John Deere OEM Engine Accessories Components Technical Manual CTM67

[Martin Welker]

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John Deere OEM Engine Accessories Components Technical Manual CTM67
Size: 8.44 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: OEM Engine Accessories
Type of Manual: Components Technical Manual
Model: John Deere OEM Engine Accessories
Part Number: CTM67
Publication Date: 2005
Number of Pages: 448 Pages

Contents:
OEM Engine Accessories
Safety
Prepare for Emergencies
Prevent Battery Explosions
Handling Batteries Safely
Handle Chemical Products Safely
Avoid High-Pressure Fluids
Support Machine Properly
Prevent Machine Runaway
Stay Clear of Rotating Drivelines
Handle Starting Fluid Safely
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Remove Paint Before Welding or Heating
Install Fan Guards
Avoid Hot Parts
Avoid Heating Near Pressurized Fluid Lines
Avoid Harmful Asbestos Dust
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live With Safety
General Information
About This Manual
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Electrical System Information and Wiring Diagrams
Electrical Circuit Malfunctions
High Resistance Circuit
Open Circuit
Grounded Circuit
Shorted Circuit
Multimeter
Seven Step Electrical Test Procedure
Wiring Diagram and Schematic Information
Reading a System Functional Schematic
Reading a Wiring Diagram
Electrical Schematic Symbols
Component Identification Table
Engine Wiring Diagram Legend—North American Series 300, 400, 300 and 700 Engines and Early Model European (Saran) Series 300 Engines
Wiring Diagram—North American Series 300, 400 and 300 Engines
Wiring Diagram—North American Series 700 (8955) Engines
Wiring Diagram—European (Saran) Series 300 Engines (Early Model)
Engine Wiring Diagram Legend - PowerTech 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)
Engine Wiring Diagram - PowerTech 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)
Engine Wiring Diagram Legend - PowerTech 10.5 L and 12.5 L Engines (With Lucas ECU)
Engine Wiring Diagram - PowerTech 10.5 L and 12.5 L Engines (With Lucas ECU)
Engine Wiring Diagram - PowerTech 8.1 L, 10.5 L and 12.5 L Engines (With John Deere ECU)
Engine Wiring Diagram - PowerTech 8.1 L, 10.5 L and 12.5 L Engines (With John Deere ECU) (Continued)
Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines
Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines (Continued)
Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines (Continued)
Engine Wiring Diagram—Saran AEZ Instrument Panel
Engine Wiring Diagram Legend—Saran VDO Instrument Panel
Engine Wiring Diagram—Saran VDO Instrument Panel
Engine Wiring Diagram—PowerTech™ 2.4L and 3.0L Engines
Electrical System Diagnostics, Tests and Operation
Service Equipment and Tools
Electrical System Specifications
General Information
Component Function—Instrument Panel (Without ECU)
Component Function—Instrument Panel (2.4L, 3.0L, and 4.5L (Later "270")-Without ECU)
Component Function—Instrument Panel (With Lucas ECU)
Component Function—Instrument Panel (With Early Deere ECU)
Component Function—Instrument Panel (PowerTech Plus 4.5 L, 6.8 L, 9.0 L,13.5 L and Later PowerTech 4.5L, 6.8L, 8.1L and 12.5L)
Component Function—Saran VDO Instrument Panel
Component Function—Saran AEZ Instrument Panel
Component Function—Crankcase Oil Level Switch/Gauge
Before You Start Diagnostics
Visually Inspect Electrical System
Diagnose Electrical System Malfunctions
Checking Fuses In Instrument Panels
Test Key Switch
Test Magnetic Safety Switch
Test Starter Relay
Electrical System Repair and Adjustments
Essential Tools
Service Equipment and Tools
Other Material
Instrument Panel Specifications
Repair WEATHERPACK™ Connector
Remove Blade Terminals from Connector Body
Repair (Pull Type) METRI-PACK™ Connectors
Repair (Push Type) METRI-PACK™ Connectors
Repair DEUTSCH™ Connectors
Repair AMP Connector
Repair SUMITOMO™ Connectors
Repair YAZAKI™ Connectors
Repair CINCH™ Flex Box Connector
Replace Instrumentation—North American Instrument Panel (Early Model Instrument Panels)
Replace Instrumentation—North American Instrument Panel (Late Model Instrument Panels W/O ECU)
Replace Instrumentation—North American Instrument Panel (2.4L, 3.0L, and 4.5L (Later "270")—W/O ECU)
Replace Instrumentation—Instrument Panel with Lucas ECU
Replace Instrumentation—Earlier Model Instrument Panels with John Deere ECU
Replace Instrumentation—Later Model Instrument Panels with John Deere ECU
Replace Instrumentation—European (Saran) Instrument Panel (Early Model)
Replace Instrumentation—Saran VDO Instrument Panel
Replace Instrumentation—Saran AEZ Instrument Panel
Remove and Install Crankcase Oil Level Switch/Gauge
Calibrate Adjustable Electronic Tachometer
Adjust Saran VDO Instrument Panel Tachometer
Adjust Saran AEZ Instrument Panel Tachometer
Replace Electronic Foot Throttle (Later Engines with ECU)
Harness Repair (Splice Broken or Cut Wire)
Harness Repair (Splice Connector)
Cold Weather Starting Aids
Other Material
Cold Weather Starting Aids Specifications
Remove Coolant Heater—Block Type (Except 2.4 L and 3.0 L Engines)
Install Coolant Heater—Block Type (Except 2.4 L and 3.0 L Engines)
Remove Coolant Heater—Block Type (2.4 L and 3.0 L Engines)
Install Coolant Heater—Block Type (2.4 L and 3.0 L Engines)
Remove Coolant Heater—Block Type (Saran Engines)
Install Coolant Heater—Block Type (Saran Engines)
Remove Coolant Heater—Tank Type
Install Coolant Heater—Tank Type
Remove and Install Fuel Heater
Remove and Install Air Heater
Remove and Install Glow Plugs (2.4 L and 3.0 L Engines)
Remove and Install Glow Plugs (4.5L and 6.8L Engines)
Service Ether Starting Aid
Fuel System Accessories
Fuel System Accessories Specifications
Check Injection Pump Solenoid—"D" Engines
Check Rack Puller—RP-20 (Stationary Engines)
Check RP-75 Rack Puller—Stationary Engines
Disassemble and Assemble RP-75 Rack Puller
Check Rotary Fuel Shut-Off Solenoid
Remove and Install Rotary Fuel Shut-Off Solenoid
Adjust Rotary Fuel Shut-Off Solenoid
UTC Electric/Isochronous Governor (8955 Engines)
Service Equipment and Tools
Governor Specifications
How the System Works
Diagnosing Electric Governor Malfunctions
Safety Guidelines when Testing Electronic Governor
Electric Governor System Tests
Test Engine Speeds
Adjust Engine Speeds
Adjust Gain and Stability
Engine Operation in Droop Mode
Electric Governor Installation Instruction
Connect Electric Governor Wiring Harness
Remove Electric Governor
Service Magnetic Pickup
Electric Fuel Supply Pump—8955 Engines
Service Equipment and Tools
Fuel Supply Pump Specifications
Relieve System Pressure
Test John Barnes Fuel Supply Pump Pressure—8955T, A Engine Serial No. (˜˜˜˜—3076)
Adjust John Barnes Fuel Supply Pump Relief Valve—8955T, A Engines Serial No. (˜˜˜˜—3076)
Remove John Barnes Electric Fuel Supply Pump—8955 Engine Serial No. (˜˜˜˜—3076)
Remove Pressure Regulating Valve
Install Pressure Regulating Valve
Repair Fuel Pump
Install John Barnes Fuel Supply Pump—8955 Engine Serial No. (˜˜˜—3076)
Test Bosch Fuel Supply Pump Pressure—8955T, A Engine Serial No. (3077—˜˜˜)
Replace Bosch Fuel Supply Pump—8955T, A Engines Serial No. (3077—˜˜˜)
Engine Cooling System Accessories
Service Equipment and Tools
Other Material
Engine Cooling System Specifications
Test Charge Air Cooler
Remove and Install Charge Air Cooler
Remove and Install Coolant Temperature Sensor
Pressure Test Cooling System and Radiator Cap
Radiator and Hoses
Install Radiator Fan—Blower and Suction Types
Check Fan and Alternator Belts
Remove and Install Fan and Alternator Belts
Manual Belt Tensioner Adjustment
Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)
Check Automatic Belt Tensioner Spring Tension and Belt Wear
Adjust Fan and Alternator Belts
Rear PTO - Rockford/Twin Disc
Essential Tools
Service Equipment and Tools
Rockford/Twin Disc Rear Power Take-Off Specifications
General Information
Diagnosing Malfunctions
Remove Power Take-Off
Power Take-Off Exploded View
Disassemble Power Take-Off
Inspect Power Take-Off Parts
Assemble Drive Shaft and Bearings—Side-Load Application
Assemble Drive Shaft and Bearings—In-Line Application
Install Yoke
Check and Adjust Drive Shaft End Play
Assemble Clutch Unit (Early Version)
Assemble Clutch Unit (Late Version)
Install Clutch Unit
Check Flywheel Housing Face Run-Out
Check Flywheel Face Flatness
Check Pilot Bearing Bore
Inspect Drive Ring
Install Power Take-Off
Check PTO Clutch Adjustment—Early Version
Check PTO Clutch Adjustment—Late Version
Rear PTO - John Deere
Special Or Essential Tools
Other Material
Rear Power Take-Off Specifications For 8.1L/9.0L and 12.5L/13.5L Engines With Primary and Auxiliary Pump Drives (Double Pump)
Rear Power Take-Off Specifications For 8.1L/9.0L and 12.5L/13.5L Engines With Primary Pump Drive (Single Pump)
General Information
Theory of Operation
Lubrication Passages
Photo Disclosure
Remove Rear PTO
Disassemble Auxiliary Pump Group
Disassemble Primary Pump Group
Disassemble Auxiliary Idler Shaft Group
Disassemble Primary Idler Shaft Group
Inspect and Assemble Engine Rear Power Take-Off Housing Group
Flywheel Access Cover Plate
Primary Idler Shaft Group
Assemble Primary Idler Shaft Group
Auxiliary Idler Shaft Group
Assemble Auxiliary Idler Shaft Group
Auxiliary Pump Access Cover Plate (For Single Pump Application Only)
Primary Pump Group
Assemble Primary Pump Group
Auxiliary Pump Group
Assemble Auxiliary Pump Group (Double Pump Rear Power Take-Off)
Input Gear Assembly and Seal Retainer Group
Install Rear PTO
Front PTO
Essential Tools
Front Power Take-Off Specifications
Checking Vibration Damper or Pulley (Engine With Front PTO)
Remove Vibration Damper or Pulley (Engine With Front PTO)
Install Vibration Damper or Pulley (Engine With Front PTO)
Installing PTO Drive Gear (Crankshaft Gear-Driven PTO)
Remove and Install Front PTO Clutch Adapter (Electric)
Remove and Install Front PTO Clutch Adapter (Mechanical)
Auxiliary Drive, 6076 (300000—˜˜˜)
Service Equipment and Tools
Other Material
Auxiliary Drive, 6076 (300000—˜˜˜) Specifications
Auxiliary Drive General Information
Remove Right-Hand Output Gear Assembly
Disassemble Right-Hand Output Gear Assembly
Assemble Right-Hand Output Gear Assembly
Install Right-Hand Output Gear Assembly
Remove Left-Hand Output Gear Assembly
Disassemble Left-Hand Output Gear Assembly
Assemble Left-Hand Output Gear Assembly
Remove Left-Hand Rear Adapter Housing
Remove Idler Housing and Idler Gear
Replace Idler Gear Bearing
Install Idler Housing and Idler Gear
Install Left-Hand Output Gear Assembly
Install Left-Hand Rear Adapter Housing
Auxiliary Drive (2.9 L)
Auxiliary Drive (2.9 L) Specifications
Remove and Install Right-Hand Auxiliary Drive
Auxiliary Drive (4.5 L and 6.8 L)
Auxiliary Drive (4.5 L and 6.8 L) Specifications
Remove and Install Auxiliary Drive
Remove and Install Offset Auxiliary Drive
Disassemble and Inspect Auxiliary Drive Adapter
Disassemble and Inspect Offset Auxiliary Drive Adapter
Auxiliary Drive (8.1 L)
Auxiliary Drive Specifications
Remove Right-Hand Output Gear Assembly
Disassemble Right-Hand Output Gear Assembly
Assemble Right-Hand Output Gear Assembly
Install Right-Hand Output Gear Assembly
Remove Left-Hand Output Gear Assembly
Disassemble Left-Hand Output Gear Assembly
Assemble Left-Hand Output Gear Assembly
Remove and Install Left-Hand Rear Adapter Housing
Remove Idler Housing and Idler Gear
Replace Idler Gear Bearing
Install Idler Housing and Idler Gear
Install Left-Hand Output Gear Assembly
Auxiliary Drive (9.0L)
Auxiliary Drive Specifications
Remove Left-Hand Output Gear Assembly
Remove Left-Hand Rear Housing
Remove Left-Hand Aux Drive Housing from Cylinder Block
Remove Left-Hand Aux Drive Housing from Timing Gear Cover
Remove and Install Idler Gear
Install Left-Hand Aux Drive Housing to Timing Gear Cover
Install Left-Hand Aux Drive Housing to Cylinder Block
Torque Left-Hand Aux Drive Assembly
Install Left-Hand Rear Housing
Install Left-Hand Output Gear Assembly
Auxiliary Drive (10.5L, 12.5L and 13.5L)
Essential Tools
Auxiliary Drive (10.5 L, 12.5 L and 13.5 L) Specifications
Remove and Install Auxiliary Drive Idler Gear and Bearing
Remove and Install SAE "A" and "B" Front and SAE "B" Rear Auxiliary Drive Assembly
Air Compressors
Essential Tools
Service Equipment and Tools
Air Compressor Specifications
Air Compressor General Information
Compressor Troubleshooting Chart
Compressor Troubleshooting Chart (Continued)
Remove And Install Air Compressor (4.5 L and 6.8 L)
Remove And Install Air Compressor Æ6076 (S.N. 300000— ) and 8.1 Lš
Remove and Install Air Compressor (10.5 L and 12.5 L)
Air Conditioning Compressors
Essential Tools
Air Conditioning Specifications
Air Conditioning General Information
Proper Refrigerant Handling
R-134a Refrigerant Cautions
Air Conditioning Retrofit
System Information
Discharge Air Conditioning System
Flush/Clean Air Conditioning Compressor
Purge Air Conditioning System
Evacuate Air Conditioning System
Check Refrigerant Oil Charge
Determine Correct Refrigerant Oil Charge
Add Refrigerant Oil to Pressurized System
Charge Air Conditioning System
Diagnosing Air Conditioning Compressor Malfunctions
Remove and Install Air Conditioning Compressor
Test Volumetric Efficiency
Compressor Leakage Test
Disassemble and Assemble Compressor Clutch (Denso Compressor)
Check Clutch Hub Clearance
Inspect Compressor Manifold (Denso Compressor)
Disassemble, Inspect, and Assemble Compressor (Denso Compressor)
Remove and Install Compressor Relief Valve (Denso Compressor)
Page Numbers