John Deere 6090 Diesel Engine Level 33 ECU Component Technical Service Repair Manual CTM117719 PDF - MJODCTM117719.zip
A full-coverage service and repair manual, complete with Electrical Wiring Diagrams, for the John Deere 6090 Diesel Engine equipped with a Level 33 ECU. It contains every technical detail needed to service, troubleshoot, fix, and rebuild the engine to professional-shop standards.
Inside the John Deere 6090 Diesel Engine Level 33 ECU workshop service repair manual, you'll find:
* 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: 2,636 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CTM117719 (14JUN19) - John Deere 6090 Diesel Engine Level 33 ECU Component Technical Manual.pdf
MAIN SECTIONS
Contents...11
General Information...13
Safety...15
Understand Signal Words...15
Recognize Safety Information...15
Replace Safety Signs...15
Follow Safety Instructions...16
California Proposition 65 Warning...16
Exhaust Filter Cleaning...16
Avoid Hot Exhaust...16
Work In Ventilated Area...17
Decommissioning Proper Recycling and Disposal of Fluids and Components...17
Prevent Machine Runaway...18
Practice Safe Maintenance...18
Work in Clean Area...19
Wear Protective Clothing...19
Service Machines Safely...19
Use Proper Tools...20
Construct Dealer-Made Tools Safely...20
Support Machine Properly...20
Use Proper Lifting Equipment...21
Protect Against Noise...21
Illuminate Work Area Safely...21
Install All Guards...22
Stay Clear of Rotating Drivelines...22
Protect Against High Pressure Spray...22
Service Cooling System Safely...23
Remove Paint Before Welding or Heating...23
Precautions for Welding...24
Wait Before Opening High-Pressure Fuel System...24
Avoid High-Pressure Fluids...25
Avoid Heating Near Pressurized Fluid Lines...25
Avoid Static Electricity Risk When Refueling...26
Handle Fluids SafelyAvoid Fires...26
Prepare for Emergencies...26
Handling Batteries Safely...27
Prevent Acid Burns...28
Prevent Battery Explosions...28
Live With Safety...29
Engine Identification...31
Engine Serial Number Plate Information...31
OEM Engine Option Code Label...32
Information Relative to Emissions Regulations...32
Emissions Control System Certification Label...33
Fuels, Lubricants, and Coolant...35
Diesel Exhaust Fluid (DEF) Use in Selective Catalytic Reduction (SCR) Equipped Engines...35
Storing Diesel Exhaust Fluid (DEF)...36
Refilling Diesel Exhaust Fluid (DEF) Tank...37
Testing Diesel Exhaust Fluid (DEF)...38
Disposal of Diesel Exhaust Fluid (DEF)...38
Diesel Fuel...39
Supplemental Diesel Fuel Additives...39
Lubricity of Diesel Fuel...40
Handling and Storing Diesel Fuel...40
Biodiesel Fuel...41
Testing Diesel Fuel...42
Fuel Filters...42
Minimizing the Effect of Cold Weather on Diesel Engines...43
John Deere Break-In Plus Engine Oil Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V...44
Diesel Engine Oil Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V...45
Diesel Engine Oil and Filter Service Intervals Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V OEM Applications...46
Diesel Engine Oil and Filter Service Intervals...46
Mixing of Lubricants...46
Alternative and Synthetic Lubricants...47
Lubricant Storage...47
Oil Filters...47
Diesel Engine Coolant (engine with wet sleeve cylinder liners)...48
Water Quality for Mixing with Coolant Concentrate...49
Operating in Warm Temperature Climates...49
Testing Coolant Freeze Point...50
Disposing of Coolant...50
Repair and Adjustments...58
Engine Rebuild...59
Check Air Intake System...59
Check and Service Cooling System...59
Check Crankcase Vent System...61
Check Electrical System...61
Check Exhaust System...62
Clean Engine...62
Disconnect Turbo Oil Inlet Line Rollover Stand...63
Engine Assembly Sequence...64
Engine Break-In Procedure...65
Engine Disassembly Sequence...67
Engine Repair Stand...68
General Tune-Up Recommendations...68
Install Adapters on Repair Stand...69
Install Lift Straps 6090HFC09...69
Lift Straps Removal...70
Lifting Procedure...71
Mount Engine on Repair Stand...72
Overhaul Guidelines...73
Safety Precautions...74
Sealant Application Guidelines...75
Cylinder Head and Valve Repair and Adjustment...77
Cylinder Block Top Deck Cleaning and Inspection...77
Cylinder Head Cleaning and Inspection...78
Cylinder Head Flatness Check...79
Cylinder Head Installation...80
Cylinder Head Removal...84
Cylinder Head Thickness Measurement...86
Cylinder Head Gasket Inspection...87
Fuel Injector Sleeves Installation...88
Fuel Injector Sleeves Removal...89
Push Rod Cleaning and Inspection...91
Rocker Arm Cover Inspection...91
Rocker Arm Cover Installation...92
Rocker Arm Cover Removal...94
Rocker Arm Shaft Assembly Assemble...96
Rocker Arm Shaft Assembly Inspection...98
Rocker Arm Shaft Assembly Installation...100
Rocker Arm Shaft Assembly Removal...101
Rocker Arm Shaft Assembly Tear Down...102
Valve Cleaning and Inspection...104
Valve Clearance Adjustment...105
Valve Grinding...108
Valve Measurement...109
Valve Recess Measurement...110
Valve Assembly Installation...110
Valve Assembly Removal...112
Valve Bridge, Valve Rotator, and Valve Keepers Inspection...113
Valve Guides Cleaning and Measurement...113
Valve Guides Installation...114
Valve Guides Removal...115
Valve Seat Cleaning and Inspection...115
Valve Seat Grinding and Measurement...116
Valve Seat Installation...117
Valve Seat Removal...117
Valve Springs Inspection and Measurement...118
Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment...119
Connecting Rod Center-to-Center Bore Measurement...119
Connecting Rod General Information...120
Connecting Rod and Cap Inspection...121
Connecting Rod Bearing Inspection and Measurement...122
Connecting Rod Bearing Inspection and Measurement (Rod and Crankshaft in Engine)...123
Connecting Rod Cap Screw Torque Procedure...124
Connecting Rod Pin Bore Cleaning and Inspection...125
Cylinder Block Oil, Coolant, and Camshaft Frost Plugs Installation...126
Cylinder Block Inspect and Reclaim...128
Cylinder Block Measurements...138
Cylinder Block, Piston, and Rod Troubleshooting Guide...139
Cylinder Liner Cleaning...139
Cylinder Liner Installation...140
Cylinder Liner Removal...142
Cylinder Liner Standout Measurement...144
Cylinder Liner Visual Inspection...145
Cylinder Liner Flange Measurement...146
Cylinder Liner O-ring Bore Cleaning...147
Cylinder Liner Packing Installation...147
Piston Cleaning...148
Piston Inspection...148
Piston and Connecting Rod Assembly Assemble...149
Piston and Connecting Rod Assembly Installation...150
Piston and Connecting Rod Assembly Removal...151
Piston and Connecting Rod Assembly Tear Down...153
Piston Cooling Orifice Inspection...154
Piston Cooling Orifice Installation...155
Piston Cooling Orifice Removal...156
Piston Height Measurement...156
Piston Pin and Bore Inspection...157
Piston Pin and Bushing Inspection...157
Piston Pin Bushing Installation...159
Piston Pin Bushing Removal...160
Piston Protrusion Measurement...161
Piston Ring Groove Wear Check...161
Piston Ring Installation...162
Piston Ring Removal...163
Piston to Liner Clearance Check...163
Crankshaft, Main Bearings, Flywheel Repair and Adjustment...165
Crankshaft End Play Check...165
Crankshaft Inspection...166
Crankshaft Installation...167
Crankshaft Measurement...170
Crankshaft Removal...171
Crankshaft Gear Installation...173
Crankshaft Gear Removal...174
Crankshaft Grinding Guidelines...175
Crankshaft Journals and Bearing Assembly Measurement...176
Crankshaft Main Bearing Oil Clearance Check...177
Crankshaft Main Bearing Cap Line Bore Specifications...177
Crankshaft Main Bearing Cap Removal...179
Crankshaft Rear Oil Seal Installation...181
Crankshaft Rear Oil Seal Removal...183
Crankshaft Rear Oil Seal Housing Installation...184
Crankshaft Rear Oil Seal Housing Removal...185
Crankshaft Thrust Bearing Inspection...185
Crankshaft Unitized Front Oil Seal Installation...186
Crankshaft Unitized Front Oil Seal Removal...187
Crankshaft Rubber Vibration Damper and Hub Installation...188
Crankshaft Rubber Vibration Damper and Hub Removal...191
Crankshaft Viscous Vibration Damper Inspection...193
Crankshaft Viscous Vibration Damper and Hub Installation...194
Crankshaft Viscous Vibration Damper and Hub Removal...198
Flywheel Inspection...201
Flywheel Installation...202
Flywheel Removal...204
Flywheel Face Flatness Check...204
Flywheel Housing Installation...205
Flywheel Housing Removal...207
Flywheel Pilot Bearing Bore Concentricity Check...208
Flywheel Ring Gear Installation...209
Flywheel Ring Gear Removal...210
Camshaft and Timing Gear Train Repair and Adjustment...211
Auxiliary Rear Drive Cover Installation...211
Auxiliary Rear Drive Cover Removal...211
Camshaft Check End Play...212
Camshaft Inspection...212
Camshaft Installation...213
Camshaft and Camshaft Followers Removal...215
Camshaft Bushing Measurement...216
Camshaft Bushing Replacement...216
Camshaft Followers Inspection and Measurement...218
Camshaft Followers Installation...219
Camshaft Gear Inspection...219
Camshaft Gears Removal...220
Camshaft Journal Measurements...220
Camshaft Lobe Lift Measurement...221
Camshaft Thrust Washer Thickness Measurement...221
Crankshaft Driven Auxiliary Drive Removal and Inspection...221
Crankshaft Driven Auxiliary Drive Installation...223
Timing Gear Cover Installation...227
Timing Gear Cover Removal...232
Timing Gears Check Backlash...234
Lubrication System Repair and Adjustment...235
Dipstick Assembly Inspection...235
Dipstick Oil Fill Tube Installation...236
Dipstick Oil Fill Tube Removal...238
Oil Cooler Assembly Assemble and Installation...240
Oil Cooler Assembly Removal and Inspection...244
Oil Cooler Cover Inspection and Repair...245
Oil Filter Assembly and Housing Adapter Installation...246
Oil Filter Assembly and Housing Adapter Removal...251
Oil Filter Changing...255