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John Deere 6059T Diesel Engine Technical Manual
Manuals Includes info on:
CHAPTER 1
INTRODUCTION ............................................................................................... 1-1
Section I.
General Information ...................................................................................................... 1-1
Section II.
Equipment Description and Data................................................................................... 1-1
Section III. Preparation forUse......................................................................................... 1-4
CHAPTER 2
OPERATION................................................................................................................. 2-1
Section I.
PRINCIPLES OF OPERATION..................................................................................... 2-1
Section II.
OPERATING INSTRUCTIONS ..................................................................................... 2-1
CHAPTER 3
MAINTENANCE............................................................................................................ 3-1
Section I.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)............................. 3-1
Section II.
Troubleshooting ............................................................................................................ 3-2
Section III.
General Maintenance.................................................................................................... 3-15
Section IV.
Cooling System Maintenance........................................................................................ 3-21
Section V.
Electrical System Maintenance ..................................................................................... 3-27
Section VI.
Intake and Exhaust System Maintenance...................................................................... 3-51
Section VII. Lubrication System Maintenance................................................................................... 3-61
Section VIII. Fuel System Maintenance............................................................................................. 3-76
Section IX.
Cylinder Head Assembly Maintenance .......................................................................... 3-139
Section X.
Flywheel and Housing Assembly Maintenance.............................................................. 3-159
Section XI.
Crankshaft Pulley and Timing Gear Cover
Assembly Maintenance.............................................................................................. 3-164
Section XII. Camshaft Assembly Maintenance ................................................................................. 3-168
Section XIII. Idler Gears and Front Plate Assembly Maintenance...................................................... 3-174
Section XIV. Crankshaft and Main Bearings Maintenance.................................................................. 3-180
Section XV. Pistons, Connecting Rods, Cylinder Liners,
and Engine Block Maintenance.................................................................................. 3-190
APPENDIX A
REFERENCES ............................................................................................................. A-1
APPENDIX B
MAINTENANCE ALLOCATION CHART........................................................................ B-1
APPENDIX C
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST..................................... C-1
APPENDIX D
FABRICATION OF TOOLS........................................................................................... D-1
APPENDIX E
MAINTENANCE PROCEDURES AND AUTHORIZED LEVEL OF MAINTENANCE...... E-11-1.
Engine Components............................................................................................. 1-3
3-1.
Connecting Test Gage to Intake Manifold......................................................................................... 3-19 3-2.
Thermostat andHousing ........................................................................................ 3-22
3-3.
Engine Oil Cooler Hoses .................................................................................................................. 3-24
3-4.
Water Pump Assembly..................................................................................................................... 3-25
3-5.
Battery Charging Alternator and Mounting Brackets.......................................................................... 3-28
3-6.
Battery Charging Alternator Assembly .............................................................................................. 3-30
3-7.
Stator and Rear Housing Separation ................................................................................................ 3-30
3-8.
Testing Brush Assembly................................................................................................................... 3-31
3-9.
Testing Diode-Trio............................................................................................................................ 3-31
3-10.
Testing Rectifier Bridge.................................................................................................................... 3-32
3-11.
Testing Stator Windings ................................................................................................................... 3-33
3-12.
Testing Rotor.................................................................................................................................... 3-33
3-13.
Battery Charging Alternator Test Circuit ........................................................................................... 3-34
3-14.
Starter Bench Test Setup ................................................................................................................. 3-36
3-15.
Starter Assembly.............................................................................................................................. 3-37
3-16.
Disconnecting Lead Wire (Typical)..................................................................................... 3-38
3-17.
Removing Through Bolts (Typical) ....................................................................................... 3-38
3-18.
Removing Starter End Frame and Yoke Assembly (Typical)...................................................... 3-39
3-19.
Removing Brushes.............................................................................................................. 3-40
3-20.
Removing Armature .............................................................................................................. 3-40
3-21.
Removing Housing (Typical) ................................................................................................. 3-41
3-22.
Removing Overrunning Clutch (Typical)................................................................................ 3-41
3-23.
Removing Steel Ball........................................................................................................... 3-42
3-24.
Removing Pinion, Retainer, and Rollers (Typical)................................................................ 3-42
3-25.
Removing Washer and Spring.............................................................................................. 3-43
3-26.
Checking Commutator Run-Out......................................................................................... 3-43
3-27.
Measuring Commutator OD................................................................................................... 3-44
3-28.
Measuring Segment MicaDepth......................................................................................... 3-44
3-29.
Inspecting and ReplacingBearings........................................................................ 3-45
3-30.
Measuring BrushLength........................................................................................ 3-45
3-31.
Checking OverrunningClutch......................................................................................... 3-46
3-32.
Starter Solenoid TestCircuit......................................................................................... 3-46
3-33.
GrowlerTest................................................................................................................... 3-47
3-34.
Testing for GroundedWindings....................................................................................... 3-47
3-35.
Checking for Open CircuitWindings............................................................................. 3-47
3-36.
Checking Brush Holder..................................................................................................... 3-48
3-37.
Checking FieldCoils................................................................................. 3-48
3-38.
Checking for Open FieldCoil........................................................................................ 3-49
3-39.
Installing Brushes .............................................................................................................. 3-49
3-40.
Installing Cover On Yoke..................................................................................................... 3-50
3-41.
Installing Yoke..................................................................................................................... 3-50
3-42.
Turbocharger................................................................................................................ 3-52
3-43.
Turbocharger Inspection Points ........................................................................................................ 3-53
3-44.
Exhaust Manifold............................................................................................................ 3-58
3-45.
Intake Manifold.................................................................................................................... 3-60
3-46.
Oil Filter and Cooler.......................................................................................................... 3-62
3-47.
Removing Oil Filter Nipple ................................................................................................. 3-63
3-48.
Installing Oil Filter Nipple .................................................................................................. 3-64
3-49.
Driving Oil Filter Nipple ..................................................................................................... 3-64
3-50.
Oil Pressure Regulating Valve and Oil Filler Assembly................................................. 3-66
3-51.
Dipstick ............................................................................................................ 3-68
3-52.
Oil Pan............................................................................................................................. 3-69
3-53.
Oil Pump Assembly............................................................................................................ 3-71
3-54.
Measuring Oil Pump Axial Clearance ................................................................................ 3-72
3-55.
Measuring Oil Pump Radial Clearance.............................................................................. 3-72
3-56.
Oil Pressure Test Setup..................................................................................................... 3-74
3-57.
Oil Bypass Valve Installation ............................................................................................ 3-74
3-58.
Fuel Filter and Fuel Supply Pump ................................................................................. 3-78
3-59.
Fuel Lines and Injection Pump Installation........................................................................ 3-83
3-60.
Flywheel Locking Tool........................................................................................................ 3-85
3-61.
Checking Timing Marks.................................................................................................... 3-85
3-62.
Fuel Infection Pump Gear Access (Cover Removed........................................................ 3-86
3-63.
Separating Gear and Shaft............................................................................................. 3-86
3-64.
Fuel Injection Pump Assembly ......................................................................................... 3-89
3-65.
Disassembly of Shut-Off Lever.......................................................................................... 3-90
3-66.
Disassembly of Throttle Shaft Assembly........................................................................... 3-90
3-67.
Speed Droop Governor ................................................................................................ 3-91
3-68.
Disengaging Governor Linkage (Typical)............................................................................. 3-92
3-69.
Removing Metering Valve ............................................................................................ 3-92
3-70.
Removing Vent Wire Screw ............................................................................................... 3-93
3-71.
Removing Transfer Pump Screw....................................................................................... 3-93
3-72.
Removing Transfer Pump End Cap.................................................................................. 3-94
3-73.
Fuel Injection Pump Hydraulic Head Assembly................................................................... 3-95
3-74.
Transfer Pump Regulator Components.............................................................................. 3-96
3-75.
Removing Transfer Pump Blades.................................................................................. 3-96
3-76.
Removing End Cap Seal............................................................................................. 3-97
3-77.
Removing Head Locating Screw.................................................................................. 3-97
3-78.
Removing Advance Screw Hole Plug ............................................................................... 3-98
3-79.
Removing Spring Side Advance Plug............................................................................... 3-98
3-80.
Disassembling Governor .................................................................................................... 3-99
3-81.
Removing Shaft Retaining Nut ............................................................................................ 3-99
3-82.
Removing Governor Arm .......................................................................................... 3-100
3-83.
Removing Rotor Retainers ............................................................................................ 3-100
3-84.
Removing Cam Ring (Typical)........................................................................................... 3-101
3-85.
Removing Delivery Valve.................................................................................................. 3-101
3-86.
Removing Leaf Spring (Typical)........................................................................................ 3-102
3-87.
Removing Rollers (Typical) ............................................................................................... 3-102
3-88.
Removing Pumping Plungers (Typical)....................................................................... 3-103
3-89.
Delivery Valve Replacement ........................................................................................... 3-108
3-90.
Installing Rollers and Shoes (Typical)......................................................................... 3-109
3-91.
Measuring Roller-To-Roller Dimension.............................................................................. 3-110
3-92.
Installing Seals and Bearing .......................................................................................... 3-112
3-93.
Installing Protection Tube................................................................................................ 3-113
3-94.
Installing Governor Arm.................................................................................................... 3-113
3-95.
Installing Weights........................................................................................................ 3-114
3-96.
Installing Thrust Washer and Sleeve ................................................................................. 3-114
3-97.
Inserting Hydraulic Head (Typical)..................................................................................... 3-115
3-98.
Installing Metering Valve .................................................................................................. 3-116
3-99.
Installing Governor Linkage...................................................................................... 3-116
3-100.
Alignment of Spacer................................................................................................. 3-117
3-101.
Alignment of Shutoff Arm .................................................................................................. 3-118
3-102.
Installing Throttle Shaft Assembly (Typical)...................................................................... 3-118
3-103.
Checking Clearance at Linkage Hook...................................................................... 3-120
3-104.
Installing Shutoff Cam.............................................................................................. 3-121
3-105.
Installing End Cap ............................................................................................... 3-122
3-106.
Installing Retaining Plate................................................................................................. 3-122
3-107.
Installing Locking Head Bolts..................................................................................... 3-123
3-108.
Installing Pilot Tube Seal............................................................................................ 3-123
3-109.
Fuel Injection Pump Installation........................................................................................ 3-129
3-110.
Checking Timing Marks................................................................................................ 3-129
3-111.
Checking Injection Pump Gear Timing .............................................................................. 3-130
3-112.
Fuel Injection Nozzle........................................................................................................ 3-133
3-113.
Fuel Injection Nozzle Seals ...................................................................................... 3-136
3-114.
Valve Cover .................................................................................................................. 3-139
3-115.
Adjusting Valve Clearance ............................................................................................... 3-140
3-116.
Checking Valve Clearance ..................................................................................... 3-141
3-117.
Installing Timing Pin............................................................................................... 3-141
3-118.
Rocker Arm Assembly.................................................................................................... 3-143
3-119.
Cylinder Head Assembly .................................................................................................. 3-147
3-120.
Valve Face Angle.............................................................................................................. 3-150
3-121.
Measuring Cylinder Head Thickness................................................................................. 3-151
3-122.
Valve Seat Bore Specifications ......................................................................................... 3-155
3-123.
Measuring Cylinder Liner Height........................................................................................ 3-156
3-124.
Cylinder Head Capscrew Tightening Sequence ........................................................... 3-157
3-125.
Flywheel and Housing Assembly ..................................................................................... 3-161
3-126.
Crankshaft Pulley .............................................................................................................. 3-164
3-127.
Timing Gear Cover..................................................................................................... 3-166
3-128.
Camshaft................................................................................................................... 3-169
3-129.
Measuring Camshaft End Play ..................................................................................... 3-170
3-130.
Measuring Thrust Plate Clearance.................................................................................... 3-171
3-131.
Measuring Camshaft Journals .................................................................................... 3-171
3-132.
Measuring Camshaft Lobe Height................................................................................ 3-172
3-133.
Aligning Timing Mark and Camshaft Gear................................................................... 3-173
3-134.
Idler Gears ..................................................................................................................... 3-175
3-135.
Spring Pin Protrusion................................................................................................. 3-176
3-136.
Front Plate ........................................................................................................................ 3-177
3-137.
Crankshaft and Main Bearings.......................................................................................... 3-182
3-138.
Critical Areas of Crankshaft Load Stress ................................................................ 3-184
3-139.
Measuring Main Thrust Journal and Thrust Bearing Width............................................. 3-185
3-140.
Fastening Cylinder Liners........................................................................................ 3-190
3-141.
Removing Carbon From Cylinder Liner ........................................................................... 3-191
3-142.
Marking Cylinder Liners................................................................................................ 3-192
3-143.
Pistons, Connecting Rods, and Cylinder Liners................................................................. 3-193
3-144.
Use of Cylinder Liner Puller............................................................................................... 3-194
3-145.
Cylinder Liner O-Rings and Packing........................................................................... 3-194
3-146.
Engine Block ................................................................................................................... 3-196
3-147.
Piston Inspection.......................................................................................................... 3-197
3-148.
Checking Piston Ring Groove Clearance.......................................................................... 3-197
3-149.
Checking Piston Pin Clearance ........................................................................................ 3-198
3-150.
Inspecting Cylinder Liner Pitting ...................................................................................... 3-199
3-151.
Inspecting Cylinder Liner for Cracks ................................................................................ 3-199
3-152.
Measuring Piston Skirt...................................................................................................... 3-200
3-153.
Measuring Piston to Liner Clearance ......................................................................... 3-201
3-154.
Checking Piston Pin Bushing....................................................................................... 3-203
3-155.
Inspecting piston Cooling Nozzles .......................................................................... 3-204
FIGURE
PAGE
3-156.
Inspecting Cylinder Block .............................................................................................. 3-205
3-157.
Measuring Main Bearing Bore Diameter.......................................................................... 3-206
3-158.
Measuring Cam Follower Bore Diameter........................................................................... 3-206
3-159.
Measuring Camshaft Bore Diameter............................................................................ 3-207
3-160.
Measuring Cylinder Block Top Deck Flatness........................................................... 3-207
3-161.
Location of Cylinder Liner Shim................................................................................... 3-209
3-162.
Deglazed 45 Degree Cross Hatch Pattern ........................................................................ 3-209
3-163.
Assembled Piston, Pin, and Connecting Rod..................................................................... 3-210
3-164.
Compression Ring Identification Marks.......................................................................... 3-211
3-165.
Location of Cylinder Liner Packings................................................................................... 3-212
3-166.
Location of Cylinder Liner Square Packing ............................................................... 3-213
3-167.
Staggered Piston Ring Gaps ........................................................................................... 3-214
3-168.
Installing Connecting Rod Bearing..................................................................................... 3-215
3-169.
Installing Connecting Rod Cap Bearing .................................................................. 3-215
3-170.
Installing Connecting Rod Cap .................................................................................... 3-215
3-171.
Tightening Connecting Rod Caps .................................................................................... 3-216
3-172.
Measuring Piston Protrusion....................................................................................... 3-217
D-1.
Fuel Injection Pump Holding Fixture...................................................................... D-1
D-2.
Fuel Injection Pump Timing Mark Template .................................................................. D-2
D-3.
Cylinder Liner Holding Fixture ........................................................................................... D-3
Index
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