Parts Manual, Engine Part John Deere 4039/4045 (TP-5434)

Service PartsEngineEngine Models:John Deere TO4039D4039TLCD4039DFCD4039TF4045DF4045TFGenerator Models:20--40ROZJ/REOZJ20--40DSJ/DSEJ50/60ROZJ serial nos. 257821 and 0DSEJBTP-5434 4/03e

Table of ContentsSUBJECTPAGEIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Number Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Find Part Numbers . . . . . . . . . . . . . . . . . . . . . . .Specification Number Index . . . . . . . . . . . . . . . . . . . . . .Group 1: Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 2a: Water Pump . . . . . . . . . . . . . . . . . . . . . . . . .Group 2b: Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .Group 2c: Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 2d: Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 3: Vent Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 4a: Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 4b: Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 4c: Rocker Arm Cover . . . . . . . . . . . . . . . . . . . .Group 5a: Fuel Injection Pump . . . . . . . . . . . . . . . . . . .Group 5b: Fuel Injection Nozzle . . . . . . . . . . . . . . . . . .Group 7: Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . .Group 8a: Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 8b: Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . .Group 9: Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . .Group 10a: Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 10b: Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 11a: Starter Motor . . . . . . . . . . . . . . . . . . . . . . . .Group 11b: Starter Motor Components . . . . . . . . . . . GEGroup 12a: Exhaust Manifold . . . . . . . . . . . . . . . . . . . .Group 12b: Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . .Group 13a: Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 13b: Flywheel Housing . . . . . . . . . . . . . . . . . . . .Group 14: Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 15: Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 16: Balancer Shafts . . . . . . . . . . . . . . . . . . . . . .Group 18: Timing Gear Cover . . . . . . . . . . . . . . . . . . . .Group 21a: Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 21b: Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . .Group 21c: Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 22: Piston and Connecting Rod . . . . . . . . . . . .Group 25: Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 26: Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 39a: Cylinder Head Gasket Set . . . . . . . . . . . .Group 39b: Overhaul Gasket Kit . . . . . . . . . . . . . . . . . .Group 42: Short Block . . . . . . . . . . . . . . . . . . . . . . . . . .Group 50a: Turbocharger and Oil Lines . . . . . . . . . . .Group 51a: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 51b: Alternator Brackets . . . . . . . . . . . . . . . . . .Group 51c: Alternator Components . . . . . . . . . . . . . . .404142434546505153585961626466676970717477

IntroductionThis manual lists service replacement parts for John Deere4039 and 4045 engines.At the time of print this manual applied to the engine modelslisted in the Specification Number Index. On occasion thismanual may apply to engines not listed in the SpecificationNumber Index.Information in this publication represents data available atthe time of print. The generator set manufacturer reservesthe right to change this publication and the productsrepresented without notice and without any obligation orliability whatsoever.This manual includes the following main sections:Table of Contents. Lists the sections of the manual.Introduction (and other information sections).Contains introductory material about part numbers,illustrations, and hardware.Index. Lists the engine models and groups.Group Parts Lists. List the part numbers of parts in thegroups.Numbering System SignificanceThis manual uses the following numbering systems:Engine Model. The product identification number locatedon the engine nameplate. Engines break down intogroups.Group Number. A unique number representing a partsgroup needed to assemble an engine function. Forexample, Group 1 is the Air Intake group.Variation Number. A group might have several variations.Each variation performs the same function with differentparts lists. For example, a 12-volt alternator and 24-voltalternator both perform the same function, but, withdifferent parts. Each difference requires a group variationor module number.Part Number. The part number identifies an individualassembly, subassembly, component, or accessory kit.IllustrationsIllustrations (or exploded-view drawings) best representingthe widest range of variations accompany most groups inthis manual. Illustrations do not depict all details and maynot show all parts. Do not use illustrations for assembly ordisassembly.x:in:004:004aTP-5434 4/03How to Find Part NumbersUse the following steps to locate a service replacementpart.1. Locate the engine nameplate to identify the enginemodel number.2. Turn to the Specification Number Index. The firstcolumn lists the engine model numbers. Theheadings identify the groups of parts that make up theengine.3. Identify the group most likely to include the servicepart number.4. Find the group variation number at the intersectionof the model row and the group column. Note thevariation number. If 2 or more variation numbers arelisted, note all variation numbers.5. Page forward to locate the group identified in step 3or find the appropriate page in the Table of Contents.6. Find the part on the illustration and note the itemnumber of the part or find the part description in theparts list.7. Select the part number that corresponds to yourgroup variation. The first column lists the illustrationitem number. Find the variation(s) identified in theSpecification Number Index in the appropriatecolumn on the right side of the parts list table. Find thequantity used at the intersection of the item numberrow and the variation column. A blank space at theintersection means the variation/module does not usethat part number.Hardware ReferencesMany common hardware items do not appear in partsmanuals or will appear as common hardware entries. Acommon hardware entry lists the size of the hardware. Forexample, an item that appears as “Hardware, 3/8-16” in thetext means that the piece is 3/8-16 size. Obtain commonhardware locally.Some hardware items require a specific size or some othercharacteristic. In that case, use the part number listed inthe text.When replacing hardware, do not substitute inferiorgrade hardware. Replacement hardware grade should beequal to or better than the grade of the manufacturer’soriginal hardware.1

Specification Number IndexGroup TitleGroup No.12a2b2c2d34a4b4c5a5b78a8bVariation NumberModel20-- 40ROZJ or 20-- 40DSJTO4039D11CD4039DF1120-- 40REOZJ or 20-- 40DSEJ57024401TO4045DF, 12 V1705200257024401TO4045DF, 24 V1705200250/60ROZJ* or 50/60DSJ4039TL21CD4039TF2150/60REOZJ or 50/60DSEJ57024401TO4045TF, 12 V1701200257024401TO4045TF, 24 V170120025702TO4045TF, 12 V440117014S7 alternator20025702TO4045TF, 24 V440117014S7 alternator200250/60REOZJB or 50/60DSEJB57024045TF120,4401170112 V, 50 Hz200257024045TF150,4401170112 V, 60 Hz[200257024045TF120,4401170124 V, 50 Hz200257024045TF150,4401170124 V, 60 1110116MAor1677[16MAor1677[460247011302* These units used John Deere 4239TL engines on early model 50/60 kW (serial numbers below 257821) generator sets and John Deere4039TL/CD4039TF engines on newer model 50/60 kW (serial number 257821 and above) generator sets. Check the generator set nameplate for theserial number and the engine nameplate for the engine model. Refer to Parts Catalog TP-5368 P/C John Deere 4239DL/TL if the generator set usesJohn Deere 4239TL engine.[ Use fuel injection pump variation 16LZ on generator set specification GM21199-GA5.only. Use variation 1656 on other specs.Use fuel injection pump variation 16MA on generator set specification GM21199-GA7.only. Use variation 1677 on other specs.2TP-5434 4/03

Specification Number IndexGroup TitleGroup No.12a2b2c2d34a4b4c5a5b78a8bVariation NumberModel80REOZJB or 80DSEJB4045TF220,12 V, 50 110116GQ16GQ4601470113014045TF250,12 V, 60 1101161C161C4601470113014045TF220,24 V, 50 110116LV16LV4601470113014045TF250,24 V, 60 1101161D161D460147011301TP-5434 4/033

Specification Number IndexGroup TitleGroup No.910a10b11a11b12a12b13a13b14151618Variation NumberModel20-- 40ROZJ or 20-- —220-- 40REOZJ or 20-- 40DSEJ4045DF, 12 44014045DF, 24 440150/60ROZJ* or /60REOZJ or 50/60DSEJTO4045TF, 12 401TO4045TF, 24 401TO4045TF, 12 V4S7 351645024401TO4045TF, 24 V4S7 35164502440150/60REOZJB or 50/60DSEJB4045TF,120,12 V, 50 4014045TF150,12 V, 60 4014045TF120,24 V, 50 4014045TF150,24 V, 60 40180REOZJB or 80DSEJB4045TF220,12 V, 50 44014045TF250,12 V, 60 44014045TF220,24 V, 50 44014045TF250,24 V, 60 4401-- Group parts not supplied with engine.* These units used John Deere 4239TL engines on early model 50/60 kW (serial numbers below 257821) generator sets and John Deere4039TL/CD4039TF engines on newer model 50/60 kW (serial number 257821 and above) generator sets. Check the generator set nameplate for theserial number and the engine nameplate for the engine model. Refer to Parts Catalog TP-5368 P/C John Deere 4239DL/TL if the generator set usesJohn Deere 4239TL engine.4TP-5434 4/03

Specification Number IndexGroup TitleGroup No.21a21b21c22252639a39b425051a51b51cVariation NumberModel20-- 40ROZJ or 20-- 40DSJTO4039D11CD4039DF1120-- 40REOZJ or 20-- 40DSEJTO4045DF, 12 V19021299TO4045DF, 24 V1902129950/60ROZJ* or 50/60DSJ4039TL21CD4039TF2150/60REOZJ or 50/60DSEJTO4045TF, 12 V19041299TO4045TF, 24 V19041299TO4045TF, 12 V190412994S7 alternatorTO4045TF, 24 V190412994S7 alternator50/60REOZJB or 50/60DSEJB4045TF120,1904129912 V, 50 Hz4045TF150,1904129912 V, 60 Hz4045TF120,1904129924 V, 50 Hz4045TF150,1904129924 V, 60 Hz80REOZJB or 80DSEJB4045TF220,1904129912 V, 50 Hz4045TF250,1904129912 V, 60 Hz4045TF220,1904129924 V, 50 Hz4045TF250,1904129924 V, 60 002360199019901465CT310462123104-- Group parts not supplied with engine.* These units used John Deere 4239TL engines on early model 50/60 kW (serial numbers below 257821) generator sets and John Deere4039TL/CD4039TF engines on newer model 50/60 kW (serial number 257821 and above) generator sets. Check the generator set nameplate for theserial number and the engine nameplate for the engine model. Refer to Parts Catalog TP-5368 P/C John Deere 4239DL/TL if the generator set usesJohn Deere 4239TL engine.TP-5434 4/035

Notes6TP-5434 4/03

Group 1: Air escriptionPlug, 3/8 NPT pipeGasketWasher, 3/8 in. lockScrew, 3/8-16 x 1 1/4 in. capScrew, M10 x 35Elbow, air intakeAir ed by permission of Deere & Company.E 1988 Deere & Company. All rights 223529360544#####223532#DescriptionClampHose, 2 in. ID x 2 1/2 in.HoseDuct, airAir IntakeScrew, 3/8-16 x 1 1/4 in.Screw, M10 x 25Washer, 3/8 lockPlug, 3/8 NPTPlugGasketPlug, 1/8 NPT pipeQuantityVariationNumber2170122241122211111# Common hardware; procure locally.Reproduced by permission of Deere & Company.E 1988 Deere & Company. All rights reserved.TP14910(was CD25559)TP-5434 4/037

Group 2a: Water Pump23Reproduced by permission of Deere & Company.E 1988 Deere & Company. All rights tImpellerPlug, 1/2 in. pipeSeal kit (w/insert tool)Screw, 3/8-16 x 1 3/8 in.Bearing, ballFitting, hoseHoseWasher, 3/8 in. lockScrew, 3/8-16 x 3 1/2 in.Screw, 3/8-16 x 2 in.PulleyScrew, 3/8-16 x 3 1/4 in.Nut, 3/8-16StudTubePump, waterHubScrew, 5/16-18 x 7/8 in.Pump assembly, waterClampWater pump 1# Common hardware, procure locally.X Item not sold separately.8TP-5434 4/03