John Deere 3029 4039 4045 6059 6068 Engines Component Technical Manual – PDF DOWNLOAD

Description

John Deere 3029 4039 4045 6059 6068 Engines Component Technical Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere 3029 4039 4045 6059 6068 Engines Component Technical Manual – PDF DOWNLOAD

FOREWORD :

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

• This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies product-model/component type-model relationship.
• See the machine technical manual for information on component removal and installation, and gaining access to the components. This manual is divided in two parts: repair and operation and tests. Repair sections contain necessary instructions to repair the component.
• Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Component Technical Manuals are concise service guides for specific components.
• Component technical manuals are written as stand-alone manuals covering multiple machine applications. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

TABLE OF CONTENTS:

John Deere 3029 4039 4045 6059 6068 Engines Component Technical Manual – PDF DOWNLOAD

Contents 1
Safety 10
HANDLE FLUIDS SAFELY—AVOID FIRES 10
PREVENT BATTERY EXPLOSIONS 10
PREPARE FOR EMERGENCIES 10
PREVENT ACID BURNS 11
AVOID HIGH-PRESSURE FLUIDS 12
WEAR PROTECTIVE CLOTHING 12
SERVICE MACHINES SAFELY 13
WORK IN VENTILATED AREA 13
WORK IN CLEAN AREA 13
REMOVE PAINT BEFORE WELDING OR HEATING 14
AVOID HEATING NEAR PRESSURIZED FLUID LINES 14
ILLUMINATE WORK AREA SAFELY 14
USE PROPER LIFTING EQUIPMENT 15
PRACTICE SAFE MAINTENANCE 15
USE PROPER TOOLS 16
DISPOSE OF WASTE PROPERLY 16
LIVE WITH SAFETY 17
General information 18
ENGINE IDENTIFICATION 18
ENGINE PLATE INFORMATION (EARLIER DESIGN) 18
ENGINE PLATE INFORMATION (LATER DESIGN) 19
REPOWER ENGINE PLATE 19
OEM ENGINE OPTION CODE LABEL 20
ENGINE REFERENCES 20
BASIC ENGINE SPECIFICATIONS (3029 – 4039 & 6059) 21
BASIC ENGINE SPECIFICATIONS (4045 & 6068) 22
DIESEL FUEL 23
DIESEL ENGINE OIL 24
DIESEL ENGINE COOLANT 25
METRIC BOLT AND CAP SCREW TORQUE VALUES 26
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES 27
Engine mounting 28
ENGINE REPAIR STAND 28
SAFETY PRECAUTIONS 29
ENGINE LIFTING PROCEDURE 29
CLEAN ENGINE 30
DISCONNECT TURBOCHARGER OIL INLET LINE 30
Engine rebuild guide 32
ENGINE DISASSEMBLY SEQUENCE 32
ENGINE DISASSEMBLY SEQUENCE – CONTINUED 33
SEALANT APPLICATION GUIDELINES 34
ENGINE ASSEMBLY SEQUENCE 35
ENGINE ASSEMBLY SEQUENCE – CONTINUED 36
Cylinder head and Valves 38
SPECIAL OR ESSENTIAL TOOLS 38
SPECIFICATIONS 41
SPECIFICATIONS – CONTINUED 42
TORQUES FOR HARDWARE 43
CYLINDER HEAD – EXPLODED VIEW 43
CHECK VALVE LIFT 44
REMOVING CYLINDER HEAD 45
CLEANING INJECTION NOZZLE BORES 45
VALVE ACTUATING PARTS 46
REMOVE VALVES AND VALVE SPRINGS 47
CHECKING CYLINDER HEAD FLATNESS 47
CLEANING VALVE SEATS 48
CLEANING VALVE GUIDES 48
MEASURE VALVE GUIDES 49
LAPPING VALVE SEATS 49
CHECK VALVE RECESS 50
REMOVE VALVE SEAT INSERTS 51
VALVE SEAT INSERT INSTALLATION 52
CHECK VALVES 53
GRIND VALVES 53
CHECK VALVE SPRING TENSION 53
INSPECT VALVE ROTATORS 54
INSTALL VALVES 54
INSTALL CYLINDER HEAD 55
TORQUE TURN TIGHTENING METHOD 56
CHECKING ROCKER ARM SHAFT 57
INSTALL ROCKER ARM ASSEMBLY 58
VALVE CLEARANCE 58
VALVE ADJUSTMENT SEQUENCE 59
INSTALL ROCKER ARM COVER 60
FINAL WORK 60
Cyl Block, Liners, Pistons & Rods 62
SPECIAL OR ESSENTIAL TOOLS 62
SPECIFICATIONS 65
SPECIFICATIONS – CONTINUED 66
SPECIFICATIONS – CONTINUED 67
SPECIFICATIONS – CONTINUED 68
TORQUES FOR HARDWARE 69
EXPLODED VIEW 70
PISTON AND CONNECTING ROD REMOVAL 71
CYLINDER LINER BORE MEASURE 72
CYLINDER LINER REMOVAL 72
CYLINDER LINER DEGLAZING 73
CYLINDER BLOCK CLEANING 73
CHECKING PISTON COOLING JETS 74
CAM FOLLOWER BORE MEASURE 74
CAMSHAFT BORE MEASURE 74
CAMSHAFT BUSHING REPLACEMENT TOOL 75
REMOVE CAMSHAFT BUSHING 76
INSTALLING CAMSHAFT BUSHING 76
CRANKSHAFT BORE MEASURE 77
CRANKSHAFT BEARING CAP REPLACEMENT 77
CYLINDER BLOCK TOP DESK FLATNESS 78
BALANCER SHAFT BORE MEASURE 78
BALANCER SHAFT BUSHING REPLACEMENT 79
OVERSIZE BALANCER SHAFT BUSHING INSTALLATION 80
CYLINDER LINER PROTRUSION MEASURE 81
LINER PACKING INSTALLATION 81
LINER O-RING INSTALLATION 82
CYLINDER LINER INSTALLATION 82
CONNECTING ROD BEARING MEASURE 83
ROD BEARING CLEARANCE 83
CONNECTING ROD BUSHING 84
CONNECTING ROD BUSHING REPLACEMENT (STRAIGHT PIN-END CONROD EXCEPT SMALL PIN) 85
CONNECTING ROD BUSHING REPLACEMENT (TAPERED PIN-END CONROD) 86
MEASURE PISTON PIN 88
PISTON CLEANING 88
MEASURE PISTON PIN BORE 89
PISTON TOP RING GROOVE 89
SECOND AND THIRD PISTON RING GROOVES 90
PISTON HEAD AND SKIRT CHECKING 90
PISTON RING IDENTIFICATION 90
INSTALL PISTON RINGS 91
PISTON RINGS STAGGERING 91
PISTON/LINER SET INFORMATION 92
PISTON AND CONNECTING ROD ASSEMBLY 92
PISTON AND CONNECTING ROD INSTALLATION 93
TORQUE-TURN METHOD 94
PISTON PROTRUSION MEASURE 95
FINAL VERIFICATIONS 95
COMPLETE FINAL ASSEMBLY 96
Crankshaft, Main Bearings and Flywheel 98
SPECIAL OR ESSENTIAL TOOLS 98
SELF-MANUFACTURED TOOPULLER FOR CRANKSHAFT PULLEY W/O THREADED HOLES100
SPECIFICATIONS101
SPECIFICATIONS – CONTINUED102
TORQUES FOR HARDWARE103
VIBRATION DAMPER CHECKIN(ENGINE WITHOUT FRONT PTO)104
PULLEY OR VIBRATION DAMPER REMOVAL104
PULLEY OR VIBRATION DAMPER INSTALLATION105
VIBRATION DAMPER OR PULLEY CHECKIN(ENGINE WITH FRONT PTO)106
VIBRATION DAMPER OR PULLEY REMOVA(ENGINE WITH FRONT PTO)107
VIBRATION DAMPER OR PULLEY INSTALLATIO(ENGINE WITH FRONT PTO)108
INSTALL VIBRATION DAMPER OR PULLEY (ENGINE WITH CRANKSHAFT-GEAR-DRIVEN AUX DRIVE)109
FLYWHEEL REMOVAL109
FLYWHEEL RING GEAR REPLACEMENT110
BALL BEARING INSTALLATION110
FLYWHEEL INSTALLATION111
CRANKSHAFT WEAR SLEEVE REMOVAL111
CRANKSHAFT WEAR SLEEVE REMOVAL (CONT’D)112
FLYWHEEL HOUSING REPLACEMENT113
OIL SEAL/WEAR SLEEVE INSTALLATION114
CRANKSHAFT END PLAY MEASURE115
CRANKSHAFT REMOVAL115
CRANKSHAFT IDENTIFICATION116
CRANKSHAFT INSPECTION116
JOURNAL OD CHECK117
MAIN BEARING CLEARANCE118
DETERMINE CRANKSHAFT MAIN BEARING CLEARANCE USING “PLASTIGAGE”118
CRANKSHAFT REGRINDING119
CRANKSHAFT REGRINDING GUIDELINES120
MICRO-FINISHING SPECIFICATIONS121
CRANKSHAFT GEAR REPLACEMENT121
MAIN BEARING INSERTS INSTALLATION122
2-PIECE THRUST BEARING INSTALLATION122
5/6-PIECE THRUST BEARING INSTALLATION*122
CRANKSHAFT INSTALLATION123
Camshaft, Balancer Shafts and Timing Gear Train 124
SPECIAL OR ESSENTIAL TOOLS124
SELF-MANUFACTURED TOOTEMPLATE FOR FRONT PLATE REPLACEMENT126
SPECIFICATIONS127
SPECIFICATIONS – CONTINUED128
SPECIFICATIONS – CONTINUED129
AUXILIARY GEAR DRIVE SPECIFICATIONS (37 KW)130
TORQUES FOR HARDWARE131
TIMING GEAR BACKLASH MEASURE132
CAMSHAFT END PLAY MEASURE132
REMOVING CAMSHAFT133
CAMSHAFT JOURNAL MEASURE133
MEASURE HEIGHT OF CAM LOBE134
CAMSHAFT GEAR REPLACEMENT134
TACHOMETER PICK-UP PIN REMOVAL134
FUEL SUPPLY PUMP REAR CAM INSTALLATION135
INSTALL CAMSHAFT135
CAM FOLLOWER CHECKING136
BALANCER SHAFT IDENTIFICATIO(4-CYLINDER ENGINES)136
BALANCER SHAFT END PLAY MEASURE137
BALANCER SHAFT REMOVAL137
BALANCER SHAFT JOURNAL MEASURE138
BALANCER SHAFT GEAR REPLACEMENT139
INSTALL BALANCER SHAFTS140
IDLER GEAR END PLAY MEASURE140
REMOVE FRONT PLATE141
IDLER GEAR BUSHING AND SHAFT MEASURE142
IDLER GEAR BUSHING REPLACEMENT143
REMOVE IDLER SHAFT143
SPRING PIN INSTALLATION (IF EQUIPPED)144
UPPER IDLER SHAFT INSTALLATION145
LOWER IDLER SHAFT INSTALLATION146
FRONT PLATE GASKET147
FRONT PLATE INSTALLATION148
UPPER TIMING GEAR TRAIN INSTALLATION150
LOWER TIMING GEAR TRAIN INSTALLATION152
AUXILIARY DRIVE GEAR INSTALLATION (37 KW)153
OIL DEFLECTOR INSTALLATION153
TIMING GEAR COVER IDENTIFICATION154
INSTALL COMPOSITE MATERIAL TIMING GEAR COVER155
INSTALL ALUMINUM TIMING GEAR COVER156
INSTALLATION OF TIMING GEAR COVER FOR 37 KW AUXILIARY DRIVE157
INSTALL CRANKSHAFT FRONT OIL SEAL157
INSTALL WEAR RING158
INSTALL AUXILIARY EQUIPMENT DRIVEN BY CAMSHAFT GEAR (19 KW AUX DRIVE)158
CRANKSHAFT-GEAR-DRIVEN AUXILIARY DRIVE (37 KW)159
AUXILIARY DRIVE GEAR REMOVAL (37 KW)159
BALL BEARING AND DOWEL INSTALLATION160
AUXILIARY GEAR AND SHAFT INSTALLATION (37 KW)160
OUTPUT SHAFT COVER INSTALLATION161
Lubrication System 162
SPECIAL OR ESSENTIAL TOOLS162
SPECIFICATIONS163
SPECIFICATIONS – CONTINUED164
SPECIFICATIONS – CONTINUED165
SPECIFICATIONS – CONTINUED166
SPECIFICATIONS – CONTINUED167
SPECIFICATIONS – CONTINUED168
SPECIFICATIONS – CONTINUED169
SPECIFICATIONS – CONTINUED170
SPECIFICATIONS – CONTINUED171
SPECIFICATIONS – CONTINUED172
SPECIFICATIONS – CONTINUED173
SPECIFICATIONS – CONTINUED174
TORQUES FOR HARDWARE175
OIL COOLER IDENTIFICATION176
STANDARD OIL COOLER REMOVAL177
STANDARD OIL COOLER ADAPTER REPLACEMENT178
STANDARD OIL COOLER/OIL FILTER BRACKETS REPLACEMENT179
REPLACE OIL FILTER ADAPTER ON ENGINE WITH REMOTE OIL FILTER182
HIGH-FLOW OIL COOLER REMOVAL183
OIL COOLER DISTRIBUTOR BASE REMOVAL183
OIL COOLER DISTRIBUTOR BASE REPAIR183
HIGH-FLOW OIL COOLER/DISTRIBUTOR BASE INSTALLATION184
OIL PRESSURE REGULATING VALVE REMOVAL185
OIL PRESSURE REGULATING VALVE SEAT REPLACEMENT185
OIL PRESSURE REGULATING VALVE INSTALLATION185
DIPSTICK GUIDE REPLACEMENT186
OIL BY-PASS VALVE REPLACEMENT187
OIL SUCTION SCREEN REPLACEMENT (ON STANDARD OIL PUMP)188
OIL SUCTION SCREEN REPLACEMENT (ON HIGH-FLOW OIL PUMP)188
OIL PUMP IDENTIFICATION188
STANDARD OIL PUMP REMOVAL189
GEAR AXIAL CLEARANCE (STANDARD OIL PUMP)189
GEAR RADIAL CLEARANCE (STANDARD OIL PUMP)189
STANDARD OIL PUMP SPECIFICATIONS190
STANDARD OIL PUMP INSTALLATION190
HIGH-FLOW OIL PUMP REMOVAL193
GEAR AXIAL CLEARANCE (HIGH-FLOW OIL PUMP)194
GEAR RADIAL CLEARANCE (HIGH-FLOW OIL PUMP)194
HIGH-FLOW OIL PUMP SPECIFICATIONS195
HIGH-FLOW OIL PUMP INSTALLATION196
OIL PAN INSTALLATION198
Cooling System 200
SPECIAL OR ESSENTIAL TOOLS200
SPECIFICATIONS201
SPECIFICATIONS – CONTINUED202
SPECIFICATIONS – CONTINUED203
SPECIFICATIONS – CONTINUED204
SPECIFICATIONS – CONTINUED205
SPECIFICATIONS – CONTINUED206
SPECIFICATIONS – CONTINUED207
SPECIFICATIONS – CONTINUED208
TORQUES FOR HARDWARE209
WATER PUMP — EXPLODED VIEW210
WATER PUMP IDENTIFICATION210
WATER PUMP REMOVAL211
DISASSEMBLE WATER PUMP (STANDARD MODEL)212
WATER PUMP BEARING SHAFT INSTALLATION213
WATER PUMP SEAL INSTALLATION213
WATER PUMP IMPELLER INSTALLATION214
INSTALL PULLEY OR HUB214
INSTALL WATER PUMP215
WATER PUMP WITH ROTATING ASSEMBLY – EXPLODED VIEW216
ROTATING ASSEMBLY REMOVAL217
DISASSEMBLING ROTATING ASSEMBLY217
REASSEMBLING ROTATING ASSEMBLY218
ROTATING ASSEMBLY INSTALLATION219
THERMOSTAT TEST AND REPLACEMENT220
COOLING SYSTEM DEAERATION221
CHECK FAN/ALTERNATOR BELT TENSION222
INSTALL FAN223
INSTALL ENGINE FAN PULLEY ON 2054 AND 2254 COMBINES (WITH CD6060HZ001 ENGINES)224
COOLANT HEATER OPERATION (4 AND 6 CYL ENGINES)225
REPLACING THE COOLANT HEATER (4 AND 6 CYL ENGINES)226
COOLANT HEATER OPERATION (ALL ENGINES)227
Air Intake and Exhaust System 230
SPECIFICATIONS230
SPECIFICATIONS-CONTINUED231
SPECIFICATIONS-CONTINUED232
SPECIFICATIONS-CONTINUED233
SPECIFICATIONS-CONTINUED234
TORQUES FOR HARDWARE235
INTAKE MANIFOLD INSPECTION236
EXHAUST MANIFOLD INSPECTION236
TURBOCHARGER REMOVAL237
RADIAL BEARING END PLAY CHEC(GARRETT TURBOCHARGER)237
CHECK RADIAL BEARING CLEARANC(SCHWITZER TURBOCHARGER)238
AXIAL END PLAY CHECK238
TURBOCHARGER REPAIR239
TURBOCHARGER DISASSEMBLY239
TURBOCHARGER REASSEMBLY240
SCHWITZER TURBOCHARGEMODEL S2A241
PRELUBE TURBOCHARGER242
TURBOCHARGER INSTALLATION243
TURBOCHARGER BREAK-IN244
RECOMMENDATIONS FOR TURBOCHARGER USE244
Fuel System 246
SPECIAL OR ESSENTIAL TOOLS246
SELF-MANUFACTURED TOOTEMPLATE FOR FRONT PLATE REPLACEMENT249
SELF-MANUFACTURED TOOEXAMPLE OF STATIONARY POINTER FOR DYNAMIC TIMING249
SPECIFICATIONS250
SPECIFICATIONS – CONTINUED251
SPECIFICATIONS – CONTINUED252
SPECIFICATIONS – CONTINUED253
SPECIFICATIONS – CONTINUED254
SPECIFICATIONS – CONTINUED255
SPECIFICATIONS – CONTINUED256
SPECIFICATIONS – CONTINUED257
SPECIFICATIONS – CONTINUED258
SPECIFICATIONS – CONTINUED259
SPECIFICATIONS – CONTINUED260
SPECIFICATIONS – CONTINUED261
SPECIFICATIONS – CONTINUED262
SPECIFICATIONS – CONTINUED263
SPECIFICATIONS – CONTINUED264
SPECIFICATIONS – CONTINUED265
SPECIFICATIONS – CONTINUED266
SPECIFICATIONS – CONTINUED267
TORQUES FOR HARDWARE268
RECTANGULAR FUEL FILTER ELEMENT REPLACEMENT269
REPLACE ROUND FUEL FILTER ELEMENT270
REPLACE ROUND FUEL FILTER ASSEMBLY271
FUEL PUMP REPLACEMENT272
LUCAS CAV FUEL INJECTION PUMP REMOVAL273
REPAIRS TO FUEL INJECTION PUMP274
LUCAS CAV FUEL INJECTION PUMP INSTALLATION274
LUCAS CAV FUEL INJECTION PUMP STATIC TIMING275
STANADYNE DB2 OR DB4 FUEL INJECTION PUMP REMOVAL276
REPAIRS TO FUEL INJECTION PUMP277
REPLACE THROTTLE LEVER (STANADYNE)277
STANADYNE DB2 OR DB4 FUEL INJECTION PUMP INSTALLATION278
STANADYNE DB2 OR DB4 FUEL INJECTION PUMP STATIC TIMING279
ENGINE FRONT PLATE REPLACEMENT280
STANADYNE DM4 FUEL INJECTION PUMP REMOVAL281
REPAIRS TO FUEL INJECTION PUMP281
STANADYNE DM4 FUEL INJECTION PUMP INSTALLATION AND TIMING282
REMOVE FUEL SUPPLY PUMP ON MICO IN-LINE FUEL INJECTION PUMP283
TEST MICO FUEL SUPPLY PUMP FOR LEAKS283
DISASSEMBLE MICO FUEL SUPPLY PUMP284
ASSEMBLE MICO FUEL SUPPLY PUMP285
INSTALL FUEL SUPPLY PUMP ON IN-LINE FUEL INJECTION PUMP285
SERVICE INJECTION PUMP OVERFLOW VALVE (IN-LINE INJECTION PUMP)286
REMOVE MICO IN-LINE INJECTION PUMP287
JDG670A MODIFICATION288
REPAIR MICO IN-LINE FUEL INJECTION PUMP289
INSTALL MICO IN-LINE FUEL INJECTION PUMP289
DYNAMIC TIMING (ALL PUMP TYPES)291
INSTALL TIMING SENSOR292
INSTALL MAGNETIC PROBE (FOR USE WITHOUT STROBOSCOPIC LAMP)293
INSTALL STATIONARY POINTER (FOR USE WITH STROBOSCOPIC LAMP)294
TIMING SENSOR AND MAGNETIC PROBE CONNECTION295
DYNAMIC TIMING AT FULL LOAD RATED SPEED USING MAGNETIC PROBE295
DYNAMIC TIMING AT NO-LOAD298
ANEROID REPLACEMENT302
ANEROID FIELD ADJUSTMENT302
ANEROID WORKSHOP ADJUSTMENT303
FUEL INJECTION NOZZLE REMOVAL304
CLEAN FUEL INJECTION NOZZLE305
FUEL INJECTION NOZZLE TEST305
FUEL INJECTION NOZZLE DISASSEMBLY307
ADJUST FUEL INJECTION NOZZLE307
INSTALL FUEL INJECTION NOZZLE308
BLEED THE FUEL SYSTEM AT FUEL FILTER309
BLEED FUEL SYSTEM (LUCAS-CAV)310
BLEED FUEL SYSTEM (STANADYNE)310
BLEED FUEL SYSTEM (MICO IN-LINE INJECTION PUMP)311
BLEED FUEL SYSTEM AT FUEL INJECTION NOZZLES311
ADJUST ENGINE SPEED ON DISTRIBUTOR INJECTION PUMP312
ADJUST ENGINE SPEED ON MICO IN-LINE INJECTION PUMP313
Engine System – Operation 314
ENGINE—SECTIONAL VIEW315
GENERAL INFORMATION316
LUBRICATION SYSTEM318
LUBRICATION SYSTEM – CONTINUED319
COOLING SYSTEM (4-CYLINDER ENGINE)320
HOW THE 37 KW AUXILIARY DRIVE WORKS321
Engine System – Diagnosis and Tests 324
SPECIAL OR ESSENTIAL TOOLS324
SPECIFICATIONS325
ENGINE BREAK-IN INSTRUCTIONS325
ENGINE BREAK-IN OIL326
DIAGNOSING ENGINE MALFUNCTIONS327
DIAGNOSING ENGINE MALFUNCTIONS – CONTINUED328
DIAGNOSING ENGINE MALFUNCTIONS – CONTINUED329
DIAGNOSING ENGINE MALFUNCTIONS – CONTINUED330
CHECKING ENGINE COMPRESSION331
CHECKING ENGINE OIL PRESSURE332
MEASURING ENGINE BLOW-BY332
USING STANADYNE “TIME-TRAC” AS TACHOMETER333
INSPECT THERMOSTAT AND TEST OPENING TEMPERATURE334
Air Intake System – Operation and Tests 336
SPECIAL OR ESSENTIAL TOOLS336
SPECIFICATIONS336
TURBOCHARGER OPERATION336
TURBOCHARGER BOOST PRESSURE CHECK337
DIAGNOSING TURBOCHARGER MALFUNCTIONS338
AIR-TO-AIR AFTERCOOLER OPERATION339
Fuel System – Operation and Tests 340
FUEL FILTER OPERATION340
SPECIFICATIONS341
FUEL SYSTEM OPERATION – DISTRIBUTOR INJECTION PUMP342
FUEL TRANSFER PUMP OPERATION (DISTRIBUTOR INJECTION PUMP)343
LUCAS CAV FUEL INJECTION PUMP – SECTIONAL VIEW345
LUCAS CAV FUEL INJECTION PUMP – OPERATION346
TEST SHUT-OFF SOLENOID ON LUCAS-CAV INJECTION PUMP347
STANADYNE FUEL INJECTION PUMP (TYPE DM4) – SECTIONAL VIEW349
STANADYNE FUEL INJECTION PUMP (DM4) – OPERATION350
STANADYNE FUEL INJECTION PUMP (TYPE DB2/DB4) – SECTIONAL VIEW351
STANADYNE FUEL INJECTION PUMP (DB2/DB4) – OPERATION352
SPECIFICATIONS (IN-LINE PUMP)354
FUEL SYSTEM OPERATION – IN-LINE INJECTION PUMP (6 CYL SHOWN)355
FUEL SYSTEM OPERATION—IN-LINE INJECTION PUMP356
FUEL TRANSFER PUMP OPERATION (IN-LINE INJECTION PUMP)356
FUEL TRANSFER PUMP OPERATION (IN-LINE INJECTION PUMP) – CONT’D357
DIAGNOSE FUEL SUPPLY PUMP MALFUNCTIONS—IN-LINE INJECTION PUMP358
IN-LINE FUEL INJECTION PUMP OPERATION359
GOVERNOR OPERATION (IN-LINE PUMP)360
DIAGNOSE IN-LINE FUEL INJECTION PUMP MALFUNCTIONS361
FUEL INJECTION NOZZLES GENERAL INFORMATION362
DIAGNOSING FUEL SYSTEM MALFUNCTIONS363
TESTING FUEL INJECTION NOZZLES ON A RUNNING ENGINE364
TIMING OF FUEL INJECTION PUMPS ON DIESEL ENGINES USING STROBOSCOPIC LAMP365
Index 1
A230
Air intake system 230
Specifications 230
Torque values 235
Air intake system – Operation and tests339
Air-to-air Aftercooler 339
Specifications 336
Turbocharger malfunctions 338
Turbocharger operation 336
Aneroid 302
Field adjustment 302
Replacement 302
Workshop adjustment 303
Assembly sequence 35
Auxiliary drive (37 kW) 160
Ball bearing and dowel installation160
Gear and shaft installation 160
Gear installation 153
Gear removal 159
Output shaft cover installation 161
Overview 159
Specifications 130
Timing gear cover installation 157
Auxiliary equipment (19 kW) 158
Installation 158
B137
Balancer shafts 137
End play measure 137
Gear replacement 139
Identification 136
Installation 140
Journal OD measure 138
Removal 137
Specifications 127
Torque values 131
Break-in engine oil 326
C 74
Cam follower bore measure 74
Camshaft 74
Bore measure 74
Bushing installation 76
Bushing removal 76
Bushing replacement tool 75
Cam follower checking 136
End play measure 132
Gear replacement 134
Installation 135
Journal OD measure 133
Lobe height measure 134
Removal 133
Specifications 127
Tachometer pick-up pin removal 134
Torque values 131
Clean engine 30
Connecting rods 92
Assembly 92
Bearing clearance 83
Bearing inspection 83
Bushing ID 84
Bushing replacement (Straight pin-e 85
Bushing replacement (Tapered pin-en 86
Installation 93
Removal 71
Specifications 65
Torque values 69
Torque-turn method 94
Coolant 25
Diesel engine 25
Coolant heater (all engines) 227
Operation 227
Coolant heater (4 and 6 cyl) 225
Operation 225
Replacement 226
Cooling system 221
Deaeration 221
Specifications 201
Torque values 209
Crankshaft 122
Bearing inserts installation 122
End play measure 115
Gear replacement 121
Identification 116
Inspection 116
Installation 123
Journal OD check 117
Main bearing clearance 118
Main bearing clearance 118
Micro-finishing specifications 121
Oil seal/wear sleeve installation 114
Regrinding 119
Regrinding guidelines 120
Removal 115
Specifications 101
Wear sleeve removal 111
2-piece thrust bearing inst 122
5/6-piece thrust bearing inst 122
Crankshaft front oil seal installation 157
Cylinder block 78
Balancer shaft bore measure 78
Balancer shaft bushing replacement 79
Bearing cap replacement 77
Cleaning 73
Crankshaft bore measure 77
ID of assembled main bearings 118
Oversize balancer shaft bushings 80
Specifications 65
Top desk flatness 78
Torque values 69
Cylinder head 47
Check flatness 47
Final work 60
Installation 55
Measure valve guide 49
Removal 45
Remove valve seat inserts 51
Torque turn tightening method 56
Cylinder head and valves 41
Specifications 41
Torques for hardware 43
Cylinder liners 72
Bore measure 72
Deglazing 73
Installation 82
O-ring installation 82
Packing installation 81
Protrusion 81
Removal 72
Specifications 65
Torque values 69
D 24
Diesel engine oil 24
Diesel fuel 23
Dipstick guide replacement 186
Disassembly sequence 32
Dynamic timing 295
Connection 295
Full load rated speed 295
Information 291
Magnetic probe 293
No-load 298
Stationary pointer 294
E315
Engine 315
Sectional view 315
Sectional view 315
Engine oil 326
Break-In 326
Diesel 24
Engine speed adjustment 312
Distributor pump 312
Mico in-line pump 313
Engine system – Diagnosis and tests 327
Diagnosing engine malfunctions 327
Engine blow-by measure 332
Engine break-in 325
Engine compression checking 331
Engine oil pressure checking 332
Engine speed checking 333
Specifications 325
Engine system – Operation 321
Auxiliary drive (37 kW) operation 321
Cooling System 320
General information 316
Lubrication system 318
Exhaust manifold 236
Inspection 236
Exhaust system 230
Specifications 230
Torque values 235
F223
Fan installation 223
Fan/Alternator belt tension 222
Flywheel 110
Ball bearing installation 110
Installation 111
Removal 109
Ring gear replacement 110
Specifications 101
Torque values 103
Flywheel housing 103
Torque values 103
Front plate 147
Gasket 147
Installation 148
Removal 141
Replacement 280
Fuel 23
Diesel 23
Fuel filter 270
Replace element (round) 270
Fuel filter element replacement 269
Fuel injection nozzle 307
Adjustment 307
Bore cleaning 45
Chatter test 306
Cleaning 305
Disassembly 307
Installation 308
Opening pressure test 306
Removal 304
Spray pattern test 306
Test 305
Valve seat checking 307
Valve stem and guide wear checking 306
Fuel pump replacement 272
Fuel system 309
Bleed 309
Specifications 250
Torque values 268
Fuel system – Operation and tests 358
Diagnose fuel supply pump (in-line)358
Diagnose in-line fuel injection pum361
Distrbutor injection pump 342
Fuel filter operation 340
Fuel injection nozzles 362
Fuel injection pump operation 359
Fuel system operation (in-line) 355
Fuel transfer pump operation 343
Fuel transfer pump operation 356
Governor operation (in-line pump) 360
Lucas CAV fuel injection pump 345
Lucas-CAV shut-off solenoid 347
Specifications 341
Specifications (in-line pump) 354
Stanadyne DB2/DB4 injection pump 351
Stanadyne DM4 fuel injection pump 349
H194
High-flow oil pump 194
Gear axial clearance 194
Gear radial clearance 194
Installation 196
Removal 193
Specifications 195
I 20
Identification 20
Option code label 20
Engine information 18
Engine plate information 18
Repower engine plate 19
Idler gears 142
Bushing and shaft measure 142
Bushing replacement 143
End play measure 140
Lower idler shaft installation 146
Shaft removal 143
Spring pin installation 144
Upper idler shaft installation 145
Inch torque values 27
Intake manifold 236
Inspection 236
L163
Lubrication system 163
Specifications 163
Torque values 175
Lucas CAV fuel injection pump 274
Installation 274
Removal 273
Repairs 274
Static timing 275
M101
Main bearings 101
Specifications 101
Torque values 103
Metric torque values 26
MICO in-line injection pump 285
Assemble fuel supply pump 285
Disassemble fuel supply pump 284
Install supply pump 285
Installation 289
JDG670A modification 288
Overflow valve 286
Remove 287
Remove fuel supply pump 283
Remove fuel supply pump 283
Repair 289
O187
Oil by-pass replacement 187
Oil cooler 178
Adapter replacement 178
Bracket replacement 179
Distributor base removal 183
Distributor base repair 183
High-flow installation 184
High-flow oil cooler removal 183
Identification 176
Standard oil cooler removal 177
Oil deflector installation 153
Oil filter 182
Adapter installation 182
Oil pan installation 198
Oil pressure regulating valve 185
Installation 185
Removal 185
Valve seat replacement 185
Oil pump identification 188
Oil suction screen 188
Replacement (on high-flow oil pump)188
Replacement (on standard oil pump) 188
P 74
Piston cooling jets checking 74
Pistons 92
Assembly 92
Cleaning 88
Head and skirt checking 90
Installation 93
Pin bore measure 89
Pin OD measure 88
Piston rings staggering 91
Protrusion 95
Removal 71
Ring installation 91
Rings identification 90
Second and third ring grooves 90
Specifications 65
Top ring groove 89
Torque values 69
Pulley 105
Installation 105
Removal 104
Pulley for front PTO 106
Inspection 106
Removal 107
R 28
Repair stand 28
Repair stand 29
Lifting procedure 29
Safety precautions 29
Rocker arm assembly 58
Installation 58
Rocker arm cover installation 60
Rocker arm shaft 57
Inspect 57
Rotating assembly 217
Disassembling 217
Installation 219
Reassembling 218
Removal 217
S 34
Sealant guidelines 34
Specifications 230
Air intake system 230
Auxiliary drive (37 kW) 130
Balancer shafts 127
Camshaft 127
Connecting rods 65
Cooling system 201
Crankshaft 101
Crankshaft micro-finishing 121
Cylinder block 65
Cylinder head and valves 41
Cylinder liners 65
Engine references 20
Exhaust system 230
Flywheel 101
Fuel system 250
Lubrication system 163
Main bearings 101
Pistons 65
Timing gear train 127
3029, 4039 & 6059 engines spec 21
4045 & 6068 engines spec 22
Stanadyne DB2/DB4 fuel injection pump 278
Installation 278
Removal 276
Repairs 277
Replace lever throttle 277
Static timing 279
Stanadyne DM4 fuel injection pump 282
Installation 282
Removal 281
Repairs 281
Static timing 282
Standard oil pump 189
Gear axial clearance 189
Gear radial clearance 189
Installation 190
Removal 189
Specifications 190
T334
Thermostat 334
Inspect and test 334
Thermostats 220
Test and replacement 220
Timing gear cover 156
Installation (aluminum) 156
Identification 154
Installation (composite material) 155
Timing gear train 152
Lower timing gear installation 152
Upper timing gear installation 150
Backlash measure 132
Specifications 127
Torque values 131
Torque values 235
Air intake system 235
Balancer shafts 131
Camshaft 131
Connecting rods 69
Cooling system 209
Cylinder block 69
Cylinder head and valves 43
Cylinder liners 69
Exhaust system 235
Flywheel 103
Flywheel housing 103
Fuel system 268
Inch 27
Lubrication system 175
Main bearings 103
Metric 26
Pistons 69
Timing gear train 131
Turbocharger 238
Axial end play check 238
Break-in 244
Installation 243
Pre-lubrication 242
Radial bearing clearance (Schwitzer238
Radial bearing end play check 237
Recommendation for use 244
Removal 237
Repair 239
Turbocharger (GARRETT) 239
Disassembly 239
Reassembly 240
Turbocharger (SCHWITZER) 241
Disassembly and reassembly 241
V 53
Valve and rocker arm 53
Check valve 53
Valve clearance adjustment 58
Valve clearance 59
Adjustment sequence 59
Valve guides 48
Clean valve guides 48
Valve lift 44
Check valve lift 44
Valve recess 50
Check valve recess 50
Valve rotators 54
Inspect 54
Valve seats 48
Clean valve seats 48
Installation 52
Lapping 49
Valve springs 53
Check tension 53
Valves 53
Grind face angle 53
Installation 54
Valves and valve springs removal 47
Vibration damper 104
Inspection 104
W213
Water pump 213
Bearing shaft installation 213
Identification 210
Impeller installation 214
Installation 215
Removal 211
Seal installation 213
Water pump (standard model) 212
Disassemble 212
Install pulley or hub 214
Wear ring 158
Installation 158
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JOHN DEERE 3029 4039 4045 6059 6068 ENGINES COMPONENT TECHNICAL MANUAL – PDF DOWNLOAD:

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