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John Deere John Deere Strong Deer Diesel Engine 3029, 4039, 4045, 6059 and 6068 Repair Technical Operation Maintenance Manual


Detailed Description:

John Deere John Deere Strong Deer Diesel Engine 3029, 4039, 4045, 6059 and 6068 Repair Technical Operation Maintenance Manual

3029/4039/4045/6059/6068 diesel

Group 00—Safety Replenishing Supplemental Coolant

Handle Fluids Safely—Avoid Fires...... 00-1 Additives (SCA's) Between Coolant

Prevent Battery Explosions ...... 00-1 Changes ........... ... 02-12

Prepare for Emergencies....... 00-1 Operating in Warm Temperature Climates...

Prevent Acid Burns....... 00-2 Flush and Service Cooling System.

Avoid High-Pressure Fluids ...... 00-3 Disposing of Coolant...... . 02-15

Wear Protective Clothing...........

Service Machines Safely......... 00-4 Group 03-Engine Mounting

Work in Ventilated Area ...... 00-4 Engine Repair Stand........ .. 03-1

Work in Clean Area..................... ............................................. ... 03-2

Remove Paint Before Welding or Heating... 00-5 Install 300 Series Adapters on Repair Stand... 03-3

Avoid Heating Near Pressurized Fluid Lines... 00-5 Engine Lifting Procedure.............

Illuminate Work Area Safely ...... 00-6 Clean Engine ........... ... 03-5

Use Proper Lifting Equipment....... 00-6 Mount Engine on Repair Stand...

Construct Dealer-Made Tools Safely ...... 00-6 Disconnect Turbocharger Oil Inlet Line... 03-8

Practice Safe Maintenance.......

Use Proper Tools............ 00-7 Group 04-Engine Rebuild Guide

Dispose of Waste Properly ...... 00-8 Engine Disassembly Sequence... 04-1

Live With Safety ... ............ 04-3

Engine Assembly Sequence........

Group 01—General Information

Unified Inch Bolt and Cap Screw Torque Group 05—Cylinder Head and Valves

Values.................... ....... .... 05-1

Metric Bolt and Cap Screw Torque Values ... 01-2 Service Equipment And Tools.......

Engine Model Designation........ 01-3 Other Material............. ... 05-6

Engine Serial Number Plate Information.... 01-4 Cylinder Head and Valves Specifications...

OEM Engine Option Code Label...... 01-5 Check and Adjust Valve Clearance...

Engine References ... ..... 01-5 Measure Valve Lift ......... ... 05-15

Engine Application Chart John Deere Remove Cylinder Head...........

Agricultural Equipment.........

Engine Application Chart John Deere Assembly................

Construction Equipment....... 01-7 Assemble Rocker Arm Assembly...

Engine Application Chart OEM Applications ... 01-10 Inspect, Measure, and Assemble Camshaft

Followers.............

Group 02—Fuels, Lubricants and Coolant Check Valve Recess In Cylinder Head.....

Diesel Fuel............... 2 Cylinder Head and Valve Checks.

Lubricity of Diesel Fuels........ Remove Valve Assembly...... 25

Engine Break-In Oil....... 02-2 Inspect and Measure Valve Springs...

Diesel Engine Oil ...... ... 02-3 Inspect Valve Rotators........ ... 05-26

Alternative and Synthetic Lubricants ... .. 02-4 Clean Valves ........

Mixing of Lubricants ...... ... 02-4 Inspect and Measure Valves ... 05 -27

OILSCAN Plusâ and COOLSCAN Plusâ ... .. 02-5 Grind Valves........

Grease............ Inspect and Clean Cylinder Head... ... 05-29

Diesel Engine Coolant Recommendations... 02-7 Check Cylinder Head Flatness.....

Engine Coolant Specifications......

Testing Diesel Engine Coolant........ 02-11 Continued on next page

Measure Cylinder Head Thickness...... 05-30 Inspect and Measure Connecting Rod

Clean Injection Nozzle Bores...... 05-30 Bearings (Rod and Crankshaft in Engine) ... 10-36

Clean Valve Guides ......... 05-31 Inspect Rod and Cap ... ... 10-37

Measure Valve Guides......... 05-31 Inspect Piston Pins and Bushings... 10-39

Knurl Valve Guides............. Remove Piston Pin Bushing ... -41

Clean and Inspect Valve Seats........ 05-32 Clean and Inspect Connecting Rod Pin Bore... 10-43

Grind Valve Seats......... 05-33 Install Piston Pin Bushing in Connecting Rod... 10-44

Remove Valve Seat Inserts ...... 05-34 Measure Rod Center-to-Center Bores... 10-47

Measure Valve Seat Bore in Cylinder Head .. 05-38 Inspect and Clean Cylinder Block...... 10-47

Install Valve Seat Inserts........ 05-39 Clean Cylinder Liner O-Ring Bore....

Install Valves............... Measure Cylinder Block Main Bearing Bore .. 10-49

Clean and Inspect Cylinder Head Cap Measure Camshaft Follower Bore..... 10-50

Screws........... 10-51

Inspect and Clean Exhaust Manifold..... 05-40 Measure Balancer Shaft Bore—4-Cylinder

Clean and Inspect Top Deck of Cylinder Engines.................

Block............ Measure Cylinder Block Top Deck Flatness .. 10-53

Measure Cylinder Liner Standout (Height Measure Liner Flange Counterbore Depth

Above Block)............... ... 10-54

Install Cylinder Head............... Measure Liner Flange Thickness...

Torque-Turn Method For Proper Torque.... 05-45 Remove, Inspect and Install Piston

Install Rocker Arm Assembly... .. 05-45 Cooling Orifices........ 10 -55

Inspect and Clean Ventilator Outlet Hose... 05-46 Measure Cylinder Liners and Block Bores... 10-56

Install Rocker Arm Cover........ 05-47 Install Steel Ball in Oil Passage of

Complete Final Assembly... .. 05-48 Cylinder Block.......... . 10-58

Perform Engine Break-In.......... 05-50 Measure Cylinder Liner Standout (Height

Above Block)............

Group 10--Cylinder Block, Liners, Pistons and Install Cylinder Liner O-Rings and Packings ... 10-61

Rods Install Cylinder Liner..............

Essential Tools................ .......................................................................................................................................

Service Equipment And Tools ... .. 10-4 Install Piston Rings ... .. 10- 65

Other Material...........

Cylinder Block, Liners, Pistons and Rods Torque-Turn Connecting Rod Cap Screws.... 10-70

... 10-6 Check Engine Rotation For Excessive

Remove Pistons and Connecting Rods ... 10-14 Tightness .................

Remove Cylinder Liners........ Measure Piston Protrusion ... .. 10-72

Complete Disassembly of Cylinder Block (If Cylinder Block Orifices (Saran Engines)... 10-74

Required)...... .. 10-20 Cylinder Block Orifices... ... 10-75

Preliminary Liner, Piston and Rod Checks ... 10-21 Complete Final Assembly ... .. 10-76

Disassemble Piston and Rod Assembly... 10-22

Clean Pistons ............. 10-23 Group 15-Crankshaft, Main Bearings and

Visually Inspect Pistons............ 10 Flywheel

Clean Cylinder Liners ...... 10-26 Essential Tools ........... ... 15-1

Visually Inspect Cylinder Liners ... 10-27 Service Equipment And Tools ... 15-4

Check Piston Ring Groove Wear ... ... 10-29 Other Material .............. . 15-6

Measure Piston Pin Bore......... 10-30 Crankshaft, Main Bearings and Flywheel

Measure Piston Skirt .................... ....... ... 15-7

Measure Piston Height......... 10-31 Crankshaft and Main Bearing Failure Analysis. 15-12

Determine Piston-to-Liner Clearance ... 10-32 Inspect Vibration Damper (6-Cylinder Engine) ... 15-13

Deglaze Cylinder Liners............ 10 ... Remove Pulley or Vibration Damper

Replace Piston and Liner Sets ... .. 10-34 Pulley (Engine W / O Front PTO) ... 15-15

Inspect and Measure Connecting Rod

Bearings (Rods Removed From Engine)... 10-34 Continued on next page

Install Pulley or Vibration Damper Pulley Measure Assembled ID of Main Bearing

(Engine W / O Front PTO) ... 15-16 Caps ............... ... 15-59

Checking Vibration Damper or Pulley Measure Crankshaft Main Bearing Bore

(Engine With Front PTO) ...... 15-18 Centerline-To-Top Deck......... 15-60

Removing Vibration Damper or Pulley Inspect Piston Cooling Orifices.......

(Engine With Front PTO)...... 15-19 Install Main and Thrust Bearing Inserts In

Installing Vibration Damper or Pulley Block.................

(Engine With Front PTO) ... 15-20 Install Crankshaft ............ .. 15-63

Installing Vibration Damper or Pulley Install Flywheel Housing...........

(Engine With Crankshaft Gear-Driven PTO) .. 15-21 Complete Final Assembly.......... 15-69

Replace Front Crankshaft Oil Seal

(Without Removing Timing Gear Cover) ... 15-22

Check Crankshaft End Play...... 15-25 Group 16—Camshaft, Balancer Shafts and Timing

Inspect Flywheel..........

Check Flywheel Housing Face Runout ... 15-27 Essential Tools ......... 16-1

Check Flywheel Face Flatness ... 15-15 Service Equipment And Tools ... 16-3

Check Pilot Bearing Bore Concentricity ... 15-28 Other Material ...........

Remove Flywheel........... 15 Camshaft, Balancer Shafts and Timing Gear

Replace Flywheel Ring Gear ... .. 15-29 Train Specifications.......

Replace Pilot Bearing In Flywheel-3029, Measure Valve Lift ...... 16-14

4039, 4045 Engines (If Equipped) ... 15-31 Remove Timing Gear Cover ... 16-16

Install Flywheel............. Remove and Install Camshaft Bushing With

Crankshaft Rear Oil Seal and Wear Sleeve Front Plate Installed Camshaft Gear-Driven

General Information......... 15-33 Auxiliary Drive Engines, Saran Built

Crankshaft Unitized Rear Oil Seal and Engines Serial No. (138541-) ... 16-18

Wear Sleeve Handling Precautions.... 15-34 Remove Auxiliary Drive Gears (Engines

Remove Two-Piece Crankshaft Rear Oil Seal With Auxiliary Gear Drive Option)...

and Wear Sleeve (Without Removing Flywheel Measure Camshaft End Play...........

Housing).............. Measure Balancer Shaft End Play (4-Cylinder

Remove Unitized (Non-Separable) Engines)..............

Crankshaft Rear Oil Seal and Wear Sleeve .. 15-36 Measure Idler Gear End Play.......

Clean and Inspect Crankshaft Flange ... 15-39 Measure Timing Gear Backlash ... 16-23

Install Crankshaft Rear Oil Seal and Wear Remove Camshaft................

Sleeve .................. ... 16-29

Remove Flywheel Housing......... 15-42 Measure Camshaft Thrust Plate Clearance

Remove Crankshaft Main Bearings ... 15-43 and Thickness ... ... 16-29

Check Main Bearing Oil Clearance..... 15-44 Inspect and Measure Camshaft Bearing

Remove and Install Crankshaft Gear Bore ID and Journal OD.......

(Crankshaft Installed In Engine) ... 15-45 Measure Camshaft Lobe Height ... 16-31

Remove Crankshaft................

Remove and Install Camshaft Gear...... 16-32

Remove Crankshaft Rear Wear Sleeve

(Crankshaft Removed From Engine) ... 15-48 Inspect Camshaft Followers ...... 16-33

Inspect Crankshaft .......... 15-49 Replace Tachometer Drive Gear... 16-34

Measure Main Bearing ID and Crankshaft Remove and Install Camshaft Bushing With

Journal OD............ 15 Front Plate Removed Engine Serial No. (-

Measure Main Thrust Journal Width and 138540)............

Thrust Bearing Width......... 15-52 Remove Balancer Shafts-If Equipped

Crankshaft Grinding Guidelines ... 15-53 (4-Cylinder Engines) ... .. 16-38

Crankshaft Grinding Specifications [Earlier Inspect and Measure Balancer Shaft

Engines With Ground (Tangential) Fillets (A)] Bushings and Journals........ 16-39

... 15-57 Remove and Install Balancer Shaft Bushings.......

Crankshaft Grinding Specifications [Later (4-Cylinder Engines)........

Engines With Undercut and Rolled Fillets (A)]

... 15-58 Continued on next page

Install Oversize Balancer Shaft Bushings Remove and Install Oil Bypass Valve—4045

In Cylinder Block (4039 Engines)... 16-41 and 6068 Engines With Pre-Common Lube

Inspect Balancer Shaft Gears and Thrust Block1................

Plates................. Remove and Install Oil Pressure Regulating

Remove and Install Balancer Shaft Gears... 16-43 Valve and Seat—3029, 4039, and 6059

Remove Cylinder Block Front Plate..... 16-44 Engines and 4045 and 6068 Engines

Measure Idler Gear Bushing and Shaft ... 16-46 With Common Lube Block1 ...... 20-20

Remove and Install Idler Gear Bushings.... 16-48 Remove, Inspect, and Install Oil Pressure

Remove Lower and Upper Idler Shafts.... 16-48 Regulating Valve—4045 and 6068

Clean and Inspect Front Plate...... 16-49 Engines With Pre-Common Lube Block1... 20-21

Replace Engine Front Plate....... 16-50 Remove and Install Oil Filter Nipple—

Transfer Fuel Injection Pump Timing Mark 3029, 4039, 6059 Engines...... 20-23

Onto Replacement Front Plate...... 16-51 Remove and Install Oil Pan Mounted Oil

Install Idler Shaft Spring Pins (If Equipped) ... 16-52 Fill / Dipstick Tube ..........

Install Upper Idler Shaft In Front Plate ... 16-53 Remove, Install, and Adjust Dipstick Nipple ... 20-26

Install Lower Idler Shaft In Front Plate... 16-53 General Oil Pump Information.....

Install Engine Front Plate........ 16-54 Remove, Inspect and Install Oil Pump

Install and Time Balancer Shafts—If Pick-Up Tube Assembly ...... 20-27

Equipped (4-Cylinder Engines) ...... 16-55 Remove Standard Capacity Oil Pump... 20-28

Install and Time Camshaft and Fuel Injection Inspect and Measure Clearances

(Standard Capacity Oil Pump).....

Pump....................

Complete Standard Capacity Oil Pump

Clean and Inspect Timing Gear Cover... 16-62

Disassembly.......... 20-30

Install Ball Bearings and Dowels (Engines

Assemble Standard Capacity Oil Pump... .. 20-32

With Crankshaft-Driven Auxiliary Gear Drive Install Standard Capacity Oil Pump...... 20-33

Option).............. Remove High Capacity Oil Pump... .. 20-35

Install Drive Gear (Engines With Inspect and Measure Clearances (High

Crankshaft-Driven Auxiliary Gear Drive Option) Capacity Oil Pump) ... 20-37

... .. 16-63 Complete High Capacity Oil Pump

Install Timing Gear Cover ... 16-64 Disassembly ......... 16-64 Disassembly ... . 20-39

Install Idler Gear and Output Gear Assemble High Capacity Oil Pump...... 20-39

(Engines With Auxiliary Gear Drive Option) .. 16-71 Install High Capacity Oil Pump.......

Complete Final Assembly ... .. 16-72 Install Oil Pan............ ... 20-42

Group 20--Lubrication System Group 25--Cooling System

Essential Tools........ 20-1 Essential Tools........ ... 25-1

Service Equipment And Tools ... .. 20-1 Service Equipment And Tools ... .. 25-2

Other Material.............. ... 25-3

Lubrication System Specifications... .. 20-3 Cooling System Specifications....

General Lubrication System Information... 20-8 Remove, Test, and Install Thermostats... 25-9

Oil Cooler Identification......... 20 Remove and Install Water

Remove, Inspect, and Install Standard-Flow Manifold / Thermostat Housing...... 25-11

Oil Cooler............ General Water Pump Information... 25 -12

Remove and Install High-Flow Oil Cooler ... 20-11 Remove Water Pump ...........

Replacing Standard Oil Cooler / Oil Filter Disassemble Low Flow, Standard-Duty

Housings............ 20-14 High Flow, and Modular Style Water Pumps

Replace Oil Filter Adapter on Engine With..................

Remote Oil Filter.......... 20-17 Disassemble Heavy-Duty High Flow Water

Remove, Inspect, and Install Oil Bypass Pump...................

Valve—3029, 4039, and 6059 Engines and Inspect and Clean Water Pump Parts... 25-21

4045 and 6068 Engines With Common Lube

Block1.............

Assemble Low Flow, Standard-Duty High Replace Round Fuel Filter Element (Early

Model Engines) ... Flow, and Modular Style Water Pumps ... 25-23 ...... 35-19

Assemble Heavy-Duty High Flow Water Replace Final Fuel Filter and Primary Fuel

Pump........................ .............................................................................

Pulley or Hub-to-Rear Face of Water Pump Engines)...........

Housing Dimensions ...... 25-36 Remove Fuel Supply Pump... 35-21

Check Water Pump Cap Screw Protrusion... 25-41 Bench Test Fuel Supply Pump........

Install Water Pump.......... 25-43 Install Fuel Supply Pump..... .. 35-24

Cooling System Deaeration ...... 25-44 Fuel Injection Pump Timing ...

Inspect and Install Fan Blade Assembly... 25-44 Remove Stanadyne Model DB2 Injection

Adjust Fan Belt Tension....... 25-45 Pump With Non-Retained Drive Shaft...

Remove and Install Coolant Heater Repair Stanadyne Fuel Injection Pump... 35-28

(Dubuque-Built Engines) —If Equipped.... 25-46 Remove Stanadyne DB2 Non-Retained

Remove and Install Coolant Heater Injection Pump Drive Shaft From Engine... 35-29

(Saran-Built Engines) —If Equipped...... 25-48 Install Non-Retained Drive Shaft In

Stanadyne DB2 Injection Pump (If

Group 30-Air Intake and Exhaust System Removed from Engine) ... 35-30

Other Material........... 30. Install Stanadyne Model DB2 Injection

Air Intake and Exhaust System Specifications ... 30-2 Pump With Non-Retained Drive Shaft ... 35-32

Extending Turbocharger Life...... 30-4 Remove Stanadyne Model DB2 (With

Remove Turbocharger........... 30-6 Retained Drive Shaft) and DB4 Injection

Turbocharger Failure Analysis ... .. 30-7 Pump.............. ... 35-35

Inspect Injection Pump Drive Gear ID and

Turbocharger Seven-Step Inspection ......

Perform Radial Bearing Clearance Test ... 30-14 Shaft OD ...... 35-37

Perform Axial Bearing End Play Test... 30-15 Repair Stanadyne Fuel Injection Pump... 35-38

Install Stanadyne Model DB2 (With

Repair Turbocharger ... 30-16

Retained Drive Shaft) and DB4 Injection

Disassemble and Inspect Turbocharger... 30-17

Pump....................

Replace Center Housing and Rotating

Remove Stanadyne Model DM4 Fuel

Assembly......... 30 Injection Pump.......... ... 35-43

Prelube Turbocharger........ 30-19 Repair Stanadyne Fuel Injection Pump... 35-45

Install Turbocharger..........

Install Stanadyne Model DM4 Fuel

Turbocharger Break-In........

Injection Pump...............

Recommendations for Turbocharger Use... 30-22 Remove Lucas CAV Fuel Injection Pump... 35-48

Remove, Inspect and Install Intake Manifold ... 30-23 Repair Lucas CAV Fuel Injection Pump... 35-50

Remove, Inspect and Install Exhaust Install Lucas CAV Fuel Injection Pump... 35-51

Manifold................... ... 35-54

Aftercooler Assembly...... 30 Aneroid Field Adjustment... 35-54

Remove and Install Aftercooler... .. 30-26 Aneroid Workshop Adjustment... 35-55

Inspect and Repair Aftercooler ... .. 30-27 Replace Engine Front Plate ... .. 35-56

Transfer Fuel Injection Pump Timing Mark

Group 35-Fuel System Onto Replacement Front Plate...... 35-57

Essential Tools...... 35-1 Remove Fuel Injection Nozzles... 35 -58

Service Equipment and Tools ...... 35-4 Clean Fuel Injection Nozzle Bore ... .. 35-59

Other Material......... Clean Injection Nozzles... ... 35-59

Fuel System Specifications ...... 35-7 Diagnose Fuel Injection Nozzle Malfunction ... 35-60

Fuel System-General Information ... .. 35-11 Test Fuel Injection Nozzles ...... 35-61

Relieve Fuel System Pressure... 35-12 Disassemble Injection Nozzles ... .. 35-67

Replace Primary Fuel Filter / Water Inspect and Clean Nozzle Body....... 35-70

Separator and Final Fuel Filter Assemblies ... 35-13 Inspect and Clean Valve and Valve Seat... 35-72

Primary Fuel Filter / Water Separator Assembly ... 35-15 Inspect Valve Adjusting Mechanism ...... 35-74

Final Fuel Filter Assembly........

Replace Rectangular Fuel Filter Element... 35-17

Assemble Injection Nozzles ...... 35-75 Service Equipment and Tools ... 110-1

Adjust Fuel Injection Nozzles ...... 35-76 Air Intake System Test Specifications... 110-3

Install Seals on Injection Nozzle ... .. 35-81 Diagnosing Air Intake Malfunctions... 110-5

Install Injection Nozzles.......... 35-82 How the Air Intake and Exhaust System

Works....... 110-6

Group 40-Starting and Charging Systems Air Cleaner Operation....... 110-7

Essential Tools........ 40-1 Air Filter Restriction Indicator Switch Test ... 110-8

Remove and Install Starter ... .. 40-2 Intake Air Leak Test......... . 110-9

Remove and Install Alternator....... 40-3 Exhaust Leak Check (Turbocharged

Engines ... 110-10

Group 100—Engine Tune-Up and Break-In Intake and Exhaust Restriction Check..... 110-11

Effects of Altitude and Temperature on Diagnosing Turbocharger Malfunctions... 110-12

Engine Performance ... .. 100-1 Turbocharger Operation... 110-13

Preliminary Engine Testing ... .. 100-1 How the Turbocharger is Lubricated ... 110-13

General Tune-Up Recommendations.... 100-2 Check Intake Manifold Pressure

Dynamometer Test....... 100-3 (Turbocharger Boost)..... 110-14

Dynamometer Test Specifications ...... 100-4 Turbocharger Oil Seal Leak Test... 110-17

Engine Break-In Guidelines.......

Perform Engine Break-In.......... 100-13

Engine Oil Consumption ...... 100-14 Group 115-Fuel System Operation and Tests

Check Crankcase Ventilation System ... 100-15 Essential Tools ...... 115-1

Check Air Intake System ...... 100-15 Service Equipment And Tools ... 115-2

Check Exhaust System ... .. 100-16 Fuel System Test Specifications... 115-3

Check and Service Cooling System... 100-17 Fuel Injection Pump Specifications... 115-4

Check Electrical System . . . . . . . . . . . . . . . . . . 100-18 Using TIME TRACâ as a Tachometer . . . . . . . . 115-13

Check and Adjust Rotary Injection Pump

Group 105—Engine System Operation and Tests Dynamic Timing. . . . . . . . . . . . . . . . . . . . . . . 115-13

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Fuel System Operation . . . . . . . . . . . . . . . . . . . 115-20

Engine Test Specifications . . . . . . . . . . . . . . . . . 105-3 Diagnose Fuel System Malfunctions . . . . . . . . . 115-22

Engine-Sectional View ...... 105-4 Fuel Supply Quality Check... 115-26

General Engine Description ... .. 105-5 Air in Fuel Test......... 115-27

How the Engine Lubrication System Works ... 105-8 Restricted Fuel Return Line Check... 115-28

How the Cooling System Works ...... 105-12 Fuel Supply Pump Operation-If Equipped ... 115-29

How the Crankshaft Gear-Driven Auxiliary Diagnose Fuel Supply Pump Malfunctions... 115-30

Drive Works.......... 105 Measure Fuel Supply Pump Pressure ... 115-31

Head Gasket Joint Construction and Fuel Shut-Off Solenoid Resistance Test

Operation...... 105-18 (Lucas Pump)... ... 115-32

Diagnosing Head Gasket Joint Failures... 105-20 Rectangular Final Fuel Filter Operation... 115-32

Head Gasket Inspection and Repair Round (Primary) Fuel Filter / Water Separator

Sequence....... 105-24 Operation......... ... 115-33

Diagnosing Engine Malfunctions.... 105-26 Final Fuel Filter / Water Separator Operation. 115-34

Test Engine Compression Pressure... 105-30 Bleed the Fuel System...... 115-35

Check Engine Oil Pressure..... 105-32 Stanadyne Fuel Injection Pump Operation.. 115-40

Measure Engine Crankcase Pressure Lucas CAV Fuel Injection Pump Operation... 115-42

(Blow-By)...............

Pressure Test Cooling System and Malfunctions ............. 115-44

Radiator Cap.......... 105-34 Check and Adjust Engine Speeds on Lucas

Inspect Thermostat and Test Opening CAV Pump................

Temperature........... 105-36 Adjust Variable Speed on Generator Set

Engine Cranking Speed Test ... 105-37 Engines (Lucas CAV Pumps Only) ... 115-46

Check and Adjust Engine Speeds on

Group 110-Air Intake and Exhaust System Stanadyne Pump.............. 115-47

Operation and Tests

Essential Tools........ 110-1

Adjust Variable Speed (Droop) on Generator

Set Engines (3—5% Govenor Regulation) —

Stanadyne DB2, DB4, DM4 Injection Pumps

... 115-48

Changing Gen Set Engine Rated Speed from

1800 RPM to 1500 RPM--Stanadyne

DB2, DB4, DM4 Injection Pumps ... 115-49

Diagnose Aneroid Malfunctions ...... 115-52

Fuel Injection Nozzles—General Information

and Operation........ 115-53

Diagnose Fuel Injection Nozzle Malfunctions.. 115-54

Test Fuel Injection Nozzles (Engine

Running) ... 115-55

Fuel Drain Back Test Procedure...... 115-56

Group 199—Dealer Fabricated Tools

How to Make Tools.......

DFRG2—Injection Pump Front Plate

Timing Mark Transfer Tool ...... 199-1

DFRG3-Cylinder Liner Holding Fixture... 199-2

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