Complete Component Technical Manual for John Deere OEM Engine Accessories, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

John Deere OEM Engine Accessories workshop service repair 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.

ctm67 - John Deere OEM Engine Accessories Component Technical Manual.pdf
ctm35 - John Deere Accessoires pour moteur OEM.pdf
Published on 2009/10/05

PRODUCT DETAILS:
Total Pages: 611 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English French

TABLE OF CONTENTS
Section : OEM Engine Accessories................13
  Group 05: Safety................13
    Prepare for Emergencies................25
    Prevent Battery Explosions................26
    Handling Batteries Safely................27
    Handle Chemical Products Safely................30
    Avoid High-Pressure Fluids................31
    Support Machine Properly................32
    Prevent Machine Runaway................33
    Stay Clear of Rotating Drivelines................34
    Handle Starting Fluid Safely................35
    Wear Protective Clothing................36
    Work in Clean Area................37
    Service Machines Safely................38
    Work In Ventilated Area................39
    Illuminate Work Area Safely................40
    Replace Safety Signs................41
    Use Proper Lifting Equipment................42
    Remove Paint Before Welding or Heating................43
    Install Fan Guards................44
    Avoid Hot Parts................45
    Avoid Heating Near Pressurized Fluid Lines................46
    Avoid Harmful Asbestos Dust................47
    Practice Safe Maintenance................48
    Use Proper Tools................49
    Dispose of Waste Properly................50
    Live With Safety................51
  Group 10: General Information................367
    About This Manual................53
    Unified Inch Bolt and Screw Torque Values................54
    Metric Bolt and Screw Torque Values................56
  Group 20: Electrical System Information and Wiring Diagrams................13
    Electrical Circuit Malfunctions................60
    High Resistance Circuit................62
    Open Circuit................64
    Grounded Circuit................66
    Shorted Circuit................68
    Multimeter................70
    Seven Step Electrical Test Procedure................71
    Wiring Diagram and Schematic Information................73
    Reading a System Functional Schematic................75
    Reading a Wiring Diagram................76
    Electrical Schematic Symbols................78
    Component Identification Table................81
    Engine Wiring Diagram Legend—North American Series 300, 400, 500 and 700 Engines and Early Model European (Saran) Series 300 Engines................83
    Wiring Diagram—North American Series 300, 400 and 500 Engines................84
    Wiring Diagram—North American Series 700 (8955) Engines................85
    Wiring Diagram—European (Saran) Series 300 Engines (Early Model)................86
    Engine Wiring Diagram Legend—   is a registered trademark of Deere & Company 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)................14
    Engine Wiring Diagram—   is a registered trademark of Deere & Company 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)................14
    Engine Wiring Diagram Legend—   is a registered trademark of Deere & Company 10.5 L and 12.5 L Engines (With Lucas ECU) Wiring diagram shown does not show ECU (Engine Control Unit) components. See engine Operation and Diagnostics Manual CTM115 for ECU components and wiring diagrams.................14
    Engine Wiring Diagram—   is a registered trademark of Deere & Company 10.5 L and 12.5 L Engines (With Lucas ECU)................14
    Engine Wiring Diagram—   is a registered trademark of Deere & Company 8.1 L, 10.5 L and 12.5 L Engines (With John Deere ECU)................14
    Engine Wiring Diagram—   is a registered trademark of Deere & Company 8.1 L, 10.5 L and 12.5 L Engines (With John Deere ECU) (Continued)................14
    Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines................95
    Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines (Continued)................99
    Engine Wiring Diagram—PowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines (Continued)................99
    Engine Wiring Diagram—Saran AEZ Instrument Panel................101
    Engine Wiring Diagram Legend—Saran VDO Instrument Panel................103
    Engine Wiring Diagram—Saran VDO Instrument Panel................104
    Engine Wiring Diagram—PowerTech™ 2.4L and 3.0L Engines................106
  Group 21: Electrical System Diagnostics, Tests and Operation................15
    Service Equipment and Tools................550
    Electrical System Specifications................110
    General Information................367
    Component Function—Instrument Panel (Without ECU)................112
    Component Function—Instrument Panel (2.4L, 3.0L, and 4.5L (Later “270”)-Without ECU)................115
    Component Function—Instrument Panel (With Lucas ECU)................117
    Component Function—Instrument Panel (With Early Deere ECU)................119
    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)................124
    Component Function—Saran VDO Instrument Panel................128
    Component Function—Saran AEZ Instrument Panel................130
    Component Function—Crankcase Oil Level Switch/Gauge................132
    Before You Start Diagnostics................133
    Visually Inspect Electrical System................134
    Diagnose Electrical System Malfunctions................136
    Checking Fuses In Instrument Panels................138
    Test Key Switch................142
    Test Magnetic Safety Switch................143
    Test Starter Relay................144
  Group 22: Electrical System Repair and Adjustments................15
    Essential Tools................572
    Service Equipment and Tools................550
    Other Material................462
    Instrument Panel Specifications................149
    Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electric Connector................15
    Remove Blade Terminals from Connector Body................153
    Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors................15
    Repair (Push Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors................15
    Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company Connectors................15
    Repair AMP Connector................163
    Repair SUMITOMO™ Connectors................166
    Repair YAZAKI™ Connectors................168
    Repair CINCH™ Flex Box Connector................170
    Replace Instrumentation—North American Instrument Panel (Early Model Instrument Panels)................177
    Replace Instrumentation—North American Instrument Panel (Late Model Instrument Panels W/O ECU)................179
    Replace Instrumentation—North American Instrument Panel (2.4L, 3.0L, and 4.5L (Later “270”)—W/O ECU)................181
    Replace Instrumentation—Instrument Panel with Lucas ECU................182
    Replace Instrumentation—Earlier Model Instrument Panels with John Deere ECU................183
    Replace Instrumentation—Later Model Instrument Panels with John Deere ECU................185
    Replace Instrumentation—European (Saran) Instrument Panel (Early Model)................187
    Replace Instrumentation—Saran VDO Instrument Panel................189
    Replace Instrumentation—Saran AEZ Instrument Panel................190
    Remove and Install Crankcase Oil Level Switch/Gauge................192
    Calibrate Adjustable Electronic Tachometer................194
    Adjust Saran VDO Instrument Panel Tachometer................196
    Adjust Saran AEZ Instrument Panel Tachometer................198
    Replace Electronic Foot Throttle (Later Engines with ECU)................199
    Harness Repair (Splice Broken or Cut Wire)................201
    Harness Repair (Splice Connector)................203
  Group 25: Cold Weather Starting Aids................16
    Other Material................462
    Cold Weather Starting Aids Specifications................206
    Remove Coolant Heater—Block Type (Except 2.4 L and 3.0 L Engines)................207
    Install Coolant Heater—Block Type (Except 2.4 L and 3.0 L Engines)................208
    Remove Coolant Heater—Block Type (2.4 L and 3.0 L Engines)................210
    Install Coolant Heater—Block Type (2.4 L and 3.0 L Engines)................212
    Remove Coolant Heater—Block Type (Saran Engines)................214
    Install Coolant Heater—Block Type (Saran Engines)................216
    Remove Coolant Heater—Tank Type................217
    Install Coolant Heater—Tank Type................218
    Remove and Install Fuel Heater................219
    Remove and Install Air Heater................220
    Remove and Install Glow Plugs (2.4 L and 3.0 L Engines)................221
    Remove and Install Glow Plugs (4.5L and 6.8L Engines)................223
    Service Ether Starting Aid................225
  Group 30: Fuel System Accessories................17
    Fuel System Accessories Specifications................228
    Check Injection Pump Solenoid—“D” Engines................229
    Check Rack Puller—RP-20 (Stationary Engines)................230
    Check RP-75 Rack Puller—Stationary Engines................231
    Disassemble and Assemble RP-75 Rack Puller................232
    Check Rotary Fuel Shut-Off Solenoid................234
    Remove and Install Rotary Fuel Shut-Off Solenoid................235
    Adjust Rotary Fuel Shut-Off Solenoid................236
  Group 31: UTC Electric/Isochronous Governor (8955 Engines)................17
    Service Equipment and Tools................550
    Governor Specifications................239
    How the System Works................240
    Diagnosing Electric Governor Malfunctions................242
    Safety Guidelines when Testing Electronic Governor................246
    Electric Governor System Tests................247
    Test Engine Speeds................249
    Adjust Engine Speeds................250
    Adjust Gain and Stability................253
    Engine Operation in Droop Mode................254
    Electric Governor Installation Instruction................255
    Connect Electric Governor Wiring Harness................257
    Remove Electric Governor................259
    Service Magnetic Pickup................260
  Group 32: Electric Fuel Supply Pump—8955 Engines................17
    Service Equipment and Tools................550
    Fuel Supply Pump Specifications................264
    Relieve System Pressure................265
    Test John Barnes Fuel Supply Pump Pressure—8955T, A Engine Serial No. (    —3076)................266
    Adjust John Barnes Fuel Supply Pump Relief Valve—8955T, A Engines Serial No. (    —3076)................268
    Remove John Barnes Electric Fuel Supply Pump—8955 Engine Serial No. (    —3076)................270
    Remove Pressure Regulating Valve................271
    Install Pressure Regulating Valve................273
    Repair Fuel Pump................274
    Install John Barnes Fuel Supply Pump—8955 Engine Serial No. (   —3076)................280
    Test Bosch Fuel Supply Pump Pressure—8955T, A Engine Serial No. (3077—   )................281
    Replace Bosch Fuel Supply Pump—8955T, A Engines Serial No. (3077—   )................283
  Group 40: Engine Cooling System Accessories................18
    Service Equipment and Tools................550
    Other Material................462
    Engine Cooling System Specifications................287
    Test Charge Air Cooler................288
    Remove and Install Charge Air Cooler................290
    Remove and Install Coolant Temperature Sensor................292
    Pressure Test Cooling System and Radiator Cap................294
    Radiator and Hoses................296
    Install Radiator Fan—Blower and Suction Types................297
    Check Fan and Alternator Belts................299
    Remove and Install Fan and Alternator Belts................301
    Manual Belt Tensioner Adjustment................303
    Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)................305
    Check Automatic Belt Tensioner Spring Tension and Belt Wear................308
    Adjust Fan and Alternator Belts................312
  Group 45: Rear PTO - Rockford/Twin Disc................18
    Essential Tools................572
    Service Equipment and Tools................550
    Rockford/Twin Disc Rear Power Take-Off Specifications................316
    General Information................367
    Diagnosing Malfunctions................320
    Remove Power Take-Off................321
    Power Take-Off Exploded View................322
    Disassemble Power Take-Off................326
    Inspect Power Take-Off Parts................330
    Assemble Drive Shaft and Bearings—Side-Load Application................335
    Assemble Drive Shaft and Bearings—In-Line Application................336
    Install Yoke................337
    Check and Adjust Drive Shaft End Play................339
    Assemble Clutch Unit (Early Version)................341
    Assemble Clutch Unit (Late Version)................344
    Install Clutch Unit................346
    Check Flywheel Housing Face Run-Out................347
    Check Flywheel Face Flatness................348
    Check Pilot Bearing Bore................349
    Inspect Drive Ring................350
    Install Power Take-Off................351
    Check PTO Clutch Adjustment—Early Version................352
    Check PTO Clutch Adjustment—Late Version................354
  Group 46: Rear PTO - John Deere................19
    Special Or Essential Tools................572
    Other Material................462
    Rear Power Take-Off Specifications For 8.1L/9.0L and 12.5L/13.5L Engines With Primary and Auxiliary Pump Drives (Double Pump)................361
    Rear Power Take-Off Specifications For 8.1L/9.0L and 12.5L/13.5L Engines With Primary Pump Drive (Single Pump)................364
    General Information................367
    Theory of Operation................368
    Lubrication Passages................369
    Photo Disclosure................370
    Remove Rear PTO................371
    Disassemble Auxiliary Pump Group................420
    Disassemble Primary Pump Group................416
    Disassemble Auxiliary Idler Shaft Group................404
    Disassemble Primary Idler Shaft Group................396
    Inspect and Assemble Engine Rear Power Take-Off Housing Group................394
    Flywheel Access Cover Plate................395
    Primary Idler Shaft Group................396
    Assemble Primary Idler Shaft Group................397
    Auxiliary Idler Shaft Group................404
    Assemble Auxiliary Idler Shaft Group................405
    Auxiliary Pump Access Cover Plate (For Single Pump Application Only)................414
    Primary Pump Group................416
    Assemble Primary Pump Group................417
    Auxiliary Pump Group................420
    Assemble Auxiliary Pump Group (Double Pump Rear Power Take-Off)................421
    Input Gear Assembly and Seal Retainer Group................427
    Install Rear PTO................429
  Group 47: Front PTO................20
    Essential Tools................572
    Front Power Take-Off Specifications................445
    Checking Vibration Damper or Pulley (Engine With Front PTO)................446
    Remove Vibration Damper or Pulley (Engine With Front PTO)................448
    Install Vibration Damper or Pulley (Engine With Front PTO)................449
    Installing PTO Drive Gear (Crankshaft Gear-Driven PTO)................451
    Remove and Install Front PTO Clutch Adapter (Electric)................453
    Remove and Install Front PTO Clutch Adapter (Mechanical)................457
  Group 50: Auxiliary Drive, 6076 (500000—   )................20
    Service Equipment and Tools................550
    Other Material................462
    Auxiliary Drive, 6076 (500000—   ) Specifications................463
    Auxiliary Drive General Information................464
    Remove Right-Hand Output Gear Assembly................504
    Disassemble Right-Hand Output Gear Assembly................505
    Assemble Right-Hand Output Gear Assembly................507
    Install Right-Hand Output Gear Assembly................509
    Remove Left-Hand Output Gear Assembly................527
    Disassemble Left-Hand Output Gear Assembly................512
    Assemble Left-Hand Output Gear Assembly................514
    Remove Left-Hand Rear Adapter Housing................479
    Remove Idler Housing and Idler Gear................518
    Replace Idler Gear Bearing................520
    Install Idler Housing and Idler Gear................521
    Install Left-Hand Output Gear Assembly................538
    Install Left-Hand Rear Adapter Housing................489
  Group 51: Auxiliary Drive (2.9 L)................21
    Auxiliary Drive (2.9 L) Specifications................491
    Remove and Install Right-Hand Auxiliary Drive................492
  Group 52: Auxiliary Drive (4.5 L and 6.8 L)................21
    Auxiliary Drive (4.5 L and 6.8 L) Specifications................495
    Remove and Install Auxiliary Drive................496
    Remove and Install Offset Auxiliary Drive................498
    Disassemble and Inspect Auxiliary Drive Adapter................500
    Disassemble and Inspect Offset Auxiliary Drive Adapter................501
  Group 53: Auxiliary Drive (8.1 L)................21
    Auxiliary Drive Specifications................526
    Remove Right-Hand Output Gear Assembly................504
    Disassemble Right-Hand Output Gear Assembly................505
    Assemble Right-Hand Output Gear Assembly................507
    Install Right-Hand Output Gear Assembly................509
    Remove Left-Hand Output Gear Assembly................527
    Disassemble Left-Hand Output Gear Assembly................512
    Assemble Left-Hand Output Gear Assembly................514
    Remove and Install Left-Hand Rear Adapter Housing................517
    Remove Idler Housing and Idler Gear................518
    Replace Idler Gear Bearing................520
    Install Idler Housing and Idler Gear................521
    Install Left-Hand Output Gear Assembly................538
  Group 54: Auxiliary Drive (9.0L)................21
    Auxiliary Drive Specifications................526
    Remove Left-Hand Output Gear Assembly................527
    Remove Left-Hand Rear Housing................528
    Remove Left-Hand Aux Drive Housing from Cylinder Block................529
    Remove Left-Hand Aux Drive Housing from Timing Gear Cover................530
    Remove and Install Idler Gear................532
    Install Left-Hand Aux Drive Housing to Timing Gear Cover................534
    Install Left-Hand Aux Drive Housing to Cylinder Block................535
    Torque Left-Hand Aux Drive Assembly................536
    Install Left-Hand Rear Housing................537
    Install Left-Hand Output Gear Assembly................538
  Group 55: Auxiliary Drive (10.5L, 12.5L and 13.5L)................22
    Essential Tools................572
    Auxiliary Drive (10.5 L, 12.5 L and 13.5 L) Specifications................542
    Remove and Install Auxiliary Drive Idler Gear and Bearing................543
    Remove and Install SAE “A” and “B” Front and SAE “B” Rear Auxiliary Drive Assembly................545
  Group 60: Air Compressors................22
    Essential Tools................572
    Service Equipment and Tools................550
    Air Compressor Specifications................551
    Air Compressor General Information................552
    Compressor Troubleshooting Chart................554
    Compressor Troubleshooting Chart (Continued)................556
    Remove And Install Air Compressor (4.5 L and 6.8 L)................558
    Remove And Install Air Compressor [6076 (S.N. 500000— ) and 8.1 L]................22
    Remove and Install Air Compressor (10.5 L and 12.5 L)................567
  Group 70: Air Conditioning Compressors................22
    Essential Tools................572
    Air Conditioning Specifications................574
    Air Conditioning General Information................575
    Proper Refrigerant Handling................576
    R-134a Refrigerant Cautions................577
    Air Conditioning Retrofit................578
    System Information................579
    Discharge Air Conditioning System................580
    Flush/Clean Air Conditioning Compressor................581
    Purge Air Conditioning System................582
    Evacuate Air Conditioning System................583
    Check Refrigerant Oil Charge................584
    Determine Correct Refrigerant Oil Charge................585
    Add Refrigerant Oil to Pressurized System................586
    Charge Air Conditioning System................588
    Diagnosing Air Conditioning Compressor Malfunctions................590
    Remove and Install Air Conditioning Compressor................592
    Test Volumetric Efficiency................595
    Compressor Leakage Test................598
    Disassemble and Assemble Compressor Clutch (Denso Compressor)................600
    Check Clutch Hub Clearance................602
    Inspect Compressor Manifold (Denso Compressor)................603
    Disassemble, Inspect, and Assemble Compressor (Denso Compressor)................604
    Remove and Install Compressor Relief Valve (Denso Compressor)................607

John Deere OEM Engine Accessories Component Technical Manual (CTM67)