John Deere 300 3179, 4239, 6359, 4276, 6414 Diesel Engine Technical Service Manual
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FILE TYPE:PDF
MANUAL LANGUAGE:ENGLISH
PAGES:547
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DESCRIPTION:
This manual is written for an experienced technician. Essential tools required in perfoming 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. A 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-modellccrnponent type-model relationship. See the machine technical manual for information on component removal and installation. and gaining access to the components.
SCREENSHOT OF THE MANUAL:
TABLE OF CONTENTS:
- John Deere 300 3179, 4239, 6359, 4276, 6414 Diesel Engine Technical Service Manual
Group—Safety
Group —General Information
Unified Inch Bolt and Cap Screw Torque
Values
Metric Bolt and Cap Screw Torque
Values
EngineModelDesignation
Engine Serial Number Plate Information
EngineApplicationChart
Group 02—Fuels, Lubricants and Coolant
DieselFuel
LubricitonDieselFuels
EngineBreak—anil
DieselEngineOil
OILSCAN9and COOLSCANW
Alternative and Synthetic Lubricants
Grease
Engine Coolant Requirements
Recommended Engine Coolant
Engine Coolant Specifications
Replenishing Supplemental Coolant
Additives(SCA’s)
Operating inTropical Conditions
Flush and Service Cooling System
DisposingofCoolant
Group Git—Engine Mounting
EngineRepairStand
SafetyPrecautions
Install 300 Series Adapters on Repair
EnginetJttingProcedure
CleanEngine
Disconnect Turbocharger Oil Inlet Line
Mount Engine on Repair Stand
Engine Mounted on Repair Stand
Group (Ml—Engine Rebuild Guide
Engine Disassembly Sequence
Sealant Application Guidelines
Engine Assembly Sequence
Group 05—Cylinder Head and Valves
Special or Essential Tools
Service Equipment and Tools
Specifications
OtherMatenal
Check and Atfiust Valve Clearance
MeasureValveLift
RemoveCMinderHead
Disassemble and Inspect Rocker Arm
ShaflAssemny
Assemble Rocker Arms on Shaft
Clean and Inspect Push Rods
Make Preliminary Valve Checks
Check Valve Recess in Cylinder Head
RemoveValveAssemny
Inspect and Measure Valve Springs
Inspect Valve Rotators and Wear Caps
CleanValves
Inspect and Measure Valves
GrindVaIves
Inspect and Clean Cylinder Head
Check (Minder Head Flatness
Measure Cylinder Head Thidmess
Clean Injection Nozzle Bores
CleanValveGuides
MeasureValveGuides
KnurIValveGuides
Clean and Inspect Valve Seats
GrindVaIveSeats
RemoveVelveSeatInserts
Measure Valve Seat Bore in Cylinder
Head
InstaIlValveSeatlnserts
InstaIIValves
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
Measure Cylinder Liner Standout (Height
AboveBIock)
Clean and Inspect Cylinder Head Cap
InstalICylinderHead
Install Cylinder Head Cap Screws
TOROUEJURN Method for Proper
Torque
Install RockerArm Assembly
InstallRockerArmCover
Complete FrnalAssemny
PerforrnEngineBreak—In
Group flit—Cylinder Block, Liners, Pistons,
Rods
SpecialorEssentiaITools
Service Equipment and Tools
OtherMaterial
Spec‘fications
Remove Pistons and Connecting Rods
RemoveQrIinderLiners
Complete Disassembly of Cylinder Block
(llRequired)
Preliminary Liner Piston and Rod Checks
Disassemble Piston and Rod Assembly
CleanPistons
\fisuallylnspectPistons
InstaIlPistonPin
CleaanlinderLiners
Visually Inspect Cylinder Liners
Check Piston Ring Groove Wear
MeasurePistonSklrt
Determine Piston~to—Liner Clearance
DeglazeCytinderLiners
Replace Piston and Liner Sets
DeterminePistchype
Measure Piston Protrusion
Inspect and Measure Connecting Rod
Bearings
InspectRcdandCap
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 Winder Liner O-Ring Bore
Measure Cylinder Block Main Bearing
Bore
Measure Camshaft Follower Bore
Measure Camshaft Bearing Bore
Measure Balancer Shaft Bore—43yfinder
Engines
Measure Cylinder Block Top Deck
Flatness
Inspect Piston Cooling Orifices
Measure Liner Flange Thickness and
BlockCounterboreDepth
Recheck Cylinder Liner Standout (Height
AboveBlock)
Install Steel Ball in OH Passage of
ServiceCyIinderBlock
Install Winder Liner O-Rings and
Packings
InstallWinderLiner
Assemble Piston and Connecting Rod
InstallPistcnRings
Install Piston and Connecting Rod
Assembly
Check Engine Rotation For Excessive
Measure Piston Protrusion
CompleteFinalAssembly
Group 15—Crankshaft Main Bearings, and
Flywheel
SpecialorEssentialTools
Service Equipment and Tools
Specifimtions
OtherMateriaI
Crankshaft and Main Bearing Failure
Analysis
Inspect \fibration Damper (ti-(Minder
Engine)
Remove Pulley or Wbraticn Damper
Pulley
Install Pulley or Vibration Damper Pulley
Checking \fibraticn Damper or Pulley
(FrontPTO)
Removing \fibration Damper or Pulley
(FrontPTO)
lllbtdu IUIUI Wu! dill UUIPUL Uudl
Complete Final Assembly
Group ZD—Lubrication System
Spec’alorEssentiaITools
Service Equipment and Tools
OtherMateriaI
Spec‘ficatioris
Engine Crankcase Oil Fill Quantities
Identify Oil Cooler Type—3179 4239
6359Engines
Remove Inspect 8 Install Standard-Flow
Oil Cooler (3179 4239, 6359)
Remove and Install Higiflow Oil Cooler
(6359Engines)
Remove Distributor Base—High-Flow
Cooler(6359)
Inspect and Repair Distributor
Base—High Flow Oil Cooler (6359)
Install Distributor Base—HighoFlow Oil
Cooler(6359)
Remove Oil Cooler (4276 6414 Engines)
Repair Oil Cooler (4276 6414 Engines)
Install Oil Cooler (4276 6414 Engines)
Remove and Inspect Ofl Bypass Valve
(3179 4239, 6359 Engines)
Measure Oil Bypass Valve Length and
CylinderBIcckBore
Install Oil Bypass Valve (3179 4239
6359Engines)
Remove and Install Oil Cooler/Filter
Bypass Valve (4276 6414 Engines)
Remove & Install Oil Pressure Regulating
Valvei‘Seat (3179, 4239 6359)
Remove Inspect and Install Oil Pressure
Regulating Valve (4276, 6414)
Repair Oil Pressure Regulating Valve
(4276 6414Engines)
Remove Oil Filter Adapter (3179 4239,
6359Engines)
Install Oil Filter Adapter (3179, 4239
6359Engines)
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 Sbndard Capacity Oil Pump
Remove High Capacity Oil Pump
Inspect and Memure Clearances (High
CapacitinlPump)
Complete High Capacity Oil Pump
Disassembly
Assemble High Capacity Oil Pump
Install High Capacity Oil Pump
InstaIIOiIPan
Group 25—Ccoling System
SpecialorEssentiaITools
Service Equipment and Tools
OtherMaterial
Specifications
Remove, Test, and Install Thermostats
Remove and Install Thermostat
HousingNVater Manifold
General Water Pump Information
Remove Low Flow (Standard Duty) Water
Pump
Disassemble Low Flow (Standard Duty)
WaterPump
Inspect and Clean Low Flow (Standard
Duty)WaterPumpParts
Assemble Low Flow (Standard Duty)
WaterPump
Install Low Flow (Standard Duty) Water
Pump 2
Remove I-figh Flow (Heavy~Duty) Water
Pump
Disassemble High Flow (Heavy-Duty)
WaterPump
Inspect and Clean High Flow
(Heavy-Duty) Water Pump Parts
Assemble High Flow (Heavy-Duty) Water
Pump 2
Checking Water Pump Cap Saew
Protrusion
Install High Flow (Heavy-Duty) Water
Pump 2
Inspect and Install Fan Blade Assembly
Remove Coolant Heater—If Equipped
Install Coolant Heater—If Equipped
Group 30—Air Intake and Exhaust System
OtherMaterial
Specifications
Extending Turbocharger Life
Remove Turbocharger—423W and
6359T&AEngines
Turbocharger Failure Analysis
Turbocharger SevemStep Inspection
Perform Radial Bea’ing Clearance
Test—KKK
Perform Axial Bearing End Play
Test—KKK
Perform Radial Bea’ing Clearance
Test—AiResearch/Garrett
Perform Axial Bearing End Play
Test—AiResearchlGarrett
RepairTur‘bocharger ,
Disassemble and Inspect Turbocharger
Replace Center Housing and Rotating
Assembly
PrelubeTurbocharger
Install K K K and AiResearch/Gan’ett
Turbocharger
TurbochargerBreak-ln
Remove Inspect and Install Intake
Manifold
Remove CrossOver Tube Assembly—If
Equipped
Inspect and Repair Cross-Over Tube
Assembly—If Equipped
Install CrossOver Tube Assembly—If
Equipped
Remove Aftercooler and Intake Manifold
(6359A)
Inspect and Repair Altercooler (6359A)
Inspect and Repair Intake Manifold
(6359A)
Install Intake Manifold and Afterccoler
(6359A)
Remove Inspect and Install Exhaust
Manifold
Group 35—Fuel System
Special or Essential Tools
Service Equipment and Tools
OtherMateriaI
Specifications
Relieve Fuel System Pressure
ReplaceFueIf-“ilter
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 lrdomiation
Remove Roto DiesellLucas CAV Fuel
InjectionPump
Repair Roto Diesel/Lucas CAV Fuel
InjectionPump
Install Rotc DieseIlLurzs CAV Fuel
InjectionPump
Timing Roto Diesel/Lucas CAV Injection
Pump (Front Plate Installed)
Remove Stanadyne Pump—Model JDB 8
D82 (Non-Retained Drive Shaft)
Remove Stanadyne Model JDB & 082
Pump with Non-Retained Drive Shaft
Repair Stanadyne Model JDB and D82
FuellnjectionPump
Install Non-Retained Drive Shaft in
Stanadyne Model JDB & DBZ Pump
Install Stanadyne Model JDB & DBZ
Pump with Non-Retained Drive Shaft
Remove Stanadyne Model 082 (Retained
Drive Shaft) 8 084 Injection Pump
Inspect Injection Pump Drive Gear I D
andShaftOD
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model 082 (Retained
DriveShaft)and DB4Pump
Remove Stanadyne Model 0M4 Fuel
InjectionPump
Repair Stanadyne Fuel Injection Pump
Install smnadyne Model 0M4 Fuel
Injectionme
Replace Engine Front Plate
Transfer Fuel Injection Pump Tirriing
Mark onto Replacement Front Plate
AneroidReplacement
Aneroid Field Adjustment
Aneroid Workshop Adjustment
Remove Fuel Injection Nozzles
Clean Fuel Injection Nozzle Bore
Clean Injectian czzles
Diagnose Injection Neale Malfunction
TestlnjectionNozzIes
Disassemble Injection Nonles
Inspect and Clean Nozzle Body
Inspect and Clean Valve and Valve Seat
Inspect Valve Adjusting Mechanism
Assemble lnjection Nozzles
Adjust Fuel Injection Nozzles
Install Seals on Injection Nozzle
Install lnjeclion Nozzles
Repair Leak-Off Line Assembly
Group 100—Engine Tune-Up and Break-In
Specialor Essential Tools
Effects of Altitude and Temperature on
Engine Performance
Preliminary Engine Testing
General Tune-Up Recommendations
DynamometerTest
Dynamometer Test Specifimtions
Engine Break-In Guidelines
Perfon’nEngineBreak-In
Check Crankcase Ventilation System
CheckAirIntakeSystem
CheckExhaustSystem
Check and Service Cooling System
CheckEIectiicalSystem
Group 105—Engine System Operation and
SpecialorEssentialTools
EngineTestSpecificaticns
Engine—SectionalView
General Engine Description
How the Lubrication System
Works—4239TShown
Oil Cooler Operation—4276 and 6414
Engines
How the Cooling System
Works4tandard Flow Oil Cooler
How the Cooling System
Works—High-Flow Oil Cooler
How the Crankshaft GeaeDrive Auxiliary
DriveWorks
Head Gasket Joint Construction and
Operation
Head Gasket Inspection and Repair
Sequence
Diagnosing Engine Malfundions
Test Engine Compression Pressure
CheckEngineOilPressure
Measure Engine Crankcase Pressure
(Blmv-By)
Operation
Stanadyne 0M4 Fuel Injection Pump
Operation
Stanadyne 082/084 Fuel Injection Pump
Operation
Diagnose Fuel Injection Pump
Malfunctions
Check and Adjust Engine Speeds on
LucasCAVPump
Adjust Variable Speed on Generator Set
Engines(LucasCAV)
Check and Adjust Engine Speeds on
StanadynePump
Adjust Variable Speed on Generator Set
Engines—Stanadyne
Changing Gen Set Engine Rated
Speed—Stanadyne
Fuel Injection Nozzles—General
InformationlOperation
Diagnose Malfunction—Fuel Injection
Nozzle
Test Fuel Injection Nozzles (Engine
Running)
Fuel Drain Back Test Procedure
Group 199—DeaIer Fabricated Tools
chtoMakeTooIs
DFRG2—Injection Pump Front Plate
fiming Mark Transfer Tool
DFRG3—Cylinder Liner Holding Fixture
Index
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