John Deere PowerTech 9.0 L OEM Diesel Engines Base Engine Repair Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere PowerTech 9.0 L OEM Diesel Engines Base Engine Repair Technical Manual – PDF DOWNLOAD
For complete service information also see:
9.0 L Diesel Engines — Level 14 Electronic
Fuel System with Denso HPCR …………………….. CTM385
OEM Engine Accessories …………………………….. CTM67
Application List……………………………………………. CTM106819
Introduction:
Foreword :
This repair manual is valid for the engines. This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Information in this manual is organized in sections and sub divided into groups.
- This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized. Read each block of material completely before performing service to check for differences in procedures or specifications.
- Follow only the procedures that apply to the component you are working on. Component Technical Manuals are concise service guides for specific components.
- Component technical manuals are written as stand-alone manuals covering multiple machine applications. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere PowerTech 9.0 L OEM Diesel Engines Base Engine Repair Technical Manual – PDF DOWNLOAD
Contents……………………………………………………………… 5
General…………………………………………………………… 7
Safety………………………………………………………… 9
Work In Ventilated Area……………………………………… 9
Recognize Safety Information…………………………………. 9
Work in Clean Area………………………………………….. 9
Dispose of Waste Properly……………………………………. 10
Avoid Harmful Asbestos Dust………………………………….. 10
Handle Fuel Safely—Avoid Fires……………………………….. 10
Prepare for Emergencies……………………………………… 11
Handle Starting Fluid Safely…………………………………. 11
Handle Fluids Safely—Avoid Fires……………………………… 11
Avoid High-Pressure Fluids…………………………………… 12
Use Proper Lifting Equipment…………………………………. 12
Illuminate Work Area Safely………………………………….. 12
Live With Safety……………………………………………. 13
Service Machines Safely……………………………………… 13
Handle Chemical Products Safely………………………………. 13
Protect Against Noise……………………………………….. 14
Remove Paint Before Welding or Heating………………………… 14
Stay Clear of Rotating Drivelines…………………………….. 15
Service Cooling System Safely………………………………… 15
Follow Safety Instructions…………………………………… 16
Use Proper Tools……………………………………………. 16
Construct Dealer-Made Tools Safely……………………………. 16
Practice Safe Maintenance……………………………………. 17
Understand Signal Words……………………………………… 17
Replace Safety Signs………………………………………… 18
Prevent Battery Explosions…………………………………… 18
Protect Against High Pressure Spray…………………………… 18
Avoid Heating Near Pressurized Fluid Lines…………………….. 19
Wear Protective Clothing…………………………………….. 19
Wait Before Opening High-Pressure Fuel System………………….. 19
Handle Agricultural Chemicals Safely………………………….. 20
Handling Batteries Safely……………………………………. 21
Install All Guards………………………………………….. 21
Avoid Hot Exhaust…………………………………………… 22
Engine Identification…………………………………………… 23
Engine Model Designation…………………………………….. 23
Engine Serial Number Plate Information………………………… 24
OEM Engine Option Code Label…………………………………. 24
Fuels, Lubricants and Coolant……………………………………. 25
Diesel Fuel………………………………………………… 25
Biodiesel Fuel……………………………………………… 26
Minimizing the Effect of Cold Weather on Diesel Engines…………. 27
Handling and Storing Diesel Fuel……………………………… 28
Lubricity of Diesel Fuel…………………………………….. 28
Testing Diesel Fuel…………………………………………. 28
Engine Oil and Filter Service Intervals……………………….. 28
Diesel Engine Oil…………………………………………… 29
Diesel Engine Break-In Oil…………………………………… 30
Oil Filters………………………………………………… 30
Grease…………………………………………………….. 31
Alternative and Synthetic Lubricants………………………….. 31
Lubricant Storage…………………………………………… 31
Mixing of Lubricants………………………………………… 32
Heavy Duty Diesel Engine Coolant……………………………… 32
Supplemental Coolant Additives……………………………….. 33
Operating in Warm Temperature Climates………………………… 33
Additional Information About Diesel Engine Coolants and John Dee…. 34
Diesel Engine Coolant……………………………………….. 35
Testing Diesel Engine Coolant………………………………… 35
Drain Intervals for Diesel Engine Coolant……………………… 36
Repair and Adjustments……………………………………………… 40
Engine Rebuild…………………………………………………. 41
Engine Overhaul Guidelines…………………………………… 41
Engine Repair Stand…………………………………………. 41
Safety Precautions………………………………………….. 42
Install Adapters on Engine Repair Stand……………………….. 42
Install Engine Lift Straps…………………………………… 43
Engine Lifting Procedure…………………………………….. 44
Clean Engine……………………………………………….. 44
Disconnect Turbocharger Oil Inlet Line………………………… 45
Mount Engine on Repair Stand…………………………………. 46
Engine Disassembly Sequence for Overhaul………………………. 48
Sealant Application Guidelines……………………………….. 49
Engine Assembly Sequence After Overhaul……………………….. 50
Engine Break-In Guidelines…………………………………… 50
Perform Engine Break-In……………………………………… 51
Check Crankcase Ventilation System……………………………. 52
Check Air Intake System……………………………………… 52
Check Exhaust System………………………………………… 52
Check and Service Cooling System……………………………… 53
Check Electrical System……………………………………… 55
General Tune-Up Recommendations………………………………. 56
Cylinder Head and Valves Repair and Adjustment…………………….. 57
Valve — Clearance Adjustment…………………………………. 57
Valve — Lift Check………………………………………….. 59
Cylinder Head—Removal……………………………………….. 60
Diagnosing Head Gasket Joint Failures…………………………. 62
Head Gasket Diagnostic Charts………………………………… 63
Head Gasket Inspection and Repair Sequence…………………….. 64
Rocker Arm Assembly — Inspection……………………………… 65
Rocker Arm Shaft — Tear Down…………………………………. 65
Valve — Recess Measurement…………………………………… 66
Preliminary Cylinder Head and Valve Checks…………………….. 67
Valve — Assembly Removal…………………………………….. 68
Valve Springs — Inspection…………………………………… 69
Valve Retainer, Valve Bridges, and Valve Retainer Locks — Inspec…. 69
Valve — Cleaning and Inspection………………………………. 69
Valve — Measurement…………………………………………. 70
Valve — Grinding……………………………………………. 71
Cylinder Head — Cleaning and Inspection……………………….. 71
Cylinder Head — Flatness Check……………………………….. 72
Cylinder Head — Thickness Measurement…………………………. 72
Fuel Injector Sleeves — Remove……………………………….. 73
Fuel Injector Sleeves — Install………………………………. 74
Valve Guide — Cleaning………………………………………. 74
Valve Guide — Measurement……………………………………. 75
Valve Seat — Cleaning and Inspection………………………….. 75
Valve Seat — Recess Measurement………………………………. 76
Valve Seat — Grinding……………………………………….. 77
Valve Seat Inserts — Removal…………………………………. 77
Valve Seat Inserts — Installation…………………………….. 78
Cylinder Head Nozzle Bore — Cleaning and Inspection…………….. 78
Push Rod — Cleaning and Inspection……………………………. 78
Cylinder Block Top Deck — Cleaning and Inspection………………. 78
Cylinder Liner — Standout Measurement…………………………. 79
Valve Assembly — Reassemble………………………………….. 80
Cylinder Head — Installation…………………………………. 81
Cylinder Head Cap Screw Torque Procedure………………………. 83
Rocker Arm Assembly — Installation……………………………. 85
Rocker Arm Cover Vent hose — Inspection……………………….. 85
Final Assembly — Fuel Pump Side of Engine……………………… 86
Final Assembly — Exhaust Manifold Side of Engine……………….. 87
Perform Engine Break— In…………………………………….. 91
Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment……… 93
Preliminary Liner, Piston, and Rod Checks……………………… 93
Remove Pistons and Connecting Rod Assemblies…………………… 94
Cylinder Liner — Standout Measurement…………………………. 97
Remove Cylinder Liners………………………………………. 98
Deglaze Cylinder Liners………………………………………100
Cylinder Liner — Cleaning…………………………………….100
Piston and Connection Rod Assembly — Tear Down………………….101
Clean Pistons……………………………………………….101
Visually Inspect Pistons……………………………………..102
Inspect Piston Pin and Bore…………………………………..102
Visually Inspect Cylinder Liners………………………………103
Cylinder Liner Manufacturing Date Code Explanation………………104
Piston to Liner — Clearance Check……………………………..104
Inspect Rod and Cap………………………………………….106
Piston Pin and Bushing — Inspection……………………………107
Piston Pin Bushing and Pin Bore — Removal………………………109
Measure Liner Flange…………………………………………109
Inspect and Measure Connecting Rod Bearings…………………….110
Piston Pin Bushing — Installation……………………………..111
Complete Disassembly of Cylinder Block (If Required)…………….111
Piston Cooling Orifices — Removal……………………………..112
Inspect and Clean Cylinder Block………………………………112
Measure Cylinder Block……………………………………….114
Piston Cooling Orifices — Installation…………………………115
Install Packing on Cylinder Liner and O-Rings in Block…………..116
Install Cylinder Liner in Block……………………………….117
Install Piston and Connecting Rod……………………………..118
Torque-Turn Connecting Rod Cap Screws………………………….122
Check Engine Rotation for Excessive Tightness…………………..122
Complete Final Assembly………………………………………123
Crankshaft, Main Bearings and Flywheel Repair and Adjustment…………125
Crankshaft and Main Bearing Failure Analysis……………………125
Crankshaft Rear Oil Seal Assembly General Information……………125
Crankshaft Rear Oil Seal Assembly Handling Precautions…………..126
Crankshaft Rear Oil Seal & Oil Seal Housing — Installation……….127
Crankshaft Unitized Rear Oil Seal — Removal…………………….129
Crankshaft Unitized Front Oil Seal — Removal (6090AFM75 & 6090HF….130
Crankshaft Unitized Front Oil Seal — Installation (6090AFM75 & 6….131
Crankshaft Unitized Rear Oil Seal — Installation (6090AFM75 & 60….132
Inspect Vibration Damper……………………………………..133
Check Crankshaft End Play…………………………………….134
Remove Crankshaft Vibration Damper…………………………….135
Remove Crankshaft Front Oil Seal and Wear Sleeve………………..136
Remove Timing Gear Cover—Engine Removed………………………..138
Inspect and Measure Flywheel………………………………….138
Check Flywheel Housing Face Runout…………………………….138
Check Flywheel Face Flatness………………………………….139
Check Pilot Bearing Bore Concentricity…………………………139
Remove Flywheel……………………………………………..140
Remove SAE 1 Flywheel Housing…………………………………140
Remove SAE 2 and 3 Flywheel Housing……………………………140
Replace Flywheel Ring Gear……………………………………141
Remove Rear Oil Seal Housing—Engine Removed…………………….142
Remove Main Bearing Caps……………………………………..143
Check Main Bearing Oil Clearance………………………………145
Remove Connecting Rod Caps and Remove Crankshaft………………..146
Crankshaft — Inspection………………………………………147
Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journa….148
Main Bearing Cap Line Bore Specifications………………………149
Thrust Bearing New Part Specifications…………………………151
Replace (Crankshaft) Oil Pump Drive Gear……………………….152
Replace Crankshaft Gear………………………………………153
Inspect Thrust Bearings………………………………………153
Install Main Bearings and Crankshaft…………………………..154
Check Crankshaft Rear Oil Seal Housing Runout…………………..156
Install Thrust Washer and Timing Gear Cover…………………….157
Install Unitized Front Crankshaft Oil Seal……………………..159
Install Vibration Damper……………………………………..161
Install SAE 2 and 3 Flywheel Housing…………………………..162
Install Flywheel…………………………………………….163
Install SAE 1 Flywheel Housing………………………………..163
Complete Final Assembly………………………………………163
Camshaft and Timing Gear Train Repair and Adjustment………………..165
Check Camshaft End Play and Measure Gear Backlash……………….165
Remove Vibration Damper and Timing Gear Cover…………………..166
Remove, Inspect, and Install Crankshaft Gear-Driven Auxiliary Dr….167
Remove Camshaft……………………………………………..170
Remove Camshaft Gears………………………………………..171
Measure Thrust Washer Thickness……………………………….171
Inspect and Measure Camshaft Followers…………………………172
Visually Inspect Camshaft…………………………………….172
Measure Camshaft Journal O.D. and Bushing I.D…………………..172
Measure Camshaft Lobe Lift……………………………………173
Camshaft Gears — Installation…………………………………173
Service Camshaft Bushings Using JDG602 Adapter Set………………174
Service Camshaft Bushings Using JDG606 Adapter Set………………176
Camshaft Roller Followers — Install……………………………178
Install Camshaft…………………………………………….179
Install Thrust Washer and Timing Gear Cover…………………….180
Complete Final Assembly………………………………………181
Lubrication System Repair and Adjustment…………………………..183
Diagnosing Lubrication System Malfunctions……………………..183
Top-Load Oil Filter Assembly………………………………….183
Top Load Oil Filter – Theory of Operation………………………184
Install Oil Filter Assembly…………………………………..185
Changing Top-Load Oil Filter………………………………….185
Engine Oil Cooler Assembly……………………………………186
Remove, Inspect, and Install Engine Oil Cooler………………….187
Remove Engine from Tractors for Access to Engine Oil Pump………..188
Remove Oil Pan………………………………………………188
Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash……………188
Remove Engine Oil Pump……………………………………….189
Inspect and Clean Oil Pump……………………………………189
Check Drive Shaft End Play……………………………………190
Check Drive Shaft Side Movement……………………………….190
Check Pumping Gear Backlash…………………………………..191
Inspect Oil Pump Drive Gear…………………………………..191
Install Engine Oil Pump………………………………………192
Install Oil Bypass & Oil Pump Tubes & Oil Pump Adapter…………..193
Remove, Inspect, and Install Oil Pump Pickup Tube……………….193
Install Engine Oil Pan……………………………………….194
Tighten Cap Screws on Front Frame/Oil Sump – Tractors……………195
Cooling System Repair and Adjustment………………………………197
Inspect Fan Hub & Replace Bearings in Heavy-Duty, Adjustable Fan….197
Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive As….200
Fan Drive Assembly…………………………………………..201
Checking Belt Tensioner Spring Tension and Belt Wear…………….204
Inspect and Install Fan Assembly………………………………205
Visually Inspect Coolant Pump…………………………………206
Remove Coolant Pump Assembly………………………………….207
Install Coolant Pump Assembly…………………………………211
Replace Bypass Tube & O-Rings in Thermostat Housing……………..212
Remove and Test Thermostats…………………………………..213
Remove Thermostat Housing…………………………………….213
Install Thermostats………………………………………….214
Install Thermostat Housing……………………………………214
Remove and Install Coolant Temperature Sensor…………………..214
Servicing of Engine Coolant Heater…………………………….215
Bleed Air from Coolant System…………………………………215
Complete Final Assembly………………………………………216
Air Intake and Exhaust System Repair and Adjustment…………………217
Extending Turbocharger Life…………………………………..217
Remove Turbocharger………………………………………….219
Remove Turbocharger Oil Drain Line…………………………….220
Remove Turbocharger Oil Supply Line……………………………221
Turbocharger Failure Analysis…………………………………222
Turbocharger Inspection………………………………………224
Repair Turbocharger………………………………………….228
Prelube Turbocharger…………………………………………228
Install Turbocharger…………………………………………229
Install Turbocharger Oil Supply Line Brackets…………………..230
Install Turbocharger Oil Supply Line…………………………..231
Install Turbocharger Oil Drain Line……………………………232
Install Heat Shield & Turbocharger Oil Supply Line Bracket……….233
Remove and Install Turbocharger Actuator……………………….234
Install Actuator Coolant Line Fittings…………………………235
Install Turbocharger Actuator Coolant Return Line……………….235
Install Turbocharger Actuator Coolant Supply Line……………….236
Install Actuator Coolant Supply Line – Tractors…………………237
Remove and Install Actuator Linkage……………………………238
Remove and Install Turbocharger Actuator Linkage – Ball Type……..241
Remove Exhaust Gas Recirculator (EGR) Assembly………………….242
Remove & Install EGR Valve……………………………………243
Remove and Install EGR Coolant Manifold………………………..244
Remove and Install EGR Cooler Supply Line………………………244
Remove and Install EGR Cooler Return Line………………………245
Remove, Inspect, and Install Exhaust Manifold…………………..246
Remove, Inspect, and Install Intake Manifold……………………248
Install EGR…………………………………………………251
Remove and Install Air Inlet/Heater……………………………252
PowerTech E Air Intake and Exhaust System Repair and Adjustment………253
Turbocharger — Extending Life…………………………………253
Turbocharger — Remove Oil Drain Line…………………………..254
Turbocharger — Install Oil Drain Line………………………….256
Turbocharger — Remove………………………………………..258
Turbocharger — Install……………………………………….259
Exhaust Manifold — Remove…………………………………….260
Exhaust Manifold — Install……………………………………261
Air Intake Assembly — Remove………………………………….263
Air Intake Assembly — Install…………………………………264
OEM Starting and Charging Systems Repair and Adjustment……………..267
Remove and Install Alternator (OEM Engines)…………………….267
Remove and Install Starter Motor (OEM Engines)………………….268
Theory of Operation…………………………………………………269
Base Engine Operation……………………………………………271
Engine Sectional View Serial Number……………………………271
General Engine Operation……………………………………..272
Lubrication System Operation………………………………….274
Cooling System Operation……………………………………..276
Exhaust Gas Recirculator (EGR) and Variable Geometry Turbocharge….278
Head Gasket Joint Construction and Operation……………………280
Air Intake and Exhaust System Operation………………………..281
Turbocharger Operation……………………………………….281
How the Turbocharger is Lubricated…………………………….282
PowerTech E Base Engine Operation…………………………………283
Engine Sectional View Serial Number……………………………283
General Engine Operation……………………………………..284
Lubrication System Operation………………………………….285
Cooling System Operation……………………………………..288
Air Intake and Exhaust System Operation………………………..289
Turbocharger Operation……………………………………….289
How the Turbocharger is Lubricated…………………………….290
Head Gasket Joint Construction and Operation……………………291
Diagnostics………………………………………………………..293
Observable Diagnostics and Tests………………………………….295
About This Group of the Manual………………………………..295
Excessive Oil Consumption…………………………………….296
9 L – L1 – Excessive Oil Consumption……………………….296
Engine Oil Consumption……………………………………….298
9.0L – L2 – Engine Oil Pressure Low……………………………299
9.0L – L2 – Engine Oil Pressure Low……………………………301
9.0L – L3 – Engine Oil Pressure High…………………………..302
9.0 L – C1 – Engine Coolant Temperature Above Normal…………….303
9.0L – C2 – Engine Coolant Temperature Below Normal……………..304
9.0L – C3 – Coolant In Oil or Oil In Coolant……………………304
Test Engine Compression Pressure with Mechanical Gauge…………..305
Check Engine Cranking Speed…………………………………..306
Check Engine Oil Pressure…………………………………….307
Check for Excessive Engine Crankcase Pressure (Blow-by)………….307
Check for Turbocharger Oil Seal Leak…………………………..308
Inspect Thermostat and Test Opening Temperature…………………308
Pressure Test Cooling System and Radiator Cap…………………..309
Pressure Test EGR Cooler for Air Leaks…………………………309
Charge Air System Diagnostic………………………………….309
Check for Head Gasket Failures………………………………..312
Measure Intake Manifold Pressure (Turbo Boost)………………….313
Check for Intake and Exhaust Restrictions………………………314
Check for Exhaust Air Leaks…………………………………..315
Tools and Other Materials……………………………………………317
Repair Tools and Other Materials………………………………….319
Group 021 — Cylinder Head and Valves – Essential Tools…………..319
Group 021 — Cylinder Head and Valves – Service Equipment and Too….321
Group 021 — Cylinder Head and Valves – Other Materials…………..322
Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential ….322
Group 030 — Cylinder Block, Liners, Pistons, and Rods Other Mate….326
Group 040 — Crankshaft, Main Bearings and Flywheel Essential Too….326
Group 040 — Crankshaft, Main Bearings and Flywheel Service Equip….330
Group 040 — Crankshaft, Main Bearings and Flywheel Other Materia….330
Group 050 — Camshaft and Timing Gear Train Essential Tools……….331
Group 050 — Camshaft and Timing Gear Train Other Materials……….334
Group 060 — Lubrication System Other Materials………………….334
Group 070 — Cooling System Other Materials……………………..334
Group 080 — Air Intake and Exhaust System Other Materials………..335
Group 100 — Starting and Charging Systems Essential Tools………..335
Diagnostic Service Tools…………………………………………337
Base Engine Diagnostic Tools………………………………….337
Dealer Fabricated Service Tools…………………………………..339
How to Make Tools……………………………………………339
DFRG3—Cylinder Liner Holding Fixture…………………………..339
Specifications……………………………………………………..341
Repair and General OEM Specifications……………………………..343
General OEM Engine Specifications……………………………..343
Unified Inch Bolt and Screw Torque Values………………………344
Metric Bolt and Screw Torque Values……………………………345
Group 020 — Cylinder Head and Valves Repair Specifications……….346
Group 030 — Cylinder Block, Liners, Pistons and Rods Repair Spec….348
Group 040 — Crankshaft, Main Bearings and Flywheel Repair Speci….351
Group 050 — Camshaft and Timing Gear Train Repair Specifications….354
Group 060 — Lubrication System Repair Specifications…………….356
Group 070 — Cooling System Repair Specifications………………..358
Group 080 — Air Intake and Exhaust System Repair Specifications ….359
Group 081 — Air Intake and Exhaust System Repair Specifications ….360
OEM Starting and Charging Systems……………………………..360
Diagnostic Specifications………………………………………..361
Base Engine Diagnostic Specifications (Includes Dynamometer Spec….361
Dynamometer Test Specifications……………………………….362
Intake Manifold Pressure (Turbocharger Boost) Specifications……..363
Effects of Altitude and Temperature on Engine Performance………..363
Page Number…………………………………………………………… 5
Section 01………………………………………………………… 7
Group 000……………………………………………………… 9
Group 001……………………………………………………… 23
Group 002……………………………………………………… 25
Section 02………………………………………………………… 40
Group 010……………………………………………………… 41
Group 021……………………………………………………… 57
Group 030……………………………………………………… 93
Group 040………………………………………………………125
Group 050………………………………………………………165
Group 060………………………………………………………183
Group 070………………………………………………………197
Group 080………………………………………………………217
Group 081………………………………………………………253
Group 100………………………………………………………267
Section 03…………………………………………………………269
Group 120………………………………………………………271
Group 121………………………………………………………283
Section 04…………………………………………………………293
Group 150………………………………………………………295
Section 05…………………………………………………………317
Group 170………………………………………………………319
Group 180………………………………………………………337
Group 190………………………………………………………339
Section 06…………………………………………………………341
Group 200………………………………………………………343
Group 210………………………………………………………361
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