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TM-1190 John Deere 300 Series OEM Engine Service Repair Manual

TM-1190 John Deere 300 Series OEM Engine Service Repair Manual, Sections Overview: General Information: Contains introductory material and explains the purpose of FOS (Fundamentals of Service) Manuals for training purposes, while this Technical Manual serves as a concise service guide for experienced technicians.

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300 Series OEM Engines TM-1190 (Dec-84) General Information Contents and Index 1 1-1 300 SERIES OEM ENGINES Technical Manual TM-1190 (Dec-S4) SECTIONAL CONTENTS OF THIS MANUAL Section I - General Information _________________ Section 4 - Engine________________________ Section 5 - Engine Auxiliary Systems Section 16 - Electrical Systems ___________________ Section 19 - Sheet Metal and Styling Section 40 - PTO Drive Section 90 - System Testing The specifications and design information contained in this manual were correct at the time it was printed. It is JohtrDeere's Policy to continually improve and update our machines. Therefore, the specifications and design information are subject to change without notice. Wherever applicable, specifications and design information are in accordance with SAE and ICED standards. Litho in U.S.A. CopyrighNl 1984 DEERE Ie COMPANY Moline, Illinois All Rights Reserved Previous Editions CopyrighNl1982 Deere Ie Company CopyrighNl 1980 Deere Ie Company CopyrighNl1978 Deere Ie Company Copyrightc> 1977 Deere Ie Company DOWNLOAD SERVICE REPAIR MANUAL
II 1 1-2 General Information Contents and Index 300 Series OEM Engines TM-1190 (Aug-78) INTRODUCTION Use FOS Manuals for Reference This technical manual is part of a twin concept of service: The two kinds of manuals work as a team to give you both the general background and technical details of shop service. .FOS Manuals-for reference Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of trouble shooting, general maintenance, and basic types of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced ser- vice technicians. E]When a service technician should refer to a FeS FOS Manual for more information, a FOS symbol like the one at the left is used in the D TM to identify the reference. •Technical Manuals-for actual service Technical Manuals are concise service guides for a specific machine. Technical manuals are on-the-job guides containing only the vital information needed by an experienced service technician. Litho in U.S.A. r t. l' " Use Technical Manuals for Actual Service This technical manual was planned and written for you-an experienced service technician. Keep it in a permanent binder in the shop where it is handy. Refer to it whenever in doubt about correct service proce- dures or specifications. Some features of this manual: • Inside front cover - "Table of Contents". • Section I - Contents • Sections 4 through 40 - Removal, repair, testing (components removed), installation, and adjustment. • Section 90 - Detailed explanation of system operation, diagnosis, visual inspection, testing, and adjustments. • Specifications grouped and illustrated at the end of each section.
300 Series OEM Engines TM-1190 (Dec-82) General Information Contents and Index SECTION ANO GROUP CONTENTS OF THIS MANUAL SECTION I - GENERAL INFORMATION Group I - Contents SECTION 4 - ENGINE Group 0400 - Removal and Installation Group 0401 - Crankshaft and Main Bearings Group 0402 - Camshaft and Valve Actuating SECTION 5 - ENGINE AUXILIARY SYSTEMS Group 0510 - Cooling Systems Group 0515 - Speed Controls Group 0520 - Intake Systems Group 0599 - Specifications and Special Tools SECTION 16 - ELECTRICAL SYSTEMS 1 1-3 Means Group 1672 - Alternator, Regulator and Charging Group 0403 - Connecting Rods and Pistons Group 0404 - Cylinder Block Group 0407 - Oiling System Group 0408 - Ventilating System Group 0409 - Cylinder Head and Valves Group 0410 - Exhaust Manifold Group 0413 - Fuel Injection System Group 0414 - Intake Manifold Group 0415 - Engine Balancer Group 0416 - Turbocharger Group 0417 - Water Pump Group 0418 - Thermostats, Housing and Piping Group 0419 - Engine Oil Cooler Group 0420 - Fuel Filter Group 0421 - Fuel Transfer Pump Group 0422 - Starting Motor and Fastening Group 0423 - Alternator and Generator Mountings Group 0429 - Fan Drive Group 0433 - Flywheel, Housing and Fastenings Group 0499 - Specifications and Special Tools System Wiring Group 1674 - Wiring Harness and Switches Group 1676 - Instruments and Indicators Group 1699 - Specifications and Special Tools SECTION 19 - SHEET METAL AND STYLING Group 1910 - Hood or Engine Enclosure SECTION 40 - PTO DRIVE Group 4052 - PTO Clutch Group 4099 - Specifications and Special Tools SECTION 90 - SYSTEM TESTING Group 9010 - Engine Group 9015 - Electrical System Group 9035 - Specifications and Special Tools OEM ENGINES SERVICEO BY THIS TECHNICAL MANUAL Litho in U.S.A. 3-1640 3-1790 4-2190 4-2390 4-239T 4-2760 4-276T 6-3290 6-3590 6-359T 6-4140 6-414T I
• 1 1·4 General Information Contents and Index Accessible Hardware Torque Values The table below gives correct torque values for various bolts and cap screws. The table lists torques in the U.S. unit of measure (lb-ft), SI metrics (Nm) and conventional metrics (kg/m). Most hardware used is high-strength (note dashes on hex. heads). 300 Series OEM Engines TM-1190 (Nov-78) The types of bolts and cap screws are identified by head markings as follows: Plain Head: regular machine bolts and cap screws. 3-Dash Head: tempered steel high-strength bolts and cap screws. 6-Dash Head: tempered steel extra high-strength bolts and cap screws. Machine bolts and cap screws 7/8-inch (22.2 mm) and larger are sometimes formed hot rather than cold, which accounts for the lower torque. RECOMMENDED TORQUE - COARSE AND FINE THREADS 0 F G 0 t /, B 0 ED @ / BOLT PLAIN THREE SIX DIAMETER HEAD DASHES DASHES LB-FT Nm Kg-m LB-FT Nm Kg-m LB-FT Nm Kg-m 1/4 NOT USED NOT USED NOT USED 10 14 1 14 19 2 5/16 NOT USED NOT USED NOT USED 20 27 3 30 41 4 3/8 NOT USED NOT USED NOT USED 35 47 5 50 68 7 7/16 35 47 5 55 75 8 80 108 11 1/2 55 75 8 85 115 12 120 163 17 9/16 75 102 10 130 176 18 175 237 24 5/8 105 142 15 170 230 24 240 325 33 3/4 185 251 26 300 407 42 425 576 59 7/8 160 217 22 445 603 62 685 929 95 1 250 339 35 670 908 93 1030 1396 142 1-1/8 330 447 46 910 1234 126 1460 1979 202 1-1/4 480 651 66 1250 1695 173 2060 2793 285 143720 Litho in U.S.A.
300 Series OEM Engines TM-1190 (Dec-82) General Information Contents and Index 1 1-5 ALPHABETICAL INDEX A Engine:-Continued Air cleaner ............................ 0520-1 Fuel filter ........................... 0420-1 Alternator and generator mounting ......... 0423-1 Fuel injection system .................. 0413-1 Alternator, regulator and charging Fuel transfer pump ................... 0421-1 system wiring ........................ 1672-3 Amp meter ............................ 1676-2 Intake manifold ...................... 0414-1 I Oil cooler ........................... 0419-1 Oiling system ........................ 0407-1 B Removal and installation ............... 0400-5 Balancer shafts ........................ 0415-1 Starting motor and fastenings ........... 0422-1 Thermostats, housings and water C piping ............................ 0418-1 Camshaft and valve actuating means ....... 0402-1 Turbocharger ........................ 0416-1 Charging circuit testing (Delco-Remy Ventilating system .................... 0408-1 alternator) ........................... 9015-8 Water pump ......................... 0417-1 Charging circuit testing (Motorola alternator) . 9015-5 Engine auxiliary systems: Connecting rods and pistons .............. 0403-1 Cooling system ...................... 0510-3 Cooling manifold ....................... 0418-1 Intake system ....................... 0520-1 Cooling system, engine .................. 0510-3 Speed controls ....................... 0515-1 Crankshaft and main bearings ............. 0401-1 Engine removal and installation ............ 0400-5 Crankshaft front oil seal ................. 0402-3 Engine system testing and adjustments: Crankshaft front wear ring ............... 0401-6 Compression pressure test ............. 9010-9 Crankshaft gear ........................ 0401-5 Engine cooling system test ............ 9010-11 Crankshaft rear oil seal .................. 0401-6 Engine oil pressure test. .............. 9010-10 Crankshaft rear wear ring ................ 0401-6 Engine preformance test using Crankshaft pulley ....................... 0429-2 turbocharger boost pressure ......... 9010-14 Cylinder block ......................... 0404-1 Fuel transfer pump pressure test ....... 9010-11 Cylinder head and valves ................ 0409-1 Governor speed droop adjustment ...... 9010-11 Injection pump cam advance ........... 9010-13 D Speed control linkage adjustment ....... 9010-12 Delco-Remy alternator ................... 1672-3 Exhaust manifold ....................... 0410-1 Delco-Remy starting motor ............... 0422-1 Diagnosing malfunctions: F Engine system testing ................. 9010-5 Fan belt .............................. 0429-1 Dipstick ............................. 0407-18 Fan drive ............................. 0429-1 Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0420-1 E Flywheel, housing and fastenings .......... 0433-2 Electrical schematic .................... 9015-11 Fuel filter ............................. 0420-1 Electrical system ....................... 1672-1 Fuel injection nozzles .................. 0413-20 Electrical system testing ................. 9015-1 Fuel injection pump ..................... 0413-1 Charging circuit ...................... 9015-5 Fuel transfer pump ..................... 0421-1 Starting circuit ....................... 9015-1 Engine: G Alternator and generator mounting ....... 0423-1 Gauge, pressure ....................... 1676-3 Camshaft and valve actuating means ..... 0402-1 Gauge, temperature ..................... 1676-3 Connecting rods and pistons ............ 0403-1 Crankshaft and main bearings ........... 0401-1 H Cylinder block ....................... 0404-1 Hood ................................ 1910-3 Cylinder head and valves .............. 0409-1 Hour meter ........................... 1676-2 Engine balancer ...................... 0415-1 Exhaust manifold ..................... 0410-1 Fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 0429-1 Flywheel, housing and fastenings ........ 0433-1 Litho in U.S.A.
II I 1-6 General Information Contents and Index Instruments and indicators ............... 1676-1 Amp meter .......................... 1676-2 Hour meter ......................... 1676-2 Pressure gauge ...................... 1676-3 Safety switch ........................ 1676-4 Tachometer ......................... 1676-1 Temperature gauge ................... 1676-3 Intake manifold ........................ 0414-1 Intake system ......................... 0520-1 J John Deere starting motor ............... 0422-11 M Malfunctions, diagnosing: Engine system testing ................. 9010-5 Manifold, exhaust ...................... 0410-1 Manifold, intake ........................ 0414-1 Motorola alternator ..................... 1672-9 N Nozzle, fuel injection ................... 0413-11 o Oil bypass valve ....................... 0407-4 Oil cooler, engine ....................... 0419-1 3-1640,4-2190,4-2390, 4-239T, 6-3290, '- 6-3590 and 6-359T engines .......... 0419-1 4-2760, 4-276T, 6-4140 and '6-414T engines .................... 0419-3 Oil filter .............................. 0407-1 Oil filter nipple ......................... 0407-2 Oiling system, engine ................... 0407-1 Oil pan ............................... 0407-4 Oil pressure control valve ................ 0407-5 Oil pump ............................ 0407-10 p Pressure gauge ........................ 1676-3 PTO clutch ............................ 4052-3 Pump, engine oil ....................... 0407-1 Pump, engine water ..................... 0417-1 Pump, fuel injection ..................... 0413-1 Pump, fuel transfer ..................... 0421-1 R Radiator .............................. 0510-3 Rocker arms and push rods ............. 0402-17 Rods and pistons ...................... 0403-1 S 300 Series OEM Engines TM-1190 (Dec-82) Safety switch .......................... 1676-4 Special tools: Camshaft and valve actuating means .... 0499-94 Connecting rods and pistons ........... 0499-96 Crankshaft and main bearings .......... 0499-93 Cylinder block ...................... 0499-97 Cylinder head and valves ............. 0499-99 Electrical system ..................... 1699-4 Electrical system testing ............... 9035-8 Engine balancer .................... 0499-103 Engine removal and installation ......... 0499-92 Engine system testing ................. 9035-4 Fuel injection system ................ 0499-101 Oiling system, engine ................ 0499-98 Starting motor and fastenings ......... 0499-106 Turbocharger ...................... 0499-104 Water pump ....................... 0499-105 Specifications and torque values: Camshaft and valve actuating means ..... 0499-4 Connecting rods and pistons ........... 0499-~ 1 Crankshaft and main bearings ........... 0499-2 Cylinder block ...................... 0499-15 Cylinder head and valves ............. 0499-23 Electrical system ..................... 1699-1 Electrical system testing ............... 9035-6 Engine balancer ..................... 0499-79 Engine break-in ...................... 0499-1 Engine cooling system ................. 0599-1 Engine system testing ................. 9035-1 Fan drive .......................... 0499-90 Flywheel, housing and fastenings ....... 0499-90 Fuel injection system ................. 0499-27 Intake manifold ..................... 0499-78 Oil cooler, engine .................... 0499-84 Oiling system, engine ................ 0499-17 PTO clutch .......................... 4099-1 Starting motor and fastenings .......... 0499-85 Thermostats, housings and water piping ........................... 0499-83 Turbocharger ....................... 0499-80 Water pump ........................ 0499-81 Speed controls, engine .................. 0515-1 Starting circuit testing ................... 9015-1 Starting motor, Oelco-Remy .............. 0422-1 Starting motor, John Deere .............. 0422-11 Switch, safety ......................... 1676-4
300 Series OEM Engines TM-1190 (Dec-82) T Tachometer ........................... 1676-1 Temperature gauge ..................... 1676-3 Tests and adjustments: Alternator components ............... 1672-14 Electrical system ..................... 9015-1 Engine system ....................... 9010-9 Starting motor, Delco-Remy ............ 0422-1 Starting motor, John Deere ............ 0422-12 Turbocharger ........................ 0416-2 Thermostats, housings and water piping .............................. 0418-1 Timing gear ........................... 0402-9 Timing gear cone ....................... 0402-2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 0416-1 Litho in U.S.A. General Information Coiiients and Imfex V J 1-7 Ventilating system ...................... 0408-1 Vertical tachometer drive ................. 0433-1 Vibration damper ....................... 0401-8 W Water pump ........................... 0417-1 • Wiring harness and switches .............. 1674-1 Wiring diagram ........................ 9015-12.
I I 1-8 General Information Contents and Index Litho in U.S.A. 300 Series OEM Engines TM-1190 (Mar-BO)
300 Series OEM Engines TM-1190 (Dec-82) Engine Removal and Instal/ation 4 0400-1 Section 4 ENGINE CONTENTS OF THIS SECTION Page GROUP 0400 - REMOVAL AND INSTALLATION General Information ................... 0400-5 Removal ............................ 0400-7 Installation ......................... 0400-10 GROUP 0401 - CRANKSHAFT AND MAIN BEARINGS Crankshaft and Main Bearings .......... 0401-1 Removal .......................... 0401-1 Crankshaft End Play ................ 0401-1 Repair ........................... 0401-2 Installation ........................ 0401-3 Crankshaft gear ...................... 0401-5 Removal .......................... 0401-5 Repair ........................... 0401-5 Crankshaft Front Wear Ring ............ 0401-6 Removal .......................... 0401-6 Installation .... : ................... 0401-6 Crankshaft Front Oil Seal .............. 0401-6 Crankshaft Rear Oil Seal and Wear Ring .. 0401-6 Removal .......................... 0401-6 Repair ........................... 0401-6 Installation ........................ 0401-7 Vibration Damper ..................... 0401-8 Installation ........................ 0401-8 GROUP 0402 - CAMSHAFT AND VALVE ACTUATING MEANS Valve Lift Check ..................... 0402-1 Timing Gear Cover ................... 0402-2 Removal .......................... 0402-2 Repair ........................... 0402-2 Installation ........................ 0402-3 Crankshaft Front Oil Seal .............. 0402-3 Removal .......................... 0402-3 Installation ........................ 0402-3 Camshaft ........................... 0402-3 Removal .......................... 0402-3 Repair ........................... 0402-6 Installation ........................ 0402-7 Litho in U.S.A. Page GROUP 0402 - CAMSHAFT AND VALVE ACTUATING MEANS-Continued Timing Gear ......................... 0402-9 Removal .......................... 0402-9 Repair .......................... 0402-11 Installation ....................... 0402-12 Rocker Arms and Push Rods .......... 0402-17 Removal ......................... 0402-17 Repair .......................... 0402-17 Installation ....................... 0402-18 Valve Clearance Adjustment ........... 0402-19 GROUP 0403 - CONNECTING RODS AND PISTONS Removal ............................ 0403-1 Repair ............................. 0403-3 Installation .......................... 0403-9 GROUP 0404 - CYLINDER BLOCK Removal ............................ 0404-1 Repair ............................. 0404-3 Installation .......................... 0404-6 GROUP 0407 - OILING SYSTEM Oil Filter ............................ 0407-1 Removal .......................'... 0407-1 Installation ........................ 0407-1 Oil Filter Nipple ...................... 0407-1 Removal .......................... 0407-2 Installation ........................ 0407-3 Oil Pan Removal .......................... 0407-4 Repair ........................... 0407-4 Installation ........................ 0407-4 Oil Bypass Valve Removal .......................... 0407-4 Repair ........................... 0407-4 Installation ........................ 0407-4 Oil Pressure Control Valve 3-1640,3-1790, 4-219D, 4-239D, 4-239T, 6-3290,6-3590, or 6-359T Engine ..... 0407-5 Removal ........................ 0407-5 Repair ......................... 0407-5 Installation ...................... 0407-6 Contents continued on next page I
• 4 0400-2 Engine Removal and Installation 300 Series OEM Engines TM-1190 (Dec-82) CONTENTS OF THIS SECTION-Continued GROUP 0407 - OILING SYSTEM-Continued Oil Pressure Control Valve-Continued 4-2760, 4-276T, 6-4140 Page or 6-414T Engine ................... 0407-7 Removal ........................ 0407-7 Disassembly ..................... 0407-7 Repair ......................... 0407-8 Assembly .. '..................... 0407-8 Installation ...................... 0407-9 Oil Pump 3-1640,3-1790,4-2190, 6-3290, or 6-3590 Engine .......... 0407-10 Removal ....................... 0407-10 Inspection and Disassembly ....... 0407-10 Repair ........................ 0407-12 Assembly ...................... 0407-12 Installation .. . . . . . . . . . . . . . . . . . . . 0407-13 4-239T, 4-2760, 4-276T, 6-359T, 6-4140, or 6-414T Engine ........... 0407-14 Removal ....................... 0407-14 Inspection and Disassembly ....... 0407-14 Repair ........................ 0407-16 Assembly ...................... 0407-16 Installation ..................... 0407-17 Dipstick and Dipstick Nipple ........... 0407-18 Removal ......................... 0407-18 Repair .......................... 0407-18 Installation ....................... 0407-19 GROUP 0408 - VENTILATING SYSTEM General Information ................... 0408-1 Removal ............................ 0408-1 Repair ............................. 0408-1 Installation .......................... 0408-i GROUP 0409 - CYLINDER HEAD AND VALVES Removal ............................ 0409-1 Disassembly ......................... 0409-2 Repair ............................. 0409-2 Assembly ........................... 0409-7 Installation .......................... 0409-7 GROUP 0410 - EXHAUST MANIFOLD General Information ................... 041 0-1 Removal ............................ 0410-1 Repair ............................. 0410-1 Installation .......................... 0410-1 Litho in U.S.A. Page GROUP 0413 - FUEL INJECTION SYSTEM Fuel Injection Pump ................... 0413-1 Removal .......................... 0413-1 Repair ........................... 0413-6 Installation ........................ 0413-9 Bleeding ......................... 0413-19 Fuel Injection Nozzles ................ 0413-20 Removal ......................... 0413-20 Repair .......................... 0413-21 Installation ....................... 0413-22 GROUP 0414 - INTAKE MANIFOLD Removal ............................ 0414-1 Repair ............................. 0414-1 Installation .......................... 0414-1 GROUP 0415 - ENGINE BALANCER General Information ................... 0415-1 Removal. ........................... 0415-1 Repair ............................. 0415-2 Installation .......................... 0415-3 GROUP 0416 - TURBOCHARGER General Information ................... 0416-1 Removal. ........................... 0416-1 Testing ............................. 0416-2 Radial Bearing Movement ............ 0416-2 Axial Bearing Movement ............. 0416-2 Repair .:-. -;-. . . . . . . . . . . . . . . . . . . . . . . . . 0416-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 0416-8 GROUP 0417 - WATER PUMP Removal. ........................... 0417-1 Disassembly 3-164,3-1790,4-2190,4-2390, 4-2760, or 6-3290 Engine ........... 0417-2 4-239T, 4-276T, 6-3590, 6-359T, 6-4140, or 6-414T Engine ..... 0417-3 Repair ............................. 0417-4 Assembly ........................... 0417-5 Installation .......................... 0417-7 GROUP 0418 - THERMOSTATS, HOUSINGS, AND WATER PIPING Thermostat ......................... 0418-1 Removal .......................... 0418-1 Repair ........................... 0418-2 Installation ........................ 0418-2 Contents continued on next page
300 Series OEM Engines TM-1190 (Dec-82) Engine Removal and Installation 4 0400-3 CONTENTS OF THIS SECTION-Continued Page GROUP 0419 - OIL COOLER 3-1640, 3-179D, 4-2190 and 6-329D Engines: Removal .......................... 0419-1 Repair ........................... 0419-2 Installation ........................ 0419-2 4-2760, 4-276T, 6-4140 and 6-414T Engines: Removal .......................... 0419-3 Repair ........................... 0419-3 Installation ........................ 0419-5 GROUP 0420 - FUEL FILTER General Information ................... 0420-1 Removal ............................ 0420-1 Installation .......................... 0420-1 GROUP 0421 - FUEL TRANSFER PUMP General Information ................... 0421-1 Removal ............................ 0421-1 Repair ............................. 0421-1 Installation .......................... 0421-2 GROUP 0422 - STARTING MOTOR AND FASTENINGS General Information ................... 0422-1 Delco-Remy Starting Motor ............. 0422-1 Removal .......................... 0422-1 Testing and Diagnosis ............... 0422-1 Testing Pull-in Windings ........... 0422-1 Testing Hold-in Windings ........... 0422-1 No Load Starting Motor Test ....... 0422-2 Repair ........................... 0422-4 Assembly ......................... 0422-8 Installation ....................... 0422-10 John Deere Starting Motor ............ 0422-11 Removal ......................... 0422-11 Tests ........................... 0422-12 Solenoid Pull-in Test ............. 0422-12 Solenoid Return Test. ............ 0422-12 No Load Test. .................. 0422-13 Repair .......................... 0422-15 Assembly ........................ 0422-20 GROUP 0423 - ALTERNATOR AND GENERATOR MOUNTING General Information ................... 0423-1 Removal ............................ 0423-1 Installation .......................... 0423-1 Litho in U.S.A. Page GROUP 0429 - FAN DRIVE Fan Belt ............................ 0429-1 Removal .......................... 0429-1 Repair ........................... 0429-1 Installation ........................ 0429-1 Crankshaft Pulley ..................... 0429-2 Removal .......................... 0429-2 I Repair ........................... 0429-2 ; Installation ........................ 0429-3 GROUP 0433 - FLYWHEEL, HOUSING, AND FASTENINGS Vertical Tachometer Drive .............. 0433-1 Removal .......................... 0433-1 Repair ........................... 0433-1 Installation ........................ 0433-1 Flywheel ............................ 0433-2 Removal .......................... 0433-2 Repair ........................... 0433-2 Installation ........................ 0433-3 Flywheel Ring Gear ................... 0433-4 Removal .......................... 0433-4 Installation . . . . . . . . . . . . . . ..'. . . . . . . . 0433-4 Flywheel Housing ..................... 0433-4 Removal'. ......................... 0433-4 Repair ........................... 0433-5 Installation ........................ 0433-5 GROUP 0499 - SPECIFICATIONS AND SPECIAL TOOLS Specifications and Torque Values: Engine Break-In .................... 0499-1 Crankshaft and Main Bearings ........ 0499-2 Camshaft and Valve Actuating Means ......................... 0499-4 Connecting Rods and Pistons ........ 0499-11 Cylinder Block .................... 0499-15 Oiling System ..................... 0499-17 Cylinder Head and Valves ........... 0499-23 Contents continued on next page
4 0400-4 Engine Removal and Installation 300 Series OEM Engines TM-1190 (Dec-84) CONTENTS OF THIS SECTION-Continued GROUP 0499 - SPECIFICATIONS AND SPECIAL TOOLS-Continued Specifications and Torque Values-Continued Page Fuel Injection System .............. 0499-27 Test Stand ....................... 0499-27 Fuel Injection Pump: R3432F900 - RE12266 ........... 0499-28 R3432F920 - RE12267 .......... 0499-28A R3448F160 - RE15699 .......... 0499-28B R3448F210 - RE15697 .......... 0499-28C R3462F950 - RE15698 .......... 0499-28D R3462F920 - RE15700 .......... 0499-28E JDB331 MD2406 - AR49904 ...... 0499-28F JDB435AL2442 - AR51747 ........ 0499-29 JDB635AL2446 - AR51568 ........ 0499-30 JDB331 CM2667 - AR66282 ....... 0499-31 DM4627MD2684 - AR66395 ....... 0499-32 JDB431 CM2701 - AR66995 ....... 0499-33 JDB635CM2757 - AR66996 ....... 0499-34 JDB435MD2793 - AR70530 ....... 0499-35 JDB435MD2802 - AR51747 ....... 0499-36 JDB435CM2819 - AR70531 ....... 0499-37 DM4627AL2824 - AR70778 ....... 0499-38 DM4627HB2825 - AR70551 ....... 0499-39 DM4627HB2826 - AR70780 ....... 0499-40 DM4427MD2876 - AR71421 ....... 0499-41 DM4427HB2915 - AR70538 ....... 0499-42 DM4427NH2957 - AR76503 ....... 0499-43 JDB435CM2974 - AR77422 ....... 0499-44 JDB333CM3009 - AR79211 ....... 0499-45 JDB435CM3010 - AR79212 ....... 0499-46 JDB635CM3011 - AR79213 ....... 0499-47 JDB435MD3021 - AR78647 ....... 0499-48 DM4427MD3051 - AR80325 ....... 0499-49 DM4627MD3052 - AR80352 ..,..... 0499-50 JDB435MD3053 - AR80230 ....... 0499-51 JDB635MD3142 - AR80603 ....... 0499-52 DM4627HB3220 - AR80353 ....... 0499-53 JDB435CM3223 - AR80233 ....... 0499-54 DM4427HB3224 - AR80326 ....... 0499-55 JDB635CM3243 - AR80604 ....... 0499-56 DM4427NW3262 - AR87186 ....... 0499-57 DM4627AL3335 - AR70778 ....... 0499-58 DM4627NH3642 - AR89482 ....... 0499-59 DM4427NH3776 - AR90716 ....... 0499-60 DM4427HB3986 - AR99951 ...... 0499-60A DM4627HB3987 - AR99952 ....... 0499-61 DM4627MD4012 - AR104000 ...... 0499-62 DM4627ABE4083 - AR100427 ..... 0499-63 DM4627ABE4118 - AR100427 ..... 0499-64 DM4427AL4299 - RE16150 ...... 0499-64A DM46274444 - RE19914 .... .'... 0499-64B Injection Pump Torque ............. 0499-65 Litho in U.S.A. GROUP 0499 - SPECIFICATIONS AND SPECIAL TOOLS-Continued Specifications and Torque Values-Continued Fuel Injection Nozzle: Page 19762 - AR56290 ............... 0499-67 20500 - AR56290 ............... 0499-68 20291 - AR68364 ............... 0499-69 20504 - AR68364 ............... 0499-70 20631 - AR73673 ............... 0499-71 22042 - AR88239 ............... 0499-72 22205 - AR88240 ............... 0499-73 22044 - AR88241 ............... 0499-74 2203 - AR89563 and AR89564 ..... 0499-75 22265 - AR90023 and AR90024 .... 0499-76 Injection Nozzle Torque ............. 0499-77 Intake Manifold ................... 0499-78 Engine Balancer ................... 0499-79 Turbocharger ..................... 0499-80 Water Pump ...................... 0499-81 Thermostats, Housings, and Water Piping ................... 0499-83 Oil Cooler ........................ 0499-84 Starting Motor and Fastenings ....... 0499-85 Fan Drive ........................ 0499-90 Flywheel, Housing, and Fastenings ..................... 0499-90 Special Tools: Removal and Installation .......... 0499-92 Crankshaft and Main Bearings ..... 0499-93 Camshaft and Valve Actuating Means ...................... 0499-94 Connecting Rods and Pistons ...... 0499-96 Cylinder Block .................. 0499-97 Oiling System ................... 0499-98 Cylinder Head and Valves ......... 0499-99 Fuel Injection System ........... 0499-101 Engine Balancer ................ 0499-103 Turbocharger .................. 0499-104 Water Pump ................... 0499-105 Starting Motor and Fastenings .... 0499-106
300 Series OEM Engines TM-1190 (Dec-82) GENERAL INFORMATION ClLearn principles of operation of engines from "Basic Engine" in Fundamentals of Service II Manual 30 - ENGINES. Design Characteristics The 3-1640, 3-1790, 4-2190, 4-2390, 4-2760, 6- 3290, 6-3590, and 6-4140 engines have: 1. Internal combustion 2. Four strokes' per cycle 3. In-line type cylinder block 4. Oiesel fueling 5. Valves in cylinder head 6. Natural aspiration 7. Liquid coolant 8. Pressure lubrication The 4-239T, 4-276T, 6-359T, and 6-414T engines have: 1. Internal combustion 2. Four strokes per cycle 3. In-line type cylinder block 4. Oiesel fueling 5. Valves in cylinder head 6. Turbocharger 7. Liquid coolant 8. Pressure lubrication Litho in U.S.A. Engine Removal and Installation 4 0400-5 Group 0400 REMOVAL AND INSTALLATION II
I 4 0400-6 Engine Engine Removal and Installation Front Reference The water pump (Fig. 1) end is the "front' of the engine. Direction of Crankshaft Rotation The crankshaft turns clockwise when viewed from the water pump end. Firing Order 3-164 and 3-179 Engine Firing order is: 1-2-3 Litho in U.S.A. T70245 300 Series OEM Engines TM-1190 (Dec-82) T70243 Fig. 1-Water Pump T70244 Fig. 2-Crankshaft Rotation 2 3 10001 T70245 Fig. 3-Cylinder Arrangement
300 Series OEM Engines TM-1190 (Mar-80) 4-219, 4-239, and 4-276 Engines Firing order is: 1-3-4-2 6-329, 6-359, and 6-414 Engines Firing order is: 1-5-3-6-2-4 REMOVAL Disconnect battery negative (-) cable. Disconnect battery positive (+) cable from starting motor. Remove engine side shields (2, Fig. 6) (Group 1910). Remove muffler. Remove hood (1, Fig. 6) (Group 1910). A CAUTION: Do not drain cooling system - until upper radiator tank feels cool. Drain engine cooling system. Drain engine oil. Disconnect fuel inlet line at fuel transfer pump. Litho in U.S.A. T70246 Engine Engine Removal and Installation 1 2 3 4 4 0400-7 100001 Fig. 4-Cylinder Arrangement 2 3 4 5 6 /0000001 T70655 Fig. 5-Cylinder Arrangement , '-:;,. - " .... ~ It '. .' Fig. 6-Engine Enclosure I
I 4 0400-8 Engine Removal and Installation Disconnect tachometer drive cable (3, Fig. 7) from flywheel housing. Disconnect air cleaner hose on right side of engine. Remove rear panel (1, Fig. 7) with air cleaner (2) attached. Remove front shroud (3, Fig. 6). Disconnect speed control cable (1, Fig. 8) and bracket (2). NOTE: Tag wires and terminals for reassembly. Disconnect fuel shut-off wiring (3, Fig. 8) from fuel injection pump (4). Disconnect alternator wiring (1, Fig. 9) from alterna- tor. Disconnect solenoid wiring (2, Fig. 9) from solenoid. Litho in U.S.A. ... TS3S0111:t , 300 Series OEM Engines TM-1190 (Mar-80) Fig. 7-Engine Enclosure Rear Panel Fig. 8-Speed Control Cable and Fuel Shut-Off Wiring Fig. 9-Solenoid and Alternator Wiring -,.
300 Series OEM Engines TM-1190 (Mar-BO) Disconnect temperature sending unit (1, Fig. 10) from rear of cylinder head. Disconnect oil pressure hose (2, Fig. 10) from rear of cylinder block. Remove rear shroud (4, Fig. 9) with instrument panel (3) attached. Attach hoist with D01043AA Load-Positioning Sling (1, Fig. 11) to engine lifting eyes (2). Remove engine mounting hardware (1, Fig. 12) at four corners of engine. Raise hoist to remove engine. Cap or plug air inlet tube, fuel inlet fitting, and exhaust manifold tube. Steam-clean engine thorough- ly. Litho in U.S.A. Engine Removal and Installation 4 0400-9 ~ .,I .:.~ t~ .4 Fig. 10-0i/ Pressure Hose and Temperature Sending Unit Fig. 11-D-01043AA Load Positioning Sling Attached Fig. 12-Engine Mounting Hardware a
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING If there is no response to click on the link above, please download the PDF document first and then click on it.
II 4 Engine 0400-10 Removal and Instal/ation INSTALLATION Mounting Engine in D01003AA Stand Attach hoist with 001043AA Load-Positioning Sling (1, Fig. 11) to engine lifting eyes (2). Lift engine into position on 001003AA Engine Stand. Refer to Fig. 13 to mount three or four cylinder engine. Refer to Fig. 14 to mount six cylinder engine. Adjust engine stand rods and install cap screws holding rod brackets to engine. Ii. CAUTION: Tighten all engine stand . . mounting hardware securely before re- moving hoist. Check that all engine stand mounting hardware is tight. Remove hoist and sling (1, Fig. 11) from engine. Litho in U.S.A. - - 300 Series OEM Engines TM-1190 (Mar-BO) Fig. 13-Three or Four Cylinder Engine Mounted in D01003AA Engine Stand :, LEFT SIOE TS3786N RIGHT REAR Fig. 14-Six Cylinder Engine Mounting Points
300 Series OEM Engines TM-1190 (Mar-80) Mounting Engine in Enclosure Attach hoist with D01043AA Load-Positioning Sling (1, Fig. 11) to engine lifting eyes (2). Lift engine into position on enclosure mounting skid. Install engine mounting hardware (1, Fig. 12) at lower four corners of engine. Remove load-positioning sling and hoist from en- gine. Install rear shroud (4, Fig. 9) with instrument panel (3) attached. Connect oil pressure hose (2, Fig. 10) to rear of cylinder block. Connect temperature sending unit (1, Fig. 10) to rear of cylinder head. Connect solenoid wiring (2, Fig. 9). Connect alternator wiring (1, Fig. 9). Connect fuel shut-off wiring (3, Fig. 8) to fuel injec- tion pump (4). Connect speed control cable (1, Fig. 8) and install bracket (2). Install front shroud (3, Fig. 6). Install rear panel (1, Fig. 7) with air cleaner (2) attached. Connect air cleaner hose to intake tube on right side of engine. Connect tachometer drive cable (3, Fig. 7) to fly- wheel housing. Litho in U.S.A. Engine Removal and Instal/ation 4 0400-11 Connect fuel inlet line to fuel transfer pump. Fill crankcase to correct level using proper oil. Fill radiator to correct level using proper coolant. Install hood (1, Fig. 6). Install muffler. Install engine side shields (2, Fig. 6). Connect battery positive (+) cable to starter. Connect battery negative (-) cable to battery. Adjust speed control linkage if necessary (Group 0515). II

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TM-1190 John Deere 300 Series OEM Engine Service Repair Manual

  • 1.
    300 Series OEMEngines TM-1190 (Dec-84) General Information Contents and Index 1 1-1 300 SERIES OEM ENGINES Technical Manual TM-1190 (Dec-S4) SECTIONAL CONTENTS OF THIS MANUAL Section I - General Information _________________ Section 4 - Engine________________________ Section 5 - Engine Auxiliary Systems Section 16 - Electrical Systems ___________________ Section 19 - Sheet Metal and Styling Section 40 - PTO Drive Section 90 - System Testing The specifications and design information contained in this manual were correct at the time it was printed. It is JohtrDeere's Policy to continually improve and update our machines. Therefore, the specifications and design information are subject to change without notice. Wherever applicable, specifications and design information are in accordance with SAE and ICED standards. Litho in U.S.A. CopyrighNl 1984 DEERE Ie COMPANY Moline, Illinois All Rights Reserved Previous Editions CopyrighNl1982 Deere Ie Company CopyrighNl 1980 Deere Ie Company CopyrighNl1978 Deere Ie Company Copyrightc> 1977 Deere Ie Company DOWNLOAD SERVICE REPAIR MANUAL
  • 2.
    II 1 1-2 General Information Contents andIndex 300 Series OEM Engines TM-1190 (Aug-78) INTRODUCTION Use FOS Manuals for Reference This technical manual is part of a twin concept of service: The two kinds of manuals work as a team to give you both the general background and technical details of shop service. .FOS Manuals-for reference Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of trouble shooting, general maintenance, and basic types of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced ser- vice technicians. E]When a service technician should refer to a FeS FOS Manual for more information, a FOS symbol like the one at the left is used in the D TM to identify the reference. •Technical Manuals-for actual service Technical Manuals are concise service guides for a specific machine. Technical manuals are on-the-job guides containing only the vital information needed by an experienced service technician. Litho in U.S.A. r t. l' " Use Technical Manuals for Actual Service This technical manual was planned and written for you-an experienced service technician. Keep it in a permanent binder in the shop where it is handy. Refer to it whenever in doubt about correct service proce- dures or specifications. Some features of this manual: • Inside front cover - "Table of Contents". • Section I - Contents • Sections 4 through 40 - Removal, repair, testing (components removed), installation, and adjustment. • Section 90 - Detailed explanation of system operation, diagnosis, visual inspection, testing, and adjustments. • Specifications grouped and illustrated at the end of each section.
  • 3.
    300 Series OEMEngines TM-1190 (Dec-82) General Information Contents and Index SECTION ANO GROUP CONTENTS OF THIS MANUAL SECTION I - GENERAL INFORMATION Group I - Contents SECTION 4 - ENGINE Group 0400 - Removal and Installation Group 0401 - Crankshaft and Main Bearings Group 0402 - Camshaft and Valve Actuating SECTION 5 - ENGINE AUXILIARY SYSTEMS Group 0510 - Cooling Systems Group 0515 - Speed Controls Group 0520 - Intake Systems Group 0599 - Specifications and Special Tools SECTION 16 - ELECTRICAL SYSTEMS 1 1-3 Means Group 1672 - Alternator, Regulator and Charging Group 0403 - Connecting Rods and Pistons Group 0404 - Cylinder Block Group 0407 - Oiling System Group 0408 - Ventilating System Group 0409 - Cylinder Head and Valves Group 0410 - Exhaust Manifold Group 0413 - Fuel Injection System Group 0414 - Intake Manifold Group 0415 - Engine Balancer Group 0416 - Turbocharger Group 0417 - Water Pump Group 0418 - Thermostats, Housing and Piping Group 0419 - Engine Oil Cooler Group 0420 - Fuel Filter Group 0421 - Fuel Transfer Pump Group 0422 - Starting Motor and Fastening Group 0423 - Alternator and Generator Mountings Group 0429 - Fan Drive Group 0433 - Flywheel, Housing and Fastenings Group 0499 - Specifications and Special Tools System Wiring Group 1674 - Wiring Harness and Switches Group 1676 - Instruments and Indicators Group 1699 - Specifications and Special Tools SECTION 19 - SHEET METAL AND STYLING Group 1910 - Hood or Engine Enclosure SECTION 40 - PTO DRIVE Group 4052 - PTO Clutch Group 4099 - Specifications and Special Tools SECTION 90 - SYSTEM TESTING Group 9010 - Engine Group 9015 - Electrical System Group 9035 - Specifications and Special Tools OEM ENGINES SERVICEO BY THIS TECHNICAL MANUAL Litho in U.S.A. 3-1640 3-1790 4-2190 4-2390 4-239T 4-2760 4-276T 6-3290 6-3590 6-359T 6-4140 6-414T I
  • 4.
    • 1 1·4 General Information Contents andIndex Accessible Hardware Torque Values The table below gives correct torque values for various bolts and cap screws. The table lists torques in the U.S. unit of measure (lb-ft), SI metrics (Nm) and conventional metrics (kg/m). Most hardware used is high-strength (note dashes on hex. heads). 300 Series OEM Engines TM-1190 (Nov-78) The types of bolts and cap screws are identified by head markings as follows: Plain Head: regular machine bolts and cap screws. 3-Dash Head: tempered steel high-strength bolts and cap screws. 6-Dash Head: tempered steel extra high-strength bolts and cap screws. Machine bolts and cap screws 7/8-inch (22.2 mm) and larger are sometimes formed hot rather than cold, which accounts for the lower torque. RECOMMENDED TORQUE - COARSE AND FINE THREADS 0 F G 0 t /, B 0 ED @ / BOLT PLAIN THREE SIX DIAMETER HEAD DASHES DASHES LB-FT Nm Kg-m LB-FT Nm Kg-m LB-FT Nm Kg-m 1/4 NOT USED NOT USED NOT USED 10 14 1 14 19 2 5/16 NOT USED NOT USED NOT USED 20 27 3 30 41 4 3/8 NOT USED NOT USED NOT USED 35 47 5 50 68 7 7/16 35 47 5 55 75 8 80 108 11 1/2 55 75 8 85 115 12 120 163 17 9/16 75 102 10 130 176 18 175 237 24 5/8 105 142 15 170 230 24 240 325 33 3/4 185 251 26 300 407 42 425 576 59 7/8 160 217 22 445 603 62 685 929 95 1 250 339 35 670 908 93 1030 1396 142 1-1/8 330 447 46 910 1234 126 1460 1979 202 1-1/4 480 651 66 1250 1695 173 2060 2793 285 143720 Litho in U.S.A.
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    300 Series OEMEngines TM-1190 (Dec-82) General Information Contents and Index 1 1-5 ALPHABETICAL INDEX A Engine:-Continued Air cleaner ............................ 0520-1 Fuel filter ........................... 0420-1 Alternator and generator mounting ......... 0423-1 Fuel injection system .................. 0413-1 Alternator, regulator and charging Fuel transfer pump ................... 0421-1 system wiring ........................ 1672-3 Amp meter ............................ 1676-2 Intake manifold ...................... 0414-1 I Oil cooler ........................... 0419-1 Oiling system ........................ 0407-1 B Removal and installation ............... 0400-5 Balancer shafts ........................ 0415-1 Starting motor and fastenings ........... 0422-1 Thermostats, housings and water C piping ............................ 0418-1 Camshaft and valve actuating means ....... 0402-1 Turbocharger ........................ 0416-1 Charging circuit testing (Delco-Remy Ventilating system .................... 0408-1 alternator) ........................... 9015-8 Water pump ......................... 0417-1 Charging circuit testing (Motorola alternator) . 9015-5 Engine auxiliary systems: Connecting rods and pistons .............. 0403-1 Cooling system ...................... 0510-3 Cooling manifold ....................... 0418-1 Intake system ....................... 0520-1 Cooling system, engine .................. 0510-3 Speed controls ....................... 0515-1 Crankshaft and main bearings ............. 0401-1 Engine removal and installation ............ 0400-5 Crankshaft front oil seal ................. 0402-3 Engine system testing and adjustments: Crankshaft front wear ring ............... 0401-6 Compression pressure test ............. 9010-9 Crankshaft gear ........................ 0401-5 Engine cooling system test ............ 9010-11 Crankshaft rear oil seal .................. 0401-6 Engine oil pressure test. .............. 9010-10 Crankshaft rear wear ring ................ 0401-6 Engine preformance test using Crankshaft pulley ....................... 0429-2 turbocharger boost pressure ......... 9010-14 Cylinder block ......................... 0404-1 Fuel transfer pump pressure test ....... 9010-11 Cylinder head and valves ................ 0409-1 Governor speed droop adjustment ...... 9010-11 Injection pump cam advance ........... 9010-13 D Speed control linkage adjustment ....... 9010-12 Delco-Remy alternator ................... 1672-3 Exhaust manifold ....................... 0410-1 Delco-Remy starting motor ............... 0422-1 Diagnosing malfunctions: F Engine system testing ................. 9010-5 Fan belt .............................. 0429-1 Dipstick ............................. 0407-18 Fan drive ............................. 0429-1 Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0420-1 E Flywheel, housing and fastenings .......... 0433-2 Electrical schematic .................... 9015-11 Fuel filter ............................. 0420-1 Electrical system ....................... 1672-1 Fuel injection nozzles .................. 0413-20 Electrical system testing ................. 9015-1 Fuel injection pump ..................... 0413-1 Charging circuit ...................... 9015-5 Fuel transfer pump ..................... 0421-1 Starting circuit ....................... 9015-1 Engine: G Alternator and generator mounting ....... 0423-1 Gauge, pressure ....................... 1676-3 Camshaft and valve actuating means ..... 0402-1 Gauge, temperature ..................... 1676-3 Connecting rods and pistons ............ 0403-1 Crankshaft and main bearings ........... 0401-1 H Cylinder block ....................... 0404-1 Hood ................................ 1910-3 Cylinder head and valves .............. 0409-1 Hour meter ........................... 1676-2 Engine balancer ...................... 0415-1 Exhaust manifold ..................... 0410-1 Fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 0429-1 Flywheel, housing and fastenings ........ 0433-1 Litho in U.S.A.
  • 6.
    II I 1-6 General Information Contents andIndex Instruments and indicators ............... 1676-1 Amp meter .......................... 1676-2 Hour meter ......................... 1676-2 Pressure gauge ...................... 1676-3 Safety switch ........................ 1676-4 Tachometer ......................... 1676-1 Temperature gauge ................... 1676-3 Intake manifold ........................ 0414-1 Intake system ......................... 0520-1 J John Deere starting motor ............... 0422-11 M Malfunctions, diagnosing: Engine system testing ................. 9010-5 Manifold, exhaust ...................... 0410-1 Manifold, intake ........................ 0414-1 Motorola alternator ..................... 1672-9 N Nozzle, fuel injection ................... 0413-11 o Oil bypass valve ....................... 0407-4 Oil cooler, engine ....................... 0419-1 3-1640,4-2190,4-2390, 4-239T, 6-3290, '- 6-3590 and 6-359T engines .......... 0419-1 4-2760, 4-276T, 6-4140 and '6-414T engines .................... 0419-3 Oil filter .............................. 0407-1 Oil filter nipple ......................... 0407-2 Oiling system, engine ................... 0407-1 Oil pan ............................... 0407-4 Oil pressure control valve ................ 0407-5 Oil pump ............................ 0407-10 p Pressure gauge ........................ 1676-3 PTO clutch ............................ 4052-3 Pump, engine oil ....................... 0407-1 Pump, engine water ..................... 0417-1 Pump, fuel injection ..................... 0413-1 Pump, fuel transfer ..................... 0421-1 R Radiator .............................. 0510-3 Rocker arms and push rods ............. 0402-17 Rods and pistons ...................... 0403-1 S 300 Series OEM Engines TM-1190 (Dec-82) Safety switch .......................... 1676-4 Special tools: Camshaft and valve actuating means .... 0499-94 Connecting rods and pistons ........... 0499-96 Crankshaft and main bearings .......... 0499-93 Cylinder block ...................... 0499-97 Cylinder head and valves ............. 0499-99 Electrical system ..................... 1699-4 Electrical system testing ............... 9035-8 Engine balancer .................... 0499-103 Engine removal and installation ......... 0499-92 Engine system testing ................. 9035-4 Fuel injection system ................ 0499-101 Oiling system, engine ................ 0499-98 Starting motor and fastenings ......... 0499-106 Turbocharger ...................... 0499-104 Water pump ....................... 0499-105 Specifications and torque values: Camshaft and valve actuating means ..... 0499-4 Connecting rods and pistons ........... 0499-~ 1 Crankshaft and main bearings ........... 0499-2 Cylinder block ...................... 0499-15 Cylinder head and valves ............. 0499-23 Electrical system ..................... 1699-1 Electrical system testing ............... 9035-6 Engine balancer ..................... 0499-79 Engine break-in ...................... 0499-1 Engine cooling system ................. 0599-1 Engine system testing ................. 9035-1 Fan drive .......................... 0499-90 Flywheel, housing and fastenings ....... 0499-90 Fuel injection system ................. 0499-27 Intake manifold ..................... 0499-78 Oil cooler, engine .................... 0499-84 Oiling system, engine ................ 0499-17 PTO clutch .......................... 4099-1 Starting motor and fastenings .......... 0499-85 Thermostats, housings and water piping ........................... 0499-83 Turbocharger ....................... 0499-80 Water pump ........................ 0499-81 Speed controls, engine .................. 0515-1 Starting circuit testing ................... 9015-1 Starting motor, Oelco-Remy .............. 0422-1 Starting motor, John Deere .............. 0422-11 Switch, safety ......................... 1676-4
  • 7.
    300 Series OEMEngines TM-1190 (Dec-82) T Tachometer ........................... 1676-1 Temperature gauge ..................... 1676-3 Tests and adjustments: Alternator components ............... 1672-14 Electrical system ..................... 9015-1 Engine system ....................... 9010-9 Starting motor, Delco-Remy ............ 0422-1 Starting motor, John Deere ............ 0422-12 Turbocharger ........................ 0416-2 Thermostats, housings and water piping .............................. 0418-1 Timing gear ........................... 0402-9 Timing gear cone ....................... 0402-2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 0416-1 Litho in U.S.A. General Information Coiiients and Imfex V J 1-7 Ventilating system ...................... 0408-1 Vertical tachometer drive ................. 0433-1 Vibration damper ....................... 0401-8 W Water pump ........................... 0417-1 • Wiring harness and switches .............. 1674-1 Wiring diagram ........................ 9015-12.
  • 8.
    I I 1-8 General Information Contents andIndex Litho in U.S.A. 300 Series OEM Engines TM-1190 (Mar-BO)
  • 9.
    300 Series OEMEngines TM-1190 (Dec-82) Engine Removal and Instal/ation 4 0400-1 Section 4 ENGINE CONTENTS OF THIS SECTION Page GROUP 0400 - REMOVAL AND INSTALLATION General Information ................... 0400-5 Removal ............................ 0400-7 Installation ......................... 0400-10 GROUP 0401 - CRANKSHAFT AND MAIN BEARINGS Crankshaft and Main Bearings .......... 0401-1 Removal .......................... 0401-1 Crankshaft End Play ................ 0401-1 Repair ........................... 0401-2 Installation ........................ 0401-3 Crankshaft gear ...................... 0401-5 Removal .......................... 0401-5 Repair ........................... 0401-5 Crankshaft Front Wear Ring ............ 0401-6 Removal .......................... 0401-6 Installation .... : ................... 0401-6 Crankshaft Front Oil Seal .............. 0401-6 Crankshaft Rear Oil Seal and Wear Ring .. 0401-6 Removal .......................... 0401-6 Repair ........................... 0401-6 Installation ........................ 0401-7 Vibration Damper ..................... 0401-8 Installation ........................ 0401-8 GROUP 0402 - CAMSHAFT AND VALVE ACTUATING MEANS Valve Lift Check ..................... 0402-1 Timing Gear Cover ................... 0402-2 Removal .......................... 0402-2 Repair ........................... 0402-2 Installation ........................ 0402-3 Crankshaft Front Oil Seal .............. 0402-3 Removal .......................... 0402-3 Installation ........................ 0402-3 Camshaft ........................... 0402-3 Removal .......................... 0402-3 Repair ........................... 0402-6 Installation ........................ 0402-7 Litho in U.S.A. Page GROUP 0402 - CAMSHAFT AND VALVE ACTUATING MEANS-Continued Timing Gear ......................... 0402-9 Removal .......................... 0402-9 Repair .......................... 0402-11 Installation ....................... 0402-12 Rocker Arms and Push Rods .......... 0402-17 Removal ......................... 0402-17 Repair .......................... 0402-17 Installation ....................... 0402-18 Valve Clearance Adjustment ........... 0402-19 GROUP 0403 - CONNECTING RODS AND PISTONS Removal ............................ 0403-1 Repair ............................. 0403-3 Installation .......................... 0403-9 GROUP 0404 - CYLINDER BLOCK Removal ............................ 0404-1 Repair ............................. 0404-3 Installation .......................... 0404-6 GROUP 0407 - OILING SYSTEM Oil Filter ............................ 0407-1 Removal .......................'... 0407-1 Installation ........................ 0407-1 Oil Filter Nipple ...................... 0407-1 Removal .......................... 0407-2 Installation ........................ 0407-3 Oil Pan Removal .......................... 0407-4 Repair ........................... 0407-4 Installation ........................ 0407-4 Oil Bypass Valve Removal .......................... 0407-4 Repair ........................... 0407-4 Installation ........................ 0407-4 Oil Pressure Control Valve 3-1640,3-1790, 4-219D, 4-239D, 4-239T, 6-3290,6-3590, or 6-359T Engine ..... 0407-5 Removal ........................ 0407-5 Repair ......................... 0407-5 Installation ...................... 0407-6 Contents continued on next page I
  • 10.
    • 4 0400-2 Engine Removal and Installation 300Series OEM Engines TM-1190 (Dec-82) CONTENTS OF THIS SECTION-Continued GROUP 0407 - OILING SYSTEM-Continued Oil Pressure Control Valve-Continued 4-2760, 4-276T, 6-4140 Page or 6-414T Engine ................... 0407-7 Removal ........................ 0407-7 Disassembly ..................... 0407-7 Repair ......................... 0407-8 Assembly .. '..................... 0407-8 Installation ...................... 0407-9 Oil Pump 3-1640,3-1790,4-2190, 6-3290, or 6-3590 Engine .......... 0407-10 Removal ....................... 0407-10 Inspection and Disassembly ....... 0407-10 Repair ........................ 0407-12 Assembly ...................... 0407-12 Installation .. . . . . . . . . . . . . . . . . . . . 0407-13 4-239T, 4-2760, 4-276T, 6-359T, 6-4140, or 6-414T Engine ........... 0407-14 Removal ....................... 0407-14 Inspection and Disassembly ....... 0407-14 Repair ........................ 0407-16 Assembly ...................... 0407-16 Installation ..................... 0407-17 Dipstick and Dipstick Nipple ........... 0407-18 Removal ......................... 0407-18 Repair .......................... 0407-18 Installation ....................... 0407-19 GROUP 0408 - VENTILATING SYSTEM General Information ................... 0408-1 Removal ............................ 0408-1 Repair ............................. 0408-1 Installation .......................... 0408-i GROUP 0409 - CYLINDER HEAD AND VALVES Removal ............................ 0409-1 Disassembly ......................... 0409-2 Repair ............................. 0409-2 Assembly ........................... 0409-7 Installation .......................... 0409-7 GROUP 0410 - EXHAUST MANIFOLD General Information ................... 041 0-1 Removal ............................ 0410-1 Repair ............................. 0410-1 Installation .......................... 0410-1 Litho in U.S.A. Page GROUP 0413 - FUEL INJECTION SYSTEM Fuel Injection Pump ................... 0413-1 Removal .......................... 0413-1 Repair ........................... 0413-6 Installation ........................ 0413-9 Bleeding ......................... 0413-19 Fuel Injection Nozzles ................ 0413-20 Removal ......................... 0413-20 Repair .......................... 0413-21 Installation ....................... 0413-22 GROUP 0414 - INTAKE MANIFOLD Removal ............................ 0414-1 Repair ............................. 0414-1 Installation .......................... 0414-1 GROUP 0415 - ENGINE BALANCER General Information ................... 0415-1 Removal. ........................... 0415-1 Repair ............................. 0415-2 Installation .......................... 0415-3 GROUP 0416 - TURBOCHARGER General Information ................... 0416-1 Removal. ........................... 0416-1 Testing ............................. 0416-2 Radial Bearing Movement ............ 0416-2 Axial Bearing Movement ............. 0416-2 Repair .:-. -;-. . . . . . . . . . . . . . . . . . . . . . . . . 0416-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 0416-8 GROUP 0417 - WATER PUMP Removal. ........................... 0417-1 Disassembly 3-164,3-1790,4-2190,4-2390, 4-2760, or 6-3290 Engine ........... 0417-2 4-239T, 4-276T, 6-3590, 6-359T, 6-4140, or 6-414T Engine ..... 0417-3 Repair ............................. 0417-4 Assembly ........................... 0417-5 Installation .......................... 0417-7 GROUP 0418 - THERMOSTATS, HOUSINGS, AND WATER PIPING Thermostat ......................... 0418-1 Removal .......................... 0418-1 Repair ........................... 0418-2 Installation ........................ 0418-2 Contents continued on next page
  • 11.
    300 Series OEMEngines TM-1190 (Dec-82) Engine Removal and Installation 4 0400-3 CONTENTS OF THIS SECTION-Continued Page GROUP 0419 - OIL COOLER 3-1640, 3-179D, 4-2190 and 6-329D Engines: Removal .......................... 0419-1 Repair ........................... 0419-2 Installation ........................ 0419-2 4-2760, 4-276T, 6-4140 and 6-414T Engines: Removal .......................... 0419-3 Repair ........................... 0419-3 Installation ........................ 0419-5 GROUP 0420 - FUEL FILTER General Information ................... 0420-1 Removal ............................ 0420-1 Installation .......................... 0420-1 GROUP 0421 - FUEL TRANSFER PUMP General Information ................... 0421-1 Removal ............................ 0421-1 Repair ............................. 0421-1 Installation .......................... 0421-2 GROUP 0422 - STARTING MOTOR AND FASTENINGS General Information ................... 0422-1 Delco-Remy Starting Motor ............. 0422-1 Removal .......................... 0422-1 Testing and Diagnosis ............... 0422-1 Testing Pull-in Windings ........... 0422-1 Testing Hold-in Windings ........... 0422-1 No Load Starting Motor Test ....... 0422-2 Repair ........................... 0422-4 Assembly ......................... 0422-8 Installation ....................... 0422-10 John Deere Starting Motor ............ 0422-11 Removal ......................... 0422-11 Tests ........................... 0422-12 Solenoid Pull-in Test ............. 0422-12 Solenoid Return Test. ............ 0422-12 No Load Test. .................. 0422-13 Repair .......................... 0422-15 Assembly ........................ 0422-20 GROUP 0423 - ALTERNATOR AND GENERATOR MOUNTING General Information ................... 0423-1 Removal ............................ 0423-1 Installation .......................... 0423-1 Litho in U.S.A. Page GROUP 0429 - FAN DRIVE Fan Belt ............................ 0429-1 Removal .......................... 0429-1 Repair ........................... 0429-1 Installation ........................ 0429-1 Crankshaft Pulley ..................... 0429-2 Removal .......................... 0429-2 I Repair ........................... 0429-2 ; Installation ........................ 0429-3 GROUP 0433 - FLYWHEEL, HOUSING, AND FASTENINGS Vertical Tachometer Drive .............. 0433-1 Removal .......................... 0433-1 Repair ........................... 0433-1 Installation ........................ 0433-1 Flywheel ............................ 0433-2 Removal .......................... 0433-2 Repair ........................... 0433-2 Installation ........................ 0433-3 Flywheel Ring Gear ................... 0433-4 Removal .......................... 0433-4 Installation . . . . . . . . . . . . . . ..'. . . . . . . . 0433-4 Flywheel Housing ..................... 0433-4 Removal'. ......................... 0433-4 Repair ........................... 0433-5 Installation ........................ 0433-5 GROUP 0499 - SPECIFICATIONS AND SPECIAL TOOLS Specifications and Torque Values: Engine Break-In .................... 0499-1 Crankshaft and Main Bearings ........ 0499-2 Camshaft and Valve Actuating Means ......................... 0499-4 Connecting Rods and Pistons ........ 0499-11 Cylinder Block .................... 0499-15 Oiling System ..................... 0499-17 Cylinder Head and Valves ........... 0499-23 Contents continued on next page
  • 12.
    4 0400-4 Engine Removal and Installation 300Series OEM Engines TM-1190 (Dec-84) CONTENTS OF THIS SECTION-Continued GROUP 0499 - SPECIFICATIONS AND SPECIAL TOOLS-Continued Specifications and Torque Values-Continued Page Fuel Injection System .............. 0499-27 Test Stand ....................... 0499-27 Fuel Injection Pump: R3432F900 - RE12266 ........... 0499-28 R3432F920 - RE12267 .......... 0499-28A R3448F160 - RE15699 .......... 0499-28B R3448F210 - RE15697 .......... 0499-28C R3462F950 - RE15698 .......... 0499-28D R3462F920 - RE15700 .......... 0499-28E JDB331 MD2406 - AR49904 ...... 0499-28F JDB435AL2442 - AR51747 ........ 0499-29 JDB635AL2446 - AR51568 ........ 0499-30 JDB331 CM2667 - AR66282 ....... 0499-31 DM4627MD2684 - AR66395 ....... 0499-32 JDB431 CM2701 - AR66995 ....... 0499-33 JDB635CM2757 - AR66996 ....... 0499-34 JDB435MD2793 - AR70530 ....... 0499-35 JDB435MD2802 - AR51747 ....... 0499-36 JDB435CM2819 - AR70531 ....... 0499-37 DM4627AL2824 - AR70778 ....... 0499-38 DM4627HB2825 - AR70551 ....... 0499-39 DM4627HB2826 - AR70780 ....... 0499-40 DM4427MD2876 - AR71421 ....... 0499-41 DM4427HB2915 - AR70538 ....... 0499-42 DM4427NH2957 - AR76503 ....... 0499-43 JDB435CM2974 - AR77422 ....... 0499-44 JDB333CM3009 - AR79211 ....... 0499-45 JDB435CM3010 - AR79212 ....... 0499-46 JDB635CM3011 - AR79213 ....... 0499-47 JDB435MD3021 - AR78647 ....... 0499-48 DM4427MD3051 - AR80325 ....... 0499-49 DM4627MD3052 - AR80352 ..,..... 0499-50 JDB435MD3053 - AR80230 ....... 0499-51 JDB635MD3142 - AR80603 ....... 0499-52 DM4627HB3220 - AR80353 ....... 0499-53 JDB435CM3223 - AR80233 ....... 0499-54 DM4427HB3224 - AR80326 ....... 0499-55 JDB635CM3243 - AR80604 ....... 0499-56 DM4427NW3262 - AR87186 ....... 0499-57 DM4627AL3335 - AR70778 ....... 0499-58 DM4627NH3642 - AR89482 ....... 0499-59 DM4427NH3776 - AR90716 ....... 0499-60 DM4427HB3986 - AR99951 ...... 0499-60A DM4627HB3987 - AR99952 ....... 0499-61 DM4627MD4012 - AR104000 ...... 0499-62 DM4627ABE4083 - AR100427 ..... 0499-63 DM4627ABE4118 - AR100427 ..... 0499-64 DM4427AL4299 - RE16150 ...... 0499-64A DM46274444 - RE19914 .... .'... 0499-64B Injection Pump Torque ............. 0499-65 Litho in U.S.A. GROUP 0499 - SPECIFICATIONS AND SPECIAL TOOLS-Continued Specifications and Torque Values-Continued Fuel Injection Nozzle: Page 19762 - AR56290 ............... 0499-67 20500 - AR56290 ............... 0499-68 20291 - AR68364 ............... 0499-69 20504 - AR68364 ............... 0499-70 20631 - AR73673 ............... 0499-71 22042 - AR88239 ............... 0499-72 22205 - AR88240 ............... 0499-73 22044 - AR88241 ............... 0499-74 2203 - AR89563 and AR89564 ..... 0499-75 22265 - AR90023 and AR90024 .... 0499-76 Injection Nozzle Torque ............. 0499-77 Intake Manifold ................... 0499-78 Engine Balancer ................... 0499-79 Turbocharger ..................... 0499-80 Water Pump ...................... 0499-81 Thermostats, Housings, and Water Piping ................... 0499-83 Oil Cooler ........................ 0499-84 Starting Motor and Fastenings ....... 0499-85 Fan Drive ........................ 0499-90 Flywheel, Housing, and Fastenings ..................... 0499-90 Special Tools: Removal and Installation .......... 0499-92 Crankshaft and Main Bearings ..... 0499-93 Camshaft and Valve Actuating Means ...................... 0499-94 Connecting Rods and Pistons ...... 0499-96 Cylinder Block .................. 0499-97 Oiling System ................... 0499-98 Cylinder Head and Valves ......... 0499-99 Fuel Injection System ........... 0499-101 Engine Balancer ................ 0499-103 Turbocharger .................. 0499-104 Water Pump ................... 0499-105 Starting Motor and Fastenings .... 0499-106
  • 13.
    300 Series OEMEngines TM-1190 (Dec-82) GENERAL INFORMATION ClLearn principles of operation of engines from "Basic Engine" in Fundamentals of Service II Manual 30 - ENGINES. Design Characteristics The 3-1640, 3-1790, 4-2190, 4-2390, 4-2760, 6- 3290, 6-3590, and 6-4140 engines have: 1. Internal combustion 2. Four strokes' per cycle 3. In-line type cylinder block 4. Oiesel fueling 5. Valves in cylinder head 6. Natural aspiration 7. Liquid coolant 8. Pressure lubrication The 4-239T, 4-276T, 6-359T, and 6-414T engines have: 1. Internal combustion 2. Four strokes per cycle 3. In-line type cylinder block 4. Oiesel fueling 5. Valves in cylinder head 6. Turbocharger 7. Liquid coolant 8. Pressure lubrication Litho in U.S.A. Engine Removal and Installation 4 0400-5 Group 0400 REMOVAL AND INSTALLATION II
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    I 4 0400-6 Engine Engine Removal andInstallation Front Reference The water pump (Fig. 1) end is the "front' of the engine. Direction of Crankshaft Rotation The crankshaft turns clockwise when viewed from the water pump end. Firing Order 3-164 and 3-179 Engine Firing order is: 1-2-3 Litho in U.S.A. T70245 300 Series OEM Engines TM-1190 (Dec-82) T70243 Fig. 1-Water Pump T70244 Fig. 2-Crankshaft Rotation 2 3 10001 T70245 Fig. 3-Cylinder Arrangement
  • 15.
    300 Series OEMEngines TM-1190 (Mar-80) 4-219, 4-239, and 4-276 Engines Firing order is: 1-3-4-2 6-329, 6-359, and 6-414 Engines Firing order is: 1-5-3-6-2-4 REMOVAL Disconnect battery negative (-) cable. Disconnect battery positive (+) cable from starting motor. Remove engine side shields (2, Fig. 6) (Group 1910). Remove muffler. Remove hood (1, Fig. 6) (Group 1910). A CAUTION: Do not drain cooling system - until upper radiator tank feels cool. Drain engine cooling system. Drain engine oil. Disconnect fuel inlet line at fuel transfer pump. Litho in U.S.A. T70246 Engine Engine Removal and Installation 1 2 3 4 4 0400-7 100001 Fig. 4-Cylinder Arrangement 2 3 4 5 6 /0000001 T70655 Fig. 5-Cylinder Arrangement , '-:;,. - " .... ~ It '. .' Fig. 6-Engine Enclosure I
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    I 4 0400-8 Engine Removal and Installation Disconnecttachometer drive cable (3, Fig. 7) from flywheel housing. Disconnect air cleaner hose on right side of engine. Remove rear panel (1, Fig. 7) with air cleaner (2) attached. Remove front shroud (3, Fig. 6). Disconnect speed control cable (1, Fig. 8) and bracket (2). NOTE: Tag wires and terminals for reassembly. Disconnect fuel shut-off wiring (3, Fig. 8) from fuel injection pump (4). Disconnect alternator wiring (1, Fig. 9) from alterna- tor. Disconnect solenoid wiring (2, Fig. 9) from solenoid. Litho in U.S.A. ... TS3S0111:t , 300 Series OEM Engines TM-1190 (Mar-80) Fig. 7-Engine Enclosure Rear Panel Fig. 8-Speed Control Cable and Fuel Shut-Off Wiring Fig. 9-Solenoid and Alternator Wiring -,.
  • 17.
    300 Series OEMEngines TM-1190 (Mar-BO) Disconnect temperature sending unit (1, Fig. 10) from rear of cylinder head. Disconnect oil pressure hose (2, Fig. 10) from rear of cylinder block. Remove rear shroud (4, Fig. 9) with instrument panel (3) attached. Attach hoist with D01043AA Load-Positioning Sling (1, Fig. 11) to engine lifting eyes (2). Remove engine mounting hardware (1, Fig. 12) at four corners of engine. Raise hoist to remove engine. Cap or plug air inlet tube, fuel inlet fitting, and exhaust manifold tube. Steam-clean engine thorough- ly. Litho in U.S.A. Engine Removal and Installation 4 0400-9 ~ .,I .:.~ t~ .4 Fig. 10-0i/ Pressure Hose and Temperature Sending Unit Fig. 11-D-01043AA Load Positioning Sling Attached Fig. 12-Engine Mounting Hardware a
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  • 19.
    II 4 Engine 0400-10 Removaland Instal/ation INSTALLATION Mounting Engine in D01003AA Stand Attach hoist with 001043AA Load-Positioning Sling (1, Fig. 11) to engine lifting eyes (2). Lift engine into position on 001003AA Engine Stand. Refer to Fig. 13 to mount three or four cylinder engine. Refer to Fig. 14 to mount six cylinder engine. Adjust engine stand rods and install cap screws holding rod brackets to engine. Ii. CAUTION: Tighten all engine stand . . mounting hardware securely before re- moving hoist. Check that all engine stand mounting hardware is tight. Remove hoist and sling (1, Fig. 11) from engine. Litho in U.S.A. - - 300 Series OEM Engines TM-1190 (Mar-BO) Fig. 13-Three or Four Cylinder Engine Mounted in D01003AA Engine Stand :, LEFT SIOE TS3786N RIGHT REAR Fig. 14-Six Cylinder Engine Mounting Points
  • 20.
    300 Series OEMEngines TM-1190 (Mar-80) Mounting Engine in Enclosure Attach hoist with D01043AA Load-Positioning Sling (1, Fig. 11) to engine lifting eyes (2). Lift engine into position on enclosure mounting skid. Install engine mounting hardware (1, Fig. 12) at lower four corners of engine. Remove load-positioning sling and hoist from en- gine. Install rear shroud (4, Fig. 9) with instrument panel (3) attached. Connect oil pressure hose (2, Fig. 10) to rear of cylinder block. Connect temperature sending unit (1, Fig. 10) to rear of cylinder head. Connect solenoid wiring (2, Fig. 9). Connect alternator wiring (1, Fig. 9). Connect fuel shut-off wiring (3, Fig. 8) to fuel injec- tion pump (4). Connect speed control cable (1, Fig. 8) and install bracket (2). Install front shroud (3, Fig. 6). Install rear panel (1, Fig. 7) with air cleaner (2) attached. Connect air cleaner hose to intake tube on right side of engine. Connect tachometer drive cable (3, Fig. 7) to fly- wheel housing. Litho in U.S.A. Engine Removal and Instal/ation 4 0400-11 Connect fuel inlet line to fuel transfer pump. Fill crankcase to correct level using proper oil. Fill radiator to correct level using proper coolant. Install hood (1, Fig. 6). Install muffler. Install engine side shields (2, Fig. 6). Connect battery positive (+) cable to starter. Connect battery negative (-) cable to battery. Adjust speed control linkage if necessary (Group 0515). II