John Deere Powertech 2.9L Engine Components Technical Manual CTM125

[Martin Welker]

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John Deere Powertech 2.9L Engine Components Technical Manual CTM125
Size: 7.81 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Engine
Type of Manual: Components Technical Manual
Model: John Deere Powertech 2.9L Engine
Part Number: CTM125
Publication Date: 2001
Number of Pages: 312 Pages

Contents:
Introduction
Foreword
John Deere Dealers
POWERTECH 2.9 L Engines
Engine application chart
Information relative to emissions regulations
Contents
Safety
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare for Emergencies
Prevent Acid Burns
Avoid High-Pressure Fluids
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Work in Clean Area
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live With Safety
General Information
Engine Identification
OEM Engine Option Code Label
Emission Certified Engine Label
Engine References
Basic Engine Specifications
Longitudinal Cut-Away
Transversal Cut-Away
General Engine Description
Diesel Fuel
Handling and Storing Diesel Fuel
Diesel Engine Oil
Lubricant Storage
Mixing of Lubricants
Diesel Engine Coolant
Operating in Warm Temperature Climates
Metric Bolt and Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Engine Mounting
Clean Engine
Engine Lifting Procedure
Engine Repair Stand
Mounting Engine on Repair Stand
Engine Rebuilt Guide
Engine Disassembly Sequence
Sealant Application Guidelines
Engine Re-Assembly Sequence
Engine break-in guidelines
Perform engine break-in
Diesel Engine Break-In Oil
Cylinder Head and Valves
Cylinder Head - Exploded View
Check Valve Lift
Remove Cylinder Head
Clean Injection Nozzle Bores
Valve Actuating Parts
Remove Valves and Valve Springs
Checking Cylinder Head Flatness
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Clean and Inspect Valve Seats
Lapping Valve Seats
Check Valve Recess
Remove Valve Seat Inserts
Valve Seat Insert Installation
Check Valves
Grind Valves
Check Valve Spring Compression
Inspect Valve Rotators
Install Valves
Install Cylinder Head
Torque Turn Tightening Method
Disassembling and Checking Rocker Arm Shaft
Reassembling Rocker Arm Shaft
Install Rocker Arm Assembly
Valve Clearance
Valve Adjustment Sequence
Install Rocker Arm Cover
Final Work
Cylinder Block, Liners, Pistons and Rods
Exploded View
Connecting Rods - General Information
Remove Pistons and Connecting Rods
Measure Cylinder Liner Bore
Remove Cylinder Liners
Cylinder Liner Deglazing
Cylinder Block Cleaning
Check Piston Cooling Jets
Cam Follower Bore Measure
Measure Camshaft Bore
Remove Camshaft Bushing
Install Camshaft Bushing
Measure Crankshaft Bore
Replace Crankshaft Bearing Caps
Cylinder Block Top Desk Flatness
Measure Cylinder Liner Protrusion
Liner Packing Installation
Liner O-Ring Installation
Install Cylinder Liners
Measure Connecting Rod Bearing
Rod Bearing Clearance
Measure Connecting Rod Bushing
Replace Connecting Rod Bushing (3029D)
Replace Connecting Rod Bushing (3029T)
Measure Piston Pin
Clean and Inspect Pistons
Measure Piston Pin Bore
Piston Top Ring Groove
Second and Third Piston Ring Grooves
Piston Head and Skirt Checking
Install Piston Rings
Piston Rings Staggering
Piston/Liner Set Information
Assemble Piston and Connecting Rod
Install Piston and Connecting Rod
Measure Piston Protrusion
Complete Final Assembly
Crankshaft, Main Bearings and Flywheel
Remove Crankshaft Pulley
Install Crankshaft Pulley
Check Pulley Wobble (Engine With Front PTO)
Remove PTO Pulley
Install PTO Pulley
Flywheel Removal
Flywheel Ring Gear Replacement
Install Ball Bearing
Install Flywheel
Remove Crankshaft Rear Oil Seal
Flywheel Housing Replacement
Install Oil Seal/Wear Sleeve
Crankshaft End Play Measure
Remove Crankshaft
Crankshaft Inspection
Check Crankshaft Journal Diameter
Determine Crankshaft Main Bearing Clearance Using PLASTIGAGE®
Regrind Crankshaft
Crankshaft Regrinding Guidelines
Micro-Finishing Specifications
Replace Crankshaft Gear
Install Main Bearing Inserts
Install 2-Piece Thrust Bearing
Install 6-Piece Thrust Bearing
Crankshaft Installation
Camshaft and Timing Gear Train
Remove Crankshaft Front Oil Seal
Remove Timing Gear Cover
Measure Timing Gear Backlash
Camshaft End Play Measure
Remove Camshaft
Measure Camshaft Journal
Measure Height of Cam Lobe
Replace Camshaft Gear
Tachometer Pick-Up Pin Removal
Install Camshaft
Check Cam Follower
Idler Gear End Play Measure
Remove Front Plate
Idler Gear Bushing and Shaft Measure
Idler Gear Bushing Replacement
Remove Idler Shaft
Install Idler Shaft Spring Pin
Install Idler Shafts
Front Plate Gasket
Install Front Plate
Install Upper Timing Gear Train
Install Lower Timing Gear Train
Install Oil Deflector
Timing Gear Cover Identification
Install Timing Gear Cover
Install Crankshaft Front Oil Seal
Install Wear Ring
Install Auxiliary Equipment
Lubrication System
Oil Cooler Identification
Remove Oil Cooler
Replace Oil Cooler Nipple
Install Oil Cooler on Standard Engine
Replace Oil Cooler/Filter Bracket on Engine with Auxiliary Drive
Replace Oil Filter Adapter on Engine with Remote Oil Filter
Remove Oil Pressure Regulating Valve
Replace Oil Pressure Regulating Valve Seat
Install Oil Pressure Regulating Valve
Replace Oil Dipstick Guide
Replace Oil By-Pass Valve
Replace Oil Pump Strainer
Remove Oil Pump
Oil Pump Gear Axial Clearance
Oil Pump Gear Radial Clearance
Oil Pump Specifications
Oil Pump Installation
Install Oil Pan
Cooling System
Water Pump — Exploded View
Remove Water Pump
Disassemble Water Pump
Assemble Water Pump
Install Water Pump
Inspect Thermostat
Cold Start Advance Switch
Cooling System Deaeration
Check Fan/Alternator Belt Tension
Install Fan
Coolant Heater
Radiator Exploded view (CD3209DF128)
Air Intake and Exhaust System
Check Air Inlet Pipe
Exhaust Manifold Inspection
Remove Turbocharger
Turbocharger Cut-Away View (SCHWITZER)
Check Radial Clearance
Check Axial Clearance
Repair Turbocharger
Prelube Turbocharger
Install Turbocharger
Turbocharger Break-In
Recommendations for Turbocharger Use
Air Filter Exploded View
Fuel System
Replace Fuel Filter Element
Replace Fuel Filter Assembly
Replace Fuel Supply Pump
Remove STANADYNE DB2 or DB4 Fuel Injection Pump
Repairs to STANADYNE Fuel Injection Pump
Replace Throttle Lever (STANADYNE)
Aneroid Replacement (STANADYNE)
Aneroid Field Adjustment (STANADYNE)
Aneroid Workshop Adjustment (STANADYNE)
Install STANADYNE DB2 or DB4 Fuel Injection Pump
Remove DELPHI/LUCAS Fuel Injection Pump
Repairs to DELPHI/LUCAS Fuel Injection Pump
Install DELPHI/LUCAS Fuel Injection Pump
Dynamic Timing
Install Timing Sensor
Install Magnetic Probe
Timing Sensor and Magnetic Probe Connection
Check Fuel Injection Pump Timing
Fuel Injection Nozzle Identification
Remove Fuel Injection Nozzle
Clean Fuel Injection Nozzle
Fuel Injection Nozzle Test
Fuel Injection Nozzle Disassembly
Adjust Fuel Injection Nozzle
Install Fuel Injection Nozzle
Bleed Fuel System
Check Engine Speed
Engine Tune-Up
Preliminary Engine Testing
General Tune-Up Recommendations
Engine System - Operation
Lubrication System
Cooling System
Engine System - Diagnosis and Tests
Diagnose Engine Malfunctions
Checking Engine Compression
Check Engine Oil Pressure
Measure Engine Blow-By
Using Stanadyne "TIME-TRAC" as Tachometer
Inspect Thermostat and Test Opening Temperature
Pressure Test Cooling System and Radiator Cap
Air Intake System - Operation and Tests
Turbocharger Operation
Check Turbocharger Boost Pressure
Diagnosing Turbocharger Malfunctions
Fuel System - Operation and Tests
General Operation
Fuel Supply Pump Operation
Measure Fuel Supply Pump Pressure
Fuel Filter Operation
STANADYNE Fuel Injection Pump (DB2/DB4) - Operation
DELPHI/LUCAS Fuel Injection Pump (DP200 shown) - Operation
Test Shut-Off Solenoid on DELPHI/LUCAS Injection Pump
Cold Start Advance System Operation
Check Cold Start Advance System Operation
Check Cold Start Switch Operation
Light Load Advance Operation
Check Light Load Advance Operation
Fuel Injection Nozzles - General Information
Diagnosing Fuel System Malfunctions
Testing Fuel Injection Nozzles on a Running Engine
Essential Tools
Essential Tools
Service Equipment & Recommended Tools
Service Equipment & Recommended Tools
Self-manufactured tools
Template for front plate replacement
Repair Specifications
Cylinder Head and Valves Specifications
Cylinder Block, Liners, Pistons and Rods Specifications
Crankshaft, Main Bearings and Flywheel Specifications
Camshaft and Timing Gear Train Specifications
Lubrication System Specifications
Oil Dipstick Guide Height Specifications
Cooling System Specifications
Distance from Pulley or Hub to Water Pump Housing Sealing Surface Specifications
Air Intake and Exhaust System Specifications
Fuel System Specifications
Diagnostic and Test Specifications
Diagnostic and Test Specifications
Page Numbers