John Deere OEM Engine Accessories Component Technical Manual CTM67 Repair & Wiring Diagrams PDF - MJODCTM67.zip

A full technical reference manual covering John Deere OEM engine accessories, packed with the details needed to service, troubleshoot, fix, and rebuild these components the way a professional technician would.

This John Deere OEM engine accessories workshop service and repair manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 611 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.

Language: English

ctm67 - John Deere OEM Engine Accessories Component Technical Manual.pdf

ctm67 - John Deere OEM Engine Accessories Component Technical Manual.epub

Foreword

This Component Technical Manual (CTM) contains the latest available instructions necessary to repair OEM engine accessories. It includes theory of operation, and diagnostic and testing procedures to help troubleshoot and understand potential failure modes.

The information is organized in groups for the various components requiring service instruction. At the beginning of each repair group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic types of failures and their causes.

MAIN SECTIONS

Foreword

Section : OEM Engine Accessories

Group 05: Safety

Prepare for Emergencies

Prevent Battery Explosions

Handling Batteries Safely

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Support Machine Properly

Prevent Machine Runaway

Stay Clear of Rotating Drivelines

Handle Starting Fluid Safely

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Install Fan Guards

Avoid Hot Parts

Avoid Heating Near Pressurized Fluid Lines

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 10: General Information

About This Manual

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Group 20: Electrical System Information and Wiring Diagrams

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Wiring Diagram and Schematic Information

Reading a System Functional Schematic

Reading a Wiring Diagram

Electrical Schematic Symbols

Component Identification Table

Engine Wiring Diagram Legend—North American Series 300, 400, 500 and 700 Engines and Early Model European (Saran) Series 300 Engines

Wiring Diagram—North American Series 300, 400 and 500 Engines

Wiring Diagram—North American Series 700 (8955) Engines

Wiring Diagram—European (Saran) Series 300 Engines (Early Model)

Engine Wiring Diagram Legend—   is a registered trademark of Deere & Company 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)

Engine Wiring Diagram—   is a registered trademark of Deere & Company 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)

Engine Wiring Diagram Legend—   is a registered trademark of Deere & Company 10.5 L and 12.5 L Engines (With Lucas ECU) Wiring diagram shown does not show ECU (Engine Control Unit) components. See engine Operation and Diagnostics Manual CTM115 for ECU components and wiring diagrams.

Engine Wiring Diagram—   is a registered trademark of Deere & Company 10.5 L and 12.5 L Engines (With Lucas ECU)

Engine Wiring Diagram—   is a registered trademark of Deere & Company 8.1 L, 10.5 L and 12.5 L Engines (With John Deere ECU)

Engine Wiring Diagram—   is a registered trademark of Deere & Company 8.1 L, 10.5 L and 12.5 L Engines (With John Deere ECU) (Continued)

Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines

Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines (Continued)

Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines (Continued)

Engine Wiring Diagram—Saran AEZ Instrument Panel

Engine Wiring Diagram Legend—Saran VDO Instrument Panel

Engine Wiring Diagram—Saran VDO Instrument Panel

Engine Wiring Diagram—PowerTech™ 2.4L and 3.0L Engines

Group 21: Electrical System Diagnostics, Tests and Operation

Service Equipment and Tools

Electrical System Specifications

General Information

Component Function—Instrument Panel (Without ECU)

Component Function—Instrument Panel (2.4L, 3.0L, and 4.5L (Later “270”)-Without ECU)

Component Function—Instrument Panel (With Lucas ECU)

Component Function—Instrument Panel (With Early Deere ECU)

Component Function—Instrument Panel (PowerTech Plus 4.5 L, 6.8 L, 9.0 L,13.5 L and Later PowerTech 4.5L, 6.8L, 8.1L and 12.5L)

Component Function—Saran VDO Instrument Panel

Component Function—Saran AEZ Instrument Panel

Component Function—Crankcase Oil Level Switch/Gauge

Before You Start Diagnostics

Visually Inspect Electrical System

Diagnose Electrical System Malfunctions

Checking Fuses In Instrument Panels

Test Key Switch

Test Magnetic Safety Switch

Test Starter Relay

Group 22: Electrical System Repair and Adjustments

Essential Tools

Service Equipment and Tools

Other Material

Instrument Panel Specifications

Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electric Connector

Remove Blade Terminals from Connector Body

Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors

Repair (Push Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors

Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company Connectors

Repair AMP Connector

Repair SUMITOMO™ Connectors

Repair YAZAKI™ Connectors

Repair CINCH™ Flex Box Connector

Replace Instrumentation—North American Instrument Panel (Early Model Instrument Panels)

Replace Instrumentation—North American Instrument Panel (Late Model Instrument Panels W/O ECU)

Replace Instrumentation—North American Instrument Panel (2.4L, 3.0L, and 4.5L (Later “270”)—W/O ECU)

Replace Instrumentation—Instrument Panel with Lucas ECU

Replace Instrumentation—Earlier Model Instrument Panels with John Deere ECU

Replace Instrumentation—Later Model Instrument Panels with John Deere ECU

Replace Instrumentation—European (Saran) Instrument Panel (Early Model)

Replace Instrumentation—Saran VDO Instrument Panel

Replace Instrumentation—Saran AEZ Instrument Panel

Remove and Install Crankcase Oil Level Switch/Gauge

Calibrate Adjustable Electronic Tachometer

Adjust Saran VDO Instrument Panel Tachometer

Adjust Saran AEZ Instrument Panel Tachometer

Replace Electronic Foot Throttle (Later Engines with ECU)

Harness Repair (Splice Broken or Cut Wire)

Harness Repair (Splice Connector)

Group 25: Cold Weather Starting Aids

Other Material

Cold Weather Starting Aids Specifications

Remove Coolant Heater—Block Type (Except 2.4 L and 3.0 L Engines)

Install Coolant Heater—Block Type (Except 2.4 L and 3.0 L Engines)

Remove Coolant Heater—Block Type (2.4 L and 3.0 L Engines)

Install Coolant Heater—Block Type (2.4 L and 3.0 L Engines)

Remove Coolant Heater—Block Type (Saran Engines)

Install Coolant Heater—Block Type (Saran Engines)

Remove Coolant Heater—Tank Type

Install Coolant Heater—Tank Type

Remove and Install Fuel Heater

Remove and Install Air Heater

Remove and Install Glow Plugs (2.4 L and 3.0 L Engines)

Remove and Install Glow Plugs (4.5L and 6.8L Engines)

Service Ether Starting Aid

Group 30: Fuel System Accessories

Fuel System Accessories Specifications

Check Injection Pump Solenoid—“D” Engines

Check Rack Puller—RP-20 (Stationary Engines)

Check RP-75 Rack Puller—Stationary Engines

Disassemble and Assemble RP-75 Rack Puller

Check Rotary Fuel Shut-Off Solenoid

Remove and Install Rotary Fuel Shut-Off Solenoid

Adjust Rotary Fuel Shut-Off Solenoid

Group 31: UTC Electric/Isochronous Governor (8955 Engines)

Service Equipment and Tools

Governor Specifications

How the System Works

Diagnosing Electric Governor Malfunctions

Safety Guidelines when Testing Electronic Governor

Electric Governor System Tests

Test Engine Speeds

Adjust Engine Speeds

Adjust Gain and Stability

Engine Operation in Droop Mode

Electric Governor Installation Instruction

Connect Electric Governor Wiring Harness

Remove Electric Governor

Service Magnetic Pickup

Group 32: Electric Fuel Supply Pump—8955 Engines

Service Equipment and Tools

Fuel Supply Pump Specifications

Relieve System Pressure

Test John Barnes Fuel Supply Pump Pressure—8955T, A Engine Serial No. ( —3076)

Adjust John Barnes Fuel Supply Pump Relief Valve—8955T, A Engines Serial No. ( —3076)

Remove John Barnes Electric Fuel Supply Pump—8955 Engine Serial No. ( —3076)

Remove Pressure Regulating Valve

Install Pressure Regulating Valve

Repair Fuel Pump

Install John Barnes Fuel Supply Pump—8955 Engine Serial No. ( —3076)

Test Bosch Fuel Supply Pump Pressure—8955T, A Engine Serial No. (3077— )

Replace Bosch Fuel Supply Pump—8955T, A Engines Serial No. (3077— )

Group 40: Engine Cooling System Accessories

Service Equipment and Tools

Other Material

Engine Cooling System Specifications

Test Charge Air Cooler

Remove and Install Charge Air Cooler

Remove and Install Coolant Temperature Sensor

Pressure Test Cooling System and Radiator Cap

Radiator and Hoses

Install Radiator Fan—Blower and Suction Types

Check Fan and Alternator Belts

Remove and Install Fan and Alternator Belts

Manual Belt Tensioner Adjustment

Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)

Check Automatic Belt Tensioner Spring Tension and Belt Wear

Adjust Fan and Alternator Belts

Group 45: Rear PTO - Rockford/Twin Disc

Essential Tools

Service Equipment and Tools

Rockford/Twin Disc Rear Power Take-Off Specifications

General Information

Diagnosing Malfunctions

Remove Power Take-Off

Power Take-Off Exploded View

Disassemble Power Take-Off

Inspect Power Take-Off Parts

Assemble Drive Shaft and Bearings—Side-Load Application

Assemble Drive Shaft and Bearings—In-Line Application

Install Yoke

Check and Adjust Drive Shaft End Play

Assemble Clutch Unit (Early Version)

Assemble Clutch Unit (Late Version)

Install Clutch Unit

Check Flywheel Housing Face Run-Out

Check Flywheel Face Flatness

Check Pilot Bearing Bore

Inspect Drive Ring

Install Power Take-Off

Check PTO Clutch Adjustment—Early Version

Check PTO Clutch Adjustment—Late Version

Group 46: Rear PTO - John Deere

Special Or Essential Tools

Other Material

Rear Power Take-Off Specifications For 8.1L/9.0L and 12.5L/13.5L Engines With Primary and Auxiliary Pump Drives (Double Pump)

Rear Power Take-Off Specifications For 8.1L/9.0L and 12.5L/13.5L Engines With Primary Pump Drive (Single Pump)

General Information

Theory of Operation

Lubrication Passages

Photo Disclosure

Remove Rear PTO

Disassemble Auxiliary Pump Group

Disassemble Primary Pump Group

Disassemble Auxiliary Idler Shaft Group

Disassemble Primary Idler Shaft Group

Inspect and Assemble Engine Rear Power Take-Off Housing Group

Flywheel Access Cover Plate

Primary Idler Shaft Group

Assemble Primary Idler Shaft Group

Auxiliary Idler Shaft Group

Assemble Auxiliary Idler Shaft Group

Auxiliary Pump Access Cover Plate (For Single Pump Application Only)

Primary Pump Group

Assemble Primary Pump Group

Auxiliary Pump Group

Assemble Auxiliary Pump Group (Double Pump Rear Power Take-Off)

Input Gear Assembly and Seal Retainer Group

Install Rear PTO

Group 47: Front PTO

Essential Tools

Front Power Take-Off Specifications

Checking Vibration Damper or Pulley (Engine With Front PTO)

Remove Vibration Damper or Pulley (Engine With Front PTO)

Install Vibration Damper or Pulley (Engine With Front PTO)

Installing PTO Drive Gear (Crankshaft Gear-Driven PTO)

Remove and Install Front PTO Clutch Adapter (Electric)

Remove and Install Front PTO Clutch Adapter (Mechanical)

Group 50: Auxiliary Drive, 6076 (500000— )

Service Equipment and Tools

Other Material

Auxiliary Drive, 6076 (500000— ) Specifications

Auxiliary Drive General Information

Remove Right-Hand Output Gear Assembly

Disassemble Right-Hand Output Gear Assembly

Assemble Right-Hand Output Gear Assembly

Install Right-Hand Output Gear Assembly

Remove Left-Hand Output Gear Assembly

Disassemble Left-Hand Output Gear Assembly

Assemble Left-Hand Output Gear Assembly

Remove Left-Hand Rear Adapter Housing

Remove Idler Housing and Idler Gear

Replace Idler Gear Bearing

Install Idler Housing and Idler Gear

Install Left-Hand Output Gear Assembly

Install Left-Hand Rear Adapter Housing

Group 51: Auxiliary Drive (2.9 L)

Auxiliary Drive (2.9 L) Specifications

Remove and Install Right-Hand Auxiliary Drive

Group 52: Auxiliary Drive (4.5 L and 6.8 L)

Auxiliary Drive (4.5 L and 6.8 L) Specifications

Remove and Install Auxiliary Drive

Remove and Install Offset Auxiliary Drive

Disassemble and Inspect Auxiliary Drive Adapter

Disassemble and Inspect Offset Auxiliary Drive Adapter

Group 53: Auxiliary Drive (8.1 L)

Auxiliary Drive Specifications

Remove Right-Hand Output Gear Assembly

Disassemble Right-Hand Output Gear Assembly

Assemble Right-Hand Output Gear Assembly

Install Right-Hand Output Gear Assembly

Remove Left-Hand Output Gear Assembly

Disassemble Left-Hand Output Gear Assembly

Assemble Left-Hand Output Gear Assembly

Remove and Install Left-Hand Rear Adapter Housing

Remove Idler Housing and Idler Gear