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

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

ctm3274 English - John Deere 3029, 4039, 4045, 6059, 6068 engines (saran) ( -499999cd) Component Technical Manual.pdf
ctm3276 Spanish - Motores Liter Saran ( -499999CD)
ctm3273 German - Motoren (Saran) 3029 4039, 4045 6059, 6068 ( -499999CD)
ctm3275 French - Moteurs litre de Saran ( -499999CD)
ctm3277 Italian - Motori (Saran) 3029, 4039, 4045, 6059, 6068 ( -499999CD)

Total Pages: 621 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English etc..

TABLE OF CONTENTS
Section MISC: Engine Application Chart................23
  Group : Engine Application Chart................23
    Engine Application Chart................23
  Section : Safety................27
    Group 00: Safety................27
      Handle Fluids Safely-Avoid Fires................40
      Prevent Battery Explosions................41
      Prepare for Emergencies................42
      Prevent Acid Burns................43
      Avoid High-Pressure Fluids................45
      Wear Protective Clothing................46
      Service Machines Safely................47
      Work in Ventilated Area................48
      Work in Clean Area................49
      Remove Paint Before Welding or Heating................50
      Avoid Heating Near Pressurized Fluid Lines................51
      Illuminate Work Area Safely................52
      Use Proper Lifting Equipment................53
      Practice Safe Maintenance................54
      Use Proper Tools................55
      Dispose of Waste Properly................56
      Live With Safety................57
    Group 01: General Information................556
      Engine Identification................59
      Engine Plate Information (Earlier Design)................60
      Engine Plate Information (Later Design)................62
      Repower Engine Plate................63
      OEM Engine Option Code Label................64
      Engine References................65
      Basic Engine Specifications (3029 - 4039 Basic Engine Specifications (3029 - 4039 & 6059){pgNO}27 6059)................66
      Basic Engine Specifications (4045 Basic Engine Specifications (4045 & 6068){pgNO}27 6068)................67
      Diesel Fuel................68
      Diesel Engine Oil................69
      Diesel Engine Coolant................70
      Metric Bolt and Cap Screw Torque Values................71
      Unified Inch Bolt and Cap Screw Torque Values................72
    Group 02: Engine Mounting................28
      Engine Repair Stand................74
      Safety Precautions................75
      Engine Lifting Procedure................76
      Clean Engine................77
      Disconnect Turbocharger Oil Inlet Line................78
    Group 03: Engine Rebuild Guide................28
      Engine Disassembly Sequence................81
      Sealant Application Guidelines................83
      Engine Assembly Sequence................84
    Group 05: Cylinder Head and Valves................28
      Special or Essential Tools................581
      Specifications................591
      Torques for Hardware................473
      Cylinder Head - Exploded View................144
      Check Valve Lift................97
      Removing Cylinder Head................98
      Cleaning Injection Nozzle Bores................99
      Valve Actuating Parts................100
      Remove Valves and Valve Springs................101
      Checking Cylinder Head Flatness................102
      Cleaning Valve Seats................103
      Cleaning Valve Guides................104
      Measure Valve Guides................105
      Lapping Valve Seats................106
      Check Valve Recess................107
      Remove Valve Seat Inserts................108
      Valve Seat Insert Installation................110
      Check Valves................111
      Grind Valves................112
      Check Valve Spring Tension................113
      Inspect Valve Rotators................114
      Install Valves................115
      Install Cylinder Head................117
      Torque Turn Tightening Method................120
      Checking Rocker Arm Shaft................121
      Install Rocker Arm Assembly................123
      Valve Clearance................124
      Valve Adjustment Sequence................125
      Install Rocker Arm Cover................127
      Final Work................129
    Group 10: Cyl. Block, Liners, Pistons & Rods................29
      Special or Essential Tools................581
      Specifications................591
      Torques for Hardware................473
      Exploded View................144
      Piston and Connecting Rod Removal................145
      Cylinder Liner Bore Measure................147
      Cylinder Liner Removal................148
      Cylinder Liner Deglazing................149
      Cylinder Block Cleaning................150
      Checking Piston Cooling Jets................151
      Cam Follower Bore Measure................152
      Camshaft Bore Measure................153
      Camshaft Bushing Replacement Tool................154
      Remove Camshaft Bushing................156
      Installing Camshaft Bushing................157
      Crankshaft Bore Measure................158
      Crankshaft Bearing Cap Replacement................159
      Cylinder Block Top Desk Flatness................160
      Balancer Shaft Bore Measure................161
      Balancer Shaft Bushing Replacement................162
      Oversize Balancer Shaft Bushing Installation................163
      Cylinder Liner Protrusion Measure................164
      Liner Packing Installation................166
      Liner O-Ring Installation................167
      Cylinder Liner Installation................168
      Connecting Rod Bearing Measure................170
      Rod Bearing Clearance................172
      Connecting Rod Bushing................173
      Connecting Rod Bushing Replacement (Straight Pin-End Conrod Except Small Pin)................174
      Connecting Rod Bushing Replacement (Tapered Pin-End Conrod)................175
      Measure Piston Pin................178
      Piston Cleaning................179
      Measure Piston Pin Bore................180
      Piston Top Ring Groove................181
      Second and Third Piston Ring Grooves................182
      Piston Head and Skirt Checking................183
      Piston Ring Identification................184
      Install Piston Rings................185
      Piston Rings Staggering................187
      Piston/Liner Set Information................188
      Piston and Connecting Rod Assembly................189
      Piston and Connecting Rod Installation................190
      Torque-Turn Method................192
      Piston Protrusion Measure................193
      Final Verifications................194
      Complete Final Assembly................195
    Group 15: Crankshaft, Main Bearings and Flywheel................30
      Special or Essential Tools................581
      Self-Manufactured Tool Puller for Crankshaft Pulley w/o Threaded Holes................203
      Specifications................591
      Torques for Hardware................473
      Vibration Damper Checking (Engine Without Front PTO)................207
      Pulley or Vibration Damper Removal................208
      Pulley or Vibration Damper Installation................209
      Vibration Damper or Pulley Checking (Engine With Front PTO)................210
      Vibration Damper or Pulley Removal (Engine With Front PTO)................212
      Vibration Damper or Pulley Installation (Engine With Front PTO)................214
      Install Vibration Damper or Pulley (Engine With Crankshaft-Gear-Driven Aux. Drive)................216
      Flywheel Removal................217
      Flywheel Ring Gear Replacement................218
      Ball Bearing Installation................219
      Flywheel Installation................220
      Crankshaft Wear Sleeve Removal................221
      Flywheel Housing Replacement................223
      Oil Seal/Wear Sleeve Installation................225
      Crankshaft End Play Measure................227
      Crankshaft Removal................229
      Crankshaft Identification................230
      Crankshaft Inspection................231
      Journal OD Check................232
      Main Bearing Clearance................233
      Determine Crankshaft Main Bearing Clearance Using PLASTIGAGEPLASTIGAGE is a trademark of DANA Corp.................31
      Crankshaft Regrinding................235
      Crankshaft Regrinding Guidelines................236
      Micro-Finishing Specifications................591
      Crankshaft Gear Replacement................238
      Main Bearing Inserts Installation................240
      2-Piece Thrust Bearing Installation................241
      5/6-Piece Thrust Bearing Installation Standard thrust washer sets for service contain now 4 thrust washers instead of 3 currently installed by the factory and previously included in service sets.................31
      Crankshaft Installation................243
    Group 20: Camshaft, Balancer Shafts and Timing Gear Train................31
      Special or Essential Tools................581
      Self-Manufactured Tool Template for Front Plate Replacement................439
      Specifications................591
      Auxiliary Gear Drive Specifications (37 kW)................254
      Torques for Hardware................473
      Timing Gear Backlash Measure................256
      Camshaft End Play Measure................257
      Removing Camshaft................258
      Camshaft Journal Measure................259
      Measure Height of Cam Lobe................260
      Camshaft Gear Replacement................261
      Tachometer Pick-Up Pin Removal................262
      Fuel Supply Pump Rear Cam Installation................263
      Install Camshaft................264
      Cam Follower Checking................265
      Balancer Shaft Identification (4-Cylinder Engines)................266
      Balancer Shaft End Play Measure................267
      Balancer Shaft Removal................268
      Balancer Shaft Journal Measure................269
      Balancer Shaft Gear Replacement................270
      Install Balancer Shafts................272
      Idler Gear End Play Measure................273
      Remove Front Plate................274
      Idler Gear Bushing and Shaft Measure................276
      Idler Gear Bushing Replacement................277
      Remove Idler Shaft................278
      Spring Pin Installation (If Equipped)................279
      Upper Idler Shaft Installation................280
      Lower Idler Shaft Installation................282
      Front Plate Gasket................283
      Front Plate Installation................285
      Upper Timing Gear Train Installation................288
      Lower Timing Gear Train Installation................290
      Auxiliary Drive Gear Installation (37 kW)................292
      Oil Deflector Installation................294
      Timing Gear Cover Identification................295
      Install Composite Material Timing Gear Cover................296
      Install Aluminum Timing Gear Cover................298
      Installation of Timing Gear Cover for 37 kW Auxiliary Drive................300
      Install Crankshaft Front Oil Seal................301
      Install Wear Ring................302
      Install Auxiliary Equipment Driven by Camshaft Gear (19 kW Aux. Drive)................303
      Crankshaft-Gear-Driven Auxiliary Drive (37 kW)................304
      Auxiliary Drive Gear Removal (37 kW)................305
      Ball Bearing and Dowel Installation................306
      Auxiliary Gear and Shaft Installation (37 kW)................307
      Output Shaft Cover Installation................308
    Group 25: Lubrication System................557
      Special or Essential Tools................581
      Specifications................591
      Specifications - Machine Model................313
      Torques for Hardware................473
      Oil Cooler Identification................322
      Standard Oil Cooler Removal................323
      Standard Oil Cooler Adapter Replacement................325
      Standard Oil Cooler/Oil Filter Brackets Replacement................326
      Replace Oil Filter Adapter On Engine With Remote Oil Filter................330
      High-Flow Oil Cooler Removal................331
      Oil Cooler Distributor Base Removal................332
      Oil Cooler Distributor Base Repair................333
      High-Flow Oil Cooler/Distributor Base Installation................334
      Oil Pressure Regulating Valve Removal................336
      Oil Pressure Regulating Valve Seat Replacement................337
      Oil Pressure Regulating Valve Installation................338
      Dipstick Guide Replacement................339
      Oil By-Pass Valve Replacement................341
      Oil Suction Screen Replacement (On Standard Oil Pump)................343
      Oil Suction Screen Replacement (On High-Flow Oil Pump)................344
      Oil Pump Identification................345
      Standard Oil Pump Removal................346
      Gear Axial Clearance (Standard Oil Pump)................347
      Gear Radial Clearance (Standard Oil Pump)................348
      Standard Oil Pump Specifications................591
      Standard Oil Pump Installation................350
      High-Flow Oil Pump Removal................354
      Gear Axial Clearance (High-Flow Oil Pump)................355
      Gear Radial Clearance (High-Flow Oil Pump)................356
      High-Flow Oil Pump Specifications................591
      High-Flow Oil Pump Installation................359
      Oil Pan Installation................361
    Group 30: Cooling System................34
      Special or Essential Tools................581
      Specifications................591
      Torques for Hardware................473
      Water Pump - Exploded View................372
      Water Pump Identification................373
      Water Pump Removal................374
      Disassemble Water Pump (Standard Model)................375
      Water Pump Bearing Shaft Installation................377
      Water Pump Seal Installation................378
      Water Pump Impeller Installation................379
      Install Pulley or Hub................380
      Install Water Pump................381
      Water Pump With Rotating Assembly - Exploded View................383
      Rotating Assembly Removal................385
      Disassembling Rotating Assembly................386
      Reassembling Rotating Assembly................387
      Rotating Assembly Installation................390
      Thermostat Test and Replacement................391
      Cooling System Deaeration................393
      Check Fan/Alternator Belt Tension................394
      Install Fan................396
      Install Engine Fan Pulley on 2054 and 2254 Combines (With CD6060HZ001 Engines)................398
      Coolant Heater Operation (4 and 6 Cyl. Engines)................400
      Replacing the Coolant Heater (4 and 6 Cyl. Engines)................401
      Coolant Heater Operation (All Engines)................403
    Group 35: Air Intake and Exhaust System................35
      Specifications................591
      Torques for Hardware................473
      Intake Manifold Inspection................414
      Exhaust Manifold Inspection................415
      Turbocharger Removal................416
      Radial Bearing End Play Check (GARRETT Turbocharger)................417
      Check Radial Bearing Clearance (SCHWITZER Turbocharger)................418
      Axial End Play Check................419
      Turbocharger Repair................420
      Turbocharger Disassembly................421
      Turbocharger Reassembly................422
      SCHWITZER Turbocharger Model S2A................424
      Prelube Turbocharger................426
      Turbocharger Installation................427
      Turbocharger Break-In................429
      Recommendations for Turbocharger Use................430
    Group 40: Fuel System................35
      Special or Essential Tools................581
      Self-Manufactured Tool Template for Front Plate Replacement................439
      Self-Manufactured Tool Example of Stationary Pointer for Dynamic Timing................440
      Specifications................591
      Specifications - Mannheim Tractors................446
      Torques for Hardware................473
      Rectangular Fuel Filter Element Replacement................475
      Replace Round Fuel Filter Element................476
      Replace Round Fuel Filter Assembly................479
      Fuel Pump Replacement................480
      Lucas CAV Fuel Injection Pump Removal................481
      Repairs to Fuel Injection Pump................498
      Lucas CAV Fuel Injection Pump Installation................484
      Lucas CAV Fuel Injection Pump Static Timing................486
      STANADYNE DB2 or DB4 Fuel Injection Pump Removal................487
      Repairs to Fuel Injection Pump................498
      Replace Throttle Lever (STANADYNE)................490
      STANADYNE DB2 or DB4 Fuel Injection Pump Installation................491
      STANADYNE DB2 or DB4 Fuel Injection Pump Static Timing................493
      Engine Front Plate Replacement................494
      STANADYNE DM4 Fuel Injection Pump Removal................496
      Repairs to Fuel Injection Pump................498
      STANADYNE DM4 Fuel Injection Pump Installation and Timing................499
      Remove Fuel Supply Pump on MICO In-Line Fuel Injection Pump................501
      Test MICO Fuel Supply Pump for Leaks................502
      Disassemble MICO Fuel Supply Pump................503
      Assemble MICO Fuel Supply Pump................504
      Install Fuel Supply Pump On In-Line Fuel Injection Pump................505
      Service Injection Pump Overflow Valve (In-Line Injection Pump)................506
      Remove MICO In-Line Injection Pump................507
      JDG670A Modification................510
      Repair MICO In-Line Fuel Injection Pump................511
      Install MICO In-Line Fuel Injection Pump................512
      Dynamic Timing (All Pump Types)................514
      Install Timing Sensor................516
      Install Magnetic Probe (For Use Without Stroboscopic Lamp)................517
      Install Stationary Pointer (For Use With Stroboscopic Lamp)................519
      Timing Sensor and Magnetic Probe Connection................520
      Dynamic Timing at Full Load Rated Speed Using Magnetic Probe................522
      Dynamic Timing at No-Load................526
      Aneroid Replacement................531
      Aneroid Field Adjustment................532
      Aneroid Workshop Adjustment................533
      Fuel Injection Nozzle Removal................535
      Clean Fuel Injection Nozzle................536
      Fuel Injection Nozzle Test................537
      Fuel Injection Nozzle Disassembly................539
      Adjust Fuel Injection Nozzle................540
      Install Fuel Injection Nozzle................541
      Bleed the Fuel System at Fuel Filter................543
      Bleed Fuel System (Lucas-CAV)................545
      Bleed Fuel System (STANADYNE)................546
      Bleed Fuel System (MICO In-Line Injection Pump)................547
      Bleed Fuel System at Fuel Injection Nozzles................548
      Adjust Engine Speed On Distributor Injection Pump................549
      Adjust Engine Speed on MICO In-Line Injection Pump................551
    Group 205: Engine System - Operation................37
      Engine-Sectional View................554
      General Information................556
      Lubrication System................557
      Cooling System (4-Cylinder Engine)................561
      How the 37 kW Auxiliary Drive Works................562
    Group 210: Engine System - Diagnosis and Tests................37
      Special or Essential Tools................581
      Specifications................591
      Engine Break-In Instructions................568
      Engine Break-In Oil................569
      Diagnosing Engine Malfunctions................570
      Checking Engine Compression................574
      Checking Engine Oil Pressure................575
      Measuring Engine Blow-By................576
      Using STANADYNE “TIME-TRAC” as Tachometer................577
      Inspect Thermostat and Test Opening Temperature................578
    Group 215: Air Intake System - Operation and Tests................37
      Special or Essential Tools................581
      Specifications................591
      Turbocharger Operation................583
      Turbocharger Boost Pressure Check................584
      Diagnosing Turbocharger Malfunctions................585
      Air-to-Air Aftercooler Operation................586
    Group 220: Fuel System - Operation and Tests................37
      Fuel Filter Operation................589
      Specifications................591
      Fuel System Operation - Distributor Injection Pump................592
      Fuel Transfer Pump Operation (Distributor Injection Pump)................594
      Lucas CAV Fuel Injection Pump - Sectional View................595
      Lucas CAV Fuel Injection Pump - Operation................597
      Test Shut-Off Solenoid on Lucas-CAV Injection Pump................599
      STANADYNE Fuel Injection Pump (Type DM4) - Sectional View................600
      STANADYNE Fuel Injection Pump (DM4) - Operation................601
      STANADYNE Fuel Injection Pump (Type DB2/DB4) - Sectional View................602
      STANADYNE Fuel Injection Pump (DB2/DB4) - Operation................603
      Specifications (In-Line Pump)................604
      Fuel System Operation - In-Line Injection Pump (6 Cyl. Shown)................605
      Fuel System Operation-In-Line Injection Pump................606
      Fuel Transfer Pump Operation (In-Line Injection Pump)................607
      Diagnose Fuel Supply Pump Malfunctions-In-Line Injection Pump................609
      In-Line Fuel Injection Pump Operation................611
      Governor Operation (In-Line Pump)................613
      Diagnose In-Line Fuel Injection Pump Malfunctions................615
      Fuel Injection Nozzles - General Information................616
      Diagnosing Fuel System Malfunctions................618
      Testing Fuel Injection Nozzles On a Running Engine................620
      Timing of Fuel Injection Pumps On Diesel Engines Using Stroboscopic Lamp................621

John Deere 3029, 4039, 4045, 6059, 6068 Engines Component Technical Manual (CTM3274)