Complete Engines Components Technical Manual  with Electrical Wiring Diagrams for John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L & Yanmar 4TNE98 Diesel Engines, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.

John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L & Yanmar 4TNE98 Diesel Engines Components Technical Manual 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.

CTM119 - John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L & Yanmar 4TNE98 Diesel Engines Components Technical Manual.pdf

Total Pages: 715 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS - Expanded View
 00 - Safety
    Avoid Harmful Asbestos Dust
    Avoid Heating Near Pressurized Fluid Lines
    Avoid High-Pressure Fluids
    Dispose of Waste Properly
    Follow Safety Instructions
    Handle Chemical Products Safely
    Handle Fluids Safely-Avoid Fires
    Illuminate Work Area Safely
    Live With Safety
    Practice Safe Maintenance
    Prepare for Emergencies
    Prevent Acid Burns
    Prevent Battery Explosions
    Protect Against Noise
    Recognize Safety Information
    Remove Paint Before Welding or Heating
    Service Cooling System Safely
    Service Machines Safely
    Understand Signal Words
    Use Proper Lifting Equipment
    Use Proper Tools
    Wear Protective Clothing
    Work in Clean Area
    Work in Ventilated Area
 01 - General Information
    Basic Engine Specifications-3009, 3011 & 3015 Engines
    Basic Engine Specifications-4020D, 4020T & 4TNE98 Engines
    Engine Application Chart-Industrial Applications
    Engine Application Chart-OEM Applications
    Engine Model Designation
    Engine Serial Number Plate Information
    Metric Bolt and Cap Screw Torque Values
    Unified Inch Bolt and Cap Screw Torque Values
 02 - Fuels, Lubricants, and Coolant
    Diesel Engine Coolant Recommendations
    Diesel Engine Coolant Specifications
    Diesel Engine Oil
    Diesel Fuel
    Disposing of Coolant
    Engine Break-In Oil
    Grease
    Lubricity of Diesel Fuels
    Mixing of Lubricants
    OILSCAN302256 and CoolScan342204242
    Operating in Warm Temperature Climates
    Testing Diesel Engine Coolant
 04 - Engine Rebuid Guide
    Clean Engine
    Disconnect Turbocharger Oil Inlet Line-4020T Only
    Engine Assembly Sequence
    Engine Disassembly Sequence
    Engine Lifting Procedure
    Sealant Application Guidelines
 05 - Cylinder Block, Pistons & Rods
    Assemble Cylinder Head and Valves
    Check and Adjust Valve Clearance
    Cylinder Head and Valves Specifications-3009
    Cylinder Head and Valves Specifications-3011
    Cylinder Head and Valves Specifications-3015
    Cylinder Head and Valves Specifications-4020
    Cylinder Head and Valves Specifications-4TNE98
    Disassemble and Assemble Rocker Arm Shaft Assembly
    Disassemble Cylinder Head and Valves
    Grind Valves
    Inspect Cam Followers
    Inspect Rocker Arm Shaft Assembly Components
    Install Cylinder Head
    Lap Valves
    Measure Piston-to-Cylinder Head Clearance
    Measure Valve Lift
    Remove and Install Exhaust Manifold
    Remove and Install Intake Manifold
    Remove and Install Rocker Arm Cover
    Remove Cylinder Head
    Service Equipment and Tools
 100 - Engine Tune-Up and Break-In
    Check Air Intake System
    Check and Service Cooling System
    Check Crankcase Ventilation System
    Check Electrical System
    Check Exhaust System
    Check Fan _ Alternator Belt
    Dynamometer Test Specifications
    Effects of Altitude and Temperature on Engine Performance
    Engine Break-In Guidelines
    General Tune-Up Recommendations
    Perform Engine Break-In After Overhaul
    Preliminary Engine Testing
 105 - Engine System Operation and Tests
    Air Cleaner Operation
    Air Intake System Leakage Test
    Alternator Regulated Amperage Test
    Alternator Regulated Voltage Test
    Alternator Unregulated Amperage Test
    Component Location-3009
    Component Location-3011, 3015, 4020 & 4TNE98
    Cooling System Pressure Test
    Crankcase Breather Operation
    Cylinder Compression Pressure Test-3009
    Cylinder Compression Pressure Test-3011, 3015, 4020 & 4TNE98
    Diagnosing Air Intake Malfunctions
    Diagnosing Turbocharger Malfunctions-4020T
    Engine Oil Pressure Test
    Engine System Diagnosis
    Engine Test Specifications-3009
    Engine Test Specifications-3011
    Engine Test Specifications-3015
    Engine Test Specifications-4020
    Engine Test Specifications-4TNE98
    For Pages 105-19 and 105-20, Substitue 11X17 Foldout Pages From File 34220023438A-G105B-Foldout342200235
    Fuel Shutoff Solenoid Adjustment -3011 Only
    Fuel Shutoff Solenoid Amperage Test-3011 Only
    General Description-3009,3015,4020 & 4TNE98
    General Description-3009
    How the Cooling System Works
    Lubrication System Operation
    Oil Cooler Operation-4020T Only
    Oil Filter Operation
    Oil Pressure Regulating Valve Operation
    Piston Cooling Nozzle Operation-4020T Only
    Radiator Bubble Test
    Radiator Cap Pressure Test
    Special or Essential Tools_{1219}
    Starter Amp Draw _ RPM Test
    Starter No-Load Amp Draw _ RPM Test_{1653}
    Starter Solenoid Test
    Turbocharger Operation-4020T Only
 10 - Cylinder Block, Pistons & Rods
    Assemble Piston and Connecting Rod
    Check Connecting Rod Bearing Clearance
    Check Connecting Rod Side Play
    Check Crankshaft End Play
    Check Engine Rotation for Excessive Tightness
    Check Piston Ring Groove Wear
    Clean Pistons
    Complete Disassembly of Cylinder Block (If Required)
    Cylinder Block, Pistons, and Rods Specifications-3009
    Cylinder Block, Pistons, and Rods Specifications-3011
    Cylinder Block, Pistons, and Rods Specifications-3015, 4020D and 4020T
    Cylinder Block, Pistons, and Rods Specifications-4TNE98
    Deglaze Cylinder Bores
    Disassemble Pistons and Connecting Rods
    Inspect and Clean Cylinder Block
    Inspect and Measure Cylinder Bore
    Inspect Piston Pins and Bushings
    Install Piston and Connecting Rod Assembly
    Install Piston Rings
    Measure Camshaft Bushing and Bores in Block
    Measure Camshaft Follower Bores in Block
    Measure Connecting Rod Bearings
    Measure Crankshaft Connecting Rod Journals
    Measure Piston Diameter
    Measure Piston Pin Bore
    Measure Piston Pin Bushings
    Measure Piston Pins
    Measure Piston Ring End Gap
    Measure Piston-to-Cylinder Head Clearance_{4302}
    Other Material
    Preliminary Piston and Rod Checks
    Rebore Cylinder Bores
    Remove Pistons and Connecting Rods
    Service Equipment and Tools_{4210}
    Visually Inspect Pistons
 110 - Fuel System Operation & Tests
    Bleed Fuel System-3009
    Bleed Fuel System-3011, 3015, 4020 & 4TNE98
    Combustion Chamber Operation (Direct Injection)-3011, 3015, 4020 & 4TNE98
    Direct Injection Nozzle Operation (Hole Type)-3011, 3015, 4020 & 4TNE98
    Fast Idle Speed Adjustment
    Fuel Drain Back Test
    Fuel Injection Nozzle Test
    Fuel Injection Pump Operation
    Fuel Injection Pump Specifications
    Fuel Injection Pump Static Timing Adjustment-3009
    Fuel Injection Pump Static Timing Adjustment-3011, 3015, 4020 & 4TNE98
    Fuel Shutoff Solenoid Adjustment -3011 Only_{2010}
    Fuel Supply Pump Pressure Test
    Fuel System Operation
    Fuel System Specifications
    Governor Operation
    Indirect Injection Nozzle Operation (Pintle Type)-3009
    Precombustion Chamber Operation (Indirect Injection)-3009
    Slow Idle Speed Adjustment
    Special or Essential Tools_{1752}
 119 - Dealer Fabricated Tools
    DFRG1 Extension Adapter Tip (For RHB3 Turbochargers)
    DFRG2 Extension Adapter Tip (For RHB5 Turbochargers)
    How To Make Tools
    Valve Guide Tool for 4TNE98 Engine
 15 - Crankshaft, Main Bearings, and Flywheel
    Check Crankshaft End Play_{4925}
    Check Crankshaft Main Bearing Clearance
    Check Flywheel Face Flatness
    Crankshaft and Main Bearing Failure Analysis
    Crankshaft, Main Bearings, and Flywheel Specifications-3009
    Crankshaft, Main Bearings, and Flywheel Specifications-3011
    Crankshaft, Main Bearings, and Flywheel Specifications-3015
    Crankshaft, Main Bearings, and Flywheel Specifications-4020
    Crankshaft, Main Bearings, and Flywheel Specifications-4TNE98
    Inspect Crankshaft and Main Bearings
    Inspect Flywheel
    Install Crankshaft and Main Bearing
    Other Material_{4817}
    Remove and Install Crankcase Extension Housing
    Remove and Install Flywheel Housing
    Remove and Install Flywheel
    Remove and Install Flywheel Plate
    Remove Crankshaft and Main Bearings
    Replace Crankshaft Front Oil Seal
    Replace Crankshaft Rear Oil Seal
 16 - Camshaft and Timing Gear Train
    Camshaft and Timing Gear Train Specification-4020
    Camshaft and Timing Gear Train Specifications-3009
    Camshaft and Timing Gear Train Specifications-3011
    Camshaft and Timing Gear Train Specifications-3015
    Camshaft and Timing Gear Train Specifications-4TNE98
    Check Camshaft End Play
    Check Timing Gear Backlash
    Inspect Camshaft
    Inspect Idler Gear-3009
    Inspect Idler Gear-3011, 3015, 4020 & 4TNE98
    Install Camshaft
    Measure Valve Lift_{5209}
    Other Material_{5117}
    Remove and Install Idler Gear
    Remove and Install Timing Gear Cover Mounting Plate-3011, 3015 & 4020
    Remove and Install Timing Gear Cover
    Remove and Install Timing Gear Housing-3009
    Remove and Install Timing Gear Housing-4TNE98
    Remove Camshaft
    Service Equipment and Tools_{5108}
 20 - Lubrication System
    Disassemble, Inspect and Assemble Oil Pump
    Lubrication System Specifications-3009
    Lubrication System Specifications-3011
    Lubrication System Specifications-3015
    Lubrication System Specifications-4020
    Lubrication System Specifications-4TNE98
    Materials Required
    Remove and Install Engine Oil Pump
    Remove and Install Oil Pan and Strainer
    Remove and Install Oil Pressure Regulating Valve
    Remove, Inspect and Install Oil Cooler-4020T Only
    Replace Piston Cooling Nozzles- 4020T Only
 25 - Cooling System
    Assemble Water Pump-3009, 3011, 3015 & 4020
    Cooling System Specifications-3009
    Cooling System Specifications-3011
    Cooling System Specifications-3015
    Cooling System Specifications-4020
    Cooling System Specifications-4TNE98
    Diagnosing Cooling System Malfunctions
    Disassemble Water Pump-3009, 3011, 3015 & 4020
    Other Material_{5556}
    Remove and Inspect Radiator
    Remove and Install Coolant Temperature Sensor or Switch
    Remove and Install Cooling Fan
    Remove and Install Thermostat-3009, 3011, 3015 & 4020
    Remove and Install Thermostat and Housing-4TNE98
    Remove, Inspect and Install Water Pump-3009, 3011, 3015 & 4020
    Remove, Inspect and Install Water Pump-4TNE98
    Replace and Adjust Fan _ Alternator Belt
    Service Equipment and Tools_{5547}
    Test Coolant Temperature Sensor _ Switch
    Test Thermostat Opening
 302256 3009DF001 Base Engine
 30 - Air Intake and Exhaust System
    Assemble Turbocharger
    Check Turbocharger Rotor Shaft Axial Play
    Check Turbocharger Rotor Shaft Radial Play
    Check Turbocharger Waste Gate Valve-4020T With RHB5 Turbo
    Disassemble Turbocharger-4020T Only
    Extending Turbocharger Life-4020T Only
    Inspect Air Cleaner-3009
    Inspect Air Cleaner-3011
    Inspect Air Cleaner-3015, 4020D & 4020T
    Inspect Turbocharger
    Install Turbocharger-4020T Only
    Other Material_{5851}
    Remove and Install Muffler-3009, 3011 & 3015
    Remove and Install Muffler-4020T
    Remove Turbocharger-4020T Only
    Special or Essential Tools
    Turbocharger Failure Analysis-4020T Only
    Turbocharger Seven-Step Inspection
    Turbocharger Specifications-4020T
 35 - Fuel System
    Clean and Inspect Fuel Injection Nozzles (Hole Type)-3011, 3015, 4020 & 4TNE98
    Clean and Inspect Fuel Injection Nozzles (Pintle Type)-3009 Only
    Disassemble and Assemble Fuel Injection Nozzles (Hole Type)-3011, 3015, 4020 & 4TNE98
    Disassemble and Assemble Fuel Injection Nozzles (Pintle Type)-3009 Only
    Fuel Control and Governor Linkage-3009
    Fuel Filter-3009
    Fuel Filter-3011, 3015 & 4020
    Fuel Filter-4TNE98
    Fuel Injection Pump Camshaft-3009
    Fuel System Specifications-3009
    Fuel System Specifications-3011
    Fuel System Specifications-3015
    Fuel System Specifications-4020
    Fuel System Specifications-4TNE98
    Install Fuel Injection Pump-3009
    Install Fuel Injection Pump-3011, 3015 & 4020
    Install Fuel Injection Pump-4TNE98
    Remove and Install Fuel Injection Nozzles (Hole Type)-3011, 3015, 4020 & 4TNE98
    Remove and Install Fuel Injection Nozzles (Pintle Type)-3009 Only
    Remove Fuel Injection Pump-3009
    Remove Fuel Injection Pump-3011, 3015 & 4020
    Remove Fuel Injection Pump-4TNE98
    Replace Fuel Supply Pump-3009
    Replace Fuel Supply Pump-3011, 3015 & 4020
    Replace Fuel Supply Pump-4TNE98
    Special or Essential Tools_{0139}
 302256 4020DF006 Generator Drive Power Unit Engine
 302256 4020TF005 Industrial Power Unit Engine
 40 - Starting and Charging Systems
    Assemble Alternator-3009 & 3011 (Nippondenso 40A)
    Assemble Starter-3011 & 3015 (Nippondenso 1.0 KW & 1.2 KW)
    Assemble Starter Gear and Overrunning Clutch-3011 & 3015 (Nippondenso 1.0 KW & 1.2 KW)
    Assemble Starter Gear Train and Solenoid-4020 (Nippondenso 1.4 kW)
    Disassemble and Inspect Starter-3009 (Hitachi 0.8 KW)
    Disassemble and Inspect Starter-3011 & 3015 (Nippondenso 1.0 KW & 1.2 KW)
    Disassemble and Inspect Starter-4020 (Nippondenso 1.4 KW)
    Disassemble and Inspect Starter Gear and Overrunning Clutch- 3011 & 3015 (Nippondenso 1.0 & 1.2 KW)
    Disassemble and Inspect Starter Gear Train and Solenoid-4020 (Nippondenso 1.4 kW)
    Disassemble, Inspect and Assemble Alternator-3015 & 4020 (Hitachi 40A)
    Disassemble, Inspect and Assemble Starter Solenoid-3011 & 3015 (Nippondenso 1.0 KW & 1.2 KW)
    Disassemble, Inspect and Test Alternator-3009 & 3011 (Nippondenso 40A)
    Electrical Schematic-3009
    Electrical Schematic-3011, 3015 & 4020
    Electrical System Wiring Diagram (Typical)
    Instrument Panel Components
    Other Material_{0556}
    Remove and Install Alternator
    Remove and Install Starter
    Replace Fuel Shut-Off Solenoid
    Service Equipment and Tools_{0547}
    Special or Essential Tools_{0538}
    Starter No-Load Amp Draw _ RPM Test
    Starting and Charging System Specifications
    Test and Assemble Starter-3009 (Hitachi 0.8 KW)
    Test and Assemble Starter-4020 (Nippondenso 1.4 KW)
    Test Starter-3011 & 3015 (Nippondenso 1.0 KW & 1.2 KW)

John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L & Yanmar 4TNE98 Diesel Engines Components Technical Manual (CTM119)