John Deere Series 500 6619 Diesel Engines Workshop Service Repair manual with Electrical Wiring Diagrams (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

John Deere Series 500 6619 Diesel Engines manual contains high quality images, circuit diagrams, instructions to help you to maintenance, troubleshoot, diagnose, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

CTM9 - John Deere Series 500 6619 Diesel Engines Component Technical Manual.pdf

TABLE OF CONTENTS
Section 01: ctm9................18
  Group 00: Safety................18
    Handle Fluids Safely-Avoid Fires................32
    Prevent Battery Explosions................33
    Prepare for Emergencies................34
    Prevent Acid Burns................35
    Avoid High-Pressure Fluids................37
    Wear Protective Clothing................38
    Work in Clean Area................39
    Service Machines Safely................40
    Work In Ventilated Area................41
    Illuminate Work Area Safely................42
    Use Proper Lifting Equipment................43
    Avoid Heating Near Pressurized Fluid Lines................44
    Remove Paint Before Welding or Heating................45
    Use Proper Tools................46
    Dispose of Waste Properly................47
    Live With Safety................48
  Group 01: General Information................423
    Unified Inch Bolt and Cap Screw Torque Values................50
    Metric Bolt and Cap Screw Torque Values................51
    Engine Model Designation................52
    Engine Serial Number Plate Information................54
    Option Code Label................57
    Engine Application Chart................58
  Group 02: Fuels, Lubricants, and Coolant................18
    Diesel Fuel................60
    Lubricity of Diesel Fuels................61
    Diesel Engine Oil................62
    Engine Break-In Oil................63
    OILSCANOILSCAN is a trademark of Deere & Company. and CoolScanCoolScan is a trademark of Deere & Company.................18
    Grease................65
    Engine Coolant Requirements................66
    Engine Coolant Recommendations................68
    Engine Coolant Specifications................69
    Replenishing Supplemental Coolant Additives (SCA's) Between Coolant Changes................71
    Testing Engine Coolant................73
    Disposing of Coolant................74
  Group 03: Engine Mounting................19
    Engine Repair Stand................76
    Safety Precautions................77
    Install 6619 Engine Adapters on Repair Stand................78
    Engine Lifting Procedure................79
    Clean Engine................80
    Mount Engine on Repair Stand................81
  Group 04: Engine Rebuild Guide................19
    Disassembly Sequence................85
    Sealant Application Guidelines................87
    Assembly Sequence................89
  Group 05: Cylinder Head and Valves................19
    Special or Essential Tools................645
    Service Equipment and Tools................418
    Other Material................507
    Cylinder Head and Valves Specifications................101
    Torques................104
    Check and Adjust Valve Clearance................105
    Check Valve Lift................335
    Remove Cylinder Head................108
    Check Valve Height In Relation to Head Surface................111
    Disassemble and Inspect Rocker Arm Shaft Assembly................112
    Assemble Rocker Arm Shaft Assembly................114
    Preliminary Cylinder Head and Valve Checks................115
    Remove Valve Assembly................117
    Inspect Valve Springs................119
    Inspect Spring Caps, Wear Caps and Valve Rotators................120
    Clean and Inspect Push Rods................121
    Clean Valves................122
    Inspect and Measure Valves................123
    Grind Valves................125
    Inspect and Clean Cylinder Head................126
    Check Cylinder Head Combustion Face Flatness................127
    Measure Cylinder Head Thickness................128
    Resurface Cylinder Head................129
    Clean Valve Guides................130
    Measure Valve Guides................131
    Knurl Valve Guides................132
    Replace Valve Guides................133
    Clean and Inspect Valve Seats................134
    Measure Valve Seats................135
    Grind Valve Seats................136
    Remove Valve Seat Inserts................138
    Measure Valve Seat Bores In Cylinder Head................140
    Install Valve Seat Inserts (Standard or Oversize)................141
    Clean and Inspect Cylinder Head Nozzle Bore................142
    Clean and Inspect Nozzle Seating Surface................143
    Clean and Inspect Top Deck of Cylinder Block................144
    Clean and Inspect Crankcase Ventilation Assembly................145
    Inspect and Clean Exhaust Manifold................148
    Install Valve Assembly................149
    Install Cylinder Head................151
    Tighten Flanged-Head Cylinder Head Cap Screws (With Flat Washers)................153
    Torque-Turn Flanged-Head Cylinder Head Cap Screws................154
    Install Push Rods................156
    Install Rocker Arm Assembly................157
    Complete Final Assembly On Injection Pump Side................158
    Complete Final Assembly On Exhaust Manifold Side-6619A Engines................160
    Complete Final Assembly On Exhaust Manifold Side-6619T Engines................163
    Perform Engine Break-In................165
  Group 10: Cylinder Block, Liners, Pistons and Rods................21
    Special or Essential Tools................645
    Service Equipment and Tools................418
    Other Material................507
    Cylinder Block, Liners, Pistons and Rods Specifications................176
    Preliminary Liner, Piston, and Rod Checks................180
    Remove Pistons and Connecting Rods................182
    Measure Cylinder Liner Standout (Height Above Block)................186
    Remove Cylinder Liners................187
    Remove Piston Rings................190
    Clean Pistons................191
    Visually Inspect Pistons................192
    Clean Cylinder Liners................193
    Visually Inspect Cylinder Liners................194
    Piston and Liner Identification Markings................196
    Check Piston Ring Groove Wear................198
    Measure Oil Control Ring Groove................199
    Inspect Piston Pin Bore In Piston................200
    Measure Piston OD................201
    Measure Cylinder Liners................202
    Determine Piston-to-Liner Clearance................204
    Deglaze Cylinder Liners................205
    Inspect and Measure Connecting Rod Bearings................206
    Inspect Connecting Rod and Cap................208
    Inspect Piston Pins and Bushings................211
    Remove 6° Taper Piston Pin Bushing................213
    Remove 19° Taper Piston Pin Bushing................214
    Clean and Inspect Piston Pin Bushing Bore in Connecting Rod................215
    Install 6° Taper Piston Pin Bushing................216
    Install 19° Taper Piston Pin Bushing................218
    Complete Disassembly of Cylinder Block (If Required)................220
    Inspect and Clean Cylinder Block................221
    Clean Cylinder Liner O-Ring Bores In Block................223
    Remove and Clean Piston Cooling Orifices................302
    Measure Cylinder Block................225
    Recheck Cylinder Liner Standout (Height Above Block)................226
    Measure Liner Flange Thickness................228
    Install Liner Shims-If Required................229
    Install Cylinder Liner O-Rings and Packings................230
    Cylinder Liner Manufacturing Date Code Explanation................232
    Install Cylinder Liners................234
    Install Pistons and Connecting Rods................236
    Torque-Turn Connecting Rod Cap Screws................240
    Check Engine Rotation for Excessive Tightness................241
    Measure Piston Protrusion................242
    Complete Final Assembly................578
  Group 15: Crankshaft Main Bearings and Flywheel................22
    Special or Essential Tools................645
    Service Equipment and Tools................418
    Other Materials................255
    Crankshaft, Main Bearings and Flywheel Specifications................256
    Crankshaft and Main Bearing Failure Analysis................259
    Replace Crankshaft Rear Oil Seal and Wear Sleeve (With Oil Seal Housing Installed)................261
    Inspect Vibration Damper................264
    Remove Vibration Damper and Pulley................339
    Remove Crankshaft Front Oil Seal (With Timing Gear Cover Installed)................267
    Remove Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed)................269
    Install Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed)................360
    Install Crankshaft Front Oil Seal................361
    Remove Timing Gear Cover................341
    Check Crankshaft End Play................274
    Remove Front Wear Sleeve (With Timing Gear Cover Removed)................342
    Remove Front Oil Seal (With Timing Gear Cover Removed)................343
    Service Clutch Shaft Pilot Bushing................277
    Check Flywheel Housing Face Runout................278
    Check Flywheel Face Flatness................279
    Remove Flywheel and Flywheel Housing................280
    Inspect and Repair Flywheel................281
    Replace Flywheel Ring Gear................282
    Remove Rear Oil Seal Housing................283
    Remove Crankshaft Rear Oil Seal and Wear Sleeve (With Oil Seal Housing Removed)................284
    Remove Crankshaft Main Bearings................285
    Check Main Bearing Clearance................286
    Remove Crankshaft................287
    Inspect Crankshaft................288
    Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journals................290
    Measure Assembled I.D. of Main Bearing Caps (Without Bearings)................292
    Crankshaft Grinding Guidelines................293
    Crankshaft Grinding Specifications................295
    Thrust Bearing New Part Specifications................296
    Replace Crankshaft Drive Gear................297
    Replace (Crankshaft) Oil Pump Drive Gear................299
    Inspect Thrust Bearings................301
    Remove and Clean Piston Cooling Orifices................302
    Install Main Bearing Inserts In Block................303
    Install Crankshaft................305
    Install Oil Pump and Check Drive Gear-to-Crankshaft Clearance................307
    Install Crankshaft Rear Oil Seal Housing................308
    Check Oil Seal Housing Runout................309
    Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions................310
    Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly................311
    Install Crankshaft Front Wear Sleeve................313
    Install Timing Gear Cover................359
    Install Crankshaft Front Oil Seal................361
    Install Vibration Damper and Pulley................316
    Install Flywheel Housing and Flywheel................320
    Complete Final Assembly................578
  Group 16: Camshaft and Timing Gear Train................23
    Special or Essential Tools................645
    Other Material................507
    Camshaft and Timing Gear Train Specifications................333
    Check Valve Lift................335
    Check Camshaft Gear-to-Oil Pump Drive Gear Backlash-(Camshaft Driven Oil Pump Engines Only) (Engine Installed)................400
    Check Camshaft Gear-to-Oil Pump Driven Gear Backlash-Camshaft-Driven Oil Pump Engines Only................402
    Remove Vibration Damper and Pulley................339
    Remove Timing Gear Cover................341
    Remove Front Wear Sleeve (With Timing Gear Cover Removed)................342
    Remove Front Oil Seal (With Timing Gear Cover Removed)................343
    Check Camshaft End Play................344
    Measure Camshaft Drive Gear-to-Crankshaft Gear Backlash................345
    Remove Tachometer Drive Assembly................346
    Remove Camshaft................347
    Remove Camshaft Gear, Spacer, and Thrust Plate................349
    Measure Thrust Plate and Spacer................350
    Inspect and Measure Camshaft................351
    Remove, Inspect, and Measure Camshaft Followers................353
    Assemble Camshaft................354
    Replace Camshaft Bushings................355
    Install Camshaft................357
    Install Timing Gear Cover................359
    Install Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed)................360
    Install Crankshaft Front Oil Seal................361
    Service Mechanical Tachometer Drive Assembly-Camshaft Driven Oil Pump Engines Serial No. (-046655)................362
    Service Mechanical Tachometer Drive Assembly-Crankshaft Driven Oil Pump Engines Serial No. (046656-)................364
    Install Mechanical Tachometer Drive Assembly................366
    Complete Final Assembly................578
  Group 20: Lubrication System................24
    Special or Essential Tools................645
    Other Material................507
    Lubrication System Specifications................371
    Diagnosing Lubrication System Malfunctions................374
    Remove Oil Pan................375
    Remove Oil Pressure Regulating Housing and Oil Cooler Assembly................376
    Oil Pressure Regulating Valve Housing and Oil Cooler Assembly................378
    Remove and Inspect Oil Cooler Bypass, Oil Filter Bypass and Oil Pressure Regulating Valve Assemblies................380
    Install Oil Cooler Bypass, Oil Filter Bypass and Oil Pressure Regulating Valves................382
    Install Oil Pressure Regulating and Oil Cooler Housing Assembly................383
    Crankshaft Driven Oil Pump................385
    Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash................387
    Remove Crankshaft Driven Oil Pump................388
    Inspect and Clean Crankshaft Driven Oil Pump................389
    Check Drive Shaft End Play-Crankshaft Driven Oil Pump................390
    Check Drive Shaft Side Movement-Crankshaft Driven Oil Pump................391
    Check Pumping Gear Backlash-Crankshaft Driven Oil Pump................392
    Inspect Oil Pump Drive Gear-Crankshaft Driven Oil Pump................393
    Adjust Oil Pump Set Screw-Crankshaft Driven Oil Pump................394
    Install Crankshaft Driven Oil Pump (Agricultural and OEM Applications)................395
    Install Crankshaft Driven Oil Pump (Industrial Applications)................397
    Check Camshaft Gear-to-Oil Pump Drive Gear Backlash-(Camshaft Driven Oil Pump Engines Only) (Engine Installed)................400
    Check Camshaft Gear-to-Oil Pump Driven Gear Backlash-Camshaft-Driven Oil Pump Engines Only................402
    Remove and Inspect Camshaft Driven Oil Pump................403
    Remove Camshaft Driven Oil Pump Gears................405
    Install Camshaft Driven Oil Pump Gears................406
    Install Camshaft Driven Oil Pump................408
    Install Oil Pan................409
    Remove Bypass Oil Filter Assembly................411
    Inspect and Clean Bypass Oil Filter Assembly................412
    Install Bypass Oil Filter Assembly................413
  Group 25: Cooling System................25
    Special or Essential Tools................645
    Service Equipment and Tools................418
    Other Material................507
    Cooling System Specifications................420
    Diagnosing Cooling System Malfunctions................422
    General Information................423
    Remove Water Pump................424
    Disassemble Standard-Duty Water Pump................426
    Inspect Standard-Duty Water Pump Parts................429
    Assemble Standard-Duty Water Pump................431
    Disassemble Heavy-Duty Water Pump................434
    Inspect Heavy-Duty Water Pump Parts................438
    Assemble Heavy-Duty Water Pump................440
    Install Water Pump................445
    Remove Water Manifold................447
    Inspect and Clean Water Manifold................448
    Install Water Manifold................449
    Remove Thermostats................450
    Install Thermostats................451
    Coolant Filter Conditioner General Information................452
    Remove Coolant Filter Conditioner-Water Manifold Mounted................453
    Remove Coolant Filter Conditioner-Intake Manifold Mounted................454
    Inspect Coolant Filter Conditioner Components................455
    Install Coolant Filter Conditioner-Water Manifold Mounted................456
    Install Coolant Filter Conditioner-Intake Manifold Mounted................458
    Complete Final Assembly................578
    Check and Adjust V-Belt Tension................460
  Group 30: Air Intake and Exhaust System................26
    Other Material................507
    Air Intake and Exhaust Systems Specifications................464
    Extending Turbocharger Life................465
    Remove Turbocharger................467
    Diagnosing Turbocharger Malfunctions................638
    Turbocharger Seven-Step Inspection................473
    Radial Bearing Clearance Test................479
    Axial End Play Bearing Test................480
    Repair Turbocharger................481
    Disassemble and Inspect Turbocharger................482
    Replace Center Housing and Rotating Assembly................484
    Prelube Turbocharger................485
    Install Turbocharger................486
    Remove Aftercooler and Intake Manifold (6619A Engines)................489
    Inspect and Repair Aftercooler (6619A Engines)................491
    Inspect and Repair Intake Manifold (6619A Engines)................492
    Install Intake Manifold and Aftercooler (6619A Engines)................493
    Remove, Inspect and Install Intake Manifold (6619T Engines)................495
    Remove, Inspect and Install Exhaust Manifold Assembly................497
  Group 35: Fuel System................27
    Special or Essential Tools................645
    Other Material................507
    Fuel System Specifications................508
    Relieve Fuel System Pressure................510
    Remove Fuel Filters................511
    Remove Fuel Check Valve Assembly................512
    Inspect Check Valve................513
    Remove Inspect and Clean Fuel Filter Body................514
    Install Fuel Check Valve Assembly................515
    Install New Fuel Filters................516
    Service Fuel Inlet Final Filter-6619AR-11, 12, and 14 Engines, Serial No. (0000-052656)................517
    Remove Fuel Supply Pump................519
    Test Fuel Supply Pump For Leaks................520
    Disassemble Fuel Supply Pump................521
    Inspect and Repair Fuel Supply Pump................525
    Assemble Fuel Supply Pump................528
    Install Fuel Supply Pump................531
    General Information for Aneroid................532
    Repair Aneroid................533
    Remove Hydraulic Aneroid Activator................534
    Disassemble and Clean Hydraulic Aneroid Activator................535
    Assemble and Install Hydraulic Aneroid Activator................537
    Service Overflow Valve................538
    Remove Fuel Injection Pump................540
    Repair Fuel Injection Pump................543
    Install Fuel Injection Pump................544
    Remove Fuel Injection Nozzles................548
    Test Fuel Injection Nozzles................551
    Perform Opening Pressure Test................552
    Test Nozzle Leakage................554
    Test Nozzle Chatter and Spray Pattern................556
    Disassemble Fuel Injection Nozzle................557
    Clean and Inspect Fuel Injection Nozzle Assembly................560
    Perform Nozzle Slide Test................561
    Clean Spray Orifices................562
    Inspect Nozzle Holder................563
    Inspect Gland Nut................565
    Assemble Fuel Injection Nozzle................566
    Inspect and Clean Cylinder Head Nozzle Bore................569
    Inspect and Clean Nozzle Seating Surface................570
    Install Fuel Injection Nozzles................571
    Install Fuel Leak-Off Line Assembly and Fuel Delivery Lines (Engine Serial No. -050290)................574
    Install Fuel Leak-Off Line Assembly and Fuel Delivery Lines (Engine Serial No. 050291-) and All 6619AR-11, 12, 14................576
    Complete Final Assembly................578
  Group 100: Tune-Up................28
    Effects of Altitude and Temperature On Engine Performance................580
    Preliminary Engine Testing................581
    General Tune-Up Recommendations................582
    Dynamometer Test................583
    Engine Break-In Guidelines................585
    Engine Break-In Instructions................586
    Check Crankcase Ventilation System................587
    Check Air Intake System................588
    Check Exhaust System................589
    Check and Service Cooling System................590
    Check Electrical System................592
  Group 105: Engine System Operation and Tests................29
    Special or Essential Tools................645
    Engine Test Specifications................600
    Engine Sectional View................601
    General Description................603
    How the Lubrication System Works................604
    How The Cooling System Works................607
    Head Gasket Joint Construction and Operation................609
    Diagnosing Head Gasket Joint Failures................611
    Head Gasket Inspection and Repair Sequence................615
    Diagnosing Engine Malfunctions................617
    Test Engine Compression Pressure................621
    Check Engine Oil Pressure................623
    Check Crankshaft End Play (Damper Installed)................625
    Measure Engine Crankcase Pressure (Blow-By)................626
    Pressure Test Cooling System and Radiator Cap................627
    Inspect Thermostat and Test Opening Temperature................629
  Group 110: Air Intake System Operation and Tests................29
    Special Or Essential Tools................632
    Air Intake and Exhaust System Test Specifications................633
    Diagnosing Air Intake Malfunctions................634
    How the Air Intake and Exhaust System Work................635
    Air Cleaner Operation................637
    Diagnosing Turbocharger Malfunctions................638
    How the Turbocharger Works................639
    How The Turbocharger Is Lubricated................640
    How the Aftercooler Works-6619A Engines................641
    Check Intake Manifold Pressure (Turbo-Boost)-6619AF Engines................642
  Group 115: Fuel System Operation and Tests................29
    Special or Essential Tools................645
    Fuel System Test Specifications................646
    Fuel System Operation................647
    Diagnose Fuel System Malfunctions................649
    Supply Pump Operation................654
    Diagnosing Fuel Supply Pump Malfunctions................657
    Check Supply Pump Operation................658
    Service Supply Pump................662
    Fuel Filter Operation................663
    Bleed Fuel System................664
    Diagnose Fuel Injection Pump Malfunctions................667
    How The Fuel Injection Pump Works................668
    Check and Adjust Injection Pump Timing................669
    Check Engine Fast Idle Speed................671
    Check and Adjust Slow Idle Speed................672
    How the Aneroid Works................675
    Diagnose Aneroid Malfunctions................677
    How the Hydraulic Aneroid Activator Works................678
    Diagnose Malfunctions-Hydraulic Aneroid Activator................680
    Fuel Injection Nozzles-General Information................681
    Fuel Injection Nozzle Operation................683
    Diagnose Malfunctions-Fuel Injection Nozzle................685
    Test Fuel Injection Nozzles (Engine Running)................687
    Fuel Drain Back Test Procedure................688
  Group 199: Fabricated Tools................30
    How to Make Tools................690
    Cylinder Liner Holding Fixture................691
    
John Deere Series 500 6619 Diesel Engines Component Technical Manual (CTM9)