John Deere 300 Series 3179 4239 6359 4276 6414 Diesel Engine Component Workshop Repair Service Manual CTM4 PDF - MJODCTM4.zip
This complete workshop service repair manual covers John Deere diesel engines from Series 300, 3179, 4239, 6359, 4276, and 6414, complete with Electrical Wiring Diagrams. Inside, you'll find every technical detail needed to service, troubleshoot, overhaul, and rebuild these engines to the standard of a professional mechanic.
The John Deere Series 300, 3179, 4239, 6359, 4276, and 6414 diesel engine service repair manual contains:
* 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.
PRODUCT DETAILS:
Total Pages: 547 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CTM4 (28OCT95) - John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual.pdf
CTM4 - John Deere Series 300 (3179, 4239, 6359, 4276, and 6414) Diesel Engines Component Technical Manual (CTM).pdf
MAIN SECTIONS
Introduction...2
FOREWORD...2
JOHN DEERE DEALERS...3
ABOUT THIS MANUAL...4
3179D ENGINE IDENTIFICATION...5
4276D ENGINE IDENTIFICATION...5
6359A ENGINE IDENTIFICATION...6
6359T ENGINE IDENTIFICATION...6
Contents...7
Group 00Safety...7
Group 01General Information...7
Group 02Fuels, Lubricants, and Coolant...7
Group 03Engine Mounting...7
Group 04Engine Rebuild Guide...7
Group 05Cylinder Head and Valves...7
Group 10Cylinder Block, Liners, Pistons, and Rods...8
Group 15Crankshaft, Main Bearings, and Flywheel...8
Group 16Camshaft, Balancer Shafts, and Timing Gear Train...9
Group 20Lubrication System...10
Group 25Cooling System...10
Group 30Air Intake and Exhaust System...10
Group 35Fuel System...11
Group 100Engine Tune-Up and Break-In...12
Group 105Engine System Operation and Tests...12
Group 110Air Intake System Operation and Tests...12
Group 115Fuel System Operation and Tests...12
Group 199Dealer Fabricated Tools...13
Safety ...15
HANDLE FLUIDS SAFELYAVOID FIRES...15
PREVENT BATTERY EXPLOSIONS...15
PREPARE FOR EMERGENCIES...15
PREVENT ACID BURNS...16
AVOID HIGH-PRESSURE FLUIDS...17
WEAR PROTECTIVE CLOTHING...17
SERVICE MACHINES SAFELY...18
WORK IN VENTILATED AREA...18
ILLUMINATE WORK AREA SAFELY...18
REMOVE PAINT BEFORE WELDING OR HEATING...19
AVOID HEATING NEAR PRESSURIZED FLUID LINES...19
USE PROPER LIFTING EQUIPMENT...19
WORK IN CLEAN AREA...20
PRACTICE SAFE MAINTENANCE...20
USE PROPER TOOLS...21
DISPOSE OF WASTE PROPERLY...21
LIVE WITH SAFETY...22
General Information ...23
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES...23
METRIC BOLT AND CAP SCREW TORQUE VALUES...24
ENGINE MODEL DESIGNATION...25
ENGINE SERIAL NUMBER PLATE INFORMATION...27
ENGINE APPLICATION CHART*...29
ENGINE APPLICATION CHARTCONTINUED...30
ENGINE APPLICATION CHARTCONTINUED...31
ENGINE APPLICATION CHARTCONTINUED...32
ENGINE APPLICATION CHARTCONTINUED...33
ENGINE APPLICATION CHARTCONTINUED...34
ENGINE APPLICATION CHARTCONTINUED...35
Fuels, Lubricants, and Coolant ...37
DIESEL FUEL...37
LUBRICITY OF DIESEL FUELS...37
ENGINE BREAK-IN OIL...38
DIESEL ENGINE OIL...39
OILSCAN AND COOLSCAN...40
ALTERNATIVE AND SYNTHETIC LUBRICANTS...40
GREASE...41
ENGINE COOLANT REQUIREMENTS...42
ENGINE COOLANT REQUIREMENTSCONTINUED...43
RECOMMENDED ENGINE COOLANT...44
ENGINE COOLANT SPECIFICATIONS...45
ENGINE COOLANT SPECIFICATIONSCONTINUED...46
REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCAS) BETWEEN COOLANT CHANGES...47
OPERATING IN TROPICAL CONDITIONS...48
FLUSH AND SERVICE COOLING SYSTEM...49
DISPOSING OF COOLANT...50
Engine Mounting ...51
ENGINE REPAIR STAND...51
SAFETY PRECAUTIONS...52
INSTALL 300 SERIES ADAPTERS ON REPAIR STAND...53
ENGINE LIFTING PROCEDURE...53
CLEAN ENGINE...54
DISCONNECT TURBOCHARGER OIL INLET LINE...54
MOUNT ENGINE ON REPAIR STAND...55
ENGINE MOUNTED ON REPAIR STAND...56
Engine Rebuild Guide ...57
ENGINE DISASSEMBLY SEQUENCE...57
SEALANT APPLICATION GUIDELINES...58
SEALANT APPLICATION GUIDELINESCONTINUED...59
ENGINE ASSEMBLY SEQUENCE...60
Cylinder Head and Valves ...61
SPECIAL OR ESSENTIAL TOOLS...61
CYLINDER HEAD AND VALVES SPECIFICATIONS...65
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...66
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...67
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...68
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...69
CHECK AND ADJUST VALVE CLEARANCE...70
MEASURE VALVE LIFT...74
REMOVE CYLINDER HEAD...76
DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY...79
ASSEMBLE ROCKER ARMS ON SHAFT...81
CLEAN AND INSPECT PUSH RODS...81
MAKE PRELIMINARY VALVE CHECKS...82
CHECK VALVE RECESS IN CYLINDER HEAD...83
REMOVE VALVE ASSEMBLY...83
INSPECT AND MEASURE VALVE SPRINGS...84
INSPECT VALVE ROTATORS AND WEAR CAPS...84
CLEAN VALVES...85
INSPECT AND MEASURE VALVES...85
GRIND VALVES...86
INSPECT AND CLEAN CYLINDER HEAD...87
CHECK CYLINDER HEAD FLATNESS...87
MEASURE CYLINDER HEAD THICKNESS...88
CLEAN INJECTION NOZZLE BORES...88
CLEAN VALVE GUIDES...89
MEASURE VALVE GUIDES...89
KNURL VALVE GUIDES...90
CLEAN AND INSPECT VALVE SEATS...90
GRIND VALVE SEATS...91
REMOVE VALVE SEAT INSERTS...93
MEASURE VALVE SEAT BORE IN CYLINDER HEAD...94
INSTALL VALVE SEAT INSERTS...95
INSTALL VALVES...95
VALVE STEM SEALSGENERAL INFORMATION...96
INSTALL VALVE STEM O-RING SEALS...96
INSTALL VALVE STEM TOWER SEALS...97
INSPECT AND CLEAN VENTILATOR OUTLET HOSE...98
INSPECT AND CLEAN EXHAUST MANIFOLD...99
CLEAN AND INSPECT TOP DECK OF CYLINDER BLOCK...99
MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)...100
CLEAN AND INSPECT CYLINDER HEAD CAP SCREWS...100
INSTALL CYLINDER HEAD...101
INSTALL CYLINDER HEAD CAP SCREWS...102
TORQUE-TURN METHOD FOR PROPER TORQUE...105
INSTALL ROCKER ARM ASSEMBLY...105
INSTALL ROCKER ARM COVER...107
COMPLETE FINAL ASSEMBLY...108
PERFORM ENGINE BREAK-IN...109
Cylinder Block, Liners, Pistons, and Rods ...111
SPECIAL OR ESSENTIAL TOOLS...111
OTHER MATERIAL...113
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONS...114
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...115
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...116
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...117
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...117
REMOVE PISTONS AND CONNECTING RODS...118
REMOVE CYLINDER LINERS...121
COMPLETE DISASSEMBLY OF CYLINDER BLOCK (IF REQUIRED)...123
PRELIMINARY LINER, PISTON AND ROD CHECKS...124
DISASSEMBLE PISTON AND ROD ASSEMBLY...125
CLEAN PISTONS...126
VISUALLY INSPECT PISTONS...127
INSTALL PISTON PIN...128
CLEAN CYLINDER LINERS...129
VISUALLY INSPECT CYLINDER LINERS...129
CHECK PISTON RING GROOVE WEAR...130
MEASURE PISTON SKIRT...131
DETERMINE PISTON-TO-LINER CLEARANCE...132
DEGLAZE CYLINDER LINERS...133
REPLACE PISTON AND LINER SETS...134
DETERMINE PISTON TYPE...135
MEASURE PISTON PROTRUSION...136
INSPECT AND MEASURE CONNECTING ROD BEARINGS...137
INSPECT ROD AND CAP...139
INSPECT PISTON PINS AND BUSHINGS...140
REMOVE PISTON PIN BUSHING...141
CLEAN AND INSPECT CONNECTING ROD PIN BORE...142
INSTALL PISTON PIN BUSHING IN CONNECTING ROD...142
INSPECT AND CLEAN CYLINDER BLOCK...143
CLEAN CYLINDER LINER O-RING BORE...144
MEASURE CYLINDER BLOCK MAIN BEARING BORE...144
MEASURE CAMSHAFT FOLLOWER BORE...145
MEASURE CAMSHAFT BEARING BORE...145
MEASURE BALANCER SHAFT BORE4-CYLINDER ENGINES...146
MEASURE CYLINDER BLOCK TOP DECK FLATNESS...147
INSPECT PISTON COOLING ORIFICES...148
MEASURE LINER FLANGE THICKNESS AND BLOCK COUNTERBORE DEPTH...148
RECHECK CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)...149
INSTALL STEEL BALL IN OIL PASSAGE OF SERVICE CYLINDER BLOCK...151
INSTALL CYLINDER LINER O-RINGS AND PACKINGS...152
INSTALL CYLINDER LINER...153
ASSEMBLE PISTON AND CONNECTING ROD...154
INSTALL PISTON RINGS...155
INSTALL PISTON AND CONNECTING ROD ASSEMBLY...156
CHECK ENGINE ROTATION FOR EXCESSIVE TIGHTNESS...158
MEASURE PISTON PROTRUSION...159
COMPLETE FINAL ASSEMBLY...159
Crankshaft, Main Bearings, and Flywheel ...161
SPECIAL OR ESSENTIAL TOOLS...161
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS...165
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONSCONTINUED...166
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONSCONTINUED...167
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONSCONTINUED...167
OTHER MATERIAL...168
CRANKSHAFT AND MAIN BEARING FAILURE ANALYSIS...169
INSPECT VIBRATION DAMPER (6-CYLINDER ENGINE)...170
REMOVE PULLEY OR VIBRATION DAMPER PULLEY...171
INSTALL PULLEY OR VIBRATION DAMPER PULLEY...172
CHECKING VIBRATION DAMPER OR PULLEY (ENGINE WITH FRONT PTO)...173
REMOVING VIBRATION DAMPER OR PULLEY (ENGINE WITH FRONT PTO)...174
INSTALL VIBRATION DAMPER OR PULLEY (ENGINE WITH FRONT PTO)...175
REPLACE FRONT CRANKSHAFT OIL SEAL (WITHOUT REMOVING TIMING GEAR COVER)...176
CHECK CRANKSHAFT END PLAY...179
INSPECT FLYWHEEL...180
CHECK FLYWHEEL HOUSING FACE RUNOUT...180
CHECK FLYWHEEL FACE FLATNESS...181
REMOVE FLYWHEEL...181
REPLACE FLYWHEEL RING GEAR...182
INSTALL FLYWHEEL...183
CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE GENERAL INFORMATION...184
REMOVE TWO-PIECE CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE (WITHOUT REMOVING FLYWHEEL HOUSING)...184
REMOVE UNITIZED (NON-SEPARABLE) CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE...187
INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE...188
REMOVE FLYWHEEL HOUSING...190
REMOVE CRANKSHAFT MAIN BEARINGS...190
CHECK MAIN BEARING CLEARANCE...191
REMOVE AND INSTALL CRANKSHAFT GEAR (CRANKSHAFT INSTALLED IN ENGINE)...192
REMOVE CRANKSHAFT...193
REMOVE CRANKSHAFT REAR WEAR SLEEVE (CRANKSHAFT REMOVED FROM ENGINE)...194
INSPECT CRANKSHAFT...195
MEASURE ASSEMBLED ID OF BEARINGS AND OD OF CRANKSHAFT JOURNAL...196
MEASURE MAIN THRUST JOURNAL WIDTH AND THRUST BEARING WIDTH...197
CRANKSHAFT GRINDING GUIDELINES...198
CRANKSHAFT GRINDING GUIDELINESCONTINUED...199
CRANKSHAFT GRINDING SPECIFICATIONS...200
MEASURE ASSEMBLED ID OF MAIN BEARING CAPS...200
INSPECT PISTON COOLING ORIFICES...202
INSTALL MAIN AND THRUST BEARING INSERTS IN BLOCK...203
INSTALL CRANKSHAFT...204
INSTALL FLYWHEEL HOUSING...206
COMPLETE FINAL ASSEMBLY...208
Camshaft, Balancer Shafts, and Timing Gear Train ...209
SPECIAL OR ESSENTIAL TOOLS...209
OTHER MATERIALS...211
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONS...212
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...213
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...214
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...215
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...216
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...217
AUXILIARY GEAR DRIVE SPECIFICATIONS...218
MEASURE VALVE LIFT...219
REMOVE TIMING GEAR COVER...221
REMOVE AUXILIARY DRIVE GEARS (ENGINES WITH AUXILIARY GEAR DRIVE OPTION)...222
MEASURE CAMSHAFT END PLAY...222
MEASURE BALANCER SHAFT END PLAY4-CYLINDER ENGINES...223
MEASURE TIMING GEAR BACKLASH...224
MEASURE IDLER GEAR END PLAY...225
REMOVE CAMSHAFT...225
VISUALLY INSPECT CAMSHAFT...226
MEASURE CAMSHAFT THRUST PLATE CLEARANCE...227
INSPECT AND MEASURE CAMSHAFT BEARING BORE ID AND JOURNAL OD...227
MEASURE CAMSHAFT LOBE HEIGHT...228
REMOVE AND INSTALL CAMSHAFT GEAR...228
INSPECT CAMSHAFT FOLLOWERS...229
REPLACE TACHOMETER DRIVE GEAR...230
REMOVE BALANCER SHAFTSIF EQUIPPED (4-CYLINDER ENGINES)...231
INSPECT AND MEASURE BALANCER SHAFT BUSHINGS AND JOURNALS...232
REMOVE AND INSTALL BALANCER SHAFT BUSHINGS IN BLOCK (4-CYLINDER, IF EQUIPPED)...233
INSTALL OVERSIZE BALANCER SHAFT BUSHINGS IN CYLINDER BLOCK 4239 ENGINES...234
INSPECT BALANCER SHAFT GEARS AND THRUST PLATES...235
REMOVE AND INSTALL BALANCER SHAFT GEARS...236
REMOVE BALANCER SHAFT...237
REMOVE CYLINDER BLOCK FRONT PLATE...237
MEASURE IDLER GEAR BUSHING AND SHAFT...239
REMOVE AND INSTALL IDLER GEAR BUSHINGS...239
REMOVE LOWER AND UPPER IDLER SHAFTS...240
CLEAN AND INSPECT FRONT PLATE...241
REPLACE ENGINE FRONT PLATE...242
TRANSFER FUEL INJECTION PUMP TIMING MARK ONTO REPLACEMENT FRONT PLATE...243
INSTALL IDLER SHAFT SPRING PINS...243
INSTALL UPPER IDLER SHAFT IN FRONT PLATE...244
INSTALL LOWER IDLER SHAFT IN FRONT PLATE...244
INSTALL ENGINE FRONT PLATE...246
INSTALL AND TIME BALANCER SHAFTSIF EQUIPPED (4-CYLINDER ENGINES)...247
INSTALL AND TIME CAMSHAFT AND FUEL INJECTION PUMP...250
CLEAN AND INSPECT TIMING GEAR COVER...252
INSTALL BALL BEARINGS AND DOWELS (ENGINES WITH CRANKSHAFT-DRIVEN AUXILIARY GEAR DRIVE OPTION)...252
INSTALL DRIVE GEAR (ENGINES WITH CRANKSHAFT-DRIVEN AUXILIARY GEAR DRIVE OPTION)...253
INSTALL TIMING GEAR COVER...254
INSTALL CRANKSHAFT FRONT OIL SEAL...257
INSTALL IDLER GEAR AND OUTPUT GEAR (ENGINES WITH AUXILIARY GEAR DRIVE OPTION)...258
COMPLETE FINAL ASSEMBLY...259