R. R. MONGEAU611 LAGOON DRIVE

DESTIN, FLOIDA 32541AREA CODE 850 837 0277

August 10, 2001

There are three manuals included in this mailing:

1. Portions of John Deere Tech Manual TM-1056 for Deere tractor 4230, which has the 6404engine inatalled. This manual describes the 6404 engine repairs, etc.

2. PARTS CATALOG, JOHN DEERE, 6404D FOR AMERICAN MARINE, PC 1294Note that page 17 lists the fresh water pumps for the std and opp rotation engineand the pictureshows the outlet in the 4:30 position. I think the position of the outlet is in error as the partnumbers are correct and the outlet is acuallv in the 12:00 position.Here is mv guess as to how this error ocurred: John Deere has a master Parts Catalog PC 1554Titled John Deere 6404D' 6404T and 6404A OEM En ienes and assessories rom which PC1294 was co ied.. When Deere ublished the Deere Cata/o or American Marine PC 1294 theysimply did not edit the pump picture to indicatethe 12:00 position.

3. AMMARINE 404 NATURALLY ASPERATED ENGINE ENGINEERING EXCEPTIONPARTS LIST DESIGNED BY AMMARINE LTD. published by AmericanMarine, LTD

The origional owner of Hull 517 42ft CL, was a Boeing727 pilot and he obtained excellentmanuals which were handed down to me in 1990.

Good sailing and I hope you can make some use of these manuals.

Ralph

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.SERVICE INFORMATION

The instructions on the followingpages will help you keep your John Deereengine perfonming efficiently and econ-omically.

Your John Deere dealer offers completeengine service. His factory trained per-sonnel have access to accurate, detailedservice information. Someof the dealerservices are listed below.

1

If there is water or an excess offoreign matter in the fuel p~p sedimentbowl, close the fuel tank shut-off valveand remove the sediment bowl. Clean thebowl and strainer. Install the bowl andstrainer using a good gasket. Open theshut-off valve and bleed the filters.

If there is water or an excess offoreign matter at the bottom of a fuelfilter, loosen the drain plug for that

Engine tune-up. filter and drain the water or foreignInjection pumpand injector service. matter from the filter. Bleed the filters.Ignition and electrical system checks. .PTOclutch service. If water was present in the fuel pumpFuel system service. sediment bowl or a fuel filter sedimentCooling system service. chamber, drain all the water from the fuelParts service. tank sump to eliminate clogging filter.

(l)(2)(3)(4)(5)(6)(7)

DIESELFUELSYSTEM

Description

"- The diesel fuel system consists of thefuel tank, fuel pump, fuel filter, injectionpump, fuel injectors and the connectingpipes. Do not run the engine while steamcleaning or washing near the injectionpump. The sudden temperature change whenthe engine is running can cause pumpdamage.

I Modification or alteration of the injec-tion pump, the injection pumptiming, orthe fuel injectors in ways not recommendedby the manufacturer will tenminate thewarranty obligation of the purchaser. Seeyour copy of the John Deere Warranty forthis enaine.

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Inspection and Cleaning

Proper servicing of the fuel system isimportant. The fuel system of turbo-charged engines has a fuel pump sedimentbowl at the injection pump. Naturallyaspirated engines do not have a fuelpump sediment bowl. Visually inspect thefuel pumpsediment bowl if 50 equippedand the fuel filters daily or after every~en hours of operation.

--- --- -- -- -

....

FUELSANDLUBRICANTS

FUELS

The quality of fuel used is an impor-tant factor in obtaining dependableperformance and satisfactory engine life.Suitable fuels must be clean. com-pletely distilled, well-refined andnon corrosive to the fuel system parts.Be sure to use fuel of a known qualityfrom a reputable supplier.

In somefuel conditions, the intervalbetween service on the fuel system maybe increased by adding John Deerediesel fuel conditioner to the fuel.

Diesel Fuel SDecifications

..

Either Grade No. l-D or Grade No. 2-Dfuel as defined by ASTMdesignationD975 for diesel fuels may be used. TheGrade No. 2-0 is heavier and will pro-duce more work per gallon. However,Grade No. 1-0 fuel will give betterperformance under certain conditions.Use the chart below to determine cor-rect grade of fuel.

Light Load. 1OWlAbove-SOoF.speed. consider-able idling.

IntermediateI

Above 400F.and heavy load, Below 400F.high speed. min-imumof idling.

At altitudes IA11above 5,000feet.

2-01-0

1-0

As further assurance of satisfactoryoperation, use fuel having less than1.0 percent sulfur, preferably lessthan 0.5 percent.

-- - - ---

2

For maximumfilter life. sediment andwater should not exceed 0.10 percent.

To maintain proper fuel delivery duringcold weather operation. use number1-D die-sel fuel with a pour point at least lOoF.below lowest surrounding air temperature.

The cetane number should be 40 minimum.Low atmospheric temperature as well ashigh altitude operation may require useof a fuel with a higher cetane number.

LUBRICANTS

Depending on the expected atmospherictemperature at start for the fill period.use oil of viscosity as shown in the fol-lowing chart.

~(I ..

-IOOF.to ISAE10W-20320F.* *

SAE lm~.

Below-lOoF.

SAE 5W-20 SAE 5W-

* * If ambient temperature at start isbelow 100F., use an engine heater. SAE5W-20oil may also be used if required. This willinsure optimumlubrication of the engine whenstarting, particularly if the engine is sub-jected to -100F. or lower for several hours.

Some increase in oil consumption may beexpected when SAE5W-20or SAE5Woils areused. Check oil level more frequently.

. .

. .3

LUBRICATIONAND PERIODIC SERVICE

DAILY OR EVERY10 HOURS

EVERY100 HOURS

EVERY200 HOURS

\..

EVERY600 HOURS

,

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- - - - - - - -

Capacity orvpe of lubricantComponent Service Measurement

Engine crankcase Check oil level To upper mark See Fuel & lubrication'Section

Fuel filter (diesel) Check sediment . ............. ..... ........ ...... ...chamber

Engine crankcase Drain and fill 15 U.S. qts. - ee Fuel & Lubration6-4040 !section

ngine crankcase Replace filter. 17 U.S. qts.- ..................... .Change oil 6-4040

an belt Check tension I-inch deflec- . ...... ........ .... ...tor @25 lbs.force

Air intake hoses Check connections .01S-inch (Intake)

Intake and exhaust Check valve clear- .02S-inch (Exhaust)valves ance

EnQine Check idle speeds Application

- - - -

GENERALENGI~E SPECIFICATIONS

ENGINES

Type...4-stroke cycle, 6-cylinder in-line, valve-in-head

Bore and Stroke 4-1/4 x 4-3/4 in.Displacement 404 cu.in.Compression ratio 16.8 to 1Firing order: :

Conventional Rotation..1-5-3-6-2-4Reverse Rotation 1-4-2-6-3-5

Engine Speeds:Working range 1500 to 2200 rpmSlow idle 800 rpm

Cooling System:Type...Pressurized system with

centrifugal pumpEngine temperature control........

Heavy-duty thermostat

c

Lubrication System:Type...Force-feed, pressurized with

full-flow oil filter

Fuel System:Direct injection, inlet metering,distributing-type

Diaphragm-type fuel pump

Capacities:Fuel tank 37 U.S. gals.Crankcase 17 U.S. n~.

~~ ~ENGINE TUNE UP ~'

Compression Test:370-400 psi It 220-250 rpm

Exhaust System:Check system for leaksCheck muffler and exhaust pipe forrestrictions

Crankcase Ventilating System:Check system for restrictions

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4

Cylinder Head and Valves:Tighten cylinder head cap screws

130 ft-lbs in torque sequenceSet valve clearance

Intake--0.OI8 in.Exhaust--0.028 in.

Fuel System:Check fuel tank for waterCheck fuel pump pressure

3-1/2 to 4-1/2 psiChange filterService and check timing TDC..50 advance at 1700 rpm (full load)Adjust speed control linkage

Fast idle--2400 rprnSlow idle--800 rp~

Lubrication System:Check engine oil pressure

40-55 psi @1900 rp7.

Charging System:Check battery specific gravity

1.240--1.250Check battery water consumption andelectrolyte levelClean battery, cables, and boxCheck alternator belt tension

25 lbs. at 1 in. belt deflection

Starting System:Check start-safety switch operationCheck battery voltage when starting

Min. 9 volts (cranking)Check starter current draw..approx. 40 ar

."

=fractor - 4230TM-1056 (Aug-72)

Basic Engine 20General Information and Diagnosis 5-1

Section 20

ENGINE

Page

CONTENTS OF THIS SECTIONPag..

[

GROUP 5-GENERAL INFORMATIONAND DIAGNOSIS

General Information 5-2Diagnosing Engine Malfunctions 5-2

GROUP 1O-CYLlNDER HEAD, VALVES,AND CAMSHAFT

General Information .10-1Diagnosing Malfunctions .10-1Preliminary Valve Checks .10-1Cylinder Head and Valves

Removal and Repair 10-2Assembly and Installation... . . .. .. . .. .10-3Valve Clearance Adjustment .10-4

CamshaftRemoval 10-4Repair 10-5Installation 10-5

GROUP 15-CYLINDER BLOCK, LINERS,PISTONS AND RODS

General Information .15-1Diagnosing Malfunctions . . .. . . .. .15-1Removal 15-2Repair

Pistons 15-2Liners 15-3Rods 15-4

Assembly 15-4Installation .15-5

GROUP2O-CRANKSHAFT, MAIN BEARINGS,AND FLYWHEEL

General Information .20-1Diagnosing Malfunctions 20-1Removal 20-1Inspection and Repair

Crankshaft and Flywheel.. . .2J-1Clutch Shaft Pilot Bushing Adapter 20-2Main Bearings and Journals 20-2Damper Pulley 20-3Rear Crankshaft Oil Seal,

Housing, and Wear Sleeve 20-3Front Oil Seal and Wear Sleeve 20-3

Assembly 20-3Installation 20-5Pistons, Connecting Rods, Oil Pump 20-5

r,I~.

Litho in U.S.A.

GROUP 25-LUBRICA TION SYSTEMGeneral Information 25-1DiagnosingMalfunctions. . .. .. .25-1Checking Oil Pressure. . . . . .. . . . . . . . . . . .25-1Adjusting Oil Pressure 25-1Diesel Oil Filter Housing .25-2Oil Coolers 25-2Engine Oil Pump ~25-3Installation 25-4

GROUP3O-COOLlNG SYSTEMGeneral Information .30-1Diagnosing Malfunctions .. .. .. .30-1Radiatorand Fan .30-1Water Pump 30-1Water Manifold and Thermostats 30-3

GR0UP 3~ASOLINE ENGINE GOVERNORGeneral Information 35-1Diagnosing Malfunctions .. . . ~...35-1Removal : .35-1Disassembly and Repair .35-1Assembly " 35-2Idler Gear 35-3

GROUP 40-SPECIFICATIONS ANDSPECIAL TOOLS

Cylinder Head, Valves, and Camshafts... .40-1Cylinder Block, Liners, Pistons, and Rods .40-1Crankshaft, M~in Bearings and Flywheel ..40-2Lubrication System 40-3Cooling System .40-3Gasoline Engine Governor .40-3Engine Break-In .40-4Special Tools .40-4

20 Basic Engine5-2 General Information and Diagnosis

Tractor - 42:¥J .TM-1056 (Aug-72)

Group 5GENERALINFORMATIONAND DIAGNOSIS

GENERAL INFORMATION

The engine is a 6-cylinder valve-in-head verticalin-line four cycle engine. Two types of fuel, eachwith the appropriate fuel delivery device, are avail-able-gasoline or diesel.

1"'1 For basic theory of engine oparation see theD FOS Manual 30-ENGINES.

DIAGNOSING ENGINE MALFUNCTIONS

Will Not Start

Fuel System Malfunction--See Section 30Foreign matter in fuelImproper fuelFaulty fuel pumpFuel shut off at tankRestricted air intake systemFaulty injection nozzlesPlugged fuel filterCarblJretor malfunctionSticking choke

Electrical System Malfunction-See Section 40Corroded or loose battery connectionsFaulty or loose wiringWeak batteryFaulty key switchFaulty safety start switchesFaulty ignition system

Unev~n Running or Frequent StallingBasic Engine Problem-5ee This Section

Improper valve clearanceCylinder head gasket leakingValves sticking or burnedWorn or broken compression ringsLow compressionIncorrect timingCoolant temperature below normalEngine overheating "

Fuel System Malfunction-See Section 30Low fuel supplyRestricted fuel lines or filtersFaulty fuel pumpFaulty injection pump

Litho in U.S.A.

Faulty injection nozzlesExhaust system restrictedCarburetor adjust~d incorrectlyLeaking carburetor or intake manifold gaskets

Electrical System Malfunction-See Section 40Faulty ignition system

Engine Misses

Basic Engine Problem-See This SectionWeak valve springsIncorrect valve clearanceBurned,"warped, pitted, or sticking valvesLow compressionWorn camshaft lobes (could be caused by

faulty damper)Incorrect timingEngine overheating

Fuel System Malfunction-5ee ~~ction 30Air in fuelFaulty injection nozzlesFaulty injection pumpWater in fuelMixture of gasoline and diesel fuelsFaulty fuel pumpFaulty carburetor

Electrical System Malfunction-See Section 40Incorrect type spark plugs (pre-ignition)Leaks in wiringFaulty ignition systems

Lack of Power

Basic Engine Problem-See This SectionBlown cylinder head gasketWorn camshaft lobesIncorrect valve clearanceIncorrect valve timingBurned, warped, pitted or sticking valvesWeak valve springsLow compressionIncorrect timingWrong viscosity crankcase oilEngine overheating

.,..."

..

.Tractor - 4230TM-1056 (Aug-72)

r:uel System Malfunction-Sea Section 30Plugged fuel filtersImproper fuelFaulty injection pumpFaulty injection nozzlesFaulty fuel pumpRestricted air cleanerRestricted exhaust systemLow intake manifold pressureObstructed fuel lineFaulty carburetor

Power Train Malfunction-See Section 50Clutch slipping

Engine Overheats

Basic Engine Problem-See This SectionDefective head gasketIncorrect engine timingCrankcase oil level lowLow coolant levelRadiator or side grille screen dirtyLoose or broken fan beltFaulty thermostats .

Cooling system limed up .

Defective radiator pressure capFaulty water pump

Service Problem-See Section 10Engine overloadedCrankcase oil level low

Improper fuel

Fuel System Malfunction-See Section :":0Excessive fuel deliveryFaulty carburetor

Excessive Oil Consumption

Basic Engine Problem-See This SectionRestricted oil passage from valve coverWorn valve guides or valve stemsOil control rings worn or brokenScored liners or pistonsExcessive ring groove wear in pistonRings sticking in Fooves of pistonOil return holes in piston cloggedInsufficient piston ring tensionPiston ring gaps not staggeredExcessive main or connecting rod bearing

clearanceWorn crankshaft thrust bearing (misaligned

piston and rod)Front or rear crankshaft oil seal faul!yCrankcase oil too thinOil pressure too highOil level too high

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Litho in U.S.A.

Basic Engine 20General Information and Diagnosis 5-3

Service Problem-See Section 10Crankcase oil too thinOil level too high

Fuel System Malfunction-See Section 30Restricted air intake

Low Oil Pressure

Basic Engine Problem-See This SectionExcessive main and connecting rod bearing

clearanceLow oil levelLeakage at internal oil passagesFaulty oil pumpImproper regulating valve adjustmentImproper oil

. Defective engine oil cooler

Service Problem-See Section 10Low oil levelImproper oil

Electrical SystemMalfunction-See Sectior. 40Defective oil pressure indicator lampFaulty oil pressure sending unit

High Oil Pressure

Basic Engine Problem..-See This SectionStuck or improperly adjusted regulating valve

Excessive Fuel Consumption

Basic Engine Problem-See This SectionLow compressionIncorrect engine timing

Service Problem-See Section 10Engine overloaded

Fuel System Malfunction-See Section 30Leaks in fuel systemRestricted air cleanerFaulty injection nozzlesFaulty injection pumpFaulty carburetor

Electrical System Malfunction-See Section 40Faulty ignition system

Black or Gray Exhaust Smoke

Basic Engine Problem-See This SectionIncorrect engine timing

.

Service. Problem-See Section 10Improper grade of fuelEngine overloaded

20 Basic Engine5-4 General Information and Diagnosis

White Exhaust Smoke

Basic Engine Problem-See This SectionLow compression

Fuel System Malfunction--See Section 30Faulty injection nozzlesImproper fuel

Slow Acceleration

Fuel System Malfunction-Seo Section 30Faulty injection pumpFaulty injection nozzles

Electrical System Malfunction-See Section 40Faulty ignition system

Detonation

Basic Engine Problem-8ee This SectionCarbon buildup in compression chambers

Fuel System Malfunction-See Section 30Oil picked up by intake air streamFaulty injection nozzles

Litho in U.S.A.

. -Tractor- 4~30

TM-1056 (Auy-72)

Engine Backfires

Fuel System Malfunction-See Section 30Faulty carburetor

Electrical System Malfunction-See Section 40Faulty ignition system

Abnormal Engine Noise

Basic Engine Problem-See This SectionExcessive valve clearanceWorn cam followersBent push rodsWorn rocker arm shafts .

Worn main or connecting rod bearingsForeign material in combustion chamberWorn piston pin bushings and pinsScored piston .

Incorrect engine timingExcessive crankshaft end playLoose main bearing capsWorn timing gearsWorn oil pump gearsBroken pump shaftLowengine oil levelCamshaft oil pump drive gear worn or broken

tractor - 4230-TM-1056 (Mar-73)

Basic Engine 20Cylinder Head, Valves, and Camshaft 10-1

Group 10CYLINDER HEAD, VALVES, AND CAi'ilSHAFT

GENERAL INFORMATION

The cylinder head holds the rocker arm assem-bly, valve springs, and valves.

The intake valve seats and intake and exhaustvalve guides are integral with the cylinder head onboth gasoline and diesel engines. The exhaustvalve seats are replaceable in the gasoline cylinderhead and integral with the diesel cylinder head.

Intake valves are equipped with valve springcaps and packings. Exhaust valves are equippedwith valve rotators. All diesel valves are equippedwith valve stem wear caps.

The camshaft is cast with an integral oil pumpdrive gear and an eccentric lobe that actuates thefuel transfer pump. All camshaft lobes are taperedand contact mushroom type cam followers.

DIAGNOSING MALFUNCTIONS

The following is a list of possible valve trainmalfunctions and causes:

Sticking ValvesCarbon deposits on valve stemWorn valve guidesWarped valve stemsCocked or broken valve springsWorn or distorted valve seatsInsufficient lubrication

Warped, Worn, or Distorted Valve GuidesLack of lubricationCylinder head distortionExcessive heatUnevenly tightened cylinder head cap screws

Distorted Cylinder Head and Cylinder HeadGasket Leakage

Improperly tightened cylinder head cap screwsFaulty gasket installationExcessive oil pressureImproper cylinder liner height above cylinder

block

Litho in U.S.A.

Worn or Bro~en Valve SeatsMisaligned valvesDistorted cylinder headCarbon deposits on seats due to incomplete

combustionValve spring tem:ion too weakExcessive heatImproper valve clearant::eImproper valve timing

Camshaft Failures

Scored camshaft lobes due to inadequatelubrication

Excessive end play due to thrust plate wearBroken or warped camshaft due te improper

timing

Burned, Pitted, Worn, or Broken ValvesWorn or distorted valve seatsWorn valve guidesInsufficient coolingInsufficient lubricationCocked or broken valve springsDetonationImproper engine operationImproper valve train timingFaulty valve rotatorsWarped or distorted valve stems"Stretched" valves due to excessive spring

tension .

Distorted cylinder headBent push rodsCarbon build-up on valve seatsRocker arm failure

PRELIMINARY VALVE CHECKS

Check condition of visible valve train parts forindication of malfunctions.

Prior to cylinder head removal, inspect andcheck engine operation.

Checking Valve Clearance

Intake valve clearance on diesel engines is0.018 inch. Diesel exhaust valve clearance is 0.028inch. Gasoline intake valve clearance is 0.015 inch.Gasoline exhaust valve clearance is 0.028 inch.

20 Basic Engine10-2 Cy!inder Head, Valves, and Camshaft

Tractor- 4230TM.1056 (Mar'73)

Checking Valve Lift

Fig. 1-Checking Valve un .

Measuring valve lift can give an indication ofwear to eam lobes, cam followers and push rods.

Set valv~ clearance to specifications.

Place dial indicator on valve spring cap or ro-tator. Manually turn engine in running directionwith engine rotation tool. When rocker arm con-tacts valve stem, check dial indicator travel asrocker arm moves valve to full open. Indicatorshould read 0.45 inch.

CYLINDER HEAD AND VALVES

Removal

Remove battery ground straps.

The engine need not be removed to service thecylinder head. It will be necessary to remove partsthat will interfere or be damaged if the cylinderhead is removed.

Drain cooling system and relieve hydraulic pres-sure. Remove and identify parts for later reassem-bly.

NOTE: Do not rotate crankshaft with cylinderhead removed unless all cylinder liners are se-cured with cap screws and washers.

Repair

Remove cotter pin, spring washers, washer, andplugs from rocker arm shaft. Slide parts from shaftand identify for reassembly.

Litho in U.S.A.

Remove valve spring retainer locks, retainers,valve springs, rotators and valves. Identify eachvalve for reassembly into the guide from whichit was removed.

R16112N

13-Rocker Arm14-Wear Caps (diesel)15-Retainer Locks16--Va/ve Rotator-Exhaust17-5pring Retainer-Intake18-D-Ring19-Valve Springs2o-Intake Valve21-Exhaust Valve22-Push Rod23-Cam Follower

I-Washer2-5pring Washer3-Plug4-Cotter Pin5-Rocker Arm Shalt6-5pring7-Rocker Arm8-Nut9-Adjusting Screw

to-Cap Screw11-Washert2-C/amp

Fig. 2-Valves and Rocker Arm Assembly

Valve Springs

Inspect valve springs for aligr;.;dnt, wear anddamage. Place springs on a flat surface to seethat they are square and parallel. Do no. usesprings that are cocked, crooked, broken, or rusty.

Check valve spring tension on a spring tester.Free length of each spring may differ, but com-pressed length for each spring must be the same.Free length of spring is 2.12 inch. The followingare the specified compressed lengths of thesprings:

Compressed at Length .54 to 62 Ibs.-valve closed .1.81 in.

133 to 153 Ibs.-valve open .1.36 in.

Valve RotatorsInspect valve rotators. If rotators will not turn

freely in one direction, replace with new.

Valve Face and StemValve stem wear caps on diesel engines should

be replaced if pitted or worn. If gasoline valve stemends are pitted or worn, a very light grind is usu-ally sufficient to square the end up and removepits or burns.

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Tractor - 4230'TM-1056(Mar-73)

jBasic Engine 20

Cylinder Head, Valves, and Camshaft 10-3

Check valve face and stem for wear or damage.See "Diagnosing Malfunctions" page 20-10-1 forcauses of valve failures.

'ot. The O.D. of a new valve stem is 0.3715 to 0.3725inch. Compare with valve guide 1.0. to determineguide-to-stem clearance.

Valve face angle on a new valve is 44.5°. Theface 0.0. of the valves are as follows:

Valve NewPartIntake-Gasoline 1.6830 to 1.6930 in.Exhaust-Gasoline .1.4950 to 1.5050 in.Intake-Diesel .1.8970 to 1.9070 in.Exhaust-Diesel '. .1.7100 to 1.7200 in.

, """ For information on valve refeelng, see

~ a "Basic Engine" in FOS-30 ENGINES manual.Valve Guides

Fig. 3-Checking Valve Guides

Measure valve guides (Fig. 3) for wear or dam-age. The 1.0. of the guide in a new head is 0.3745to 0.3755 inch. Clearance between new gUide andnew valve stem is 0.0020 to 0.0040 inch. Wornguides can allow a clearance of 0.0060 inch andstill be acceptable.

Worn guides can be knurled if they do not allowmore than 0.0060 to 0.0080 inch clearance. UseNo. 1002 knurling tool from United Tool ProcessesCo. EXACTLYas directed by the manufacturer.

Valve Seats

Check valve seats for cracks, pits, carbon de-posits and excessive wear. Measure width andconcentricity with valve guide. The width of theseat is 0.0830 to 0.0930 inch. Runout betweenguide and seat should be no more than 0.0020inch.

Repair seats as directed in FOS-30 Enginesmanual and by directions given by the seat refac-ing tool manufacturer. Dimensions of valve re-cessed in seat limits are as follows:

Litho in U.S.A.-- --- - -

ValveIntakeExhaust

NewPari0.0360 to 0.0500 in.0.0540 to 0.0680 in.

Wear Tolerance0.0300 in.0.0300 in.

VI.LVESEAT

INSERTPULl.ER

Fig. 4-RemovingVaive Seat Inserts-Gasoline

If necessary, replace exhaust valve seat insertin the gasoline engine. Use JDE-41296 puller (Fig.4) to pull insert. .

Chill both new insert and JDE-8 replacementring before inst'allation. Use JDE-7 driver to driveinsert and replacement ring into place.

NOTE: Some ,diesel engine cylinder heads m~yhave valve seat inserts. If necessary, use JDE-41296puller to remove. Chill and install exhaust valveseat insert with JDE-66 driver and intake valve seatinsert with JDE-67 driver.'

Rocker Arm Assembly

Examine rocker arms and rocker arm shaft forunusual signs of wear. Wear could indicate weakvalve springs, bent push rods, or loose r()cker ~rmshaft clamps. If rocker armS ends show, only nor-mal wear, resurface them. ; '" '

If the rocker arm has been damaged by a valvefailure, replace it and the push rod, when replac-ing valves.

Clean holes in rocker arms, rocker arm shaft,and rocker arm mounting brackets to insure prop-er lubrication of the rocker arm assembly.

Assembly

Assemble parts on rocker arm shaft in sequenceremoved. Position plugs correctly in each end ofthe rocker arm shaft.

Apply AR44402 Lubricant to valve stems andguides and install valves in guides from which theywere removed. Valves must move freely and seatproperly.

Install valve springs, making certain that cylin-der head end of spring is located correctly in themachined counterbore of the head.

20 Basic Engine.10-4 Cylinder Head, Valves, and Camshaft

Install rotators or spring retainers and retainerlocks on valves. "Pop" each valve three or fourtimes with a soft mallet to insure proper position-ing of the retainer locks.

Installation

Install cylinder head gasket dry. (Note select fitcylinder head gasket information on page 5 ofGroup 15.) Dip cap screws in engine oil beforeinstallation. Install cylinder head, using hardenedflat washers under atl. cap screws. Tighten capscrews evenly to 100 ft-Ibs torque following se-quence shown in Fig. 5, then retighten to 110-120ft-Ibs torque using same sequence.

Fig. S-C:ylinder Head Cap Screw Tightening Sequence

NOTE: After eflgine assembly has been com-pleted, run engine for one-half hour and retightencap screws in same sequence to 125 to 135 ft-Ibstorque. .

Install push rods in holes from which they wereremoved.

Install valve stem wear caps on diesel valvesmaking certain caps rotate freely.

Install rocker arm assembly. Make sure thatspring pin in head aligns with pin hole in rocker

. arm shaft. This will align lubricating holes in shaftand head. Tighten rocker arm shaft clamps to 50to 60 ft-Ibs torque.

Litho in U.S.A.

- -

Tractor- 4230TM-1056 (Mar-:73)

CAMSHAFT

\t,!

RemovalTo service camshaft, engine normally need not

be removed from the tractor.

Disconnect battery ground straps.

Remove parts necessary to separate enginefrom tractor front end.

NOTE:See Section 10, Group25, for separationinstructions.Use caution if fuel tc.rJk is full. Sup-port front end as necessary.

Remove all parts as necessary to remove cam-shaft. Cylinder head need not be removed unlessdesired. Remove crankshaft damper pulley withpuller. Identify parts for reassembly.

NOTE: Set No. 1 piston at "TDC" on compres-sion stroke to align timing marks on crankshafta'nd camshaft gears. This .will aid timing on re-assembly.

Remove push rods. Use ND425 magnetic hold-ing tool set to hold cam followers away from cam-shaft. If followers are removed, mark them foridentification on reassembly. ~.

To determine which cylinder is at"TDC" on the compression stroke, .IJ~.,!.. ~O..:.~~_T_~C_~~~~R"~S~!ONSTROKE

examine the exhaust valves of Nos. 2 J)~~~~ ~Valve Adjusting Sequence forand 5 cylinders. If the exhaust valve<~~J1Couflt~jc1ock\l;3e Rotating Engineof No.2 cylinder is partially open, li FRONT OF ENGINE- '--"- -"""

No. 1 cylinder is at "TDC" on the com- \: 6 5 4 3 2 1pression stroke. If the exhaust valve eEl r EEl lEE I I Eof No. 5 cylinder is partially open, ~No.6 cylinder is at "TDC" on the com- ~pression stroke~ J ~

~riv""",,'

c..',-:.!,. I~....\.' \,\...,

'20"

10-1a

VALVE CLEARANCE ADJUSTMENT

6-404 ENGINES

All the valves can be adjustedaccurately by turning the crankshaftto only two positions - "TDC" withNo.1 cylinder on the compressionstroke and "TDC"with No. 6 cylinderon the compression stroke. It doesnot matter which valves are adjustedfi rst.

., With No.1 cylinder at "TDC"onthe compression stroke, adjust thefollowing valve clearances: intakevalve on cylinders 1, 2 and 4 and theexhaust valve on cylinder 1, 3 and 5.These are the first, second, third,fifth, seventh and ninth valves fromthe front of the engine. See thechart below for the correct valveclearance.

VALVE CLEARANCE

EngineIntakeValves

ExhaustValves

..6-4040 0.018 in. 0.028 in.

FRONT OF ENGINE-

5 4 3 2IE EI IE EI

tNO. I TOC COMPRESSION STROKE

NO. 1 TOC COMPRESSION STROKE

6E I

4E I

2E I

1I E

3I E

R 13117 NO.6 TOC COMPRESSION STROKE._- '. - --- _. .. -- '

Valve Adjusti ng SeqlJence for. .C+e€k~i5~ Rotating Engine ~.~ ~~~~-

{.'i/r'.:::.,-7<."/l~~ '. k.'.With ~to.~6 cy1\nder at "TDC"on the com-

pres\ion stroke, a~ust.:the follo,wingval ve"c~earance.~ :/l~tak~a.lve orf'c.y]inders3, 5 an.~'6 and the ex~aust "'(Cilveson cY,l-inders 2~ aild!6. ~ese ar~ the first,'.second, thl~d,/fifth, s~venth ~nd ninthvalves from the rear of the engine.

To adjust valve clearance, loosen theRotate (with JOE-81 engine rotation lock nut and turn the adjusting screw in or

tool on diesel engine) fl~~hee] 360 out. Recheck the clearance after tighteningdegrees. . the lock nuts.

T ~ ~~_:t-i.~"-" 1>j qJt'--"\ 1\11"uc..) J{l.~ ~~~\~..t A M..'~ {"".., ~ " O-SJlA--t(...~ !{~~ "'~...~.iQ.D After all valve clearances are correct,

~ ~~\.. ~ ~ "'0.1 t.l1 o.U ~ t'-4> ~ close the timing hole cover and install~~..:.~ (' l,..\o~ J\ trCk (,l.'I,.o')tLt. r?cker arm cover and crankcase breather

~~'. (~ d- ().- t> S -1.. <1 ~ .1.~l:cf ()v1~ rfe H - II 0L)~J cJj.~V~ I ~

- - -

......

-- ..- ... .....-.

. .: Tractor - 4230TM-1056 (Mar-73)

Basic Engine 20Cylinder Head, Valves, and Camshaft 10-5

~,

iJefore removing camshaft, check camshaft endplay. End play on a new engine should be 0.0025to 0.0085 inch. However, end play of 0.0150 inch on'an engine that has been in operation is acceptable.Excessive end play would indicate a worn thrustwasher.

Remove oil pan and oil pump.

Remove four cap screws from thrust plate andremove camshaft from cylinder block.

Do not allow cam lobes to drag in bores whenremoving camshaft.

Repair

Bushings

Check camshaft bushing journals and bushingsfor wear or damage. Journal O.D. is 2.3745 to2.3755 inches on a new camshaft. New bushingI.D. is 2.3775 to 2.3795 inches. However, a total0.0060 inch clearance between the two is accept-able.

To remove and install camshaft bushings, useJDE-6 camshaft bushing replacement set. The firstthree bushings can be reached from the front ofthe engine. To reach the fourth bushing, separatethe engine from the clutch housing. See Section10, Group 25 for separation instructions. Whenbushings are installed, make sure that bushing oilholes align with oil holes in block. The elongatedbushing hole is to the top.

fJ~K'I~9~-':'~ '.~~',A:'~~;~' .' ~''; ~~~{IN~' t".,"_,. :':~"';':h,.'T KEY - "'. , "KEY . '. .. ~~

~ \.;:~i__.~.:..:._. ~ :,.~::.:":.~~~~:~~.~. ".~~ : _ 'c...:\_:L(t~

Fig. 7-Details 01 Installation

Gears and Lobes

Check camshaft lobes and oil pump drive gearfor wear or damage. Replace camshaft if neces-sary. If cam shaft is replaced due to a damagedoil pump drive gear, check gear and shaft on oilpump for damage and replace as necessary.

If camshaft is replaced, cam followers must alsobe replaced.

Litho in U.S.A.

WOODRUFF SPACERKEY

/;,.~" ~... ~I"; !:,.o

~ \\ \t\.~

,':. " . /. '..THRUST \

PLATE CAMSHAFTGEAR

8190530

Fig. 8--Camshalt and Geara

Examine camshaft gear (Fig. 8) on gasoline en-gines or camshaft gear, camshaft injection pumpdrive gear and injection pump gear on diesel en-gines for worn or broken teeth and damage. If onegear is replaced on the diesel engine, all threegears must be replaced with a matched set.

If necessary, replace camshaft gear(s) by re-moving cap screw and special washer and press-ing shaft from gears.

NOTE: Do not separate camshaft gear and cam-shaft injection pump drive gear on diesel engines.Thrust Plate

Check thrust plate for proper thickness. Newpart dimension is 0.1870 to 0.1890 inch. Thrustplate wear to 0.1820 inch is acceptable. If thrustplate wear or camshaft end play are excessive,check camshaft lobes, journals and bushings forwear or damage.

Camshaft Assembly

To reinstall gear or gears, install thrust plateand spacer. Support camshaft under first journal,install Woodruff key, and place gear on camshaftwith timing mark facing away from camshaft. Pressgear on until tight against camshaft shoulder.

Installation,

If the cam followers have been removed, rein-stall, using the magnetic holding tools to holdthem away 'iromthe camshaft bore until camshaftis installed.

---

20 Basic Engine10-6 Cylinder Head, Valves, and Camshaft--

Coat camshaft with high temperature greasesuch as Texaco "Molytex Grease 0" or its equiva-lent and install camshaft in block.

Fig. 9-Camshaft Adjustment

With No. 1 piston on "TDC" of compressionstroke, align timing marks on camshaft and crank-shaft (Fig. 9).

Litho jn U.S.A.

- - -

Tractor- 4230TM-1056 .(Ma.--"l3)

Turn camshaft gear to align thrust plate holeswith cylinder block holes. Secure thrust plate,washer, and cap screw in camshaft.

Tighten thrust plate cap screws to 20 ft-Ibstorque. Install special washer on camshaft andtighten cap screw to 85 ft-Ibs torque.

Check camshaft for 0.0025 to 0.0085 inch endplay.

Install cylinder head, push rods, and timing gearcover. Tighten cylinder head as described on page20-10-3.

Check injection pump timing on diesel enginesand valve clearance on both engines. See Section30 for injection pump information.

Install remaining tractor parts.

Glue rocker arm cover gasket on rocker armcover and install.

!~

..,;~.

. .

Tractor - 4230TM-1056 (Aug-72)

Basic Engine 20Cylinder Block, Liners, Pistons, and Rods 15-1

Group 15CYLINDER BLOCK, LINERS, PISTONS AND RODS

GENERAL INFORMATION

The cylinder block is a one-piece castingequipped with four main bearings on the gasolinemodel and seven main bearings on the dieselmodel.

The cylinder liners are wet sleeve replaceabletype. Each liner has a square rubber packing whichseals at a shoulder on the liner. An O-ring packingfits in a groove in the block on gasoline engines toaid in sealing. The diesel engines have two suchO-ring packing grooves per cylinder. The squareand O-ring packings aid in sealing the liner at thebottom of the liner bore. The top of the liner issealed by the cylinder head gasket compression.

Line(s for both gasoline and diesel engines havethe same 0.0. and J.D. However, the diesel liner islonger.

The pistons are forged aluminum-alloy, cam-ground and weight controlled. Each has two com-pression rings and one oil control ring. The topcompression ring of the diesel piston is of a key-stone design and fitted into a Ni-Resist ring grooveinsert.

[

DIAGNOSING MALFUNCTIONS

Scuffed or Scored PistonsInsufficient lubricationInsufficient coolingImproper piston-liner clearanceInsufficient ring gapPre-detonationCoolant leakage in crankcaseMisaligned or bent connecting rodImproperly installed pistonLow oil levelImproper operationIncorrect connecting rod bearing clearanceCarbon buildup in ring grooveImproper break-inWorn piston .

Contaminated oilDistorted cylinder liner

Litho in U.S.A.

Worn or Broken Compre5sion Rings and GroovesPre-detonationInsufficient lubricationInsufficient coolingImproper ring installationImproper cvmbustionImproper timingAbrasives in combustion chamberFailure to remove cylinder liner wear ridge

(top ring)

Clogged Oil Control FtingImproper oilExcessive blow-byImproper periodic serviceLow operating temperature

Stuck RingsPre-detonationImproper oilImproper periodic servicePoor operating conditionsCoolant leakage in crankcaseExcessive cylinder .liner taper

Cylinder liner Wear and DistortionIncorrectly installed compression ringsInsufficient lubricationUneven cooling around linerImproper j.1iston-liner clearanceLiner bore damage

Warped Cylinder BlockInsufficient cooling

Broken Connecting RodInadequate piston-liner clearanceDistorted cylinder liner.Piston pin failure

Piston Pin and Snap Ring. FailureMisaligned connecting rodExcessive crankshaft end playIncorrect snap rings

Mottled, Grayish or Pitted Compression RingsInternal coolant leaks

Dull Satin Finish and Fine Vertical Scratches onRings

Dirt and abrasives in air intake system

20 Basic Engine15-2 Cylinder Block, Liners, Pistons, and Rods

---

v .'

Tractor- 4230

TM-1056 (Aug':'72)

REMOV AL REPAIR

Under normal conditions, the engine need notbe removed to service pistons, rods, and liners. Ifengine removal is desirable, see Section 10, Group25.

Drain crank::ase and remove oil pan, cylinderhead and related parts.

Fig. 1-Removing Ridge from Cylinder Uner Bore

Remove carbon or ridge from liner bore with aridge reamer (Fig. 1).

Do not rotate crankshaft with head removed un-less liners are bolted down.

Keep bearing inserts with their respective rodsand caps and mark rods, pistons, and caps toassure correct reassembly.

TO 0.004 INCH

LINER

R121.9SN

Fig. 2-Location of Uner in Cylinder Block

Measure height of bolted down liners before re-moval from block. Height is 0.001 to 0.004 inchabove block (Fig. 2).

-Litho in U.S.A.

Pistons

KEYSTONE

--<:)COMPRESSION.

RING

12 COMPRESSIO~RING

~_OIL RING

~__OIL RING~ EXPANDER

PISTONPISTON

P!~bR1430411

Fig. 3-Piston with Three Rings

Clean the pistons by using Immersion-SolventUO-Part" and Hydra-Jet Rinse Gun Qr Glass BeadBlasting machine.

/\.. CAUTION: Follow' manufactw,"'s instruc-~ tions exactly. AVOID CONTA, :JF CHEMI-

CAL WITH YOUR SKIN OR EYES; 1 .:1ical con-tains creosols which can be very harmful.

Piston Rings and Ring Grooves

Examine piston rings for damage, wear, scuffed,scored or scratched conditions. Damaged ringscan give an indication of malfunctions in otherareas.

PISTON

KEYSTONERING GROOVE

KEYSTONE RINGGROOVEWEARGAUGE

WORNRINGGROOVE

GOOD RINGGROOVE

R1627211

Fig. 4-Uslng Ring Groove Wear Gauge

".

"T"-.

Tractor - 42307/0..1-1056 (Mar-73)

Use a JDE-62 ring groove wear gauge to checkwear of top compression ring groove on diesel pis-tons (Fig. 4). Gauge shoulders should not contactring land.

Check No. 2 compression ring on diesel pistonsand both compression rings on gasoline pistons byinserting a new ring in groove and measuring atseveral points with a feeler gauge. Ring side clear-ance should not be more than 0.0100 inch.

r

Piston Pins

Inspect and measure piston pin, pin bore in pis-ton and connecting rod pin bushing. Excessivewear can cause scored pistons or broken connect-ing rods. Specifications are as follows:

WearItem New Part ToleranceO.D. of piston pin

Gasoline 1.2497 to 1.2500 in. 1.2492 in:"Diesel... . .. . . .1.4997 to 1.5003 in. 1.4992 in.

J.D. of pin bore in pistonGasoline .1.2503 to 1.2509 in. 1.2519 in.Diesel. .. . . . . . .1.5003 to 1.5009 in. 1.5019 in.

J.D.of pin bore in rod bushing (after honing)Gasoline .1.2510 to 1.2520 in.Diesel. . . . . . . . .1.5010 to 1.5020 in.

Hone worn pin bores if new oversize pins areused. Pins 0.0030 to 0.0050 inch oversize are avail-able. .

Always use new snap rings when reinstallingpiston pins.

Piston Skirt

Measure piston skirt section for wear. Take mea-surement at right angles to piston. pin bore; thelargest diameter. New skirt dimensions are asfollows:

NOTE: Later model diesel engines are equippedwith selectively fitted pistons and cylinder linersto maintain piston-to-liner clearance. "Low" sizedpistons, marked with green, are matched with"low" sized liners stamped "LV." "High" sized pis-tons, marked yellow are matched with "high" sizedliners stamped "HV".

Location Measurement

Top of Skirt (3.03 in. from bottom of piston)Gasoline 4.2395 to 4.2405 in.Diesel - early model. . .. 4.2404 to 4.2414 in.Diesel - "low" 4.2409 to 4.2416 in.Diesel - "high" 4.2406 to 4.2423 in.

Litho in U.S.A.- -

Basic EngineC}'linderBlock, Liners, Pistons,and Rods

Bottom of SkirtGasoline ...............Diesel - early model .. ..Diesel - "low" ........Diesel - "high" ........

2015-3

4.2455 to 4.2465 in.4.2455 to 4.24135in.4.2459 to 4.2466 in.4.2466 to 4.2473 in.

Measure cylinder liner wear as follows:

1. Measure the liner bore parallel to the pistonpin at the top end of ring travel.

P.155~9f:

Fig. 5-Cylinder Unpr Dimension

2. Measure bore in same position .at bottom endof ring travel.

3. Measure bore at right angles to piston pin attop end of ring travel.

4. Measure bore in same position at bo~tom endof ring travel.

Compare all four measurements to determine if'liner has worn tapered. Maximum taper is 0.0020inch at the ring land area. Liner 1.0. is as follows:

Cylinder liner I.D.Gasoline ................Diesel- earlymodel ......Diesel- "low" .. . . . . . . . . .Diesel- "high" ..........

Measurement

4.2493 to 4.2507 in.4.2493 to 4.2507 in.4.2493 to 4.2500 in.4.2500 to 4.2507 in.

Compare liner measurements with piston skirtdiameters:

LocatJon

Top of skirt to linerGasoline ..............Diesel - early model ....Diesel - later model ...

Bottom of skirt to linerGasoline ...............Diesel - early model ....Diesel - later model ....

Clearance

0.0088 to 0.0112 in.0.0079 to 0.0103 in.0.0077 to 0.0091 in.

0.0028 to 0.0052 in.0.0028 to 0.0053 in.0.0027 to 0.0041 in.

20 Basic Engine15-4 Cylinder Block, Liners, Pistons, and Rods

Deglazing Cylinder Liners

LINERPULLER

Fig. 6-Removing Cylinder Liner

NOTE: Remove liners (Fig. 6) for cleaning or de-glazing. Place liners in a holding fixture while de-glazing.

To deglaze liners use a 180-grit deglazing toolor cylinder hone or a "GBD-4-1f2"Tynex nylon cyl-inder brush. Operata tool up and down to obtaina 45-degree crosshatch pattern.

l. "'"IRefer to "Basic Engines" in FOS Manual-30,.Engines, for information on deglazing cylin-

o der liners. .

Rods

<¥oo

BEARINGS

R UJDf ~CAP SCREW

Fig. 7-Connecting Rod and Bearings

Clean and inspect connecting rods (Fig. 7) capsand bearings. Be sure rod oil gallery to pin bushingis clean and open.

, :~h, : " ("' "

. .

Tractor- 4230TM-1056 (Mar.J3)

. "'. ,. " " '. '. ~.....

.!.' .. .. - .!."}. .4

:'", -;~,J. ~.' '. '. ~:.. .

Fig. S-Gheck Bearing Diameter

Rod bearings can be checked with "Plastigage"if rod is connected to crankshaft or by measuringassembled J.D. of connecting rod bearings (Fig. 8),if rod is out of the engine.

NOTE: Use "Plastigage" as directed by the man-ufacturer. Remember, the use of "Plastigage" willdetermine bearing-journal clearance, but will notindicate the condition of the bearing or journal. .

The assembled J.D. of the bearing is 3.0010 ,3.0030 inches on gasoline engines and 3.00H3.0025 inches on diesel engines. Gasoline connect-ing rod journal 0.0. is 2.9985 to 2.9995 inches. Die-sel connecting rod journal 0.0. is 2.9982 to 2.9992inches. Oil clearance is 0.0015 to 0.0045 inch witha maximum allowable clearance of 0.0065 inch.

Undersize bearing inserts are available in 0.002,0.010,0.020, and 0.030 inch sizes.

Rod and cap are an assembly; if one is dam-aged, both must be replaced.

Check assembly for straightness. If piston con-tact pattern is not centered on center of piston attop and bottom skirt, the rod needs to be straight-ened.

Check piston pin bushings and replace asnecessary. Hone bushings after they are installedfor a "thumb press fit" with piston units.

If it is necessary to replace piston pin bushings,use JDE-4 driver on gasoline engine pin bushingsand JDE-S driver on diesel engine pin bushings.

Assemble caps to rods with inserts in place andtighten to 100 to 110 ft-Ibs torque. Again ctbearing clearance.

/Tractor - 4230

. TM-1055 (Mar-73)Basic Engine 20

Cylinder Block, Uners, Pistons, and Rods 15-5

Block

Clean block thoroughly with cleaning solvent orpressure steam cleaning. Make sure all passagesand crevices are cleared of sludge, rust. andgrease. 8e sure all coolant passages are cleanedof lime deposits and scale. Clean counterbore forliner flange.

Inspect the block for cracks or damage. Crackscan, in some cases, be repaired by the cold weldprocess.

NOTE: Clean counterbore lor liner by scrapingor using a "10-5" Tynex nylon brush.

Replace dowel pins, pipe plugs and studs asnecessary. Coat parts with joint sealing compoundbefore installing.

ASSEMBLY

.....

Be sure that identification marks on piston androd are in the same position as they were at timeof disassembly. Make certain that piston pin snaprings are securely seated in piston grooves.

Use a JDE-47 ring. expander to install rings intheir respective grooves.

NOTE: New rings are lurnished with the correctend gap; therefore, fitting to the liner is not neces-sary.

Install expander in oil ring groove. Install the oilring on the piston with the expander to the top ofthe piston on gasoline engines. Position oil ringgap opposite expander gap.

INSTALLATION

Liners

Be sure liner bore is clean. First, install linerwithout packings and secure with cap screws andwashers. Check liner height in several places fora 0.0010 to 0.0040 inch height specification. Re-move liner. Apply AR54749 Lubricating Soap tosquare packing and slide firmly against linershoulder. Make sure that packing is not twisted.

Install O-ring(s) in groove(s) in bore and applylubricating soap to O-rings.

r

....

Utho in U.S.A.-----

Fig. 9-lnstalling Cylinder liner

Work liners in place by hand and seat withwood block and hammer (Fig.g)..

NOTE: Cylinder liner will protrude above .thecylinder block more than normal due to uncom-pressed packing.

Pistons and Rods

Lock liners in place. Coat pistons and. linerswith engine oil.

Fig. fo-Installing Piston

Stagger ring gaps on piston so the gap of eachring is 45° from gap on adjacent ring. Carefullyslide JDE-57 ring compressor over piston andplace ring compressor with piston and rod overliner. With piston and rings centered, push pistoninto liner.

NOTE: Be sure the words "front" on head ofpiston and rod face front of engine.

Apply engine oil to bearing inserts and crank-shaft rod journals. 8e certain that inserts are cor-rectly installed in rod and cap.

Install caps on rods and tighten cap screws to100 to 110 ft-Ibs torque. Rotate crankshaft severalrevolutions to be sure there are no binding parts.

20 Basic Engine15-6 Cylinder Block, Uner3, Pistons, and ,Cfods

--- --.--

v .Tractor- 4230

TM-1056 (Mar-73)

Cylinde-r Head Gasket Installation

DIAL INDICATORMEASURINGPOSITION

Fi;;. J1-Measuling Piston Height-Diesel

On diesel engines meaSUi"eheight of each pistonabove cylinder block (Fig. 11) to determine thesize of cylinder head gasket that should be used.

Rotate engine 360' to determine each piston'shighest point.

Piece a dial indicator on the center line of thecylinder block. "Zero" indicator at a point on theblock past the cylinder liner flange and to the rearof the piston being measured. Be sure that indica-tor has sufficient travel to clear cylinder linerflange.

Utho in U.S.A.

Keep dial indicator arm in place and move dialindicator base so that !=fialindicator is at rear edgeof piston.

If the height of anyone piston measures morethan 0.0090 inch above the cylinder block, useR53438 (Grey) cylinder head gasket. If height of allpistons is less than 0.0090 inch, use R48291 (Red)cylinder head gasket.

If the height of any piston is more than 0.0140inch, replace that piston and connecting rod.

Install oil pan, cylinder head and related parts.Use the following torque specifications. Torquespecifications not found in this group may be foundin Group 40, "General Specifications."

.Location Torque (Itoltls)

Oil pan to block-Yz in. cap screws. . . 85% in. cap screws. . . 35

Cylinder head to block. . . . ... . . 0. . . . 110 to 120

NOTE: Follow cylinder head tightening proced-ure as outlined in Group10.

RU with engine oil and coolant.

_ .._.. 4 .

(.f'i

'.,

Tractor - 4230.TM-1056 (Aug-72)

-- -- --- - -- - -- ----

Basic Engine 20Crankshaft, Main Bearings, and Flywheel 20-1

~."...,;; Group 20CRANKSHAFT, MAIN BEARINGS AND FLYVJI-IEEL

GENERAL INFORMATION

The crankshaft is a dynamically balanced one-piece steel forging. It is supported on the blockby replaceable steel-backed bearings. Four bear-ings are used in the gasoline engine and sevenare used in the diesel engine.

The crankshaft end thrust is taken up by thesecond main bearing from the rear in the sparkignition engine and by the third main bearingfrom the rear in the diesel engine. These bear-ings and crankshaft journals are referred to as"main thrust bearings and bearing journals."

The crankshaft is drilled for pressure lubri-cation to all main bearings.

DIAGNOSING MALFUNCTIONS

Scored Main Bearings (Diagnosis applies to Con-necting Rod Bearings, also--See Group 15, thisSection)

Contaminated oilEngine parts failureExcessive heatPoor periodic service

Galled or "Wiped" BearingsFuel in lubricating oil (incomplete combustion)Coolant in lubrication system (cracked block or

liner seal failure)Parts not lubricated prior to engine operationInsufficient beari"g oil clearanceWrong bearing si..:e

Inconsistent Wear Pat1ernMisaligned or bent connecting rodWarped or bowed crankshaftDistorted cylinder block

Broken Main Bearing CapsImproper installationDirt between bearing and crankshaft journalLow oil pressureLow oil levelOil pump failure

Litho in U.S.A.

Cracked, Chipped or Broken BearingsOverspeedingExcessive idlingLuggingExcessive: oil clea:-.mceImproper installation

CHECKING END PLAY

Use th.e following p.rocedure to check crank-.shaft end play before removing crankshaft:

1. Completely depress and release the clutchpedal.

2. Place dial indicator on crankshaft pulley ordamper.

3. Pry between. the pulley and timing gear c.over.Use care not to distort the timing gear cover ordamage the bearing inserts when prying. .

New part end play should be 0.0025 to 0.0085inch. Excessive end' play indicates a worn thrustbearing. However, a maximum end play of 0.0150inch is acceptable.

REMOVAL

Remove engine from tractor (see Section 10,Group 25) and install on No. 1700-8 engine stand.

Remove cylinder head as described in Group 10of this Section.

Remove oil pan and oil pump,

Remove pistons and connecting rods.

Remove damper or pulley and timing gear cover.

INSPECTION AND REPAIR

Crankshaft and Flywheel

Examine clutch friction surface on flywheel forheat checks or roughness.

- - - - - -- - --- - - - --

20 Basic Engine20-2 Crankshaft, Main Bearings, and Flywheel

NOTE: For further information on clutches, seeSection 50, Group 5.

Examine flywheel ring gear for wear or damage.If new gear is needed, heat gear evenly to 300"Fand install hot with chamfered edge of teeth towardfront of flywheel. Do not overheat.

Check clutch pilot bearing for wear or tightspots. Replace with new bearing and thrust washerif defective. Drive new bearing onto outer raceuntil bearing bottoms in bore. Pack with 'hightemperature grease.

Clutch Shaft Pilot Bushing Adapter

Fig. 1-Transmission Pump Drive Assembly Removal

On tractors equipped with Perma-Clutch, checkclutch shaft pilot bushing adapter in the end ofthe crankshaft.

Check adapter bushing and end of clutch shaftfor wear. Bushing 1.0. is 1.0025 to 1.0055 inches.

. Shaft O.D. at the bushing is 0.9995 to 1.0005 inches.Check hex. drive in the adapter and the trans-

mission pump drive shaft for wear or damage.

If it is necessary to remove adapter, first re-move the bushing. Use a "blind-hole" puller suchas supplied by Service Tools, Inc. in Set No. 981Dr remove the adapter as shown in Fig. 1 and asdescribed below:

1. Place a % x 5-inch cap screw and R43696washer in adapter bushing bore.

2. Install a H 214 R snap ring in adapter bushingbore groove.

3. Using a cross-block and two cap screws inthe crankshaft flange, pull the adapter.

Push crankshaft against thrust bearing. Drivethe adapter in until it is against the crankshaft

Litho in U.S.A.

Tractor- 4230TM-t056 (Aug-72)

flange. Take care not to damage the face of theadapter.

Drive in new bushing until it is 0.020 to O.l,~inch below the face of the adapter.

Front Crankshaft Gear

Check crankshaft gear for wear or damage. Ifnecessary, remove old gear with knife edge puller.Heat new gear to 360"F (don't overheat). WithWoodruff key in place and gear timing mark visible,place the gear on the crankshaft. Seat with JDH-7driver. .

Main Bearings and Crankshaft Jouanals

Inspect crankshaft journals and main bearingsfor wear, scoring, or damage.

If main bearings are assembled on journals,"Plastigage" can be used to determine clearance.

NOTE: If the engine is in the tractor, use a lightjack to hold the crankshaft tight against the upperhalf of the bearing while using "PJastigage." Keepall caps tight except the one being checked. Donot turn the crankshaft.

;: ..'0 :<._":.~.:" .., ~.---:. '".~'

R ntH.' .-

Fig. 2-Determining Main Bearing Clearance

Remove main bearing cap and place a strip of"Plastigage" in the center of the cap (about 3f4ofthe width of the bearing). Install cap and tightento 150 ft-lbs torque.

Remove the cap and compare width of "Plasti-gage" with scale provided on side of package todetermine clearance.

NOTE: Use of IIPlastigage" will determine wear,but will not determine the condition of either bear-ing or journal.

If main bearings are disassembled, note thaTthe caps are numbered so that they can be rein-stalled on the main bearing bosses from whichthey were removed.

-. -- -------

.Tractor- 4230

TM-1056 (Aug-72)

When the crankshaft is removed and main bea:--ings disassembled, measure the assembled 1.0. ofthe main bearing. Then measure each main bearingjournal at several points. Compare the bearing andjournal measurements to determine oil clearance...Also, use the journal measurements to determine ifjournals are out-of-round or tapered. Specificationsfor journals and main bearings are as follows:

Measurement NewPartSpecificationO.D. of main bearing journal. .3.3715 to 3.3725 in.I.D. of assembled main

bearings .3.3742 to 3.3762 in.Journal taper per inch of

journal length 0.0001 in.Journal out-of-roundness .0.0040 in.Bearing-to-journal clearance .0.0017 to 0~0047in.

0.0077 in. max.

If wear is even, but out of specifications, dressjournals and select proper undersize bearing in-serts. Undersize inserts are available in 0.002,0.010, 0.020, and 0.030 inch sizes. If journals. areout-of-round or 'tapered, regrind crankshaft anduse undersize bearing inserts.

NOTE: If undersize bearings are used, checkbearing clearance after bearing caps have beentightened to specified torque. If undersize bearingsare too tight and clearance is not within specifica-tions, the journal and bearing will be wiped cleanof oil, resulting in premature wear on parts.

Check thrust surfaces of the thrust bearing andthrust bearing journal. Excessive wear will causeexcessive endplay. Be sure that journal will notdamage thrust flange on thrust bearing.

Damper PulleyInspect damper assembly on diesel engines for

damage. A faulty damper can allow vibration,causing excessive wear of camshaft lobes.

Rear Crankshaft Oil Seal, HousingAnd Wear Sleeve

Check rear cr;.~nkshaft oil seal for damage orleaking. Replace with lip-type oil seal, wear sleeveand housi:'.-.

To rem ,wear sleeve, score LIGHTLYwith adull chiseL Do NOT score too deeply, or the crank-shaft rear flange might be damaged.

( Inspect the crankshaft flange for burrs or nicks.If necessary, clean flange with light file and fineemory cloth.'-

Litho in U.S.A.

-----

Basic Engine 20Crankshaft, Main Bearings, and F/}'wheel 20-3

NOTE: If cleaning is necessary, also use a lightcoat of Permatex on the flange before installingnew wear sleeve. Be sure that excess Permatex isremoved and no Permatex comes in contact withnew oil seal.

Front on Seal And Wear SJeeveCheck front crankshaft wear sleeve and oil seal

for damage or leaking.

Fig. 3-Removing Front Wear Sleeve

To remove wear sleeve, score LIGHTLYwith adull chisel. Do NOT score too deeply. Inspectcrankshaft flange for burrs or. nicks. If necessary,clean up flange with a light file and fine emorycloth. .

INS i }\lLATION

Main Bearing

~ -;-. ~-"\

-1.-. '..

".. ..~.:. {""\~..t~ : :~~."

Fig. 4-Main Bearing Installalio"

20 Basic Engine20-4 Crankshaft, Main Bearings, and .Flywheel

Before installing main bearings and crankshaft,check the piston cooling orifice (Fig. 4) mountedin each main bearing fillet. Be sure that orifice isnot clogged or damaged.

Install bearing with thrust flange in the mainthrust bearing bore. Make sure the tangs on allbearings hit the recesses in the bore and that theoil holes line up with oil passages in the block.

Apply a film of ctean light oil to bearing surfacesand to r.rankshaft main bearing journals.

Fig. 5-Afigning Timing Marks

Install crankshaft and align crankshaft and cam-shaft gear timing marks (Fig. 5).

Install e<.:chbearing cap with the recesses andtabs toward the same side of the engine as thoseon the respective upper bearings in the block.Also make sure bearing caps are installed on thebearing bosses from which they were removed.The numbers stamped on the caps should be onthe same side as the numbers on the block and insequence.

Before tightening cap screws on main bearingcaps, align upper and lower thrust flanges on mainthrust bearings. "Tap the crankshaft to the rearand then to the front to line up the flanges. Tightenmain bearing cap screws to 150 ft-Ibs torque.

Rear Oil Seal, Wear Sleeve, and HousingCarefully center new wear sleeve on crankshaft

flange with the O.D. chamfer of the sleeve towardthe rear of the tractor. Use a JDE-2A driver todrive sleeve flush with the crankshaft flange.

NOTE: On crankshafts with clutch pilot bushingadapter, use JDE-2A driver to drive sleeve untildriver bottoms on adapter face. Place a shim that

Litho in U.S.A.

--

Tractor - 42:30 .TM-1056 (Aug-72)

is 0.10 inch thick in the sleeve driving step of thedriver and continue to drive sleeve until it is f/t.-~with crankshaft flange.

..

O.D. OFOIL SEAL

HOUS~NG FLANGE. _cr,

~R IITJ2

. .

Fig. 7-Checking Oil Seal Housing Run-out

Attach a dial indicator base to the crankshaftflange (Fig. 7). Locate the dial indicator on the 0.0.of the oil seal housing flange. Turn the crankshaftand check housing bore run-out. Lightly tap thehousing to bring into 0.0060 inch maximum run-out.Tighten cap screws to 20 ft-Ibs torque.

Tractor - 42301M-1056 (Aug-72)

Basic Engine 20Crankshaft, Main Bearings and Flywheel 20-5

Front Oil Seal and Wear Sleeve

Coat 1.0. of new wear sleeve with joint sealingcompolJnd and drive sleeve onto flange with JDE-3driver.

Fig.B-Instafling FrontOilSeal

Install new front oil seal (Fig. 8) with spring sideof seal toward the engine. Support timing gearcover around seal bore and press seal in with No.27522 and No. 27537 of No. 27797 bushing driverset. Lubricate seal before installing cover onengine.

Litho in U.S.A.

--- - -- --

Pistons, Connecting Rods, Oil Pump

Install pistons, connecting rods, oil pump, oilpan, flywheel, and clutch pack.

Use the following torque specifications to installparts covered in this group. See 'Group 40, GeneralSpecifications for other torque &pecifications.

Location Torque (It.Jbs)

Main bearings caps 150Connecting rod bearings 100 to 110Rear crankshaft oil seal~ousing 20Flywheel to crankshaft 85Cylinder head to block (in sequence) 110 to 120Oil pan to block-Yz in. 85

% in. _. . . . 35Damper or pulley-to-crankshaft '150

Install remaining engine parts and install enginein tractor.

Fill crankcase and cooling system.

0.. ----

'.

'Tractor- 4230T.Af-1056(Aug-72)

/Basic Engine 20

Lubrication System 25-1

r

Fig. 1-Engine Oil Pump-Diese#

The engine lubrication system consists of agear-driven positive displacement pump, oil cooler,oil filter, cooler bypass valve, oil pressure regulat-.ing valve and filter relief valve.

The gasoline engine lubrication system differsfrom the diesel system. The gasoline engine hasan externally mounted oil cooler assembly includ-ing cooler bypass valve. The oil filter is mounteddirectly on the oil pump and is accessible throughthe oil pan. The filter relief valve is mounted inthe pump.

The diesel oil cooler is mounted in the blockwater passage on the. left-hand side of the engine.A cooler bypass valve housing is inside the block,below the crankshaft and connected by tubing tothe oil pump and oil cooler.

An externally mounted .oil filter housing withspin-on type filter and oil filter relief valve filtersdiesel engine oil. The engine oil pressure regulat-ing valve is also contained in the base of the filterrelief valve.

The oil pump in both engines is driven at 1/2en-gine speed by an integral oil pump drive gear onthe camshaft. A slot in the top of the pump drivengear drives the distributor on gasoline engines. Thepump drive gear also drives the speed-hour meteron both engines.

Litho in U.S.A.-- - -

Group 25LUBRICATION SYSTEiV1

The engine oil pressure regulator is in the speed-hour meter drive housing on gasoline tractors.

DIAGNOSING. MALFUNCTIONSLow Oil Pressure .

Oil pressure regulating valve failureExcessive clearance. between oj) pump gears

and coverClogg~d oil pump screenExcessive main bearing clearanceLow oil levelImproper oilExcessive oil temperature

High Oil PressureClogged oil linesOil pressure regulating valve failureWrong oil viscosity

Oil Sludge and DilutionImproper operationCoolant leakage into lubrication systemIncomplete combustionExcessive oil temperature

CHECKING OIL PRESSURE

Check engine oil pressure by removing pipeplug from main oil gallery. Install pressure gaugeand run engine at 1900 rpm; Oil pressure shouldbe ~ fe 40 psi In bott1 gasoline and diesel engines.

~O.- JJ.On gasoline engines, check pressure regulating

spring in speed-hour meter drive housing (Fig. 2).Spring should compress to 0.72 Inch at 6.75 to 8.24Ibs.

Check speed-hour meter drive gear on bothgasoline and diesel engines. Worn or damagedgear c: !1Indicate oil pump and camshaft oil pumpdrive gears are worn or damaged.

ADJUSTINC OIL PRESSURE

To adjust oil pressure on gasoline engines, re-move speed-hour meter cover and add or subtractshims. Each shim added will increase pressure by6 psi.

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2025-2

Basic EngineLubrication System

Tractor- 4230

TM-105? (Aug-72)

OIL COOLER REPAIRTo adjust oil pressure on diesel engines. re-move regulating valve spring at filter base and addor subtract washers as necessary.

SPEEDHOUREHETER DRIV

I DHOURGEAR

\ e ~~~~R HOUSINGBYJ;;.

RElIEF~ SPRING

Q 'rjfJ1.11V SHIH

· U~4lJa~'PR"" ?....OIL PR

AET

~~U~~USING ~REGUL

Fig. 2--Engin9 Oil Pressure Regulator-Gasoline

DIESEL OIL FILTER ANDHOUSING REPAIR

.'~. '":.~"" ~7;:'-. .jFILTER; RELIEF.\ VALVE

.d~-G

OILFILTER

. HOUSING-.- -------

Fig.3-oil FilterHousing-Diesel

Remove oil pressure regulator plug, spring andvalve in base of oil filter housing. Check valveand valve bore for damage.

Check oil pressure regulator spring. Springshould compress to 1.71 inches at 30 to 33 Ibs.pressure. Check for proper number of adjustingwashers.

Service filter as directed in tractor operator'smanual.

Check filter rehef valve spring. Spring shouldcompress to 2.38 inches at 18 to 22 Ibs. pressure.

Clean oil filter housing passages.

lns~",11 oil filter housing on engine. Install filterhand t;ght.

Litho in U.S.A.

/' ....

Gasoline Engines

o

EtlGINE COOLANTINLET

ENGINE

'IT COOLANT

U OllTLET

R14SS1

Fig.4-Engine Oil Coo/er-Gasolin9

Drain cooling .system and disconnect oil re~urnpipe and coolant hoses at the top and bottom ofthe cooler.

Disassemble end caps and cooler relief valve.Inspect cooler for cracks or clogged passages.

Check cooler bypass valve and spring. Springshould compress to 1.00 inch at 3.7 to 4 Ibs. pres-sure. .

Reassemble oil cooler and install with newgaskets. Refill cooling system.

Diesel Engine

Fig. 5-Engine Oil Cooler-Diesel

....

Tractor - 4230'TM-1056 (Aug-72)

Drain cooling system (Fig. 5).

Check for clogged passage and scale build up.Clean with suitable brush, solvent and compressedair.

Install cooler as shown.

Oil Cooler Bypass Valve - Diesel

BYPASS O-RINGVALVE ~LUG

GL':'ND .NUT . .-;:~

~'J ...,., \ (9 PIN

/) ~ i\ . 'Q OUTER

~ t \ SPRING

O-RING' O-RING. ,~~~~~.TOBLOCK

Fig. ~Engine Oil Cool9#' Reliel Varve-Diesel

Check cooler bypass valve assembly in block.Inner valve spring should compress to 1.38 inchesat 18 to 22 Ibs. pressure. The outer spring shouldcompress to 0.75 inches at 27 to 33 Ib~. pressure.

Be sure that cooler bypass valve housing tubesare clean.

Install the long end of the cooler bypass hous-ing-to-block tube into the housing. Install the otherend into the block.

Adjust tube and housing so that housing is flatagainst the block mounting pad. Attach housing toblock, but do not tighten cap screws.

Install oil pump-to-bypass housing tube to pump.Place gland nut with O-ring on tube.

Align tube and gland nut with bypass housingand tighten gland nut. Fasten oil cooler bypasshousing to cylinder block.

ENGINE OIL PUMPRemoval

Drain crankcase and remove oil pan.On gasoline engines, set No.1 piston on "TDC"

on compression stroke. If possible, do not disturbengine timing after pump has been removed.

Remove oil pump assembly from block.

Litho in U,S.A.

/Basic Engine 20

Lubrication Sy::;tem 25-3

OIL PUMP

~~~USING ,.~~'4.:>', '\..,.~::..

J :' ,'J ,. ''?', ".,-, .!-I ,...:..'~'

:: .,.>.../Yi%'o.j;.; /', ~;;:

I;ii~ 1:;(.'1__IDLER .I'~~;' ~ 'J ~GEAR ~~ ~SHAFT'vi',~

.

FILTER RELIEFY..

IiJti VALVE ASSEMBLY~ ~DRIVEN'IDLER GEAR

~"" GEAR

~ FILTER5b '"~ SCREEN

4 Ci> AND COVER

.! R 14606Fig. 7-Expfoded View 01 Engine Oil Pump-Giisoline

Repair

On gasoline engines, check oil filter and filterrelief valve assemblies for damage. The valvespring should compress to 1.19 inches at 18 to20 Ibs. pressure.

Fig. 8-Driven GearRemoval

Remove intake screen and pump housing cover.

Examine gears and housing for wear or damage.Note sealing edge of pump housing for signs ofdamage that could cause leakage. Worn gears,shafts or housing can reduce pump output andcould indicate oil contamination, sludge, or bentor warped shafts. The gear, shaft, and housingspecifications are as follows:

Measurement New Part SpecificationDepth of gear bore in housing

Gasoline .1.5100 to 1.5140 in.Diesel .1.7530 to 1.7570 in.

u - ---.-.---.--.--

20 Basic E!1gin925-4 Lubricatio/1 System

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/Tractor- 4230

TM-tOS6 (Aug-72)

Measurement New Part Specification

Gear thickness. Gaso!ine .. . . . . . . . . . . . . .1.5000 to 1.5070 in.

Diese] ..1.7500 to 1.7520 in.O.D. of gears

Gasoline .2.2680 to 2.2700 in.Diesel .3.2801 to 3.3811 in.

I.D. of housing gear boreGasoline .2.2720 to 2.2740 in.Diesel ..3.3840 to 3.3860 in.

I.D. of gearsDriven . . . . . . . . . . . . .0.6220to 0.6230in.Idler .0.6330 to 0.6340 in.

O.D. of idler shaft 0.6284 to 0.6290 in.O.D. of driven shaft 0.6235 to 0.6245 in.

If the drive gear on the top of the shaft is exces-sively worn or damaged, check the integral oilpump drive gear on the camshaft for wear ordum age. Replace pump drive gear and camshaftas necessary.

If either the idler gear or driven gear must be re-placed, replace both gears.

The idler gear is removed by sliding from theidler gear shaft.

. To remove driven gear, press from shaft asshown in Fig. 8. To install, support shaft and pressgear onto ~tlaft flu~h to 0.004 inch below sealingedge of housing. The drive and idler shafts willextend above the pump housing.

Install idler gear and pump cover, and intakescreen. Spin drive gear. Driven and idler gearsmust turn freely.

I ith"" -r m("o-~

Installation

Install gasoline engine oil pump as follows:

1. If engine timing position has been changed,reset No.1 piston at "TDC" on compression stroke.

2. Remove speed-hour meter drive housing anddrive gear.

..J

.0-f[}io'~E..

.. -.- -..

". ~".. ~. . .Ri~6"'jfi ~. . . ~ .. ... # ... -,. . . ~.

Fig. 9-Guide to Oil Pump Timing

3. Set "V" timing mark on drive gear as shown inFig. 9. The bottom of the gear tooth that is directlyin line with the drive slot must line up with thesmall cast mark next to the small oil hole on thepump housing.

4. Install oil pump so that drive slot is approxi-mately 15 degrees from parallel with the crankshaftand the "V" mark is toward the crankshaft.

Install diesel engine oil pump, making surethat pump drive gear and camshaft oil pump dtivegear mesh.

Install oil pan and tighten the 1/2-inch cap screwsto 85 ft-Ibs torque. Tighten the % -inch cap screwsto 35 ft-Ibs torque.

Fill crankcase and cooling system.