John Deere 6090HF484, 6090HF485, 6090HFG86 Engine Parts Catalog Manual

Service Parts Engine

Engine Models:

John Deere 6090HF484 6090HF485 6090HFG86 Generator Models: 230--275REOZJD 230--275REOZJE 300REOZJ

TP-6438 1/11c

Table of Contents Subject Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Numbering System Significance . . . . . . . . . . . . . . . .

Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Find Part Numbers . . . . . . . . . . . . . . . . . . . . .

Hardware References . . . . . . . . . . . . . . . . . . . . . . . . .

Specification Number Index . . . . . . . . . . . . . . . . . . . .

Group 1: Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 2: Water Pump . . . . . . . . . . . . . . . . . . . . . . . .

Group 4: Water Pump Inlet . . . . . . . . . . . . . . . . . . . .

Group 5: Thermostat . . . . . . . . . . . . . . . . . . . . . . . . .

Group 6: Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 7: Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 10: Vent Tube . . . . . . . . . . . . . . . . . . . . . . . . .

Group 11: Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 12: Valve Train . . . . . . . . . . . . . . . . . . . . . . . .

Group 13: Rocker Arm Cover . . . . . . . . . . . . . . . . . .

Group 14: Fuel Injection System . . . . . . . . . . . . . . .

Group 18: Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . .

Group 19: Crankshaft . . . . . . . . . . . . . . . . . . . . . . . .

Group 20: Crankshaft Pulley . . . . . . . . . . . . . . . . . . .

Group 21: Piston and Connecting Rod . . . . . . . . . .

Group 22: Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Page 3 3 3 3 3 4 8 9 10 11 12 12 13 13 15 17 19 21 22 23 24 24

Subject

Page

Group 23: Flywheel Housing . . . . . . . . . . . . . . . . . .

Group 24: Cylinder Head . . . . . . . . . . . . . . . . . . . . . .

Group 25: Exhaust Manifold . . . . . . . . . . . . . . . . . . .

Group 26: Exhaust Elbow . . . . . . . . . . . . . . . . . . . . .

Group 28: Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 29: Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 30: Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . .

Group 31: Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 32: Cylinder Block . . . . . . . . . . . . . . . . . . . . .

Group 34: Timing Gear Cover . . . . . . . . . . . . . . . . .

Group 35: Turbocharger and Oil Lines . . . . . . . . . .

Group 36: Starter Motor . . . . . . . . . . . . . . . . . . . . . . .

Group 37: Alternator . . . . . . . . . . . . . . . . . . . . . . . . .

Group 38: Alternator Brackets . . . . . . . . . . . . . . . . .

Group 40: Cylinder Head Gasket Set . . . . . . . . . . .

Group 41: Overhaul Gasket Set . . . . . . . . . . . . . . . .

Group 43: Wiring Harness . . . . . . . . . . . . . . . . . . . . .

Group 45: Turbo Air Inlet . . . . . . . . . . . . . . . . . . . . . .

Group 47: Engine Gas Recirculation . . . . . . . . . . . .

Group 48: Lifting Straps . . . . . . . . . . . . . . . . . . . . . .

Appendix A Common Hardware Identification . . . .

Appendix B Common Hardware List . . . . . . . . . . . . .

25 26 28 29 30 30 32 34 35 37 38 40 41 42 43 44 45 48 49 50 52 53

TP-6438 1/11

Introduction This manual lists service replacement parts for John Deere engine models 6090HF484/485 and 6090HFG86.

At the time of print this manual applied to the engine models listed in the Model Index. On occasion this manual may apply to engines not listed in the Model Index.

Information in this publication represents data available at the time of print. The generator set manufacturer reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

How to Find Part Numbers Use the following steps to locate a service replacement part.

1. Locate the engine nameplate to identify the engine model number.

2. Turn to the Model Index. The first column lists the engine model numbers. The headings identify the groups of parts that make up the engine.

3. Identify the group most likely to include the service part number.

Table of Contents. Lists the sections of the manual.

4. Find the group variation number at the intersection of the model row and the group column. Note the variation number.

Introduction (and other information sections).

Contains introductory material about part numbers, illustrations, and hardware.

5. Page forward to locate the group identified in step 3 or find the appropriate page in the Table of Contents.

Index. Lists the engine models and groups.

6. Find the part on the illustration and note the item number of the part or find the part description in the parts list.

This manual includes the following main sections:

Group Parts Lists. List the part numbers of parts in the groups.

Numbering System Significance This manual uses the following numbering systems: Engine Model. The product identification number located on the engine nameplate. Engines break down into groups.

Group Number. A unique number representing a parts group needed to assemble an engine function. For example, Group 1 is the Air Intake group.

Variation Number. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 12-volt alternator and 24-volt alternator both perform the same function, but, with different parts. Each difference requires a group variation or module number.

Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit.

Illustrations Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly.

TP-6438 1/11

7. Select the part number that corresponds to your group variation. The first column lists the illustration item number.

Find the variation identified in the Model Index in the appropriate column on the right side of the parts list table. Find the quantity used at the intersection of the item number row and the variation column. A blank space at the intersection means the variation/ module does not use that part number.

Hardware References Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware.

For example, an item that appears as “Hardware, 3/8-16” in the text means that the piece is 3/8-16 size.

Obtain common hardware locally.

Some hardware items require a specific size or some other characteristic. In that case, use the part number listed in the text.

When replacing hardware, do not substitute inferior grade hardware. Replacement hardware grade should be equal to or better than the grade of the manufacturer’s original hardware.

3

Specification Number Index Group Title

Group No.

1

2

4

5

6

7

10

11

12

13

14

18

19

20

Variation Number Spec No. 230 kW (6090HF485) GM46340-GA1

1701

2001

5701

3908

2437

234A

2901

4601

4901

1101

1601

3511

4701

1319

2001 2001 2001

5708 5708 5708

3913 3913 3913

2437 2437 2437

234A 234A 234A

2901 2901 2901

4601 4601 4601

4901 4901 4901

1101 1101 1101

1601 1601 1601

3511 3511 3511

4701 4701 4701

1319 1319 1319

2001

5701

3908

2437

234A

2901

4601

4901

1101

1601

3511

4701

1319

2001 2001 2001

5708 5708 5708

3913 3913 3913

2437 2437 2437

234A 234A 234A

2901 2901 2901

4601 4601 4601

4901 4901 4901

1101 1101 1101

1601 1601 1601

3511 3511 3511

4701 4701 4701

1319 1319 1319

2001

5701

3908

2437

234A

2901

4601

4901

1101

1601

3511

4701

1319

2001 2001 2001

5708 5708 5708

3913 3913 3913

2437 2437 2437

234A 234A 234A

2901 2901 2901

4601 4601 4601

4901 4901 4901

1101 1101 1101

1601 1601 1601

3511 3511 3511

4701 4701 4701

1319 1319 1319

5708

3913

2437

234A

2901B

4609

4901B

1101B

1601B

3511

4705

1354

230 kW (6090HF484) GM46340-GA5 GM66100-GA1 GM66100-GA4

1707 1707 1707

250 kW (6090HF485) GM46340-GA2

1701

250 kW (6090HF484) GM46340-GA6 GM66100-GA2 GM66100-GA5

1707 1707 1707

275 kW (6090HF485) GM46340-GA3

1701

275 kW (6090HF484) GM46340-GA7 GM66100-GA3 GM66100-GA6

1707 1707 1707

300 kW (6090HFG86) GM66100-GA7

4

1707

2001

TP-6438 1/11

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Specification Number Index Group Title

Group No.

21

22

23

24

25

26

28

29

30

31

32

34

35

Variation Number Spec. No. 230 kW (6090HF485) GM46340-GA1

4801

1506

1426

5101

2805

6402

4003

1916

5921

5001

4601

7701

6519

1506 1506 1506

1426 1426 1426

5101 5101 5101

2811 2811 2811

6402 6402 6402

4003 4003 4003

1916 1916 1916

5925 5925 5925

5001 5001 5001

4601 4601 4601

7701 7701 7701

6535 6535 6535

1506

1426

5101

2805

6402

4003

1916

5921

5001

4601

7701

6519

1506 1506 1506

1426 1426 1426

5101 5101 5101

2811 2811 2811

6402 6402 6402

4003 4003 4003

1916 1916 1916

5925 5925 5925

5001 5001 5001

4601 4601 4601

7701 7701 7701

6535 6535 6535

1506

1426

5101

2805

6402

4003

1916

5921

5001

4601

7701

6519

1506 1506 1506

1426 1426 1426

5101 5101 5101

2811 2811 2811

6402 6402 6402

4003 4003 4003

1916 1916 1916

5925 5925 5925

5001 5001 5001

4601 4601 4601

7701 7701 7701

6535 6535 6535

1550

1435

6402

4003

1916B

5925

5003

4609

7706

6535

230 kW (6090HF484) GM46340-GA5 GM66100-GA1 GM66100-GA4

4801 4801 4801

250 kW (6090HF485) GM46340-GA2

4801

250 kW (6090HF484) GM46340-GA6 GM66100-GA2 GM66100-GA5

4801 4801 4801

275 kW (6090HF485) GM46340-GA3

4801

275 kW (6090HF484) GM46340-GA7 GM66100-GA3 GM66100-GA6

4801 4801 4801

300 kW (6090HFG86) GM66100-GA7

TP-6438 1/11

4804

5101B 2811B

5

Specification Number Index Group Title

Group No.

36

37

38

40

41

43

45

47

50

Variation Number Spec No. 230 kW (6090HF485) GM46340-GA1

3005

3119

6202

9902

9902

8401

5405

8902

3118 3118 3118

6217 6217 6217

9902 9902 9902

9902 9902 9902

8414 8414 8498

----

----

3119

6202

9902

9902

8401

5405

8902

3118 3118 3118

6217 6217 6217

9902 9902 9902

9902 9902 9902

8414 8414 8498

----

----

3118

6202

9902

9902

8401

5405

8902

3118 3118 3118

6217 6217 6217

9902 9902 9902

9902 9902 9902

8414 8414 8498

----

----

3118

6217

8498

--

8997

230 kW (6090HF484) GM46340-GA5 GM66100-GA1 GM66100-GA4

3005 3005 3005

250 kW (6090HF485) GM46340-GA2

3005

250 kW (6090HF484) GM46340-GA6 GM66100-GA2 GM66100-GA5

3005 3005 3005

275 kW (6090HF485) GM46340-GA3

3005

275 kW (6090HF484) GM46340-GA7 GM66100-GA3 GM66100-GA6

3005 3005 3005

300 kW (6090HFG86) GM66100-GA7

6

3005

9804

TP-6438 1/11

Notes

TP-6438 1/11

7

Group 1: Air Intake

Item 1 2 3 4 5 6 7

Part Number # GM50218 GM50142 GM50168 # GM49999 GM50003

Qty. Variation 1701

Description Screw, M8 x 35 Intake manifold Gasket Washer, sealing Screw, M8 x 110 Sensor, manifold air press Sensor, temperature

7 1 1 7 7 1 1

8

9

10

1 11

12 1707

Item 1 2 3 4 5 6 7 8 9 10 11 12

Part Number GM67302 # # # GM50168 GM67288 GM50142 GM50003 # # GM79826 GM79827

Description Intake manifold Plug Plug Screw, M8 x 110 Washer, sealing Screw Gasket Sensor, temperature Pipe plug Screw, M8 x 60 Air intake Gasket

4397

Qty. Variation 1707 4397 1 1 2 7 7 7 1 1 1 4 1 1

# Common hardware; procure locally.

8

TP-6438 1/11

Group 2: Water Pump

Item 1 2 3

TP-6438 1/11

Part Number GM50245 GM50172 GM50205

Description Kit, water pump Snap ring O-ring Kit

Qty. Variation 2001 1 1 1

9

Group 4: Water Pump Inlet

Item 1 2 3 4 5

Item 1 2 3 4 5

Part Number 352737 GM18862 223461 # GM50197

Part Number GM67274 GM67275 # GM50233 223435

Description Gasket Pipe plug, 1/2 in.

Fitting, hose Screw Hose

Description Screw Screw Screw, M10 x 30 Connection, water pump Drain valve

Qty. Variation 5701 1 2 1 3 1

Qty. Variation 5708 3 1 2 1 1

Item 6 7 8 9

Item 6 7 8 9 10 11

Part Number # 223435 # GM50233

Part Number GM18862 GM53024 GM67276 GM18862 352726 352737

Description Screw Drain valve Screw, M10 x 30 Connection, water pump

Description Pipe plug Pipe plug Cover Pipe plug Dowel pin Gasket

Qty. Variation 5701 1 1 1 1

Qty. Variation 5708 2 1 1 1 2 1

# Common hardware; procure locally.

10

TP-6438 1/11

Group 5: Thermostat 14

13

15

Item 1 2 3 4 5 6 7 7 8 8

Part Number GM50244 GM50134 GM53024 223409 # # GM18785 GM50195 GM21508 GM50114

Description Housing Gasket Pipe plug Plug Screw, M10 x 25 Screw, M10 x 100 Sensor, coolant temp.

Sensor, coolant temp.

O-ring O-ring

Qty. Variation 3908 3913 1 1 1 1 3 1 1 1 1

1 1 1 1 3 1 1 1

Item 9 10 11 12 13 14 15 15 15

Part Number 360013 GM21508 GM50203 GM50131 GM50185 # GM50047 GM49907 GM67301

Description Fitting plug O-ring Tube O-ring Housing Screw, M10 x 45 Thermostat Seal Thermostat

Qty. Variation 3908 3913 1 1 1 3 2 2

1 1 1 2 1 3 2

# Common hardware; procure locally.

TP-6438 1/11

11

Group 6: Fan Belt

Item 1

Part Number 352793

Description V-belt

Qty. Variation 2437 1

Group 7: Fan Drive

Item 1 2 3 4 5 6

Part Number GM50110 352708 GM50189 # GM50188 #

Description Snap ring Bearing Hub Plug Pulley Screw

Qty. Variation 234A 1 1 1 1 1 6

# Common hardware; procure locally.

12

TP-6438 1/11

Group 10: Vent Tube

Item 1 1 2 2

Part Number 336705 GM79815 GM50118 GM79814

Description Clamp, hose Clamp Tube Hose

Qty. Variation 2901 2901B 1 1 1 1

Group 11: Camshaft

Item 16 17 18 19 20 21 22

TP-6438 1/11

Part Number GM50214 223889 352700 GM50141 GM50138 GM50132 GM50167

Description Cam follower roller Bushing Shaft key Gear Gear Washer Camshaft

Qty. Variation 4601 12 6 1 1 1 1 1

13

Group 11: Camshaft, continued

Item 9 10 11 12 13 22 23

14

Part Number GM79820 GM50141 GM50132 352700 GM79821 223866 GM79823

Description Gear Gear Washer Shaft Key Camshaft Plug Bushing

Qty. Variation 4609 1 1 1 1 1 1 6

TP-6438 1/11

Group 12: Valve Train

Item 1 2 3 4 5 6

Part Number GM50111 GM50182 GM50123 GM50154 GM50212 GM50137

TP-6438 1/11

Description Snap ring Washer Washer Guide Rocker arm Pedestal

Qty. Variation 4901 2 4 2 12 6 6

Item 7 8 9 10 11

Part Number GM50211 GM50136 # 223877 GM50213

Description Rocker arm Spring Cap screw Push rod Rocker arm shaft

Qty. Variation 4901 6 5 6 12 1

15

Group 12: Valve Train, continued

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

16

Part Number GM79835 GM79836 GM79837 GM79838 GM79839 GM50136 GM50111 GM50182 GM50123 GM79840 GM79841 GM79842 GM79843 223877

Description Rocker Arm Cap Screw Pedestal Rocker Arm Nut Spring Snap Ring Washer Washer Rocker Arm Shaft Plug Rocker Arm Guide Push Rod

Qty. Variation 4901B 1 6 6 6 1 5 2 4 2 1 2 6 12 12

TP-6438 1/11

Group 13: Rocker Arm Cover

Item 1 2 3 4

Part Number # GM50143 GM50287 GM50275

TP-6438 1/11

Description Screw, M8 x 35 Gasket Cover Filler cap

Qty. Variation 1101 15 1 1 1

Item 5 6 7

Part Number GM50190 GM50285 360170

Description

Qty. Variation 1101

O-ring Fitting, elbow O-ring

1 1 1

# Common hardware; procure locally.

17

Group 13: Rocker Arm Cover, continued

Item 1 2 3 4 5 6 7 8 9 10

18

Part Number GM79794 GM79795 # # GM50190 GM50275 360170 GM50285 # GM79796

Description Cover Breather Screw, M6 x 30 Screw, M6 x 16 O-Ring Filler Cap O-Ring Elbow Fitting Screw, M8 x 35 Gasket

Qty. Variation 1101B 1 1 1 2 1 1 1 1 15 1

TP-6438 1/11

Group 14: Fuel Injection System 1

2 3 40 39

33 34

41 35

42

36

4

5

43

6 7

8

38

16

10

37

14

9

17 18

13

11

15

19 21

20

12

23

26 32

28 30

27

29

24

22

44

25

31

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Part Number GM50229 GM50170 GM50256 GM50257 GM50258 GM50259 GM50260 GM50261 GM50202 GM50216 GM50224 GM46637 GM50252 GM50243 GM50250 360555 GM32896 GM50210 GM46641 GM50251 224161 GM50140 GM50177

TP-6438 1/11

Description Wiring harness Connector Fuel line Fuel line Fuel line Fuel line Fuel line Fuel line Fitting, adapter Line Fuel line Restrictor Pressure relief valve Sensor Fitting, adapter O-ring O-ring, 8.100 x 1.600 mm Fuel pump Sensor, fuel temperature Kit Nut Gear O-ring

Qty. Variation 1601 1 1 1 1 1 1 1 1 2 1 1 6 1 1 1 1 1 1 1 1 1 1 1

Item 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Part Number GM50215 GM50116 GM21508 GM50106 360555 # # # # GM50279 360165 GM50225 GM50153 GM50119 GM46635 GM49839 GM46623 GM50262 GM50274 GM50033 GM77150

Description Fuel line Fitting, adapter O-ring Fitting, adapter O-ring Washer, 8.400 x 15 x 1.600 mm Screw, M8 x 35 Screw, M8 x 30 Screw Kit, nozzle O-ring Fitting Tube nut Washer O-ring Clamp Cap screw Clamp Screw with washer Cap screw Control Valve

Qty. Variation 1601 1 1 1 1 1 1 1 2 4 1 6 6 6 6 6 6 6 3 1 3 1

# Common hardware; procure locally.

19