John Deere 6090 Diesel Engine Level 14 ECU Component Technical Manual CTM385 (CTM385) - MJODCMT385.zip
A full Component Technical manual featuring complete Electrical Wiring Diagrams for the John Deere 6090 Diesel Engine — Level 14 ECU (Worldwide Edition), packed with every technical detail needed to service, troubleshoot, fix, and rebuild these engines the way professional technicians do.
The John Deere 6090 Diesel Engines workshop Component Technical Service 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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Total Pages: 2,503 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
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ctm385 - 6090 Diesel Engine — Level 14 ECU -: (Worldwide Edition)
Component Technical Manual
Table of Contents
Foreword
Section 01: General
Group 000: Safety
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 Agricultural Chemicals Safely
Handle Fluids Safely—Avoid Fires
Handling Batteries Safely
Illuminate Work Area Safely
Install All Guards
Live With Safety
Park Machine Safely
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
Understand Signal Words
Use Proper Lifting Equipment
Use Proper Tools
Use Steps and Handholds Correctly
Wait Before Opening High-Pressure Fuel System
Wear Protective Clothing
Work in Clean Area
Work In Ventilated Area
Group 001: Engine Identification
Engine Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
Emissions Control System Certification Label
Group 002: Fuels, Lubricants and Coolants
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 090: Electronic Fuel System Repair and Adjustments
Fuel System - General Information
Relieve Fuel System Pressure
Remove and Install Fuel Filters
Remove and Install Fuel Transfer Pump Assembly
Remove and Install High Pressure Fuel Pump Assembly
Remove and Install Fuel Suction Control Valve
Remove and Install High Pressure Common Rail
Remove and Install Flow Dampers
Remove and Install Pressure Limiter
Remove and Install Leak-off Lines
Remove and Install Electronic Injectors (EIs)
Remove and Install Fuel Injector Wiring Harness
Clean Electronic Injector (EI) Bore
Clean Electronic Injector (EI) Orifice
Clean Electronic Injector (EI) Body
Inspect Electronic Injector (EI) Body
Remove and Install Jet Fuel Lubricity Doser Header
Remove and Replace Jet Fuel Lubricity Doser Elements
Clean Electronic injectors (In Engine)
Group 100: Electronic Air System Repair and Adjustment
Remove & Install EGR Valve
Group 110: Electronic Engine Control Repair and Adjustment
Fuel System - General Information
Remove and Install Coolant Temperature Sensor
Remove and Install Fuel Rail Pressure Sensor
Remove and Install High Pressure Pump (Camshaft Timing) Sensor
Remove and Install Oil Pressure Sensor
Remove and Install Water in Fuel (WIF) Sensor
Remove and Install Crankshaft Position Sensor
Remove and Install Turbo Speed Sensor
Remove and Install Manifold Air Pressure (MAP) Sensor
Remove and Install Manifold Air Temperature (MAT) Sensor
Remove and Install EGR Temperature Sensor
Remove and Install Charge Air Cooler Outlet Air Temperature Sensor
Remove and Replace Air Intake Temperature - Turbocharger Compressor Inlet
Engine Control Unit (ECU) Maintenance
Remove and Install Engine Control Unit (ECU)
Remove and Install Low Pressure Fuel Pressure Sensor
Remove and Install Air Bleed/Check Valve
Welding
Using High-Pressure Washing
Connectors
Installation of Repair Wire Assembly (RWA)
Connector Repair
Repair WEATHERPACK Connector
Repair METRI-PACK Connector (Push Type)
Repair Cinch FlexBox Connector
Repair DT Series DEUTSCH Connectors
Repair HD Series DEUTSCH Connectors
Section 03: Theory Of Operation
Group 130: Electronic Fuel System Operation
About This Group
Fuel System Operation
Fuel System Operation - Jet Fuel
Fuel Transfer Pump Operation
Primary Filter Operation
Doser Operation
Secondary Fuel Filter Operation
High Pressure Fuel Pump Operation
High Pressure Common Rail (HPCR) Operation
Electronic Injector (EI) Operation
Group 135: Electronic Air System Operation
About This Group
Electronic Air System Control Operation
Exhaust Gas Recirculation Flow and Calculations
Turbocharger
Turbocharger Actuator
Exhaust Gas Recirculation Cooler
Exhaust Gas Recirculation Valve
Group 140: Electronic Control System Operation
About This Group
Electronic Control System Terminology
Component Location Diagram 1
Component Location Diagram 2
Component Location Diagram 3
Component Location Diagram 4
Component Location Diagram 5
Component Location Diagram 6
Component Location Diagram 7
Component Location Diagram 8
Component Location Diagram 9
Engine Control Unit (ECU) System Operation
Controller Area Network (CAN)
Pilot Injection Operation
Measuring Temperature
Engine Control Unit (ECU) Temperature Sensor
Engine Coolant Temperature (ECT) Sensor
Fuel Temperature Sensor
Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor
Charge Air Cooler Outlet Air Temperature Sensor
Intake Manifold Air Temperature (MAT) Sensor
Turbo Compressor Inlet Temperature Sensor
Turbo Turbine Inlet Temperature
Measuring Pressure
Barometric Air Pressure (BAP) Sensor
Fuel Rail Pressure Sensor
Fuel Transfer Pump Pressure Sensor
Manifold Air Pressure (MAP) Sensor
Oil Pressure Sensor
Dual Fuel Rail Pressure Sensor (Redundant ECU Applications)
Measuring Speed
Crank Position Sensor
Pump Position Sensor
Turbo Speed Sensor
Throttle Descriptions
CAN Throttle
Pulse-Width-Modulated (PWM) Throttle
Analog Throttle
Digital Multi-State Throttle
Dual-State Throttle
Tri-State Throttle
Ramp Throttle
Throttle Adjustments
Throttle Offsets
Self-Calibration
Combination Throttle
Marine Throttle
Engine Derate and Shutdown Protection
Electronic Injector (EI) Wiring Harness Connector
Intake Air Heater Operation
Torque Curve Selection
Governor Droop Mode Selection
Suction Control Valve
Water in Fuel (WIF) Sensor
Engine Coolant Level Switch
Cruise Control Operation
Power Supply #1
Power Supply #2
Power Supply #3
Power Supply #4
Power Supply #5
Section 04: Diagnostics
Group 150: Observable Diagnostics and Tests
About This Group
A1 - Intake Air Heater Check
D1 - ECU Does Not Communicate with Service ADVISOR
D2 - ECU Does Not Communicate with Diagnostic Gauge or Gauge Displays CAN Bus Error
D3 - ECU Does Not Program With Service ADVISOR
E1 - Engine Cranks/Won't Start
E2 - Engine Misfires/Runs Irregularly
E3 - Engine Does Not Develop Full Power
E4 - Engine Emits Excessive White Exhaust Smoke
E5 - Engine Emits Excessive Black or Gray Exhaust Smoke
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
E9 - Primary Analog Throttle Does Not Respond
E10 - Secondary Analog Throttle Does Not Respond
E11 - Engine Emits Excessive Blue Exhaust Smoke
F1 - Low-Pressure Fuel System Check
F2 - High-Pressure Fuel System Check
F3 - Excessive Fuel Consumption
F4 - Fuel in Oil
F5 - Fuel in Coolant
F6 - Excessive Fuel Filter Replacement
Fuel System Leakage Diagnostic Procedure
Check Fuel Supply Quality
Test The Fuel Bleed System
Test for Air in Fuel
Bleed The Fuel System
Check for Restricted Fuel Leak-off Line
Check High-Pressure Fuel Pump Static Timing
Excessive Engine Crankcase Pressure (Blow-By)
Charge Air System Diagnostic
Charge Air Cooler Test
EGR Cooler Test
Variable Geometry Turbocharger (VGT) Component Test
Temperature Sensor Validity Test
EGR-VGT System Temperature and Flow Test
Bleed Coolant System
Group 160: Trouble Code Diagnostics and Tests
About This Group
Connecting to Service ADVISOR
Communication Error Test Instructions
Control Unit Information and Overview Test
Cylinder Cutout Test Instructions
Cylinder Electronic Compression Test Instructions
Cylinder Misfire Test Instructions
Diagnostic Gauge Active DTC Viewing Instructions
Diagnostic Gauge Stored DTC Clearing Instructions
Diagnostic Gauge Stored DTC Viewing Instructions
Diagnostic Trouble Code Designations
Diagnostic Trouble Codes List
Digital Multimeter — Using
EGR Valve — Clean Test Instructions
Electrical Circuit Concepts
Electronic Injector — Calibration Information
Engine Control Unit (ECU) — Level Identification
Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU
Engine Control Unit (ECU) — Reprogramming Current ECU
Engine Control Unit (ECU) — Reprogramming Instructions
Engine Hours — Updating Instructions
Exhaust Gas Recirculation Valve Calibration
Failure Mode Indicator Designations
Fuel Rail Cap and Plug Kit
Harness Diagnostic Mode Test
Interactive Tests and Calibration Results — Printing, Exporting, or Saving Instruction
Internal Data Monitor — Instructions
Intermittent DTC Diagnostics
Keep Electronic Control Unit Connectors Clean
Load Profile Information Test — Instructions
Service ADVISOR Data Parameter Description
Snapshot Instructions
Software and Hardware Verification
Terminal Test