John Deere 6090 Diesel Engine Level 21 ECU Workshop Service Manual (CTM104819) Worldwide PDF - MJODCTM104819.zip
This is the full Component Technical Manual (CTM) covering the John Deere Diesel Engine 6090 (Level 21 ECU - Worldwide), packed with the workshop data professionals rely on to service, troubleshoot, fix, and rebuild the engine to dealer standards.
Inside the John Deere Diesel Engine 6090 (Level 21 ECU - Worldwide) 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.
ctm104819 - John Deere 6090 Diesel Engine — Level 21 ECU - (Worldwide Edition) Component Technical Manual.pdf
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Total Pages: 4,298 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Category: CTM
Language: English Spanish Italian Chinese Czech Dutch Finnish French German Hungarian Japanese Polish Portuguese Romanian Russian Swedish Danish
Published on 2019/06/07
ctm104819 - 6090 Diesel Engine — Level 21 ECU -: (Worldwide Edition)
Component Technical Manual
Main Sections
Foreword
Identification Views
Related Manuals
Training Information
Definition of Terms
Section 01: General Information
Group 000: Safety
Replace Safety Signs
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Illuminate Work Area Safely
Work in Clean Area
Use Proper Tools
Construct Dealer-Made Tools Safely
Support Machine Properly
Use Proper Lifting Equipment
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
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
Precautions for Welding
Avoid High-Pressure Fluids
Protect Against High Pressure Spray
Wait Before Opening High-Pressure Fuel System
Prevent Battery Explosions
Avoid Hot Exhaust
Exhaust Filter Cleaning
Work In Ventilated Area
Service Cooling System Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Group 001: Engine Identification
Engine Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
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
Overhaul Guidelines
Check and Service Cooling System
Check Air Intake System
Check Crankcase Vent System
Check Electrical System
Check Exhaust System
Clean Engine
Disconnect Turbo Oil Inlet Line
Engine Assembly Sequence
Engine Break-In Guidelines
Engine Disassembly Sequence
Engine Repair Stand
General Tune-Up Recommendations
Install Adapters on Repair Stand
Install Lift Straps — 6090HFC94
Install Lift Straps — 6090HFC95
Lifting Procedure
Mount Engine on Repair Stand
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 — Removal
Cylinder Head — Thickness Measurement
Fuel Injector Sleeves — Installation
Fuel Injector Sleeves — Removal
Push Rod — Cleaning and Inspection
Rocker Arm Cover Vent hose — Inspection
Rocker Arm Cover — Removal
Rocker Arm Cover — Installation
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 Guides — Knurling
Valve Guides — Measurement
Valve Guides — Cleaning
Valve Guide — Removal
Valve Guide — Installation
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
Valve Springs — Measurement
Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment
Piston Ring — Installation
Connecting Rod — Installation
Connecting Rod and Cap — Inspection
Connecting Rod Cap Screw — Torque Procedure
Connecting Rod Bearing — Inspection and Measurement
Cylinder Block — Cleaning and Inspection
Cylinder Block — Inspect and Reclaim
Cylinder Block — Measurements
Cylinder Block Oil, Coolant, and Camshaft Frost Plugs — Installation
Cylinder Liner — Cleaning
Cylinder Liner — Deglazing
Cylinder Liner — Installation and Height Measurement
Cylinder Liner Manufacturing Date Code Explanation
Cylinder Liner — Measure Liner Flange Thickness
Cylinder Liner — Removal
Cylinder Liner — Visual Inspection
Dipstick Assembly — Inspection
Dipstick Assembly — Installation
Dipstick Assembly — Removal
Piston — Cleaning
Piston — Visually Inspection
Piston and Connecting Rod Assemblies — 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
Piston Pin and Bushing — Inspection
Piston Pin Bushing — Installation
Piston Pin Bushing — Removal and Inspection
Piston to Liner — Clearance Check
Group 040: Crankshaft, Main Bearings and Flywheel Repair and Adjustment
Crankshaft — End Play Check
Crankshaft — Removal
Crankshaft — Inspection
Crankshaft — Installation
Crankshaft Unitized Front Oil Seal — Removal
Crankshaft Unitized Front Oil Seal — Installation
Crankshaft Unitized Rear Oil Seal — Removal (Straight Nose Crankshaft)
Crankshaft Unitized Rear Oil Seal — Installation
Crankshaft Rear Oil Seal Housing — Removal
Crankshaft Rear Oil Seal Housing — Installation
Crankshaft Vibration Damper and Hub — Removal
Crankshaft Vibration Damper and Hub — Installation
Crankshaft Dual Damper — Removal
Crankshaft Dual Damper — Installation
Crankshaft Gear — Replace
Flywheel — Removal
Flywheel — Inspection
Flywheel Face — Runout Check
Flywheel — Installation
Flywheel Housing — Removal
SAE 1 Flywheel Housing — Inspection
SAE 2 Flywheel Housing — Inspection
Flywheel Housing — Installation
Check Main Bearing Oil Clearance
Flywheel Ring Gear — Removal
Flywheel Ring Gear — Installation
Main Bearing Cap — Removal
Main Bearing Cap — Line Bore Specs
Pilot Bearing Bore — Runout Check
Thrust Bearing — Inspection
Open Crankcase Vent System — Removal
Open Crankcase Vent System — Installation
Group 050: Camshaft and Timing Gear Train Repair and Adjustment
Camshaft — Removal
Camshaft — Visual Inspection
Camshaft and Gears — Installation
Camshaft Bushings Service
Camshaft End Play and Gear Backlash — Check
Camshaft Gears — Removal
Camshaft Followers — Inspection and Measurement
Camshaft Journal — Measurements
Camshaft Lobe — Lift Measurement
Crankshaft Driven Auxiliary Drive — Removal and Inspection
Crankshaft Driven Auxiliary Drive — Installation
Camshaft Roller Followers — Installation
Fan Drive, Variable Speed — Removal
Fan Drive, Variable Speed — Installation
Thrust Washer — Thickness Measurement
Timing Gear Cover — Removal
Timing Gear Cover — Install Plugs
Timing Gear Cover — Installation
Group 060: Lubrication System Repair and Adjustment
Oil Cooler — Assembly
Oil Cooler — Removal
Oil Cooler — Inspection
Oil Cooler — Installation
Oil Cooler Cover — Inspection and Repair
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
Oil Pump — Removal
Oil Pump — Tear Down and Inspect
Oil Pump — Assemble
Oil Pump — Installation
Oil Pump Adapter and Tubes — Removal
Oil Pump Adapter and Tubes — Installation
Oil Pump Drive Gear — Backlash Check (Pump Removed)
Oil Pump Drive Gear to Crank Gear — Backlash Check (Pump Installed)
Oil Pump Drive Shaft — End Play Check
Oil Pump Drive Shaft — Side Movement Check
Oil Pump Oil Pickup Tube — Removal and Inspection
Oil Pump Oil Pickup Tube — Installation
Top-Load Oil Filter Assembly
Top Load Oil Filter — Theory of Operation
Group 070: Cooling System Repair and Adjustment
Belt Tensioner — Spring Tension and Belt Wear Check
Coolant Pump — Visual Inspection
Coolant Pump Assembly — Removal
Coolant Pump Assembly — Installation
Coolant System — Air Bleeding
Fan Assembly — Removal
Fan Assembly — Inspection and Installation
Fixed Fan Drive Assembly — Assemble
Fixed Fan Drive Assembly — Removal
Fixed Fan Drive Assembly — Installation
Fixed Fan Drive Assembly — Tear Down, Inspection and Measurement
Thermostat — Removal
Thermostat — Testing
Thermostat — Installation
Thermostat Housing — Removal
Thermostat Housing — Tear Down
Thermostat Housing — Assemble
Thermostat Housing and Bypass Tube — Installation
Group 080: Air System Repair and Adjustment — Dual Turbocharger Option
Air Bleed/Check Valve — Installation
Air Bleed/Check Valve — Removal
Air Intake Tube, Duct, and Air Throttle Actuator — Installation