John Deere約翰迪爾強鹿柴油發動機3029、4039、 4045、6059和6068維修技術操作保養手冊

3029 / 4039 / 4045 / 6059 / 6068柴油機

Group 00—Safety Replenishing Supplemental Coolant

Handle Fluids Safely—Avoid Fires . . . . . . . . . . . . 00-1 Additives (SCA’s) Between Coolant

Prevent Battery Explosions . . . . . . . . . . . . . . . . . . 00-1 Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-12

Prepare for Emergencies. . . . . . . . . . . . . . . . . . . . 00-1 Operating in Warm Temperature Climates . . . . . 02-13

Prevent Acid Burns . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Flush and Service Cooling System . . . . . . . . . . . 02-14

Avoid High-Pressure Fluids . . . . . . . . . . . . . . . . . . 00-3 Disposing of Coolant . . . . . . . . . . . . . . . . . . . . . . 02-15

Wear Protective Clothing. . . . . . . . . . . . . . . . . . . . 00-3

Service Machines Safely . . . . . . . . . . . . . . . . . . . . 00-4 Group 03—Engine Mounting

Work in Ventilated Area . . . . . . . . . . . . . . . . . . . . 00-4 Engine Repair Stand . . . . . . . . . . . . . . . . . . . . . . . 03-1

Work in Clean Area. . . . . . . . . . . . . . . . . . . . . . . . 00-4 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 03-2

Remove Paint Before Welding or Heating . . . . . . . 00-5 Install 300 Series Adapters on Repair Stand . . . . . 03-3

Avoid Heating Near Pressurized Fluid Lines . . . . . 00-5 Engine Lifting Procedure . . . . . . . . . . . . . . . . . . . . 03-4

Illuminate Work Area Safely . . . . . . . . . . . . . . . . . 00-6 Clean Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-5

Use Proper Lifting Equipment . . . . . . . . . . . . . . . . 00-6 Mount Engine on Repair Stand . . . . . . . . . . . . . . . 03-6

Construct Dealer-Made Tools Safely . . . . . . . . . . . 00-6 Disconnect Turbocharger Oil Inlet Line . . . . . . . . . 03-8

Practice Safe Maintenance . . . . . . . . . . . . . . . . . . 00-7

Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 Group 04—Engine Rebuild Guide

Dispose of Waste Properly . . . . . . . . . . . . . . . . . . 00-8 Engine Disassembly Sequence . . . . . . . . . . . . . . . 04-1

Live With Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8 Sealant Application Guidelines . . . . . . . . . . . . . . . 04-3

Engine Assembly Sequence . . . . . . . . . . . . . . . . . 04-5

Group 01—General Information

Unified Inch Bolt and Cap Screw Torque Group 05—Cylinder Head and Valves

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1

Metric Bolt and Cap Screw Torque Values . . . . . . 01-2 Service Equipment And Tools . . . . . . . . . . . . . . . . 05-5

Engine Model Designation. . . . . . . . . . . . . . . . . . . 01-3 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-6

Engine Serial Number Plate Information . . . . . . . . 01-4 Cylinder Head and Valves Specifications . . . . . . . 05-7

OEM Engine Option Code Label . . . . . . . . . . . . . . 01-5 Check and Adjust Valve Clearance . . . . . . . . . . . 05-11

Engine References . . . . . . . . . . . . . . . . . . . . . . . . 01-5 Measure Valve Lift . . . . . . . . . . . . . . . . . . . . . . . 05-15

Engine Application Chart John Deere Remove Cylinder Head . . . . . . . . . . . . . . . . . . . 05-17

Agricultural Equipment . . . . . . . . . . . . . . . . . . . 01-6 Disassemble and Inspect Rocker Arm

Engine Application Chart John Deere Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-20

Construction Equipment. . . . . . . . . . . . . . . . . . . 01-7 Assemble Rocker Arm Assembly . . . . . . . . . . . . 05-21

Engine Application Chart OEM Applications . . . . 01-10 Inspect, Measure, and Assemble Camshaft

Followers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-21

Group 02—Fuels, Lubricants and Coolant Check Valve Recess In Cylinder Head . . . . . . . . 05-23

Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1 Preliminary Cylinder Head and Valve Checks . . 05-24

Lubricity of Diesel Fuels . . . . . . . . . . . . . . . . . . . . 02-1 Remove Valve Assembly . . . . . . . . . . . . . . . . . . 05-25

Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . . . 02-2 Inspect and Measure Valve Springs . . . . . . . . . . 05-26

Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 02-3 Inspect Valve Rotators . . . . . . . . . . . . . . . . . . . . 05-26

Alternative and Synthetic Lubricants . . . . . . . . . . 02-4 Clean Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-27

Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . . 02-4 Inspect and Measure Valves . . . . . . . . . . . . . . . . 05-27

OILSCAN Plusâ and COOLSCAN Plusâ . . . . . . . . 02-5 Grind Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-28

Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6 Inspect and Clean Cylinder Head . . . . . . . . . . . . 05-29

Diesel Engine Coolant Recommendations. . . . . . . 02-7 Check Cylinder Head Flatness . . . . . . . . . . . . . . 05-29

Engine Coolant Specifications . . . . . . . . . . . . . . . . 02-8

Testing Diesel Engine Coolant . . . . . . . . . . . . . . 02-11 Continued on next page

Measure Cylinder Head Thickness . . . . . . . . . . . 05-30 Inspect and Measure Connecting Rod

Clean Injection Nozzle Bores . . . . . . . . . . . . . . . 05-30 Bearings (Rod and Crankshaft in Engine) . . . . 10-36

Clean Valve Guides . . . . . . . . . . . . . . . . . . . . . . 05-31 Inspect Rod and Cap . . . . . . . . . . . . . . . . . . . . . 10-37

Measure Valve Guides . . . . . . . . . . . . . . . . . . . . 05-31 Inspect Piston Pins and Bushings . . . . . . . . . . . 10-39

Knurl Valve Guides . . . . . . . . . . . . . . . . . . . . . . . 05-32 Remove Piston Pin Bushing . . . . . . . . . . . . . . . . 10-41

Clean and Inspect Valve Seats . . . . . . . . . . . . . 05-32 Clean and Inspect Connecting Rod Pin Bore . . . 10-43

Grind Valve Seats . . . . . . . . . . . . . . . . . . . . . . . 05-33 Install Piston Pin Bushing in Connecting Rod . . . 10-44

Remove Valve Seat Inserts. . . . . . . . . . . . . . . . . 05-34 Measure Rod Center-to-Center Bores . . . . . . . . . 10-47

Measure Valve Seat Bore in Cylinder Head . . . . 05-38 Inspect and Clean Cylinder Block . . . . . . . . . . . . 10-47

Install Valve Seat Inserts. . . . . . . . . . . . . . . . . . . 05-39 Clean Cylinder Liner O-Ring Bore . . . . . . . . . . . 10-49

Install Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-39 Measure Cylinder Block Main Bearing Bore . . . . 10-49

Clean and Inspect Cylinder Head Cap Measure Camshaft Follower Bore . . . . . . . . . . . . 10-50

Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-40 Measure Camshaft Bearing Bore . . . . . . . . . . . . 10-51

Inspect and Clean Exhaust Manifold . . . . . . . . . 05-40 Measure Balancer Shaft Bore—4-Cylinder

Clean and Inspect Top Deck of Cylinder Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52

Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-41 Measure Cylinder Block Top Deck Flatness . . . . 10-53

Measure Cylinder Liner Standout (Height Measure Liner Flange Counterbore Depth

Above Block) . . . . . . . . . . . . . . . . . . . . . . . . . . 05-42 in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54

Install Cylinder Head . . . . . . . . . . . . . . . . . . . . . 05-43 Measure Liner Flange Thickness. . . . . . . . . . . . . 10-54

Torque-Turn Method For Proper Torque . . . . . . 05-45 Remove, Inspect and Install Piston

Install Rocker Arm Assembly. . . . . . . . . . . . . . . . 05-45 Cooling Orifices . . . . . . . . . . . . . . . . . . . . . . . . 10-55

Inspect and Clean Ventilator Outlet Hose . . . . . . 05-46 Measure Cylinder Liners and Block Bores . . . . . 10-56

Install Rocker Arm Cover . . . . . . . . . . . . . . . . . . 05-47 Install Steel Ball in Oil Passage of

Complete Final Assembly . . . . . . . . . . . . . . . . . . 05-48 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 10-58

Perform Engine Break-In. . . . . . . . . . . . . . . . . . . 05-50 Measure Cylinder Liner Standout (Height

Above Block) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59

Group 10—Cylinder Block, Liners, Pistons and Install Cylinder Liner O-Rings and Packings . . . . 10-61

Rods Install Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . 10-62

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Assemble Piston and Connecting Rod . . . . . . . . 10-64

Service Equipment And Tools . . . . . . . . . . . . . . . . 10-4 Install Piston Rings . . . . . . . . . . . . . . . . . . . . . . 10-65

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Install Piston and Connecting Rod Assembly . . . 10-67

Cylinder Block, Liners, Pistons and Rods Torque-Turn Connecting Rod Cap Screws . . . . . 10-70

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Check Engine Rotation For Excessive

Remove Pistons and Connecting Rods . . . . . . . 10-14 Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71

Remove Cylinder Liners . . . . . . . . . . . . . . . . . . . 10-18 Measure Piston Protrusion . . . . . . . . . . . . . . . . . 10-72

Complete Disassembly of Cylinder Block (If Cylinder Block Orifices (Saran Engines) . . . . . . . 10-74

Required). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Cylinder Block Orifices . . . . . . . . . . . . . . . . . . . . 10-75

Preliminary Liner, Piston and Rod Checks . . . . . 10-21 Complete Final Assembly . . . . . . . . . . . . . . . . . . 10-76

Disassemble Piston and Rod Assembly . . . . . . . 10-22

Clean Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Group 15—Crankshaft, Main Bearings and

Visually Inspect Pistons . . . . . . . . . . . . . . . . . . . 10-24 Flywheel

Clean Cylinder Liners . . . . . . . . . . . . . . . . . . . . . 10-26 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Visually Inspect Cylinder Liners . . . . . . . . . . . . . 10-27 Service Equipment And Tools . . . . . . . . . . . . . . . . 15-4

Check Piston Ring Groove Wear. . . . . . . . . . . . . 10-29 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Measure Piston Pin Bore. . . . . . . . . . . . . . . . . . . 10-30 Crankshaft, Main Bearings and Flywheel

Measure Piston Skirt . . . . . . . . . . . . . . . . . . . . . . 10-30 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Measure Piston Height . . . . . . . . . . . . . . . . . . . . 10-31 Crankshaft and Main Bearing Failure Analysis . . 15-12

Determine Piston-to-Liner Clearance. . . . . . . . . . 10-32 Inspect Vibration Damper (6-Cylinder Engine) . . 15-13

Deglaze Cylinder Liners . . . . . . . . . . . . . . . . . . . 10-33 Remove Pulley or Vibration Damper

Replace Piston and Liner Sets . . . . . . . . . . . . . . 10-34 Pulley (Engine W/O Front PTO) . . . . . . . . . . . 15-15

Inspect and Measure Connecting Rod

Bearings (Rods Removed From Engine) . . . . 10-34 Continued on next page

Install Pulley or Vibration Damper Pulley Measure Assembled ID of Main Bearing

(Engine W/O Front PTO) . . . . . . . . . . . . . . . . 15-16 Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-59

Checking Vibration Damper or Pulley Measure Crankshaft Main Bearing Bore

(Engine With Front PTO) . . . . . . . . . . . . . . . . . 15-18 Centerline-To-Top Deck. . . . . . . . . . . . . . . . . . 15-60

Removing Vibration Damper or Pulley Inspect Piston Cooling Orifices . . . . . . . . . . . . . . 15-61

(Engine With Front PTO) . . . . . . . . . . . . . . . . . 15-19 Install Main and Thrust Bearing Inserts In

Installing Vibration Damper or Pulley Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-61

(Engine With Front PTO) . . . . . . . . . . . . . . . . . 15-20 Install Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 15-63

Installing Vibration Damper or Pulley Install Flywheel Housing . . . . . . . . . . . . . . . . . . . 15-65

(Engine With Crankshaft Gear-Driven PTO). . . 15-21 Complete Final Assembly . . . . . . . . . . . . . . . . . . 15-69

Replace Front Crankshaft Oil Seal

(Without Removing Timing Gear Cover) . . . . . 15-22

Check Crankshaft End Play . . . . . . . . . . . . . . . . 15-25 Group 16—Camshaft, Balancer Shafts and Timing

Inspect Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . 15-26 Gear Train

Check Flywheel Housing Face Runout . . . . . . . . 15-27 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Check Flywheel Face Flatness . . . . . . . . . . . . . . 15-28 Service Equipment And Tools . . . . . . . . . . . . . . . . 16-3

Check Pilot Bearing Bore Concentricity . . . . . . . 15-28 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4

Remove Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 15-29 Camshaft, Balancer Shafts and Timing Gear

Replace Flywheel Ring Gear . . . . . . . . . . . . . . . 15-29 Train Specifications . . . . . . . . . . . . . . . . . . . . . . 16-5

Replace Pilot Bearing In Flywheel—3029, Measure Valve Lift . . . . . . . . . . . . . . . . . . . . . . . 16-14

4039, 4045 Engines (If Equipped) . . . . . . . . . 15-31 Remove Timing Gear Cover . . . . . . . . . . . . . . . . 16-16

Install Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 15-32 Remove and Install Camshaft Bushing With

Crankshaft Rear Oil Seal and Wear Sleeve Front Plate Installed Camshaft Gear-Driven

General Information . . . . . . . . . . . . . . . . . . . . 15-33 Auxiliary Drive Engines, Saran Built

Crankshaft Unitized Rear Oil Seal and Engines Serial No. (138541—) . . . . . . . . . . . . 16-18

Wear Sleeve Handling Precautions . . . . . . . . . 15-34 Remove Auxiliary Drive Gears (Engines

Remove Two-Piece Crankshaft Rear Oil Seal With Auxiliary Gear Drive Option) . . . . . . . . . . 16-21

and Wear Sleeve (Without Removing Flywheel Measure Camshaft End Play. . . . . . . . . . . . . . . . 16-21

Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-34 Measure Balancer Shaft End Play (4-Cylinder

Remove Unitized (Non-Separable) Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22

Crankshaft Rear Oil Seal and Wear Sleeve . . 15-36 Measure Idler Gear End Play . . . . . . . . . . . . . . . 16-22

Clean and Inspect Crankshaft Flange . . . . . . . . . 15-39 Measure Timing Gear Backlash . . . . . . . . . . . . . 16-23

Install Crankshaft Rear Oil Seal and Wear Remove Camshaft. . . . . . . . . . . . . . . . . . . . . . . . 16-27

Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-39 Visually Inspect Camshaft . . . . . . . . . . . . . . . . . . 16-29

Remove Flywheel Housing . . . . . . . . . . . . . . . . . 15-42 Measure Camshaft Thrust Plate Clearance

Remove Crankshaft Main Bearings . . . . . . . . . . 15-43 and Thickness . . . . . . . . . . . . . . . . . . . . . . . . 16-29

Check Main Bearing Oil Clearance . . . . . . . . . . 15-44 Inspect and Measure Camshaft Bearing

Remove and Install Crankshaft Gear Bore ID and Journal OD . . . . . . . . . . . . . . . . . 16-30

(Crankshaft Installed In Engine) . . . . . . . . . . . 15-45 Measure Camshaft Lobe Height . . . . . . . . . . . . . 16-31

Remove Crankshaft. . . . . . . . . . . . . . . . . . . . . . . 15-47

Remove and Install Camshaft Gear . . . . . . . . . . 16-32

Remove Crankshaft Rear Wear Sleeve

(Crankshaft Removed From Engine) . . . . . . . . 15-48 Inspect Camshaft Followers . . . . . . . . . . . . . . . . 16-33

Inspect Crankshaft . . . . . . . . . . . . . . . . . . . . . . . 15-49 Replace Tachometer Drive Gear . . . . . . . . . . . . 16-34

Measure Main Bearing ID and Crankshaft Remove and Install Camshaft Bushing With

Journal OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50 Front Plate Removed Engine Serial No. ( —

Measure Main Thrust Journal Width and 138540) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-36

Thrust Bearing Width . . . . . . . . . . . . . . . . . . . 15-52 Remove Balancer Shafts—If Equipped

Crankshaft Grinding Guidelines . . . . . . . . . . . . . . 15-53 (4-Cylinder Engines) . . . . . . . . . . . . . . . . . . . . 16-38

Crankshaft Grinding Specifications [Earlier Inspect and Measure Balancer Shaft

Engines With Ground (Tangential) Fillets (A)] Bushings and Journals . . . . . . . . . . . . . . . . . . 16-39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-57 Remove and Install Balancer Shaft Bushings

Crankshaft Grinding Specifications [Later (4-Cylinder Engines) . . . . . . . . . . . . . . . . . . . . 16-40

Engines With Undercut and Rolled Fillets (A)]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-58 Continued on next page

Install Oversize Balancer Shaft Bushings Remove and Install Oil Bypass Valve—4045

In Cylinder Block (4039 Engines) . . . . . . . . . . 16-41 and 6068 Engines With Pre-Common Lube

Inspect Balancer Shaft Gears and Thrust Block1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19

Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42 Remove and Install Oil Pressure Regulating

Remove and Install Balancer Shaft Gears . . . . . 16-43 Valve and Seat—3029, 4039, and 6059

Remove Cylinder Block Front Plate . . . . . . . . . . 16-44 Engines and 4045 and 6068 Engines

Measure Idler Gear Bushing and Shaft . . . . . . . 16-46 With Common Lube Block1 . . . . . . . . . . . . . . . 20-20

Remove and Install Idler Gear Bushings . . . . . . 16-48 Remove, Inspect, and Install Oil Pressure

Remove Lower and Upper Idler Shafts . . . . . . . 16-48 Regulating Valve—4045 and 6068

Clean and Inspect Front Plate . . . . . . . . . . . . . . 16-49 Engines With Pre-Common Lube Block1 . . . . . 20-21

Replace Engine Front Plate . . . . . . . . . . . . . . . . 16-50 Remove and Install Oil Filter Nipple—

Transfer Fuel Injection Pump Timing Mark 3029, 4039, 6059 Engines . . . . . . . . . . . . . . . 20-23

Onto Replacement Front Plate . . . . . . . . . . . . 16-51 Remove and Install Oil Pan Mounted Oil

Install Idler Shaft Spring Pins (If Equipped) . . . . 16-52 Fill/Dipstick Tube . . . . . . . . . . . . . . . . . . . . . . 20-25

Install Upper Idler Shaft In Front Plate . . . . . . . . 16-53 Remove, Install, and Adjust Dipstick Nipple . . . . 20-26

Install Lower Idler Shaft In Front Plate . . . . . . . . 16-53 General Oil Pump Information . . . . . . . . . . . . . . 20-27

Install Engine Front Plate . . . . . . . . . . . . . . . . . . 16-54 Remove, Inspect and Install Oil Pump

Install and Time Balancer Shafts—If Pick-Up Tube Assembly. . . . . . . . . . . . . . . . . . 20-27

Equipped (4-Cylinder Engines) . . . . . . . . . . . . 16-55 Remove Standard Capacity Oil Pump . . . . . . . . 20-28

Install and Time Camshaft and Fuel Injection Inspect and Measure Clearances

(Standard Capacity Oil Pump) . . . . . . . . . . . . 20-29

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-58

Complete Standard Capacity Oil Pump

Clean and Inspect Timing Gear Cover . . . . . . . . 16-62

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30

Install Ball Bearings and Dowels (Engines

Assemble Standard Capacity Oil Pump . . . . . . . 20-32

With Crankshaft-Driven Auxiliary Gear Drive Install Standard Capacity Oil Pump . . . . . . . . . . 20-33

Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-62 Remove High Capacity Oil Pump . . . . . . . . . . . . 20-35

Install Drive Gear (Engines With Inspect and Measure Clearances (High

Crankshaft-Driven Auxiliary Gear Drive Option) Capacity Oil Pump) . . . . . . . . . . . . . . . . . . . . . 20-37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-63 Complete High Capacity Oil Pump

Install Timing Gear Cover . . . . . . . . . . . . . . . . . 16-64 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39

Install Idler Gear and Output Gear Assemble High Capacity Oil Pump . . . . . . . . . . . 20-39

(Engines With Auxiliary Gear Drive Option) . . 16-71 Install High Capacity Oil Pump . . . . . . . . . . . . . . 20-40

Complete Final Assembly . . . . . . . . . . . . . . . . . . 16-72 Install Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42

Group 20—Lubrication System Group 25—Cooling System

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1

Service Equipment And Tools . . . . . . . . . . . . . . . . 20-1 Service Equipment And Tools . . . . . . . . . . . . . . . . 25-2

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3

Lubrication System Specifications . . . . . . . . . . . . . 20-3 Cooling System Specifications . . . . . . . . . . . . . . . 25-4

General Lubrication System Information . . . . . . . . 20-8 Remove, Test, and Install Thermostats . . . . . . . . 25-9

Oil Cooler Identification . . . . . . . . . . . . . . . . . . . . 20-9 Remove and Install Water

Remove, Inspect, and Install Standard-Flow Manifold/Thermostat Housing . . . . . . . . . . . . . 25-11

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10 General Water Pump Information . . . . . . . . . . . . 25-12

Remove and Install High-Flow Oil Cooler . . . . . . 20-11 Remove Water Pump . . . . . . . . . . . . . . . . . . . . . 25-15

Replacing Standard Oil Cooler/Oil Filter Disassemble Low Flow, Standard-Duty

Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14 High Flow, and Modular Style Water Pumps

Replace Oil Filter Adapter on Engine With . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-16

Remote Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 20-17 Disassemble Heavy-Duty High Flow Water

Remove, Inspect, and Install Oil Bypass Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18

Valve—3029, 4039, and 6059 Engines and Inspect and Clean Water Pump Parts . . . . . . . . 25-21

4045 and 6068 Engines With Common Lube

Block1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18

Assemble Low Flow, Standard-Duty High Replace Round Fuel Filter Element (Early

Model Engines) . . . . . Flow, and Modular Style Water Pumps . . . . . . 25-23 . . . . . . . . . . . . . . . . . . . 35-19

Assemble Heavy-Duty High Flow Water Replace Final Fuel Filter and Primary Fuel

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29 Filter/Water Separator Elements (Later

Pulley or Hub-to-Rear Face of Water Pump Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-20

Housing Dimensions . . . . . . . . . . . . . . . . . . . . 25-36 Remove Fuel Supply Pump. . . . . . . . . . . . . . . . . 35-21

Check Water Pump Cap Screw Protrusion . . . . . 25-41 Bench Test Fuel Supply Pump . . . . . . . . . . . . . . 35-22

Install Water Pump . . . . . . . . . . . . . . . . . . . . . . . 25-43 Install Fuel Supply Pump. . . . . . . . . . . . . . . . . . . 35-24

Cooling System Deaeration. . . . . . . . . . . . . . . . . 25-44 Fuel Injection Pump Timing . . . . . . . . . . . . . . . . 35-25

Inspect and Install Fan Blade Assembly . . . . . . . 25-44 Remove Stanadyne Model DB2 Injection

Adjust Fan Belt Tension . . . . . . . . . . . . . . . . . . . 25-45 Pump With Non-Retained Drive Shaft . . . . . . . 35-26

Remove and Install Coolant Heater Repair Stanadyne Fuel Injection Pump . . . . . . . . 35-28

(Dubuque-Built Engines)—If Equipped . . . . . . 25-46 Remove Stanadyne DB2 Non-Retained

Remove and Install Coolant Heater Injection Pump Drive Shaft From Engine . . . . . 35-29

(Saran-Built Engines)—If Equipped . . . . . . . . . 25-48 Install Non-Retained Drive Shaft In

Stanadyne DB2 Injection Pump (If

Group 30—Air Intake and Exhaust System Removed from Engine) . . . . . . . . . . . . . . . . . . 35-30

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 Install Stanadyne Model DB2 Injection

Air Intake and Exhaust System Specifications. . . . 30-2 Pump With Non-Retained Drive Shaft . . . . . . . 35-32

Extending Turbocharger Life . . . . . . . . . . . . . . . . . 30-4 Remove Stanadyne Model DB2 (With

Remove Turbocharger. . . . . . . . . . . . . . . . . . . . . . 30-6 Retained Drive Shaft) and DB4 Injection

Turbocharger Failure Analysis. . . . . . . . . . . . . . . . 30-7 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-35

Inspect Injection Pump Drive Gear I.D. and

Turbocharger Seven-Step Inspection . . . . . . . . . . 30-8

Perform Radial Bearing Clearance Test . . . . . . . 30-14 Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-37

Perform Axial Bearing End Play Test . . . . . . . . . 30-15 Repair Stanadyne Fuel Injection Pump . . . . . . . . 35-38

Install Stanadyne Model DB2 (With

Repair Turbocharger . . . . . . . . . . . . . . . . . . . . . . 30-16

Retained Drive Shaft) and DB4 Injection

Disassemble and Inspect Turbocharger . . . . . . . 30-17

Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-39

Replace Center Housing and Rotating

Remove Stanadyne Model DM4 Fuel

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . 35-43

Prelube Turbocharger . . . . . . . . . . . . . . . . . . . . . 30-19 Repair Stanadyne Fuel Injection Pump . . . . . . . . 35-45

Install Turbocharger . . . . . . . . . . . . . . . . . . . . . . 30-20

Install Stanadyne Model DM4 Fuel

Turbocharger Break-In . . . . . . . . . . . . . . . . . . . . 30-21

Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . 35-45

Recommendations for Turbocharger Use . . . . . . 30-22 Remove Lucas CAV Fuel Injection Pump . . . . . . 35-48

Remove, Inspect and Install Intake Manifold . . . 30-23 Repair Lucas CAV Fuel Injection Pump . . . . . . . 35-50

Remove, Inspect and Install Exhaust Install Lucas CAV Fuel Injection Pump . . . . . . . . 35-51

Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 Aneroid Replacement . . . . . . . . . . . . . . . . . . . . . 35-54

Aftercooler Assembly . . . . . . . . . . . . . . . . . . . . . 30-25 Aneroid Field Adjustment . . . . . . . . . . . . . . . . . . 35-54

Remove and Install Aftercooler . . . . . . . . . . . . . . 30-26 Aneroid Workshop Adjustment . . . . . . . . . . . . . . 35-55

Inspect and Repair Aftercooler . . . . . . . . . . . . . . 30-27 Replace Engine Front Plate . . . . . . . . . . . . . . . . 35-56

Transfer Fuel Injection Pump Timing Mark

Group 35—Fuel System Onto Replacement Front Plate . . . . . . . . . . . . 35-57

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Remove Fuel Injection Nozzles . . . . . . . . . . . . . 35-58

Service Equipment and Tools . . . . . . . . . . . . . . . . 35-4 Clean Fuel Injection Nozzle Bore . . . . . . . . . . . . 35-59

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6 Clean Injection Nozzles . . . . . . . . . . . . . . . . . . . 35-59

Fuel System Specifications . . . . . . . . . . . . . . . . . . 35-7 Diagnose Fuel Injection Nozzle Malfunction . . . . 35-60

Fuel System—General Information . . . . . . . . . . . 35-11 Test Fuel Injection Nozzles . . . . . . . . . . . . . . . . 35-61

Relieve Fuel System Pressure . . . . . . . . . . . . . . 35-12 Disassemble Injection Nozzles . . . . . . . . . . . . . . 35-67

Replace Primary Fuel Filter/Water Inspect and Clean Nozzle Body . . . . . . . . . . . . . 35-70

Separator and Final Fuel Filter Assemblies . . 35-13 Inspect and Clean Valve and Valve Seat . . . . . . 35-72

Primary Fuel Filter/Water Separator Assembly . . 35-15 Inspect Valve Adjusting Mechanism . . . . . . . . . . 35-74

Final Fuel Filter Assembly . . . . . . . . . . . . . . . . . . 35-16

Replace Rectangular Fuel Filter Element . . . . . . 35-17

Assemble Injection Nozzles . . . . . . . . . . . . . . . . 35-75 Service Equipment and Tools . . . . . . . . . . . . . . . 110-1

Adjust Fuel Injection Nozzles . . . . . . . . . . . . . . . 35-76 Air Intake System Test Specifications . . . . . . . . . 110-3

Install Seals on Injection Nozzle . . . . . . . . . . . . . 35-81 Diagnosing Air Intake Malfunctions . . . . . . . . . . . 110-5

Install Injection Nozzles . . . . . . . . . . . . . . . . . . . 35-82 How the Air Intake and Exhaust System

Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-6

Group 40—Starting and Charging Systems Air Cleaner Operation . . . . . . . . . . . . . . . . . . . . . 110-7

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 Air Filter Restriction Indicator Switch Test . . . . . . 110-8

Remove and Install Starter . . . . . . . . . . . . . . . . . . 40-2 Intake Air Leak Test . . . . . . . . . . . . . . . . . . . . . . 110-9

Remove and Install Alternator . . . . . . . . . . . . . . . . 40-3 Exhaust Leak Check (Turbocharged

Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-10

Group 100—Engine Tune-Up and Break-In Intake and Exhaust Restriction Check. . . . . . . . 110-11

Effects of Altitude and Temperature on Diagnosing Turbocharger Malfunctions . . . . . . . 110-12

Engine Performance . . . . . . . . . . . . . . . . . . . . 100-1 Turbocharger Operation . . . . . . . . . . . . . . . . . . 110-13

Preliminary Engine Testing . . . . . . . . . . . . . . . . . 100-1 How the Turbocharger is Lubricated . . . . . . . . . 110-13

General Tune-Up Recommendations . . . . . . . . . 100-2 Check Intake Manifold Pressure

Dynamometer Test . . . . . . . . . . . . . . . . . . . . . . . 100-3 (Turbocharger Boost) . . . . . . . . . . . . . . . . . . 110-14

Dynamometer Test Specifications . . . . . . . . . . . 100-4 Turbocharger Oil Seal Leak Test. . . . . . . . . . . . 110-17

Engine Break-In Guidelines . . . . . . . . . . . . . . . 100-12

Perform Engine Break-In. . . . . . . . . . . . . . . . . . 100-13

Engine Oil Consumption . . . . . . . . . . . . . . . . . . 100-14 Group 115—Fuel System Operation and Tests

Check Crankcase Ventilation System . . . . . . . . 100-15 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 115-1

Check Air Intake System . . . . . . . . . . . . . . . . . 100-15 Service Equipment And Tools . . . . . . . . . . . . . . . 115-2

Check Exhaust System . . . . . . . . . . . . . . . . . . . 100-16 Fuel System Test Specifications . . . . . . . . . . . . . 115-3

Check and Service Cooling System . . . . . . . . . 100-17 Fuel Injection Pump Specifications . . . . . . . . . . . 115-4

Check Electrical System . . . . . . . . . . . . . . . . . . 100-18 Using TIME TRACâ as a Tachometer . . . . . . . . 115-13

Check and Adjust Rotary Injection Pump

Group 105—Engine System Operation and Tests Dynamic Timing. . . . . . . . . . . . . . . . . . . . . . . 115-13

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Fuel System Operation . . . . . . . . . . . . . . . . . . . 115-20

Engine Test Specifications . . . . . . . . . . . . . . . . . 105-3 Diagnose Fuel System Malfunctions . . . . . . . . . 115-22

Engine—Sectional View . . . . . . . . . . . . . . . . . . . 105-4 Fuel Supply Quality Check . . . . . . . . . . . . . . . . 115-26

General Engine Description. . . . . . . . . . . . . . . . . 105-5 Air in Fuel Test . . . . . . . . . . . . . . . . . . . . . . . . 115-27

How the Engine Lubrication System Works . . . . 105-8 Restricted Fuel Return Line Check . . . . . . . . . . 115-28

How the Cooling System Works . . . . . . . . . . . . 105-12 Fuel Supply Pump Operation—If Equipped . . . . 115-29

How the Crankshaft Gear-Driven Auxiliary Diagnose Fuel Supply Pump Malfunctions . . . . 115-30

Drive Works . . . . . . . . . . . . . . . . . . . . . . . . . 105-15 Measure Fuel Supply Pump Pressure . . . . . . . . 115-31

Head Gasket Joint Construction and Fuel Shut-Off Solenoid Resistance Test

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-18 (Lucas Pump) . . . . . . . . . . . . . . . . . . . . . . . . 115-32

Diagnosing Head Gasket Joint Failures . . . . . . 105-20 Rectangular Final Fuel Filter Operation. . . . . . . 115-32

Head Gasket Inspection and Repair Round (Primary) Fuel Filter/Water Separator

Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-24 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-33

Diagnosing Engine Malfunctions . . . . . . . . . . . . 105-26 Final Fuel Filter/Water Separator Operation . . . 115-34

Test Engine Compression Pressure . . . . . . . . . 105-30 Bleed the Fuel System . . . . . . . . . . . . . . . . . . . 115-35

Check Engine Oil Pressure . . . . . . . . . . . . . . . 105-32 Stanadyne Fuel Injection Pump Operation . . . . 115-40

Measure Engine Crankcase Pressure Lucas CAV Fuel Injection Pump Operation . . . . 115-42

(Blow-By) . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-33 Diagnose Rotary Fuel Injection Pump

Pressure Test Cooling System and Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 115-44

Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . 105-34 Check and Adjust Engine Speeds on Lucas

Inspect Thermostat and Test Opening CAV Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 115-45

Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 105-36 Adjust Variable Speed on Generator Set

Engine Cranking Speed Test. . . . . . . . . . . . . . . 105-37 Engines (Lucas CAV Pumps Only) . . . . . . . . 115-46

Check and Adjust Engine Speeds on

Group 110—Air Intake and Exhaust System Stanadyne Pump . . . . . . . . . . . . . . . . . . . . . . 115-47

Operation and Tests

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 110-1

Adjust Variable Speed (Droop) on Generator

Set Engines (3—5% Govenor Regulation)—

Stanadyne DB2, DB4, DM4 Injection Pumps

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-48

Changing Gen Set Engine Rated Speed from

1800 RPM to 1500 RPM—Stanadyne

DB2, DB4, DM4 Injection Pumps . . . . . . . . . 115-49

Diagnose Aneroid Malfunctions . . . . . . . . . . . . . 115-52

Fuel Injection Nozzles—General Information

and Operation . . . . . . . . . . . . . . . . . . . . . . . . 115-53

Diagnose Fuel Injection Nozzle Malfunctions . . 115-54

Test Fuel Injection Nozzles (Engine

Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-55

Fuel Drain Back Test Procedure . . . . . . . . . . . . 115-56

Group 199—Dealer Fabricated Tools

How to Make Tools . . . . . . . . . . . . . . . . . . . . . . . 199-1

DFRG2—Injection Pump Front Plate

Timing Mark Transfer Tool. . . . . . . . . . . . . . . . 199-1

DFRG3—Cylinder Liner Holding Fixture . . . . . . . 199-2

CTM8