Orifice—Cleaning and Inspection
Piston Cooling Orifice—Installation
Piston Cooling Orifice—Removal
Piston Pin and Bore—Inspection
Piston Pin and Bushing—Inspection
Piston Pin Bushing—Installation
Piston Pin Bushing—Removal
Piston Protrusion—Measurement
Piston Rings—Inspection
Piston Rings—Installation
Piston Rings—Removal
Piston Skirt—Measurement
Crankshaft, Main Bearings, and Flywheel Repair and Adjustment
Crankshaft—End Play Check
Crankshaft—Inspection
Crankshaft—Installation
Crankshaft—Removal
Crankshaft Front Oil Seal—Installation
Crankshaft Front Oil Seal—Removal
Crankshaft Gear—Installation
Crankshaft Gear—Removal
Crankshaft Main Bearing—Measurement
Crankshaft Main Bearing—Oil Clearance Check
Crankshaft Main Bearing Cap—Installation
Crankshaft Main Bearing Cap—Removal
Crankshaft Pulley—Installation
Crankshaft Pulley—Removal
Crankshaft Pulley Adapter—Installation
Crankshaft Pulley Adapter—Removal
Crankshaft Rear Oil Seal—Installation
Crankshaft Rear Oil Seal—Removal
Flywheel—Inspection
Flywheel—Installation
Flywheel—Removal
Flywheel Housing—Installation
Flywheel Housing—Removal
Camshaft and Timing Gear Train Repair and Adjustment
Camshaft—Check End Play
Camshaft—Inspection
Camshaft—Installation
Camshaft—Removal
Camshaft—Visual Inspection
Camshaft Bushing—Installation
Camshaft Bushing—Removal
Camshaft Bushing and Bore—Measurement
Camshaft Follower—Inspection and Measurement
Camshaft Follower—Installation
Camshaft Follower—Removal
Camshaft Gear—Inspection
Camshaft Gear—Installation
Camshaft Gear—Removal
Camshaft Journal—Measurement
Camshaft Lobe—Height Measurement
High-Pressure Fuel Pump Gear Cover—Installation
High-Pressure Fuel Pump Gear Cover—Removal
Idler Gear—Inspection
Idler Gear—Installation
Idler Gear—Removal
Timing Gear Cover—Installation
Timing Gear Cover—Removal
Timing Gear Housing—Installation
Timing Gear Housing—Removal
Timing Gears—Check Backlash
Lubrication System Repair and Adjustment
Dipstick Tube and Dipstick—Installation
Dipstick Tube and Dipstick—Removal
Oil Cooler Assembly—Assemble and Installation
Oil Cooler Assembly—Removal and Inspection
Remove Oil Cooler Assembly
Inspect Oil Cooler Assembly
Oil Filter—Installation
Oil Filter—Removal
Oil Pan—Installation
Oil Pan—Removal
Oil Pick-Up Tube—Installation
Oil Pick-Up Tube—Removal
Oil Pump—Assemble and Installation
Oil Pump—Assemble
Oil Pump—Installation
Oil Pump—Cleaning and Inspection
Oil Pump—Removal and Tear Down
Cooling System Repair and Adjustment
Coolant Pump Assembly—Inspection
Coolant Pump Assembly—Installation
Coolant Pump Assembly—Removal
Cooling System—Testing
Cooling System Testing Procedure
Temperature Sensor Testing Procedure
Thermostat Testing Procedure
Radiator Cap Testing Procedure
Thermostat—Installation
Thermostat—Removal
Air Intake and Exhaust System Repair and Adjustment
Air Inlet Elbow—Installation
Air Inlet Elbow—Removal
Air Throttle Actuator—Installation
Air Throttle Actuator—Removal
EGR Cooler—Cleaning
EGR Cooler—Installation
EGR Cooler—Removal
EGR Cooler Coolant Return Tube—Installation
EGR Cooler Coolant Return Tube—Removal
EGR Cooler Coolant Supply Hose—Installation
EGR Cooler Coolant Supply Hose—Removal
EGR Cooler Gas Outlet Elbow—Cleaning
EGR Cooler Gas Outlet Elbow—Installation
EGR Cooler Gas Outlet Elbow—Removal
EGR Cooler Gas Outlet Pipe—Cleaning
EGR Cooler Gas Outlet Pipe—Installation
EGR Cooler Gas Outlet Pipe—Removal
EGR Valve—Cleaning
EGR Valve—Inspection
EGR Valve—Installation
EGR Valve—Removal
Exhaust Manifold—Installation
Exhaust Manifold—Removal
Intake Manifold—Installation
Intake Manifold—Removal
Reed Valve—Cleaning
Reed Valve—Inspection
Reed Valve—Installation
Reed Valve—Removal
Reed Valve Cover—Installation
Reed Valve Cover—Removal
Turbocharger—Break-In
Turbocharger—Failure Analysis
Turbocharger—Inspection
Compressor Housing Inlet and Compressor Wheel
Compressor Housing Outlet
Turbine Housing Inlet
Turbine Housing Outlet and Turbine Wheel
External Center Housing and Joints
Perform Axial Bearing End Play Test
Check Axial Bearing Run Out
Turbocharger—Recommendations for Use
Wastegate Turbocharger Assembly—Installation
Wastegate Turbocharger Assembly—Removal
Wastegate Turbocharger Exhaust Elbow—Installation
Wastegate Turbocharger Exhaust Elbow—Removal
Wastegate Turbocharger Oil Drain Line—Installation
Wastegate Turbocharger Oil Drain Line—Removal
Wastegate Turbocharger Oil Supply Line—Installation
Wastegate Turbocharger Oil Supply Line—Removal
Electronic Fuel System Repair and Adjustment
Electronic Injectors—Installation
Electronic Injectors—Removal
Electronic Injector Fuel Return Line—Installation
Electronic Injector Fuel Return Line—Removal
High-Pressure Common-Rail (HPCR)—Installation
High-Pressure Common-Rail (HPCR)—Removal
High-Pressure Fuel Pump—Disassembly and Reassembly
High-Pressure Fuel Pump—Installation
High-Pressure Fuel Pump—Removal
High-Pressure Injection Lines and Injection Line Seals—Installation
High-Pressure Injection Lines and Injection Line Seals—Removal
Injector Wiring Harness—Installation
Injector Wiring Harness—Removal
Low-Pressure Fuel Pump—Installation
Low-Pressure Fuel Pump—Removal
Pressure Limiter—Installation
Pressure Limiter—Removal
Primary Fuel Filter Assembly—Installation
Primary Fuel Filter Assembly—Removal
Primary Fuel Filter Element—Installation
Primary Fuel Filter Element—Removal
Secondary Fuel Filter—Installation
Secondary Fuel Filter—Removal
Secondary Fuel Filter Assembly—Installation
Secondary Fuel Filter Assembly—Removal
Suction Control Valve—Installation
Suction Control Valve—Removal
Starting System Repair and Adjustment
Starter Motor—Assemble
Starter Motor—Installation
Starter Motor—No-Load Test
Starter Motor—Removal
Starter Motor—Tear Down
Starter Motor Armature—Cleaning and Inspection
Commutator Surface Inspection
Measure Commutator Outside Diameter
Measure Commutator Insulation Depth
Armature Coil Continuity Test
Armature Coil Insulation Test
Measure Armature and Commutator Runout
Starter Motor Field Coil—Cleaning and Inspection
Field Coil Continuity Test
Field Coil Insulation Test
Measure Brush Length
Starter Motor Magnetic Switch—Cleaning and Inspection
Hold Coil Continuity Test
Pull Coil Continuity Test
Coil Resistance Test
Contact Continuity Test
Starter Motor Pinion Clutch Assembly—Cleaning and Inspection
Pinion Clutch Assembly Inspection
Ball Bearing Inspection
Electrical Engine Control Repair and Adjustment
Aftertreatment Inlet NOx Sensor—Installation
Aftertreatment Inlet NOx Sensor—Removal
Aftertreatment Outlet NOx Sensor—Installation
Aftertreatment Outlet NOx Sensor—Removal
Aftertreatment Pressure Sensor—Installation
Aftertreatment Pressure Sensor—Removal
Camshaft Position Sensor—Installation
Camshaft Position Sensor—Removal
Crankshaft Position Sensor—Installation
Crankshaft Position Sensor—Removal
DOC Inlet Temperature Sensor—Installation
DOC Inlet Temperature Sensor—Removal
DOC Outlet Temperature Sensor—Installation
DOC Outlet Temperature Sensor—Removal
EGR Temperature Sensor—Installation
EGR Temperature Sensor—Removal
Engine Control Unit (ECU)—Installation
Engine Control Unit (ECU)—Removal
Engine Coolant Temperature Sensor—Installation
Engine Coolant Temperature Sensor—Removal
Engine Oil Pressure Switch—Installation
Engine Oil Pressure Switch—Removal
Exhaust Manifold Temperature Sensor—Installation
Exhaust Manifold Temperature Sensor—Removal
Fuel Rail Pressure Sensor—Installation
Fuel Rail Pressure Sensor—Removal
Fuel Temperature Sensor—Installation
Fuel Temperature Sensor—Removal
Manifold Air and Exhaust Pressure Sensor—Installation
Manifold Air and Exhaust Pressure Sensor—Removal
Manifold Air Temperature (MAT) Sensor—Installation
Manifold Air Temperature (MAT) Sensor—Removal
Turbocharger Compressor Inlet Temperature Sensor—Installation
Turbocharger Compressor Inlet Temperature Sensor—Removal
Water-In-Fuel (WIF) Sensor—Installation
Water-In-Fuel (WIF) Sensor—Removal
Wiring Harness—Installation
Fuel System Wiring Harness Installation
Lower Wiring Harness Installation
Upper Rear Wiring Harness Installation
Upper Front Wiring Harness Installation
Wiring Harness—Removal
Fuel System Wiring Harness Removal
Front Wiring Harness Removal
Rear Wiring Harness Removal
Aftertreatment Devices Repair and Adjustment
Diesel Particulate Filter—Maintenance and Service
Exhaust Filter—Ash Handling and Disposal
Exhaust Filter—Assemble
Exhaust Filter—Cleaning
Exhaust Filter—Inspection
Exhaust Filter—Tear Down
Exhaust Filter, Brackets, and Piping—Installation
Exhaust Filter, Brackets, and Piping—Removal
DEF Dosing Aftertreatment Devices Repair and Adjustment
DEF Decomposition Tube—Cleaning
DEF Decomposition Tube—Installation
DEF Decomposition Tube—Removal
DEF Dosing Injector—Cleaning
DEF Dosing Injector—Installation
DEF Dosing Injector—Removal
DEF Dosing System Coolant Filter—Installation
DEF Dosing System Coolant Filter—Removal
DEF Dosing System Coolant Lines—Installation
DEF Dosing System Coolant Lines—Removal
DEF Dosing System Lines—Installation
Connecting DEF Pressure Line to DEF Dosing Unit and Dosing Injector
Connecting Suction/Return Lines to DEF Dosing Unit and DEF Dosing Injector
DEF Dosing System Lines—Removal
Disconnecting DEF Pressure Line
Disconnecting Suction and Return line
DEF Dosing Unit—Installation
DEF Dosing Unit—Removal
DEF Dosing Unit Filter—Installation
DEF Dosing Unit Filter—Removal
DEF Dosing Unit Fittings—Installation
DEF Dosing Unit Fittings—Removal
DEF Tank Header Assembly—Installation
DEF Tank Header Assembly—Removal
DEF Tank Header Suction Screen—Installation
DEF Tank Header Suction Screen—Removal
DEF Tank Heater Coolant Control Valve Solenoid—Installation
DEF Tank Heater Coolant Control Valve Solenoid—Removal
Selective Catalyst Reduction (SCR)—Cleaning and Inspection
Selective Catalyst Reduction (SCR)—Disposal
Selective Catalyst Reduction (SCR)—Handling
Selective Catalyst Reduction (SCR)—Installation
Selective Catalyst Reduction (SCR)—Removal
Theory of Operation
Base Engine Operation
General Engine Operation
Head Gasket Joint Construction and Operation
Cooling System
Cooling System Component Location Diagram
Cooling System Operation
Lubrication System
Lubrication System Component Location Diagram
Lubrication System Operation
Electronic Fuel System
Electronic Fuel System Component Location Diagram 1
Electronic Fuel System Component Location Diagram 2
Electronic Fuel System Component Location Diagram 3
Electric Low-Pressure Fuel Pump Operation
Electric Low-Pressure Fuel System Operation
Low-Pressure Fuel System Flow
Electronic Injector (EI) Operation
EI – No Injection
EI – Begin Injection
EI – Ending Injection
High-Pressure Common-Rail (HPCR) Operation
High-Pressure Fuel Pump Operation
High-Pressure Fuel System Operation
Primary and Secondary Fuel Filter Operation
Air Intake and Exhaust System
Air Intake and Exhaust System Operation
Air Throttle Actuator Operation
Cold Start Aid Operation
Air Intake and Exhaust System Component Location Diagram 1
Air Intake and Exhaust System Component Location Diagram 2
Air Intake and Exhaust System Component Location Diagram 3
Air Intake and Exhaust System Component Location Diagram 4
EGR Cooler Operation
EGR Valve Operation
Aftertreatment System
Aftertreatment System Component Location Diagram
Aftertreatment System Operation
Exhaust Filter Operation
System Operation
Regeneration
Passive (Self) Regeneration
Enhanced Passive (Assisted) Regeneration
Active (Reset) Regeneration
Parked (Stationary) Regeneration
DPF Recovery
DEF Dosing Injector Operation
DEF Dosing Unit Operation
DEF Tank Header Operation
SCR Operation
SCR System Derates
Electronic Control System
B5100—Fuel Rail Pressure Sensor
B5109—Aftertreatment Pressure Sensor
B5114—Manifold Air and Exhaust Pressure Sensor
B5115—Engine Oil Pressure Switch
B5201—DOC Inlet Temperature Sensor
B5202—DOC Outlet Temperature Sensor
B5206—Manifold Air Temperature (MAT) Sensor
B5207—EGR Temperature Sensor
B5208—Engine Coolant Temperature Sensor
B5209—Fuel Temperature Sensor
B5212—SCR Temperature Sensor
B5215—Turbocharger Compressor Inlet Temperature Sensor
B5216—Exhaust Manifold Temperature Sensor
B5301—Crankshaft Position Sensor
B5302—Camshaft Position Sensor
B5501—DEF Dosing Unit
B5502—Aftertreatment Inlet NOx Sensor
B5503—Aftertreatment Outlet NOx Sensor
B5600—Water-In-Fuel Sensor
Controller Area Network (CAN)
Determining Engine Speed and Piston Position
Dosing Control Unit (DCU) Connector Identification
Dosing Control Unit (DCU) System Operation
Basic Functions of the Dosing Control System
Sensor Monitoring
Diagnostic Trouble Codes (DTC)
E5601—DEF Dosing Unit Pressure Line Heater
E5602—DEF Dosing Unit Supply Line Heater
E5603—DEF Dosing Unit Return Line Heater
Engine Control Unit (ECU) Connector Identification
Engine Control Unit (ECU) System Operation
Main Components of the Engine Control Unit (ECU)
Analog-to-Digital and Digital-to-Analog Converters (A/D and D/A)
Microprocessor (CPU)
Memory
Internal Power Supplies for External Components
Basic Functions of the Engine Control System
Sensor Monitoring
Diagnostic Trouble Codes (DTC)
Engine Starting Mode
Engine Running Mode
Engine Derate and Shutdown Protection
Measuring Pressure
Measuring Speed
Measuring Temperature
Pilot Injection Operation
R5600—Resistor (120 Ohm)
R5601—CAN Termination Resistor
R5606—Resistor
R5607—Glow Plug
Sensor Supply #1
Sensor Supply #2
Y5020—DEF Dosing Injector
X5000—Fuel Injector Harness Connector
Y5002—Suction Control Valve
Y5400—EGR Valve Actuator
Y5401—Air Throttle Actuator
Y5501—Low-Pressure Fuel Pump
Diagnostics
Observable Diagnostics and Tests
Abnormal Engine Noise
Coolant in Oil or Oil in Coolant
Crankshaft and Main Bearing Failure Analysis
ECU Does Not Communicate with Service ADVISOR
ECU Does Not Program with Service ADVISOR
Engine Coolant Temperature Below Normal
Engine Cranks and will Not Start
Engine Does Not Develop Full Power
Engine Emits Excessive Black or Gray Exhaust Smoke
Engine Emits Excessive Blue Exhaust Smoke
Engine Emits Excessive White Exhaust Smoke
Engine Misfires or Runs Irregularly
Engine Will Not Crank
Excessive DEF Consumption
Excessive Fuel Consumption
Excessive Oil Carryover
Excessive Oil Consumption
Fuel in Coolant
Fuel in Oil
Throttle Not Responding
Checks, Tests, and Procedures
Aftertreatment Verification Procedure
Air in Fuel Check
Camshaft to Crankshaft Timing Check
Carbon Cleaning Procedure
Charge Air Cooler Test
Cooling System Test
Crankcase Pressure (Blow-By) Test
DEF Dosing System—Cleaning
DEF Quantity Test
EGR Cooler Test
Engine Cranking Speed Check
Engine Oil Pressure Check
Exhaust Condition Check
Fuel Return Lines (Leak off) Restriction Check
Fuel Supply Quality Check
Fuel System Bleeding
High-Pressure Fuel System Check
Low-Pressure Fuel System Check
Mechanical Compression Test
Problem Not Found Procedure
Short to Voltage Procedure
Terminal Test
Thermostat—Testing
Turbocharger Oil Seal Leak Check
Verification Procedure
Wiggle Test
Diagnostic Instructions and Information
Actuator Test—Instructions
Connecting to Service ADVISOR
Connecting to Service ADVISOR with EDL Adaptor using USB Cable
Connecting to Service ADVISOR with EDL Adaptor using Bluetooth
Control Unit Information and Overview Test
Cylinder Cutout Test Instructions
DEF Dosing System Test
DEF Header Coolant Purge Test
DEF Pump Diagnostic Test
Diagnostic Test Box—Using
Diagnostic Test Box—Functionality
Before Connecting Diagnostic Test Box
Diagnostic Test Box—User Instructions
Diagnostic Test Box—Operational Test Procedure
Diagnostic Trouble Code Designations
Digital Multimeter—Using
Measuring Voltage
Measuring Resistance
DOC Calibration—Instructions
DPF Calibration—Instructions
DPF Service Recovery—Instructions
Electrical Circuit Concepts
Circuit Malfunctions
High-resistance circuit, Open circuit, Grounded circuit, and Shorted circuit.
Locations of Circuit Malfunctions:
Electrical Circuit—Malfunction Troubleshooting
Electrical Noise—Possible Causes
Emission Control System Derate Temporary Override
Engine Control Unit (ECU)—Reprogramming Instructions
Engine Hours—Updating Instructions
Enhanced Passive Regeneration—Instructions
Fuel Pump Calibration—Instructions
Injector Calibration—Instructions
Interactive Tests and Calibration Results—Printing, Exporting, or Saving Instructions
Keep Electronic Control Unit Connectors Clean
Payload File—ECU Payload Downloading Instructions
SCR Calibration—Instructions
Service Regeneration—Instructions
SCR System Actuator Test—Instructions
Servicing Electronic Control Units
Snapshot Instructions
Viewing a Snapshot Capture
Viewing a Snapshot Capture Off-Line
Welding Near Electronic Control Units
DTC SPN – 000001 – 000199
000028.03— Primary Analog Throttle Signal Out of Range High
000028.04— Primary Analog Throttle Signal Out of Range Low
000029.03— Secondary Analog Throttle Signal Out of Range High
000029.04— Secondary Analog Throttle Signal Out of Range Low
000051.03— Air Throttle Actuator Position Signal Out of Range High
000051.04— Air Throttle Actuator Position Signal Out of Range Low
000091.03— Primary Analog Throttle Signal Out of Range High
000091.04— Primary Analog Throttle Signal Out of Range Low
000100.01— Engine Oil Pressure Signal Extremely Low
000100.04— Engine Oil Pressure Signal Out of Range Low
000102.03— Manifold Air Pressure Signal Out of Range High
000102.04— Manifold Air Pressure Signal Out of Range Low
000102.10— Manifold Air Pressure Signal Out of Range Low
000102.13— Manifold Air Pressure Signal Calibrations Fault
000105.03— Manifold Air Temperature Signal Out of Range High
000105.04— Manifold Air Temperature Signal Out of Range Low
000105.10— Manifold Air Temperature Sensor Error
000108.03— Barometric Pressure Signal Out of Range High
000108.04— Barometric Pressure Signal Out of Range Low
000108.10— Barometric Pressure Signal Abnormal
000110.00— Engine Coolant Temperature Signal Extremely High
000110.03— Engine Coolant Temperature Signal Out of Range High
000110.04— Engine Coolant Temperature Signal Out of Range Low
000110.10— Engine Coolant Temperature Sensor Error
000157.00— Fuel Rail Pressure Signal Extremely High
000157.03— Fuel Rail Pressure Signal Out of Range High
000157.04— Fuel Rail Pressure Signal Out of Range Low
000157.18— Fuel Rail Pressure Signal Moderately Low
000167.01— Charging System Voltage Extremely Low
000167.05— Charging System Circuit Has High Resistance
000172.03— Turbocharger Compressor Inlet Temperature Signal Out Of Range High
000172.04— Turbocharger Compressor Inlet Temperature Signal Out Of Range Low
000172.10— Turbocharger Compressor Inlet Temperature Sensor Error
000173.03— Exhaust Manifold Temperature Signal Out Of Range High
000173.04— Exhaust Manifold Temperature Signal Out Of Range Low
000173.10— Exhaust Manifold Temperature Sensor Error
000174.00— Fuel Temperature Signal Extremely High
000174.03— Fuel Temperature Signal Out Of Range High
000174.04— Fuel Temperature Signal Out Of Range Low
000190.00— Engine Speed Extremely High
DTC SPN – 000200 – 000699
000237.13— Vehicle Communication Error
000237.31— Vehicle Communication Time Out
000412.03— EGR Temperature Signal Out of Range High
000412.04— EGR Temperature Signal Out Of Range Low
000412.10— EGR Temperature Error
000630.02— ECU Internal Error #1
000633.03— Suction Control Valve Circuit Out of Range High
000633.05— Suction Control Valve Circuit Has High Resistance
000633.07— Suction Control Valve Sticking and Fuel Rail Pressure Moderately High
000651.05— Injector #1 Circuit Has High Resistance
000652.05— Injector #2 Circuit Has High Resistance
000653.05— Injector #3 Circuit Has High Resistance
000654.05— Injector #4 Circuit Has High Resistance
DTC SPN – 000700 – 001999
001209.03— Exhaust Manifold Pressure Signal Out of Range High
001209.04— Exhaust Manifold Pressure Signal Out of Range Low
001209.13— Exhaust Manifold Pressure Signal Calibration Fault
001347.00— High-Pressure Injection Pump Protection Fault
001347.15— High-Pressure Injection Pump Protection Limit
001485.02— ECU Main Relay Error
DCU 001761.01— DEF Tank Fluid Level Below Normal
DCU 001761.03— DEF Tank Fluid Level Signal Out of Range High
DCU 001761.04— DEF Tank Fluid Level Signal Out of Range Low
DCU 001761.13— DEF Tank Fluid Level Calibration Error
DCU 001761.15— DEF Tank Fluid Level Sensor Error
DCU 001761.18— DEF Tank Fluid Signal Moderately Low
DTC SPN – 002000 – 002999
002791.00— EGR Valve Supply Voltage Extremely High
002791.01— EGR Valve Supply Voltage Extremely Low
002791.07— EGR Valve Feedback Error
002791.09— EGR Valve Data Error
002791.12— EGR Valve Actuator Internal Error
002797.03— Injector High Voltage Supply #1 Out of Range High
002797.05— Injector High Voltage Supply #1 Circuit Has High Resistance
002797.06— Injector High Voltage Supply #1 Circuit Has Low Resistance
002798.03— Injector High Voltage Supply #2 Out of Range High
002798.05— Injector High Voltage Supply #2 Circuit Has High Resistance
002798.06— Injector High Voltage Supply #2 Circuit Has Low Resistance
002950.03— Air Throttle Actuator Drive Circuit Out of Range High
002950.05— Air Throttle Actuator Drive Circuit Has High Resistance
DTC SPN – 003000 – 003999
003031.00— DEF Tank Temperature Extremely High
003031.02— DEF Tank Temperature Signal Invalid
003031.03— DEF Tank Temperature Signal Out of Range High
003031.04— DEF Tank Temperature Signal Out of Range Low
003031.13— DEF Tank Temperature Sensor Calibration Error
003031.15— DEF Tank Temperature Slightly High
003031.17— DEF Tank Temperature Slightly Low
DCU 003216.15— Aftertreatment Inlet NOx Sensor Data Invalid
DCU 003216.17— Aftertreatment Inlet NOx Sensor Data Invalid
003242.00— DOC Inlet Temperature Signal Extremely High
003242.03— DOC Inlet Temperature Signal Out of Range High
003242.04— DOC Inlet Temperature Signal Out of Range Low
003250.00— DOC Outlet Temperature Extremely High
003250.01— DOC Outlet Temperature Extremely Low
003250.03— DOC Outlet Temperature Signal Out of Range High
003250.04— DOC Outlet Temperature Signal Out of Range Low
003251.00— DPF Differential Pressure Extremely High
003251.03— DPF Differential Pressure Signal Out of Range High
003251.04— DPF Differential Pressure Signal Out of Range Low
003251.13— Aftertreatment Pressure Sensor Calibration Error
003515.02— DEF Temperature Sensor Signal Invalid
003515.03— DEF Temperature Sensor Signal Out of Range High
003515.04— DEF Temperature Sensor Signal Out of Range Low
003515.13— DEF Temperature Sensor Calibration Error
003516.00— DEF Quality Sensor Signal Extremely High
003516.01— DEF Quality Sensor Signal Extremely Low
003516.03— DEF Quality Sensor Signal Out of Range High
003516.04— DEF Quality Sensor Signal Out of Range Low
003516.13— DEF Quality Sensor Calibration Error
003521.13— DEF Quality Contamination
003609.03— DPF Inlet Pressure Signal Out of Range High
003609.04— DPF Inlet Pressure Signal Out of Range Low
003719.00— Soot Level Extremely High
003719.07— Soot Level Moderately High and Service Recovery Inhibited
003719.09— DPF Service Regeneration Failed
003719.16— Soot Level Moderately High
003720.00— Calculated Ash Level Extremely High
003720.16— Calculated Ash Level Moderately High
DTC SPN – 004000 – 529999
DCU 004334.03— DEF Dosing Unit Pressure Signal Out of Range High
DCU 004334.04— DEF Dosing Unit Pressure Signal Out of Range Low
DCU 004334.15— DEF Dosing Unit Pressure Signal Slightly High
DCU 004334.17— DEF Dosing Unit Pressure Signal Slightly Low
DCU 004341.00— DEF Dosing Unit Pressure Line Heater Drive Circuit Temperature Extremely High
DCU 004341.03— DEF Dosing Unit Pressure Line Heater Circuit Has Low Resistance
DCU 004341.05— DEF Dosing Unit Pressure Line Heater Circuit Has High Resistance
DCU 004343.00— DEF Dosing Unit Return Line Heater Drive Circuit Temperature Extremely High
DCU 004343.03— DEF Dosing Unit Return Line Heater Circuit Has Low Resistance
DCU 004343.05— DEF Dosing Unit Return Line Heater Circuit Has High Resistance
DCU 004345.00— DEF Dosing Unit Supply Line Heater Drive Circuit Temperature Extremely High
DCU 004345.03— DEF Dosing Unit Supply Line Heater Circuit Has Low Resistance
DCU 004345.05— DEF Dosing Unit Supply Line Heater Circuit Has High Resistance
DCU 004360.00— SCR Inlet Temperature Invalid
DCU 004360.03— SCR Inlet Temperature Sensor Voltage Out of Range High
DCU 004360.04— SCR Inlet Temperature Sensor Voltage Out of Range Low
DCU 004360.10— SCR Inlet Temperature Error
DCU 004360.15— SCR Inlet Temperature Signal Out of Range High
DCU 004360.17— SCR Inlet Temperature Signal Out of Range Low
DCU 004375.00— DEF Dosing Unit Pump Driver Circuit Temperature Extremely High
DCU 004375.03— DEF Dosing Unit Pump Position Signal Circuit Out of Range High
DCU 004375.04— DEF Dosing Unit Pump Position Signal Circuit Out of Range Low
DCU 004375.05— DEF Dosing Unit Pump Motor Circuit Has High Resistance
DCU 004375.07— DEF Dosing Unit Temperature Signal Not Received Error
DCU 004375.10— DEF Dosing Unit Pump Motor Error
DCU 005137.00— DEF Tank Heating Valve Signal Extremely High
DCU 005137.04— DEF Tank Heating Valve Signal Out of Range Low
DCU 005137.05— DEF Tank Heating Valve Circuit has High Resistance
522243.05— Engine Starter Solenoid Lockout Relay Driver Circuit Has High Resistance
522243.06— Engine Starter Solenoid Lockout Relay Driver Circuit Has Low Resistance
522323.00— Air Filter Pressure Differential Extremely High
522329.00— Water-In-Fuel Level Extremely High
522400.02— Crankshaft Position Signal Invalid
522400.05— Crankshaft Position Signal Missing
522401.02— Camshaft Position Signal Invalid
522401.05— Camshaft Position Signal Missing
522573.00— Calculated Soot Level High
522574.00— DPF Differential Pressure Soot Level High
522575.07— Parked Regeneration Failed
522577.11— Parked Regeneration Not Performed
522579.12— EGR Valve Actuator Low Resistance Error
522580.12— EGR Valve Position Internal Error
522581.07— EGR Valve Stuck Open
522582.07— EGR Valve Initialization Error
522583.01— EGR Valve Actuator High Temperature Sensor Fault
522584.01— EGR Valve Actuator Low Temperature Sensor Fault
522596.09— No CAN Message Received From Source Address 1
522597.09— No CAN Message Received From Source Address 2
522600.09— Vehicle Communication Time Out
522610.09— EGR Valve CAN Communication Error
522617.12— EGR Valve Position Mismatch
522618.09— Vehicle Controller Communications Error
522619.09— Vehicle Controller Communications Error
522803.13— High-Pressure Fuel Pump Calibration Invalid
522993.12— ECU Internal Failure
522994.12— ECU Processor Internal Failure
522995.12— Injector Calibration Invalid
522996.04— Injector Drive Circuit Internally Low
522997.03— Injector Drive Circuit Internally High
522998.12— ECU Internal Error #2
523074.00— Sensor Supply #1 Voltage Out of Range High
523074.01— Sensor Supply #1 Voltage Out of Range Low
523075.00— Sensor Supply #2 Voltage Out of Range High
523075.01— Sensor Supply #2 Voltage Out of Range Low
523221.12— Injector Calibration Data Missing
523221.13— Injector Calibration Data Error
523249.05— Crankshaft Position and Camshaft Position Signals Invalid
DCU 523554.03— DEF Dosing Unit Pump and Reversing Valve Drive Error
DCU 523554.04— DEF Dosing Unit Pump and Reversing Valve Drive Fault
DCU 523555.03— DEF Heated Line Relay and Tank Coolant Control Valve Drive Shorted To Voltage
DCU 523555.04— DEF Heated Line Relay and Tank Coolant Control Valve Drive Shorted To Ground
DCU 523556.03— DEF Dosing Unit Heater Circuit Out of Range High
DCU 523556.04— DEF Dosing Unit Heater Circuit Out of Range Low
DCU 523556.05— DEF Supply Module Heater Circuit Has High Resistance
DCU 523556.10— DEF Dosing Unit Temperature Error
DCU 523557.03— DEF Dosing System Heater Circuit Shorted to Voltage
DCU 523557.07— SCR Termination
DCU 523558.03— DCU Voltage Slightly High
DCU 523558.04— DCU Voltage Slightly Low
DCU 523559.03— DCU Voltage Extremely High
DCU 523559.04— DCU Voltage Extremely Low
DCU 523560.02— DCU Power Down Error
DCU 523560.07— DCU Internal Error
DCU 523562.09— Aftertreatment Inlet NOx Sensor Loss of Communication
DCU 523563.09— Aftertreatment Outlet NOx Sensor Loss of Communication
DCU 523570.09— CAN Message Not Received From DCU
DCU 523574.03— DCU Internal Voltage Supply Out of Range High
DCU 523574.04— DCU Internal Voltage Supply Out of Range Low
DCU 523576.12— DEF Dosing Unit Pressure Sensor Voltage Supply Error
DCU 523577.12— DCU Internal Communication Error
DCU 523578.12— DCU Internal Communication Error 2
DCU 523579.12— DCU Internal Error 1
DCU 523580.12— DCU Internal Error 2
DCU 523581.00— DCU Internal Temperature Extremely High
DCU 523582.03— DCU Internal Temperature Sensor Out of Range High
DCU 523582.04— DCU Internal Temperature Sensor Out of Range Low
DCU 523584.00— DEF Dosing Injector Driver Temperature Extremely High
DCU 523585.03— DEF Dosing Injector Drive Circuit Out of Range High
DCU 523586.03— DEF Dosing Injector Drive Circuit Fault
DCU 523586.04— DEF Dosing Injector Drive Circuit Has Low Resistance
DCU 523586.05— DEF Dosing Injector Drive Circuit Out of Range Low
DCU 523588.07— DEF Dosing Injector Error
DCU 523589.12— DCU EEPROM Error 1
DCU 523590.12— DCU EEPROM Error 2
DCU 523591.12— DCU EEPROM Error 3
DCU 523592.00— DEF Dosing Unit Line Heater Circuit Temperature Extremely High
DCU 523592.03— DEF Dosing Unit Heater Line Circuit Has Low Resistance
DCU 523592.04— DEF Dosing Unit Line Heater Circuit Short to Ground
DCU 523592.05— DEF Dosing Unit Line Heater Circuit Has High Resistance
DCU 523593.03— DEF Dosing Unit Heater Short Circuit
DCU 523594.03— DEF Tank Heating Valve Signal Out of Range High
DCU 523595.00— Aftertreatment Inlet NOx Sensor Fault
DCU 523595.03— Aftertreatment Inlet NOx Sensor Out of Range High
DCU 523595.05— Aftertreatment Inlet NOx Sensor Circuit Has High Resistance
DCU 523596.00— Aftertreatment NOx Outlet Value Error
DCU 523596.03— SCR Outlet NOx Sensor Circuit Short to Ground
DCU 523596.05— SCR Outlet NOx Sensor Circuit Has High Resistance
DCU 523597.07— SCR Inlet NOx Temperature Error
DCU 523598.07— SCR Outlet NOx Temperature Invalid
DCU 523599.00— DEF Dosing Unit Reverting Valve has Low Resistance
DCU 523600.03— DEF Dosing Unit Reverting Valve Short to Ground
DCU 523600.04— DEF Dosing Unit Reverting Valve Short Circuit
DCU 523600.05— DEF Dosing Unit Reverting Valve has High Resistance
DCU 523601.01— SCR Catalyst Conversion Efficiency Extremely Low
DCU 523606.10— Aftertreatment Outlet NOx Sensor Data Invalid
DCU 523610.00— DEF Dosing Unit Heater Short Circuit
DCU 523610.01— DEF Dosing Unit Heater Short Circuit
DCU 523610.10— DEF Dosing Unit Fault
DCU 523611.01— DEF Dosing Unit Temperature Signal Extremely Low
DCU 523611.10— DEF Dosing Unit Temperature Rate of Change Abnormal
DCU 523612.02— DEF Dosing Unit Temperature Signal Invalid
DCU 523613.02— DEF Dosing Unit Temperature Signal Invalid
DCU 523614.08— DEF Dosing Unit Signal Missing
DCU 523615.08— DEF Dosing Unit Signal Missing
DCU 523616.02— DEF Dosing Unit Temperature Signal Invalid
DCU 523617.02— DEF Dosing Unit Temperature Signal Invalid
DCU 523618.07— DEF Dosing Unit Fault
DCU 523619.00— DEF Dosing Unit Pressure Fault
DCU 523620.07— DEF Dosing Unit Pressure Reduction Fault
DCU 523621.00— DEF Hose Pressure Signal Extremely High
DCU 523622.07— DEF Hose Pressure Mismatch
DCU 523623.02— DEF Dosing Unit Pressure Signal Invalid
DCU 523624.07— DEF Dosing Unit Pressure Mismatch
DCU 523625.00— DEF Reverting Valve Signal Extremely High
DCU 523626.00— DEF Dosing Unit Pressure Signal Extremely High
DCU 523627.01— DEF Dosing Unit Pressure Signal Extremely Low
DCU 523628.10— DEF Dosing Unit Pressure Signal Rate of Change Abnormal
DCU 523630.02— DEF Tank Temperature Signal Invalid
DCU 523634.09— DEF Header Signal Error
DCU 523635.09— DEF Header Signal Error
DCU 523636.00— Engine Power Derate Condition Exists
DCU 523637.00— Engine Power Derate Condition Exists
DCU 523636.16— Engine Power Derate Condition Exists
DCU 523640.05— Key Switch Disconnected
U Codes
U0167— CAN Communication Error
U0426— CAN Communication Error
U1292— Vehicle Communication Time Out
U1302— Vehicle Communication Time Out
U1501— CAN Communication Time Out
U1502— CAN Communication Time Out
U1503— DCU System Error
U1504— DCU System Error
U1505— DCU System Error
U1506— DCU System Error
U1507— DCU System Error
U1508— DCU System Error
U1509— DCU System Error
U1510— DCU System Error
Tools and Other Materials
Special Tools
D01045AA
D01168AA
D05012ST-A
D05223ST
D15001NU
D17024BR
D17511CI
D17525CI
D17527CI
D17526CI
J-35616-20
JDE138
JDG23
JDG451
JDG1322
JDG1676
JDG10233
JDG10234
JDG10243
JDG10273
JDG10407
JDG10408
JDG10444
JDG10445
JDG10446
JDG10447
JDG10450
JDG10451
JDG10456
JDG10457
JDG10460
JDG10461
JDG10462
JDG10463
JDG10464
JDG10465
JDG10466
JDG10785
JDG10786
JDG10787
JDG10788
JDG10789
JDG10790
JDG11005
JDG11100A
JDG11233
JDG11348
JDG11349
JDG11507
JDG11524
JDG11525
JDG11536
JDG11537
JDG11574
JDG11575
JDG11594
JDG11602
JDG11684
JDG11796
JDG11896
JT05470
JT05697A
JT07253
JT07306
JT07336
KJD10140
Lubricants, Sealants, and Cleaners
Other Materials
Anti-Seize:
Gasket:
Grease:
Lubricants:
Lubricating Soap:
Thread lockers and Sealers
Specifications
Repair and General Specifications
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Diagnostic Specifications
Engine Schematic 1
Engine Schematic 2
Engine Control Unit (ECU) Connector Identification
Dosing Control Unit (DCU) Connector Identification