John Deere PowerTech 9.0 L OEM Diesel Engines 6090 Base Engine Repair Workshop Manual CTM400 PDF - MJODCTM400.zip
A full technical reference manual with complete electrical wiring schematics covering John Deere PowerTech 9.0 L OEM diesel engines, Base Engine Repair (Worldwide Edition), offering every specification needed to service, troubleshoot, fix, and overhaul these units at a professional shop standard.
The John Deere PowerTech 9.0 L OEM Diesel Engines Base Engine Repair (Worldwide Edition) 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.
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ctm400 - PowerTech™ 9.0 L OEM Diesel Engines Base Engine Repair -: (Worldwide Edition)
Component Technical Manual
Table of Contents
Foreword
About this Manual
Identification Views - 6090 Tier 3 / Stage IIIA Emissions Certified Engines
Section 01: General
Group 000: Safety
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Replace Safety Signs
California Proposition 65 Warning
Illuminate Work Area Safely
Work in Clean Area
Use Proper Tools
Live With Safety
Prevent Machine Runaway
Handle Fuel Safely—Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
In Case of Fire
Handle Fluids Safely—Avoid Fires
Avoid Static Electricity Risk When Refueling
Service Machines Safely
Wear Protective Clothing
Protect Against Noise
Handling Batteries Safely
Prevent Acid Burns
Stay Clear of Rotating Drivelines
Install All Guards
Practice Safe Maintenance
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Do Not Open High-Pressure Fuel System
Protect Against High Pressure Spray
Prevent Battery Explosions
Avoid Hot Exhaust
Work In Ventilated Area
Service Cooling System Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Group 001: Engine Identification
Engine Model Designation
Engine Serial Number Plate Information
OEM Engine Option Code Label
Group 002: Fuels, Lubricants and Coolant
Diesel Fuel
Supplemental Diesel Fuel Additives
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
BioDiesel Fuel
Testing Diesel Fuel
Fuel Filters
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Engine Oil and Filter Service Intervals
Diesel Engine Oil — Tier 3 and Stage III
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Oil Filters
Grease
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Water Quality for Mixing with Coolant Concentrate
Operating in Warm Temperature Climates
Testing Coolant Freeze Point
Disposing of Coolant
Section 02: Repair and Adjustments
Group 010: Engine Rebuild
Engine Overhaul Guidelines
Engine Repair Stand
Safety Precautions
Install Adapters on Engine Repair Stand
Install Engine Lift Straps
Engine Lifting Procedure
Clean Engine
Disconnect Turbocharger Oil Inlet Line
Mount Engine on Repair Stand
Engine Disassembly Sequence for Overhaul
Sealant Application Guidelines
Engine Assembly Sequence After Overhaul
Engine Break-In Guidelines
Perform Engine Break-In
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check and Service Cooling System
Check Electrical System
General Tune-Up Recommendations
Group 021: Cylinder Head and Valves Repair and Adjustment
Valve — Clearance Adjustment
Valve — Lift Check
Cylinder Head — Removal
Cylinder Head—Preparation and Measurement
Diagnosing Head Gasket Joint Failures
Head Gasket Diagnostic Charts
Head Gasket Inspection and Repair Sequence
Rocker Arm Assembly — Inspection
Rocker Arm Shaft Assembly — Removal and Tear Down
Valve — Recess Measurement
Preliminary Cylinder Head and Valve Checks
Valve — Assembly Removal
Valve Springs — Inspection
Valve Retainer, Valve Bridges, and Valve Retainer Locks — Inspection
Valve — Cleaning and Inspection
Valve — Measurement
Valve — Grinding
Cylinder Head — Cleaning and Inspection
Cylinder Head — Flatness Check
Cylinder Head — Thickness Measurement
Fuel Injector Sleeves — Remove
Fuel Injector Sleeves — Install
Valve Guide — Cleaning
Valve Guide — Measurement
Valve Guides — Removal
Valve Guides — Installation
Valve Seat — Cleaning and Inspection
Valve Seat — Recess Measurement
Valve Seat — Grinding
Valve Seat Inserts — Removal
Valve Seat Inserts — Installation
Cylinder Head Nozzle Bore — Cleaning and Inspection
Push Rod — Cleaning and Inspection
Cylinder Block Top Deck — Cleaning and Inspection
Valve Assembly — Reassemble
Cylinder Head — Installation
Cylinder Head Cap Screw Torque Procedure
Rocker Arm Shaft Assembly — Assemble
Rocker Arm Assembly — Installation
Rocker Arm Cover Vent hose — Inspection
Final Assembly — Fuel Pump Side of Engine
Final Assembly — Exhaust Manifold Side of Engine
Perform Engine Break— In
Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment
Preliminary Liner, Piston, and Rod Checks
Remove Pistons and Connecting Rod Assemblies
Cylinder Liner — Standout Measurement
Remove Cylinder Liners
Deglaze Cylinder Liners
Cylinder Liner — Cleaning
Piston and Connection Rod Assembly — Tear Down
Piston Ring — Removal
Clean Pistons
Visually Inspect Pistons
Inspect Piston Pin and Bore
Visually Inspect Cylinder Liners
Cylinder Liner Manufacturing Date Code Explanation
Piston to Liner — Clearance Check
Inspect Rod and Cap
Piston Pin and Bushing — Inspection
Piston Pin Bushing and Pin Bore — Removal
Measure Liner Flange
Inspect and Measure Connecting Rod Bearings
Piston Pin Bushing — Installation
Complete Disassembly of Cylinder Block (If Required)
Piston Cooling Orifices — Removal
Clean Cylinder Block
Measure Cylinder Block
Cylinder Block — Inspect and Reclaim
Piston Cooling Orifices — Installation
Install Packing on Cylinder Liner and O-Rings in Block
Install Cylinder Liner in Block
Piston Ring — Installation
Install Piston and Connecting Rod
Connecting Rod Cap Screw — Torque Procedure
Check Engine Rotation for Excessive Tightness
Complete Final Assembly
Group 040: Crankshaft, Main Bearings and Flywheel Repair and Adjustment
Crankshaft and Main Bearing Failure Analysis
Inspect Vibration Damper
Check Crankshaft End Play
Remove Crankshaft Vibration Damper (Straight Nose Crankshaft)
Remove Crankshaft Vibration Damper and Hub (Tapered Nose Crankshaft)
Crankshaft Dual Damper — Removal
Remove Crankshaft Front Oil Seal and Wear Sleeve (Straight Nose Crankshaft)
Remove Crankshaft Front Unitized Oil Seal (Tapered Nose Crankshaft)
Remove Timing Gear Cover—Engine Removed
Inspect and Measure Flywheel
Check Flywheel Housing Face Runout
Check Flywheel Face Flatness
Check Pilot Bearing Bore Concentricity
Remove Flywheel
Remove Flywheel (Tapered Nose Crankshaft)
Crankshaft Unitized Rear Oil Seal — Removal (Straight Nose Crankshaft)
Remove SAE 1 Flywheel Housing
Remove SAE 2 and 3 Flywheel Housing
Replace Flywheel Ring Gear
Remove Rear Oil Seal Housing—Engine Removed
Remove Main Bearing Caps
Check Main Bearing Oil Clearance
Remove Connecting Rod Caps and Remove Crankshaft
Crankshaft — Inspection
Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journals
Main Bearing Cap Line Bore Specifications
Thrust Bearing New Part Specifications
Replace (Crankshaft) Oil Pump Drive Gear
Replace Crankshaft Gear
Inspect Thrust Bearings
Install Main Bearings and Crankshaft
Check Crankshaft Rear Oil Seal Housing Runout
Install Crankshaft Front Unitized Oil Seal (Straight Nose Crankshaft)
Install Crankshaft Front Unitized Oil Seal (Tapered Nose Crankshaft)
Install Vibration Damper (Straight Nose Crankshaft)
Install Vibration Damper and Hub (Tapered Nose Crankshaft)
Crankshaft Dual Damper — Installation (Tapered Nose Crankshaft)
Install Crankshaft Rear Oil Seal Housing
Crankshaft Rear Oil Seal Assembly Handling Precautions
Install Crankshaft Rear Unitized Oil Seal (Straight Nose Crankshaft)
Install Crankshaft Rear Unitized Oil Seal (Tapered Nose Crankshaft)
Install SAE 2 and 3 Flywheel Housing
Install Flywheel
Install Flywheel (Tapered Nose Crankshaft)
Install SAE 1 Flywheel Housing
Complete Final Assembly
Group 050: Camshaft and Timing Gear Train Repair and Adjustment
Check Camshaft End Play and Measure Gear Backlash
Remove Vibration Damper and Timing Gear Cover
Remove, Inspect, and Install Crankshaft Gear-Driven Auxiliary Drive — If Equipped
Remove Camshaft
Remove Camshaft Gears
Measure Thrust Washer Thickness
Inspect and Measure Camshaft Followers
Visually Inspect Camshaft
Measure Camshaft Journal O.D. and Bushing I.D.
Measure Camshaft Lobe Lift
Camshaft Gears — Installation
Service Camshaft Bushings Using JDG602 Adapter Set
Service Camshaft Bushings Using JDG606 Adapter Set
Camshaft Roller Followers — Install
Install Camshaft
Install Thrust Washer and Timing Gear Cover
Complete Final Assembly
Group 060: Lubrication System Repair and Adjustment
Diagnosing Lubrication System Malfunctions
Dipstick Tube and Dipstick — Installation
Dipstick Tube and Dipstick — Removal
Top-Load Oil Filter Assembly
Top Load Oil Filter - Theory of Operation
Install Oil Filter Assembly
Changing Top-Load Oil Filter
Oil Pressure Regulating Valve — Removal
Oil Pressure Regulating Valve — Installation
Engine Oil Cooler Assembly
Remove, Inspect, and Install Engine Oil Cooler
Remove Engine from Tractors for Access to Engine Oil Pump
Remove Oil Pan
Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash
Remove Engine Oil Pump
Inspect and Clean Oil Pump
Check Drive Shaft End Play
Check Drive Shaft Side Movement
Check Pumping Gear Backlash
Inspect Oil Pump Drive Gear
Install Engine Oil Pump
Install Oil Bypass & Oil Pump Tubes & Oil Pump Adapter
Remove, Inspect, and Install Oil Pump Pickup Tube
Install Engine Oil Pan
Tighten Cap Screws on Front Frame/Oil Sump - Tractors
Group 070: Cooling System Repair and Adjustment
Inspect Fan Hub & Replace Bearings in Heavy-Duty, Adjustable Fan Drive Assembly
Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive Assembly
Fan Drive Assembly
Checking Belt Tensioner Spring Tension and Belt Wear
Inspect and Install Fan Assembly
Visually Inspect Coolant Pump
Remove Coolant Pump Assembly
Install Coolant Pump Assembly
Replace Bypass Tube & O-Rings in Thermostat Housing
Remove and Test Thermostats
Remove Thermostat Housing
Install Thermostats
Install Thermostat Housing
Remove and Install Coolant Temperature Sensor
Servicing of Engine Coolant Heater
Remove Heat Exchanger or Top Tank (Marine)
Install Heat Exchanger or Top Tank (Marine)