Complete service repair manual with Electrical Wiring Diagrams for John Deere Series 300 3029 (S.N. -499999), 4039, 4045, 6059 and 6068 Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Jonn Deere Series 300 3029 (S.N. -499999), 4039, 4045, 6059 and 6068 Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

ctm8 - Series 300 3029 (S.N. -499999), 4039, 4045, 6059 and 6068 Diesel Engines Component Technical Manual.pdf
ctm8 - Series 300 3029 (S.N. -499999), 4039, 4045, 6059 and 6068 Diesel Engines Component Technical Manual.epub

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Total Pages: 853 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English

MAIN SECTIONS

ctm8 - Series 300 3029 (S.N. -499999), 4039, 4045, 6059 and 6068 Diesel Engines
Component Technical Manual

Table of Contents

Forward

Engine Identification Views

Section : 3029/4039/4045/6059/6068 Diesel Engines

Group 00: Safety

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Wear Protective Clothing

Service Machines Safely

Work In Ventilated Area

Work in Clean Area

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Use Proper Lifting Equipment

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 01: General Information

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Engine Model Designation

Engine Serial Number Plate Information

OEM Engine Option Code Label

Engine References

Engine Application ChartJohn Deere Agricultural Equipment

Engine Application Chart John Deere Construction Equipment

Engine Application Chart OEM Applications

Group 02: Fuels, Lubricants and Coolant

Diesel Fuel

Lubricity of Diesel Fuels

Engine Break-In Oil

Diesel Engine Oil

Alternative and Synthetic Lubricants

Mixing of Lubricants

OILSCAN Plus® and COOLSCAN Plus®

Grease

Diesel Engine Coolant Recommendations

Engine Coolant Specifications

Testing Diesel Engine Coolant

Replenishing Supplemental Coolant Additives (SCA’s) Between Coolant Changes

Operating in Warm Temperature Climates

Flush and Service Cooling System

Disposing of Coolant

Group 03: Engine Mounting

Engine Repair Stand

Safety Precautions

Install 300 Series Adapters on Repair Stand

Engine Lifting Procedure

Clean Engine

Mount Engine on Repair Stand

Disconnect Turbocharger Oil Inlet Line

Group 04: Engine Rebuild Guide

Engine Disassembly Sequence

Sealant Application Guidelines

Engine Assembly Sequence

Group 05: Cylinder Head and Valves

Essential Tools

Service Equipment And Tools

Other Material

Cylinder Head and Valves Specifications

Check and Adjust Valve Clearance

Measure Valve Lift

Remove Cylinder Head

Disassemble and Inspect Rocker Arm Assembly

Assemble Rocker Arm Assembly

Inspect, Measure, and Assemble Camshaft Followers

Check Valve Recess In Cylinder Head

Preliminary Cylinder Head and Valve Checks

Remove Valve Assembly

Inspect and Measure Valve Springs

Inspect Valve Rotators

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

Clean and Inspect Cylinder Head Cap Screws

Inspect and Clean Exhaust Manifold

Clean and Inspect Top Deck of Cylinder Block

Measure Cylinder Liner Standout (Height Above Block)

Install Cylinder Head

Torque-Turn Method For Proper Torque

Install Rocker Arm Assembly

Inspect and Clean Ventilator Outlet Hose

Install Rocker Arm Cover

Complete Final Assembly

Perform Engine Break-In

Group 10: Cylinder Block, Liners, Pistons and Rods

Essential Tools

Service Equipment And Tools

Other Material

Cylinder Block, Liners, Pistons and Rods 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

Clean Cylinder Liners

Visually Inspect Cylinder Liners

Check Piston Ring Groove Wear

Measure Piston Pin Bore

Measure Piston Skirt

Measure Piston Height

Determine Piston-to-Liner Clearance

Deglaze Cylinder Liners

Replace Piston and Liner Sets

Inspect and Measure Connecting Rod Bearings (Rods Removed From Engine)

Inspect and Measure Connecting Rod Bearings (Rod and Crankshaft in Engine)

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

Measure Rod Center-to-Center Bores

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

Measure Liner Flange Counterbore Depth in Block

Measure Liner Flange Thickness

Remove, Inspect and Install Piston Cooling Orifices

Measure Cylinder Liners and Block Bores

Install Steel Ball in Oil Passage of Cylinder Block

Measure Cylinder Liner Standout (Height Above 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

Torque-Turn Connecting Rod Cap Screws

Check Engine Rotation For Excessive Tightness

Measure Piston Protrusion

Cylinder Block Orifices (Saran Engines)

Cylinder Block Orifices

Complete Final Assembly

Group 15: Crankshaft, Main Bearings and Flywheel

Essential Tools

Service Equipment And Tools

Other Material

Crankshaft, Main Bearings and Flywheel Specifications

Crankshaft and Main Bearing Failure Analysis

Inspect Vibration Damper (6-Cylinder Engine)

Remove Pulley or Vibration Damper Pulley (Engine W/O Front PTO)

Install Pulley or Vibration Damper Pulley (Engine W/O Front PTO)

Checking Vibration Damper or Pulley (Engine With Front PTO)

Removing Vibration Damper or Pulley (Engine With Front PTO)

Installing Vibration Damper or Pulley (Engine With Front PTO)

Installing Vibration Damper or Pulley (Engine With Crankshaft Gear-Driven PTO)

Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover)

Check Crankshaft End Play

Inspect Flywheel

Check Flywheel Housing Face Runout

Check Flywheel Face Flatness

Check Pilot Bearing Bore Concentricity

Remove Flywheel

Replace Flywheel Ring Gear

Replace Pilot Bearing In Flywheel—3029, 4039, 4045 Engines (If Equipped)

Install Flywheel

Crankshaft Rear Oil Seal and Wear Sleeve General Information

Crankshaft Unitized Rear Oil Seal and Wear Sleeve Handling Precautions

Remove Two-Piece Crankshaft Rear Oil Seal and Wear Sleeve (Without Removing Flywheel Housing)

Remove Unitized (Non-Separable) Crankshaft Rear Oil Seal and Wear Sleeve

Clean and Inspect Crankshaft Flange

Install Crankshaft Rear Oil Seal and Wear Sleeve

Remove Flywheel Housing

Remove Crankshaft Main Bearings

Check Main Bearing Oil Clearance

Remove and Install Crankshaft Gear (Crankshaft Installed In Engine)

Remove Crankshaft

Remove Crankshaft Rear Wear Sleeve (Crankshaft Removed From Engine)

Inspect Crankshaft

Measure Main Bearing ID and Crankshaft Journal OD

Measure Main Thrust Journal Width and Thrust Bearing Width

Crankshaft Grinding Guidelines

Crankshaft Grinding Specifications [Earlier Engines With Ground (Tangential) Fillets (A)]

Crankshaft Grinding Specifications [Later Engines With Undercut and Rolled Fillets (A)]

Measure Assembled ID of Main Bearing Caps

Measure Crankshaft Main Bearing Bore Centerline-To-Top Deck

Inspect Piston Cooling Orifices

Install Main and Thrust Bearing Inserts In Block

Install Crankshaft

Install Flywheel Housing

Complete Final Assembly

Group 16: Camshaft, Balancer Shafts and Timing Gear Train

Essential Tools

Service Equipment And Tools

Other Material

Camshaft, Balancer Shafts and Timing Gear Train Specifications

Measure Valve Lift

Remove Timing Gear Cover

Remove and Install Camshaft Bushing With Front Plate Installed Camshaft Gear-Driven Auxiliary Drive Engines, Saran Built Engines Serial No. (138541—)

Remove Auxiliary Drive Gears (Engines With Auxiliary Gear Drive Option)

Measure Camshaft End Play

Measure Balancer Shaft End Play (4-Cylinder Engines)

Measure Idler Gear End Play

Measure Timing Gear Backlash

Remove Camshaft

Visually Inspect Camshaft

Measure Camshaft Thrust Plate Clearance and Thickness

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 and Install Camshaft Bushing With Front Plate Removed Engine Serial No. ( —138540)

Remove Balancer Shafts—If Equipped (4-Cylinder Engines)

Inspect and Measure Balancer Shaft Bushings and Journals

Remove and Install Balancer Shaft Bushings (4-Cylinder Engines)

Install Oversize Balancer Shaft Bushings In Cylinder Block (4039 Engines)

Inspect Balancer Shaft Gears and Thrust Plates

Remove and Install Balancer Shaft Gears

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 (If Equipped)

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 (Engines With Crankshaft-Driven Auxiliary Gear Drive Option)

Install Drive Gear (Engines With Crankshaft-Driven Auxiliary Gear Drive Option)

Install Timing Gear Cover

Install Idler Gear and Output Gear (Engines With Auxiliary Gear Drive Option)

Complete Final Assembly

Group 20: Lubrication System

Essential Tools

Service Equipment And Tools

Other Material

Lubrication System Specifications

General Lubrication System Information

Oil Cooler Identification

Remove, Inspect, and Install Standard-Flow Oil Cooler

Remove and Install High-Flow Oil Cooler

Replacing Standard Oil Cooler/Oil Filter Housings

Replace Oil Filter Adapter on Engine With Remote Oil Filter

Remove, Inspect, and Install Oil Bypass Valve—3029, 4039, and 6059 Engines and 4045 and 6068 Engines With Common Lube Block See GENERAL LUBRICATION SYSTEM INFORMATION earlier in this group for an explanation of "Common-Lube" blocks.

Remove and Install Oil Bypass Valve—4045 and 6068 Engines With Pre-Common Lube Block See GENERAL LUBRICATION SYSTEM INFORMATION earlier in this group for an explanation of "Common-Lube" blocks.

Remove and Install Oil Pressure Regulating Valve and Seat—3029, 4039, and 6059 Engines and 4045 and 6068 Engines With Common Lube Block See GENERAL LUBRICATION SYSTEM INFORMATION earlier in this group for an explanation of "Common-Lube" blocks.

Remove, Inspect, and Install Oil Pressure Regulating Valve—4045 and 6068 Engines With Pre-Common Lube Block See GENERAL LUBRICATION SYSTEM INFORMATION earlier in this group for an explanation of "Common-Lube" blocks.

Remove and Install Oil Filter Nipple—3029, 4039, 6059 Engines

Remove and Install Oil Pan Mounted Oil Fill/Dipstick Tube

Remove, Install, and Adjust Dipstick Nipple

General Oil Pump Information

Remove, Inspect and Install 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

Group 25: Cooling System

Essential Tools

Service Equipment And Tools

Other Material

Cooling System Specifications

Remove, Test, and Install Thermostats

Remove and Install Water Manifold/Thermostat Housing

General Water Pump Information

Remove Water Pump

Disassemble Low Flow, Standard-Duty High Flow, and Modular Style Water Pumps

Disassemble Heavy-Duty High Flow Water Pump

Inspect and Clean Water Pump Parts

Assemble Low Flow, Standard-Duty High Flow, and Modular Style Water Pumps

Assemble Heavy-Duty High Flow Water Pump

Pulley or Hub-to-Rear Face of Water Pump Housing Dimensions

Check Water Pump Cap Screw Protrusion

Install Water Pump

Cooling System Deaeration

Inspect and Install Fan Blade Assembly

Adjust Fan Belt Tension

Remove and Install Coolant Heater (Dubuque-Built Engines)—If Equipped

Remove and Install Coolant Heater (Saran-Built Engines)—If Equipped

Group 30: Air Intake and Exhaust System

Other Material

Air Intake and Exhaust System Specifications

Extending Turbocharger Life

Remove Turbocharger

Turbocharger Failure Analysis

Turbocharger Seven-Step Inspection

Perform Radial Bearing Clearance Test

Perform Axial Bearing End Play Test

Repair Turbocharger

Disassemble and Inspect Turbocharger

Replace Center Housing and Rotating Assembly

Prelube Turbocharger

Install Turbocharger

Turbocharger Break-In

Recommendations for Turbocharger Use

Remove, Inspect and Install Intake Manifold

Remove, Inspect and Install Exhaust Manifold

Aftercooler Assembly

Remove and Install Aftercooler

Inspect and Repair Aftercooler

Group 35: Fuel System

Essential Tools

Service Equipment and Tools

Other Material

Fuel System Specifications

Fuel System—General Information

Relieve Fuel System Pressure

Replace Primary Fuel Filter/Water Separator and Final Fuel Filter Assemblies

Primary Fuel Filter/Water Separator Assembly

Final Fuel Filter Assembly

Replace Rectangular Fuel Filter Element

Replace Round Fuel Filter Element (Early Model Engines)

Replace Final Fuel Filter and Primary Fuel Filter/Water Separator Elements (Later Engines)

Remove Fuel Supply Pump

Bench Test Fuel Supply Pump

Install Fuel Supply Pump

Fuel Injection Pump Timing

Remove Stanadyne Model DB2 Injection Pump With Non-Retained Drive Shaft

Repair Stanadyne Fuel Injection Pump

Remove Stanadyne DB2 Non-Retained Injection Pump Drive Shaft From Engine

Install Non-Retained Drive Shaft In Stanadyne DB2 Injection Pump (If Removed from Engine)

Install Stanadyne Model DB2 Injection Pump With Non-Retained Drive Shaft

Remove Stanadyne Model DB2 (With Retained Drive Shaft) and DB4 Injection Pump

Inspect Injection Pump Drive Gear I.D. and Shaft O.D.

Repair Stanadyne Fuel Injection Pump

Install Stanadyne Model DB2 (With Retained Drive Shaft) and DB4 Injection Pump

Remove Stanadyne Model DM4 Fuel Injection Pump

Repair Stanadyne Fuel Injection Pump

Install Stanadyne Model DM4 Fuel Injection Pump

Remove Lucas CAV Fuel Injection Pump

Repair Lucas CAV Fuel Injection Pump

Install Lucas CAV Fuel Injection Pump

Aneroid Replacement

Aneroid Field Adjustment

Aneroid Workshop Adjustment

Replace Engine Front Plate

Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate

Remove Fuel Injection Nozzles

Clean Fuel Injection Nozzle Bore

Clean Injection Nozzles

Diagnose Fuel Injection Nozzle Malfunction

Test Fuel 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

Group 40: Starting and Charging Systems

Essential Tools

Remove and Install Starter

Remove and Install Alternator

Group 100: Engine Tune-Up and Break-In

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

Engine Oil Consumption

Check Crankcase Ventilation System

Check Air Intake System

Check Exhaust System

Check and Service Cooling System

Check Electrical System

Group 105: Engine System Operation and Tests

Essential Tools

Engine Test Specifications

Engine—Sectional View

General Engine Description

How the Engine Lubrication System Works

How the Cooling System Works

How the Crankshaft Gear-Driven 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

Engine Cranking Speed Test

Group 110: Air Intake and Exhaust System Operation and Tests

Essential Tools

Service Equipment and Tools

Air Intake System Test Specifications

Diagnosing Air Intake Malfunctions

How the Air Intake and Exhaust System Works

Air Cleaner Operation

Air Filter Restriction Indicator Switch Test

Intake Air Leak Test

Exhaust Leak Check (Turbocharged Engines)

Intake and Exhaust Restriction Check

Diagnosing Turbocharger Malfunctions

Turbocharger Operation

How the Turbocharger is Lubricated

Check Intake Manifold Pressure (Turbocharger Boost)

Turbocharger Oil Seal Leak Test

Group 115: Fuel System Operation and Tests

Essential Tools

Service Equipment And Tools

Fuel System Test Specifications

Fuel Injection Pump Specifications

Using TIME TRAC TIME TRAC is a registered trademark of Stanadyne Automotive Corp. as a Tachometer

Check and Adjust Rotary Injection Pump Dynamic Timing

Fuel System Operation

Diagnose Fuel System Malfunctions

Fuel Supply Quality Check

Air in Fuel Test

Restricted Fuel Return Line Check

Fuel Supply Pump Operation—If Equipped

Diagnose Fuel Supply Pump Malfunctions

Measure Fuel Supply Pump Pressure

Fuel Shut-Off Solenoid Resistance Test (Lucas Pump)

Rectangular Final Fuel Filter Operation

Round (Primary) Fuel Filter/Water Separator Operation

Final Fuel Filter/Water Separator Operation

Bleed the Fuel System

Stanadyne Fuel Injection Pump Operation

Lucas CAV Fuel Injection Pump Operation

Diagnose Rotary Fuel Injection Pump Malfunctions

Check and Adjust Engine Speeds on Lucas CAV Pump

Adjust Variable Speed on Generator Set Engines (Lucas CAV Pumps Only)

Check and Adjust Engine Speeds on Stanadyne Pump

Adjust Variable Speed (Droop) on Generator Set Engines (3—5% Govenor Regulation)—Stanadyne DB2, DB4, DM4 Injection Pumps

Changing Gen Set Engine Rated Speed from 1800 RPM to 1500 RPM—Stanadyne DB2, DB4, DM4 Injection Pumps

Diagnose Aneroid Malfunctions

Fuel Injection Nozzles—General Information and Operation

Diagnose Fuel Injection Nozzle Malfunctions

Test Fuel Injection Nozzles (Engine Running)

Fuel Drain Back Test Procedure

Group 199: Dealer Fabricated Tools

How to Make Tools

DFRG2—Injection Pump Front Plate Timing Mark Transfer Tool

DFRG3—Cylinder Liner Holding Fixture

John Deere Series 300 Diesel Engines 3029, 4039, 4045, 6059 and 6068 Component Technical Manual (CTM8)