John Deere 6090 Diesel Engine Level 24 ECU Worldwide Component Technical Manual CTM115419 Repair PDF - MJODCTM115419.zip

A full Component Technical Manual (CTM) covering the John Deere 6090 Diesel Engine (Level 24 ECU - Worldwide), packed with every piece of shop-level guidance you need to service, troubleshoot, fix, and overhaul the engine the way trained technicians do.

ctm115419 - 6090 Diesel Engine — Level 24 ECU - (Worldwide Edition) Component Technical Manual.pdf

ctm115419 - 6090 Diesel Engine — Level 24 ECU - (Worldwide Edition) Component Technical Manual.epub

Total Pages: 1,912 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

ctm115419 - 6090 Diesel Engine — Level 24 ECU -: (Worldwide Edition) Component Technical Manual

TABLE OF CONTENTS

Foreword

Identification Views - 6090 Stage II Emissions Certified Engines

Related Manuals

Training Information

Definition of Terms

Section 01: General Information

Group 000: Safety

Understand Signal Words

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

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

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

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

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

BioDiesel Fuel

Fuel Filters

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV — OEM Applications

Engine Oil and Filter Service Intervals

Oil Filters

Lubricant Storage

Mixing of Lubricants

Alternative and Synthetic Lubricants

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

Check Air Intake System

Check and Service Cooling System

Check Crankcase Ventilation System

Check Electrical System

Check Exhaust System

Clean Engine

Disconnect Turbocharger Oil Inlet Line

Engine Assembly Sequence

Engine Break-In Guidelines

Engine Disassembly Sequence

Engine Repair Stand

General Tune-Up Recommendations

Install Adapters on Engine Repair Stand

Install Engine Lift Straps

Lifting Procedure

Mount Engine on Repair Stand

Overhaul Guidelines

Perform Engine Break-In

Safety Precautions

Sealant Application Guidelines

Group 020: Cylinder Head and Valves Repair and Adjustment

Cylinder Head — Cleaning and Inspection

Cylinder Head — Flatness Check

Cylinder Head — Installation

Cylinder Head Cap Screw Torque Procedure

Cylinder Head — Removal

Cylinder Head — Thickness Measurement

Fuel Injector Sleeves — Install

Fuel Injector Sleeves — Remove

Push Rod — Cleaning and Inspection

Rocker Arm Cover Vent hose — Inspection

Rocker Arm, Intake and Exhaust — Inspection

Rocker Arm Shaft — Inspection

Rocker Arm Shaft Assembly — Assemble

Rocker Arm Shaft Assembly — Installation

Rocker Arm Shaft Assembly — Removal and Tear Down

Valve — Assembly Removal

Valve — Cleaning and Inspection

Valve — Clearance Adjustment

Valve — Grinding

Valve — Lift Check

Valve — Measurement

Valve — Recess Measurement

Valve Assembly — Installation

Valve Guide — Measurement

Valve Guide — Cleaning

Valve Guide — Installation

Valve Guide — Removal

Valve Retainer, Valve Bridges, and Valve Retainer Locks — Inspection

Valve Seat — Cleaning and Inspection

Valve Seat — Grinding

Valve Seat — Recess Measurement

Valve Seat Inserts — Installation

Valve Seat Inserts — Removal

Valve Springs — Inspection and Measurement

Group 030: Block, Liners, Pistons, and Rods Repair and Adjustment

Piston Ring — Installation

Piston and Connecting Rod — Installation

Connecting Rod and Cap — Inspection

Connecting Rod Bearings — Inspection and Measurement

Connecting Rod Cap Screw — Torque Procedure

Cylinder Block — Cleaning and Inspection

Cylinder Block — Measurements

Cylinder Block Oil, Coolant, and Camshaft Frost Plugs — Installation

Cylinder Liner — Cleaning

Cylinder Liner — Deglazing

Cylinder Liner — Installation

Cylinder Liner — Packing Installation

Cylinder Liner — Height Measurement

Cylinder Liner — Manufacturing Date Code Explanation

Cylinder Liner — Measure Liner Flange Thickness

Cylinder Liners — Removal

Cylinder Liners — Visual Inspection

Pistons — Cleaning

Piston — Visual Inspection

Pistons and Connecting Rod Assembly — Removal

Piston and Connecting Rod Assembly — Tear Down

Piston Ring — Removal

Piston Cooling Orifice — Removal and Inspection

Piston Cooling Orifice — Installation

Piston Pin and Bore — Inspection

Dipstick Assembly — Inspection

Dipstick Assembly — Installation

Dipstick Assembly — Removal

Piston Pin and Bushing (A) — Inspection

Piston Pin and Bushing (B) — Inspection

Piston Pin Bushing — Installation

Piston Pin Bushing and Pin Bore — Removal

Piston to Liner — Clearance Check

Group 040: Crankshaft, Bearings, Flywheel Repair and Adjustment

Crankshaft — End Play Check

Crankshaft — Removal

Crankshaft — Inspection

Crankshaft — Installation

Remove Crankshaft Front Unitized Oil Seal

Unitized Front Crankshaft Oil Seal — Installation

Crankshaft Unitized Rear Oil Seal — Removal

Crankshaft Rear Oil Seal Housing — Removal

Crankshaft Rear Oil Seal & Oil Seal Housing — Installation

Crankshaft Vibration Damper and Hub — Removal

Install Vibration Damper

Crankshaft Gear — Replace

Flywheel — Removal

Inspect and Measure Flywheel

Check Flywheel Housing Face Runout

Flywheel — Installation

Flywheel Housing — Removal

SAE 1 Flywheel Housing — Inspection

Install SAE 1 Flywheel Housing

Install SAE 2 and 3 Flywheel Housing

Check Main Bearing Oil Clearance

Replace Flywheel Ring Gear

Main Bearing Cap — Removal

Main Bearing Cap — Line Bore Specifications

Check Pilot Bearing Bore Concentricity

Thrust Bearings — Inspection

Group 050: Camshaft and Timing Gear Train Repair and Adjustment

Camshaft End Play and Gear Backlash — Check

Camshaft — Removal

Camshaft — Visual Inspection

Install Camshaft

Camshaft Gears — Installation

Service Camshaft Bushings Using JDG602 Adapter Set

Service Camshaft Bushings Using JDG606 Adapter Set

Measure Camshaft Journal O.D. and Bushing I.D.

Camshaft Lobe — Lift Measurement

Remove, Inspect, and Install Crankshaft Gear-Driven Auxiliary Drive — If Equipped

Fan Drive, Variable Speed — Removal

Fan Drive, Variable Speed — Installation

Camshaft Roller Followers — Install

Thrust Washer — Thickness Measurement

Remove Vibration Damper and Timing Gear Cover

Install Thrust Washer and Timing Gear Cover

Group 060: Lubrication System Repair and Adjustment

Oil Cooler — Assembly

Remove, Inspect, and Install Engine Oil Cooler

Oil Filter Assembly — Removal

Oil Filter — Changing

Oil Filter Assembly — Installation

Oil Pressure Regulating Valve — Removal

Oil Pressure Regulating Valve — Installation

Oil Pan — Removal

Oil Pan — Installation

Tighten Cap Screws on Front Frame/Oil Sump — Tractors

Oil Pump — Removal

Inspect and Clean Oil Pump

Oil Pump — Installation

Oil Pump — Remove Engine from Tractors for Access

Install Oil Bypass & Oil Pump Tubes & Oil Pump Adapter

Remove, Inspect, and Install Oil Pump Pickup Tube

Check Pumping Gear Backlash

Oil Pump Drive Gear — Inspection

Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash

Check Drive Shaft End Play

Check Drive Shaft Side Movement

Oil Pump Oil Pickup Tube — Removal and Inspection

Oil Pump Oil Pickup Tube — Installation

Top-Load Oil Filter Assembly — Installation

Group 070: Cooling System Repair and Adjustment

Belt Tensioner — Spring Tension and Belt Wear Check

Fan Drive Assembly

Inspect Fan Hub & Replace Bearings in Heavy-Duty, Adjustable Fan Drive Assembly

Inspect and Install Fan Assembly

Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive Assembly

Fixed Fan Drive Assembly — Removal

Visually Inspect Coolant Pump

Remove Coolant Pump Assembly

Install Coolant Pump Assembly

Bleed Air from Coolant System

Fan Assembly — Removal

Fan Assembly — Inspection and Installation

Remove and Test Thermostat

Install Thermostat

Install Thermostat Housing and Bypass Tube

Remove Thermostat Housing and Bypass Tube

Servicing of Engine Coolant Heater

Group 080: Air Intake and Exhaust System Repair and Adjustment

Remove and Install Air Bleed/Check Valve

Exhaust Manifold — Installation

Exhaust Manifold — Remove

Turbocharger — Failure Analysis

Turbocharger — Extending Life

Intake Manifold — Installation

Air Intake Assembly — Removal

Turbocharger Inspection

Turbocharger — Install

Turbocharger — Remove

Turbocharger Oil Drain Line — Installation

Turbocharger Oil Drain Line — Removal

Group 090: Electronic Fuel System Repair and Adjustments

General Information

Clean Electronic injectors (In Engine)

Clean Electronic Injector (EI) Body

Inspect Electronic Injector (EI) Body

Clean Electronic Injector (EI) Bore

Clean Electronic Injector (EI) Orifice

Remove and Install Flow Dampers

Remove and Install Fuel Filters

Fuel Filter Header Assembly and Jumper Harness Assembly — Remove

Fuel Filter Header — Inspect and Component Assembly

Fuel Filter Header Assembly and Jumper Harness Assembly — Installation

Remove and Install High Pressure Common Rail

Remove and Install High-Pressure Fuel Pump Assembly

Remove and Install Electronic Injectors (EIs)

Remove and Install Fuel Injector Wiring Harness

Remove and Install Leak-off Lines

Remove and Install Fuel Transfer Pump Assembly

Remove and Install Pressure Limiter

Remove and Install Fuel Suction Control Valve

Relieve Fuel System Pressure

Group 100: OEM Starting and Charging Systems Repair and Adjustment

Remove and Install Alternator (OEM Engines)

Remove and Install Starter Motor (OEM Engines)

Group 110: Electrical Engine Control Repair and Adjustment

Component Location

Remove and Install High Pressure Pump (Camshaft Timing) Sensor

Remove and Install Charge Air Cooler Outlet Air Temperature Sensor

Remove and Install Crankshaft Position Sensor

Remove and Install Engine Control Unit (ECU)

Remove and Install Coolant Temperature Sensor

Remove and Install Oil Pressure Sensor

Remove and Install Fuel Rail Pressure Sensor

Fuel Temperature Sensor — Installation