Complete Component Technical Manual with Electrical Wiring Diagrams for John Deere PowerTech 2.9 L Diesel Engines Worldwide Edition, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere PowerTech 2.9 L Diesel Engines Component Technical Manua includes:
* 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.
ctm125 – PowerTech 2.9 L Diesel Engines – (Worldwide Edition) Component Technical Manual.pdf
ctm126 – Motores diésel de 2,9 l PowerTech™ (Edición mundial) Spanish.pdf
French
ctm127 – Moteurs diesel PowerTech™ 2,9 l (Édition internationale)
Published on 2017/03/26
German
ctm128 – PowerTech™ 2,9-l- Dieselmotoren (Weltweite Ausgabe)
Published on 2017/03/26
Italian
ctm129 – Motori diesel PowerTech™ da 2,9 l (Edizione universale)
Published on 2017/03/26
Portuguese
ctm318 – Motores Diesel PowerTech™ de 2,9 L (Edição Mundial)
Published on 2017/03/26
Polish
ctm706 – Silniki wysokoprężne PowerTech™ 2,9 l (Edycja ogólnoświatowa)
Published on 2017/03/26
Turkish
ctm707 – PowerTech™ 2,9 l Dizel Motorlar (Dünya Çapındaki Sürüm)
Published on 2017/03/26
PRODUCT DETAILS:
Total Pages: 654 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
ctm125 – PowerTech™ 2.9 LDiesel Engines (Worldwide Edition)
Component Technical Manual
Table of Contents
Foreword
PowerTech PowerTech is a trademark of Deere & Company 3.9 L Engines
Information relative to emissions regulations
Section 01: General Information
Group 000: Safety
Handle Fluids Safely—Avoid Fires
Avoid Static Electricity Risk When Refueling
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
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Live With Safety
Group 001: Engine Identification Information
Engine Identification
OEM Engine Option Code Label
Emission Certified Engine Label
Engine References
Basic Engine Specifications
Longitudinal Cut-Away
Transversal Cutaway
General Engine Description
Diesel Fuel
Diesel Fuel Additive Products
BioDiesel Fuel
Handling and Storing Diesel Fuel
Oil Information for Non-certified, Tier 1 or Trem 3 Engines (see application list)
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I
Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I
Oil Information for Tier 2 Engines (see application list)
Diesel Engine Oil — Tier 2 and Stage II
Diesel Engine Oil and Filter Service Intervals
Oil Information for Tier 3 Engines (see application list)
Diesel Engine Oil — Tier 3 and Stage III
Diesel Engine Oil and Filter Service Intervals
Oil Information for Interim Tier 4 Engines (see application list)
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV
Diesel Engine Oil and Filter Service Intervals
Lubricant Storage
Mixing of Lubricants
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Drain Intervals for Diesel Engine Coolant
Operating in Warm Temperature Climates
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Group 02: Engine Mounting
Clean Engine
Engine Lifting Procedure
Engine Repair Stand
Mounting Engine on Repair Stand
Group 03: 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 — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Section 02: Repair and Adjustments
Group 05: 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
Group 10: 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 (Straight Pin-End)
Replace Connecting Rod Bushing (Tapered Pin-End)
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
Group 15: 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
Crankshaft Identification
Check Crankshaft Journal Diameter
Determine Crankshaft Main Bearing Clearance Using PLASTIGAGE PLASTIGAGE is a trademark of DANA Corp.
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
Group 20: 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
Group 25: 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
Oil Pump – Exploded View
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
Group 30: 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 (Typical Installation)
Group 35: Air Intake and Exhaust System
Check Air Inlet Pipe
Exhaust Manifold Inspection
Turbocharger Failure Analysis
Remove Turbocharger
Turbocharger Cut-Away View (Borg-Warner/Schwitzer)
Check Radial Clearance
Check Axial Clearance
Repair Turbocharger
Prelube Turbocharger
Install Turbocharger
Turbocharger Break-In
Recommendations for Turbocharger Use
Remove and Install Air Heater Glow Plug
Air Filter Exploded View
Group 40: Fuel System
Replace Fuel Filter Element (Rotary Fuel Injection Pump)
Replace Fuel Filter Assembly (Rotary Fuel Injection Pump)
Replace Fuel Filter Assembly (MICO – BOSCH in-Line Injection Pump)
Replace Fuel Filter Element (MICO – BOSCH in-Line Injection Pump)
Replace Fuel Supply Pump (Rotary Fuel Injection Pump)
STANADYNE Rotary Fuel Injection Pump Identification
Remove STANADYNE models DB2 or DB4 Fuel Injection Pump (Without Lock Shaft Timing)
Remove STANADYNE Model DB4 Fuel Injection Pump (with Lock Shaft Timing)
Inspect STANADYNE Injection Pump Drive Gear Inside Diameter and Shaft Diameter (all pumps)
Repair STANADYNE Fuel Injection Pump
Install STANADYNE DB2 or DB4 Fuel Injection Pump (Without Lock Shaft timing)
Install STANADYNE Model DB4 Injection Pump (with Lock Shaft Timing)
Remove DELPHI/LUCAS Fuel Injection Pump
Repairs to DELPHI/LUCAS Fuel Injection Pump
Install DELPHI/LUCAS Fuel Injection Pump
Remove Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
Test Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
Disassemble Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
Assemble Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
Install Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
Service Injection Pump Overflow Valve (MICO – BOSCH in-Line Injection Pump)
Remove MICO – BOSCH in-Line Fuel Injection Pump
Repair MICO – BOSCH in-Line Fuel Injection Pump
Install MICO – BOSCH in-Line Fuel Injection Pump
Check and Adjust Rotary Injection Pump Dynamic Timing Using TIME TRAC TIME TRAC is a registered trademark of Stanadyne Automotive Corp.
Check and Adjust Rotary Injection Pump Dynamic Timing Using TACH-N-TIME™ (JDG10534)
Check and Adjust Rotary Injection Pump Dynamic Timing Using TACH-N-TIME™ (JDG11411)
Replace Throttle Lever (STANADYNE)
Aneroid Replacement (STANADYNE)
Aneroid Field Adjustment (STANADYNE)
Aneroid Workshop Adjustment (STANADYNE)
Fuel Injection Nozzle Identification
Remove Fuel Injection Nozzle (9.5mm)
Clean Fuel Injection Nozzle (9.5 mm)
Fuel Injection Nozzle Test (9.5 mm)
Fuel Injection Nozzle Disassembly
Adjust Fuel Injection Nozzle (9.5 mm)
Install Fuel Injection Nozzle (9.5 mm)
Remove Fuel Injection Nozzles (17 mm)
Clean Fuel Injection Nozzle Bore(17 mm)
Clean Fuel Injection Nozzles (17 mm)
Test Fuel Injection Nozzles (17 mm)
Install Seals on Fuel Injection Nozzle(17 mm)
Install Fuel Injection Nozzles (17 mm)
Bleed Fuel System
Check Engine Speed on Rotary Fuel Injection Pump
Check Engine Speed on MICO – BOSCH in-Line Fuel Injection Pump
Section 03: Theory of Operation
Group 100: Engine Tune-Up
Preliminary Engine Testing
General Tune-Up Recommendations
Group 105: Engine System – Operation
Lubrication System
Cooling System
Section 04: Diagnostics and Tests
Group 110: Engine System – Diagnosis and Tests
Diagnose Engine Malfunctions
Check Engine Compression using JT01674A Tool (9.5 and 17 mm Injector)
Check Engine Compression using FKM10021 Tool (9.5 mm Injector only)
Check Engine Oil Pressure
Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)
Using Stanadyne “TIME-TRAC” as Tachometer
Using JDG10534 TACH-N-TIME as Tachometer
Using JDG11411 TACH-N-TIME as Tachometer
Inspect Thermostat and Test Opening Temperature
Pressure Test Cooling System and Radiator Cap
Excessive Engine Vibration
Group 115: Air Intake System – Operation and Tests
Turbocharger Operation
Wastegate Operation
Test Turbocharger Wastegate
Check Turbocharger Boost Pressure
Diagnosing Turbocharger Malfunctions
Group 120: Fuel System – Operation and Tests
General Operation (Rotary Fuel Injection Pump)
Fuel Supply Pump Operation (Rotary Fuel Injection Pump)
Measure Fuel Supply Pump Pressure (Rotary Fuel Injection Pump)
Fuel Filter Operation (Rotary Fuel Injection Pump)
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
General Operation (MICO – BOSCH in-Line Fuel Injection Pump)
Fuel Supply Pump Operation (MICO – BOSCH in-Line Fuel Injection Pump)
Diagnose Fuel Supply Pump Malfunctions (MICO – BOSCH in-Line Fuel Injection Pump)
Fuel Filter Operation (MICO – BOSCH in-Line Fuel Injection Pump)
MICO – BOSCH in-Line Fuel Injection Pump Operation
Governor Operation (MICO – BOSCH in-Line Fuel Injection Pump)
Diagnose MICO – BOSCH in-Line Fuel Injection Pump Malfunctions
Fuel Injection Nozzles Operation (9.5 mm)
Fuel Injection Nozzles Operation (17 mm)
Diagnosing Fuel System Malfunctions
Testing Fuel Injection Nozzles on a Running Engine
Section 05: Special Tools
Group 200: Essential Tools
Essential Tools
Group 205: Service Equipment & Recommended Tools
Service Equipment & Recommended Tools
Group 210: Self-manufactured tools
Template for front plate replacement
Modification of JDG670A
Section 06: Specifications
Group 300: 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
Fuel Injection Pump Specifications
Group 305: Diagnostic and Test Specifications
Diagnostic and Test Specifications
John Deere PowerTech 2.9 L Diesel Engines Component Technical Manual (CTM125)