Factory Technical Manual For John Deere Diesel Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 547
Issued: october 1995
Model
John Deere Foley Engine
Series 300
3179
4239
6359
4276
6414
Contents
INTRODUCTION
SAFETY
-GENERAL INFORMATION
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Engine Model Designation
Engine Serial Number Plate Information
Engine Application Chart
-FUELS, LUBRICANTS, AND COOLANT
Diesel Fuel
Lubricity of Diesel Fuels
Engine Break-In Oil
Diesel Engine Oil
Oilscan And Coolscan
Alternative and Synthetic Lubricants
Grease
Engine Coolant Requirements
Recommended Engine Coolant
Engine Coolant Specifications
Replenishing Supplemental Coolant Additives (SCA’s)
Operating in Tropical Conditions
Flush and Service Cooling System
Disposing of Coolant
-ENGINE MOUNTING
Engine Repair Stand
Safety Precautions
Install 300 Series Adapters on Repair Stand
Engine Lifting Procedure
Clean Engine
Disconnect Turbocharger Oil Inlet Line
Mount Engine on Repair Stand
Engine Mounted on Repair Stand
-ENGINE REBUILD GUIDE
Engine Disassembly Sequence
Sealant Application Guidelines
Engine Assembly Sequence
-CYLINDER HEAD AND VALVES
Special or Essential Tools
Service Equipment and Tools
Specifications
Other Material
Check and Adjust Valve Clearance
Measure Valve Lift
Remove Cylinder Head
Disassemble and Inspect Rocker Arm Shaft Assembly
Assemble Rocker Arms on Shaft
Clean and Inspect Push Rods
Make Preliminary Valve Checks
Check Valve Recess in Cylinder Head
Remove Valve Assembly
Inspect and Measure Valve Springs
Inspect Valve Rotators and Wear Caps
Clean Valves
Inspect and Measure Valves
Grind Valves
Inspect and Clean Cylinder Head
Check Cylinder Head Flatness
Measure Cylinder Head Thickness
Clean Injection Nozzle Bores
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Clean and Inspect Valve Seats
Grind Valve Seats
Remove Valve Seat Inserts
Measure Valve Seat Bore in Cylinder Head
Install Valve Seat Inserts
Install Valves
Valve Stem Seals—General Information
Install Valve Stem O-Ring Seals
Install Valve Stem Tower Seals
Inspect and Clean Ventilator Outlet Hose
Inspect and Clean Exhaust Manifold
Clean and Inspect Top Deck of Cylinder Block
Measure Cylinder Liner Standout (Height Above Block)
Clean and Inspect Cylinder Head Cap Screws
Install Cylinder Head
Install Cylinder Head Cap Screws
Torque-Turn Method for Proper Torque
Install Rocker Arm Assembly
Install Rocker Arm Cover
Complete Final Assembly
Perform Engine Break-In
-CYLINDER BLOCK, LINERS, PISTONS, AND RODS
Special or Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove Pistons and Connecting Rods
Remove Cylinder Liners
Complete Disassembly of Cylinder Block (If Required)
Preliminary Liner, Piston and Rod Checks
Disassemble Piston and Rod Assembly
Clean Pistons
Visually Inspect Pistons
Install Piston Pin
Clean Cylinder Liners
Visually Inspect Cylinder Liners
Check Piston Ring Groove Wear
Measure Piston Skirt
Determine Piston-to-Liner Clearance
Deglaze Cylinder Liners
Replace Piston and Liner Sets
Determine Piston Type
Measure Piston Protrusion
Inspect and Measure Connecting Rod Bearings
Inspect Rod and Cap
Inspect Piston Pins and Bushings
Remove Piston Pin Bushing
Clean and Inspect Connecting Rod Pin Bore
Install Piston Pin Bushing in Connecting Rod
Inspect and Clean Cylinder Block
Clean Cylinder Liner O-Ring Bore
Measure Cylinder Block Main Bearing
Bore
Measure Camshaft Follower Bore
Measure Camshaft Bearing Bore
Measure Balancer Shaft Bore—4-Cylinder Engines
Measure Cylinder Block Top Deck Flatness
Inspect Piston Cooling Orifices
Measure Liner Flange Thickness and Block Counterbore Depth
Recheck Cylinder Liner Standout (Height Above Block)
Install Steel Ball in Oil Passage of Service Cylinder Block
Install Cylinder Liner O-Rings and Packings
Install Cylinder Liner
Assemble Piston and Connecting Rod Install Piston Rings
Install Piston and Connecting Rod Assembly
Check Engine Rotation For Excessive Tightness
Measure Piston Protrusion
Complete Final Assembly
-CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL
Special or Essential Tools
Service Equipment and Tools
Specifications
Other Material
Crankshaft and Main Bearing Failure Analysis
Inspect Vibration Damper (6-Cylinder Engine)
Remove Pulley or Vibration Damper Pulley
Install Pulley or Vibration Damper Pulley
Checking Vibration Damper or Pulley (Front PTO)
Removing Vibration Damper or Pulley (Front PTO)
Install Vibration Damper or Pulley (Front PTO)
Replace Front Crankshaft Oil Seal (Without Removing Cover)
Check Crankshaft End Play
Inspect Flywheel
Check Flywheel Housing Face Runout
Check Flywheel Face Flatness
Remove Flywheel
Replace Flywheel Ring Gear
Install Flywheel
Crankshaft Rear Oil Seal and Wear Sleeve General Information
Remove Two-Piece Crankshaft Oil Seal and Wear Sleeve
Remove Unitized Crankshaft Rear Oil Seal and Wear Sleeve
Install Crankshaft Rear Oil Seal and Wear Sleeve
Remove Flywheel Housing
Remove Crankshaft Main Bearings
Check Main Bearing Clearance
Remove and Install Crankshaft Gear with Crankshaft Installed
Remove Crankshaft
Remove Crankshaft Rear Wear Sleeve with Crankshaft Removed
Inspect Crankshaft
Measure Assembled ID of Bearings and OD of Crankshaft Journal
Measure Main Thrust Journal Width and Thrust Bearing Width
Crankshaft Grinding Guidelines
Crankshaft Grinding Specifications
Measure Assembled ID of Main Bearing Caps
Inspect Piston Cooling Orifices
Install Main and Thrust Bearing Inserts in Block
Install Crankshaft
Install Flywheel Housing
Complete Final Assembly
-CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN
Special or Essential Tools
Service Equipment and Tools
Other Materials
Specifications
Auxiliary Gear Drive Specifications
Measure Valve Lift
Remove Timing Gear Cover
Remove Auxiliary Drive Gears
Measure Camshaft End Play
Measure Balancer Shaft End Play—4-Cylinder Engines
Measure Timing Gear Backlash
Measure Idler Gear End Play
Remove Camshaft
Visually Inspect Camshaft
Measure Camshaft Thrust Plate Clearance
Inspect and Measure Camshaft Bearing Bore ID and Journal OD
Measure Camshaft Lobe Height
Remove and Install Camshaft Gear
Inspect Camshaft Followers
Replace Tachometer Drive Gear
Remove Balancer Shafts—If Equipped (4-Cylinder Engines)
Inspect and Measure Balancer Shaft Bushings and Journals
Remove and Install Balancer Shaft Bushings in Block
Install Oversize Balancer Shaft Bushings in Block—4239 Engines
Inspect Balancer Shaft Gears and Thrust Plates
Remove and Install Balancer Shaft Gears
Remove Balancer Shaft
Remove Cylinder Block Front Plate
Measure Idler Gear Bushing and Shaft
Remove and Install Idler Gear Bushings
Remove Lower and Upper Idler Shafts
Clean and Inspect Front Plate
Replace Engine Front Plate
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate
Install Idler Shaft Spring Pins
Install Upper Idler Shaft in Front Plate
Install Lower Idler Shaft in Front Plate
Install Engine Front Plate
Install and Time Balancer Shafts—If Equipped (4-Cylinder Engines)
Install and Time Camshaft and Fuel Injection Pump
Clean and Inspect Timing Gear Cover
Install Ball Bearings and Dowels
Install Drive Gear
Install Timing Gear Cover
Install Crankshaft Front Oil Seal
Install Idler Gear and Output Gear
Complete Final Assembly
-LUBRICATION SYSTEM
Special or Essential Tools
Service Equipment and Tools
Other Material
Specifications
Engine Crankcase Oil Fill Quantities
Identify Oil Cooler Type—3179, 4239, 6359 Engines
Remove, Inspect, & Install Standard-Flow Oil Cooler (3179, 4239, 6359)
Remove and Install Fligh-Flow Oil Cooler (6359 Engines)
Remove Distributor Base—High-Flow Cooler (6359)
Inspect and Repair Distributor Base—High Flow Oil Cooler (6359)
Install Distributor Base—High-Flow Oil Cooler (6359)
Remove Oil Cooler (4276, 6414 Engines)
Repair Oil Cooler (4276, 6414 Engines)
Install Oil Cooler (4276, 6414 Engines)
Remove and Inspect Oil Bypass Valve (3179, 4239, 6359 Engines)
Measure Oil Bypass Valve Length and Cylinder Block Bore
Install Oil Bypass Valve (3179, 4239, 6359 Engines)
Remove and Install Oil Cooler/Filter Bypass Valve (4276, 6414 Engines)
Remove & Install Oil Pressure Regulating Valve/Seat (3179, 4239, 6359)
Remove, Inspect and Install Oil Pressure Regulating Valve (4276, 6414)
Repair Oil Pressure Regulating Valve (4276, 6414 Engines)
Remove Oil Filter Adapter (3179, 4239, 6359 Engines)
Install Oil Filter Adapter (3179, 4239, 6359 Engines)
Remove, Install, and Adjust Dipstick Tube
General Oil Pump Information
Replace Oil Pump Pick-Up Tube Assembly
Remove Standard Capacity Oil Pump
Inspect and Measure Clearances (Standard Capacity Oil Pump)
Complete Standard Capacity Oil Pump Disassembly
Assemble Standard Capacity Oil Pump
Install Standard Capacity Oil Pump
Remove High Capacity Oil Pump
Inspect and Measure Clearances (High Capacity Oil Pump)
Complete High Capacity Oil Pump Disassembly
Assemble High Capacity Oil Pump
Install High Capacity Oil Pump
Install Oil Pan
-COOLING SYSTEM
Special or Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove, Test, and Install Thermostats
Remove and Install Thermostat Housing/Water Manifold
General Water Pump Information
Remove Low Flow (Standard Duty) Water Pump
Disassemble Low Flow (Standard Duty) Water Pump
Inspect and Clean Low Flow (Standard Duty) Water Pump Parts
Assemble Low Flow (Standard Duty) Water Pump
Install Low Flow (Standard Duty) Water Pump
Remove High Flow (Heavy-Duty) Water Pump
Disassemble High Flow (Heavy-Duty) Water Pump
Inspect and Clean High Flow (Heavy-Duty) Water Pump Parts
Assemble High Flow (Heavy-Duty) Water Pump
Checking Water Pump Cap Screw Protrusion
Install High Flow (Heavy-Duty) Water Pump
Inspect and Install Fan Blade Assembly
Remove Coolant Heater—If Equipped
Install Coolant Heater—If Equipped
-AIR INTAKE AND EXHAUST SYSTEM
Other Material
Specifications
Extending Turbocharger Life
Remove Turbocharger—4239T and 6359T & A Engines
Turbocharger Failure Analysis
Turbocharger Seven-Step Inspection
Perform Radial Bearing Clearance Test—KKK
Perform Axial Bearing End Play Test—KKK
Perform Radial Bearing Clearance Test—Ai Research/Garrett
Perform Axial Bearing End Play Test—AiResearch/Garrett
Repair Turbocharger
Disassemble and Inspect Turbocharger
Replace Center Housing and Rotating Assembly
Prelube Turbocharger
Install KKK and AiResearch/Garrett Turbocharger
Turbocharger Break-In
Remove, Inspect, and Install Intake Manifold
Remove Cross-Over Tube Assembly—If Equipped
Inspect and Repair Cross-Over Tube Assembly—If Equipped
Install Cross-Over Tube Assembly—If Equipped
Remove Aftercooler and Intake Manifold (6359A)
Inspect and Repair Aftercooler (6359A)
Inspect and Repair Intake Manifold (6359A)
Install Intake Manifold and Aftercooler (6359A)
Remove, Inspect, and Install Exhaust Manifold
-FUEL SYSTEM
Special or Essential Tools
Service Equipment and Tools
Other Material
Specifications
Relieve Fuel System Pressure
Replace Fuel Filter
Remove Fuel Supply Pump
Bench Test Fuel Supply Pump
Repair Sofabex and AC Fuel Supply Pumps
Repair Corona Fuel Supply Pump
Install Fuel Supply Pump
Fuel Injection Pump Timing
Fuel Injection Pump—General Information
Remove Roto Diesel/Lucas CAV Fuel Injection Pump
Repair Roto Diesel/Lucas CAV Fuel Injection Pump
Install Roto Diesel/Lucas CAV Fuel Injection Pump
Timing Roto Diesel/Lucas CAV Injection Pump (Front Plate Installed)
Remove Stanadyne Pump—Model JDB & DB2 (Non-Retained Drive Shaft)
Remove Stanadyne Model JDB & DB2 Pump with Non-Retained Drive Shaft
Repair Stanadyne Model JDB and DB2 Fuel Injection Pump
Install Non-Retained Drive Shaft in Stanadyne Model JDB & DB2 Pump
Install Stanadyne Model JDB & DB2 Pump with Non-Retained Drive Shaft
Remove Stanadyne Model DB2 (Retained Drive Shaft) & DB4 Injection Pump
Inspect Injection Pump Drive Gear ID and Shaft OD
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model DB2 (Retained Drive Shaft) and DB4 Pump
Remove Stanadyne Model DM4 Fuel Injection Pump
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model DM4 Fuel Injection Pump
Replace Engine Front Plate
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate
Aneroid Replacement
Aneroid Field Adjustment
Aneroid Workshop Adjustment
Remove Fuel Injection Nozzles
Clean Fuel Injection Nozzle Bore
Clean Injection Nozzles
Diagnose Injection Nozzle Malfunction
Test Injection Nozzles
Disassemble Injection Nozzles
Inspect and Clean Nozzle Body
Inspect and Clean Valve and Valve Seat
Inspect Valve Adjusting Mechanism
Assemble Injection Nozzles
Adjust Fuel Injection Nozzles
Install Seals on Injection Nozzle
Install Injection Nozzles
Repair Leak-Off Line Assembly
-ENGINE TUNE-UP AND BREAK-IN
Special or Essential Tools
Effects of Altitude and Temperature on Engine Performance
Preliminary Engine Testing
General Tune-Up Recommendations
Dynamometer Test
Dynamometer Test Specifications
Engine Break-In Guidelines
Perform Engine Break-In
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check and Service Cooling System
Check Electrical System
-ENGINE SYSTEM OPERATION AND TESTS
Special or Essential Tools
Engine Test Specifications
Engine—Sectional View
General Engine Description
How the Lubrication System Works—4239T Shown
Oil Cooler Operation—4276 and 6414 Engines
How the Cooling System Works—Standard Flow Oil Cooler
How the Cooling System Works—High-Flow Oil Cooler
How the Crankshaft Gear-Drive Auxiliary Drive Works
Head Gasket Joint Construction and Operation
Diagnosing Head Gasket Joint Failures
Head Gasket Inspection and Repair Sequence
Diagnosing Engine Malfunctions
Test Engine Compression Pressure
Check Engine Oil Pressure
Measure Engine Crankcase Pressure (Blow-By)
Pressure Test Cooling System and Radiator Cap
Inspect Thermostat and Test Opening Temperature
-AIR INTAKE SYSTEM OPERATION AND TESTS
Special or Essential Tools
Service Equipment and Tools
Test Specifications
Diagnosing Air Intake Malfunctions
How the Air Intake and Exhaust System Works
Air Cleaner Operation
Diagnosing Turbocharger Malfunctions
How the Turbocharger is Lubricated
Turbocharger Operation
How the Aftercooler Works
Check Intake Manifold Pressure (Turbo Boost)
Air Filter Restriction Indicator Switch Test
-FUEL SYSTEM OPERATION AND TESTS
Special or Essential Tools
Service Equipment and Tools
Fuel System Test Specifications
Saran Fuel Injection Pump Specifications
Dubuque Fuel Injection Pump Specifications
Fuel Injection Pump Timing
Check and Adjust Injection Pump Dynamic Timing
Check Roto Diesel/Lucas CAV Injection
Pump Static Timing
Check Stanadyne DB2 Pump Static Timing
Check Stanadyne JDB Injection Pump Static Timing
Check Stanadyne DM4 Injection Pump Static Timing
Fuel System Operation
Diagnose Fuel System Malfunctions
Fuel Supply Pump Operation—If Equipped
Diagnose Supply Pump Malfunction
Measure Fuel Supply Pump Pressure—If Equipped
Rectangular Final Fuel Filter Operation
Bleed the Fuel System
Roto Diesel/Lucas CAV Fuel Injection Pump Operation
Stanadyne DM4 Fuel Injection Pump Operation
Stanadyne DB2/DB4 Fuel Injection Pump Operation
Diagnose Fuel Injection Pump Malfunctions
Check and Adjust Engine Speeds on Lucas CAV Pump
Adjust Variable Speed on Generator Set Engines (Lucas CAV)
Check and Adjust Engine Speeds on Stanadyne Pump
Adjust Variable Speed on Generator Set Engines—Stanadyne
Changing Gen Set Engine Rated Speed—Stanadyne
Fuel Injection Nozzles—General Information/Operation
Diagnose Malfunction—Fuel Injection Nozzle
Test Fuel Injection Nozzles (Engine Running)
Fuel Drain Back Test Procedure
-DEALER FABRICATED TOOLS
How to Make Tools
DFRG2—Injection Pump Front Plate Timing Mark Transfer Tool
DFRG3—Cylinder Liner Holding Fixture
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