Day: September 4, 2018

Pages from CTM77 (30OCT00) – John Deere Alternators & Starter Motors Component Technical Manual

Complete Component Technical Manual for John Deere Alternators & Starter Motors. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This John Deere Alternators & Starter Motors Component Technical Manual is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

CTM77 (30OCT00) – John Deere Alternators & Starter Motors Component Technical Manual.pdf; 576 pages (bookmarked, Searchable, Printable, high quality PDF)

EXCERPT:
TABLE OF CONTENTS
SECTION 05—Introduction and Safety Information
Group 05—Safety
Group 10—General Information
Group 15—Electrical System Basic Information and Wiring Diagrams
SECTION 10—Delco-Remy Alternators
Group 05—Delco-Remy Alternator Theory of Operation
Group 10—Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair
Group 15—Delco-Remy (Delcotron) 21SI Alternator Repair
SECTION 15—Motorola Alternators
Group 05—Motorola Alternator Theory of Operation Group 10—Motorola 8E-Series Alternator Repair Group 15—Motorola HC-, MA-, MR-Series Alternator Repair
Group 20—Motorola A-, RA-, 8AR-Series Alternator Repair
Group 25—Motorola SA-Series Alternator Repair Group 30—Motorola TA-Series Alternator Repair
SECTION 20—Niehoff Alternators
Group 05—Niehoff Alternator Theory of Operation Group 10—Niehoff 12-Volt, 110-Amp Alternator Repair
Group 15—Niehoff 24-Volt, 50-Amp Alternator Repair
SECTION 25—Denso Alternators
Group 05—Denso Alternator Theory of Operation Group 10—Denso Alternator with Add-On Regulator Repair
Group 15—Denso Alternator with Built-In Regulator Repair
SECTION 30—Robert Bosch Alternators
Group 05—Robert Bosch Alternator Theory of Operation
Group 10—Robert Bosch Alternator Repair
SECTION 35—Valeo Alternators
Group 05—Valeo Alternator Theory of Operation Group 10—Valeo Alternator Repair
Group 15—Valeo A13N-Series Alternator Repair
SECTION 40—Magneton Alternators
Group 05—Magneton Alternator Theory of Operation
Group 10—Magneton Alternator Repair
SECTION 45—Leece-Neville Alternators
Group 05—Leece-Neville Alternator Theory of Operation
Group 10—Leece-Neville Alternator Repair
SECTION 50—Prestolite Alternators 15 Group 05—Prestolite Alternator Theory of Operation Group 10—Prestolite Alternator Repair
SECTION 60—Delco-Remy Starter Motors
Group 05—Starting Circuit Theory of Operation
Group 10—Delco-Remy 10/20/22/25/27/28MT 20 Starter Motor Repair
Group 15—Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair
Group 20—Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair 25
SECTION 65—John Deere/Denso Starter Motors
Group 05—Starting Circuit Theory of Operation Group 10—John Deere/Denso Conventional Starter Motor Repair
Group 15—John Deere/Denso Gear Reduction Starter Motor Repair
SECTION 70—Robert Bosch Starter Motors 30
Group 05—Starting Circuit Theory of Operation
Group 10—Robert Bosch Starter Motor Repair 35
SECTION 75—Iskra Starter Motors
Group 05—Starting Circuit Theory of Operation Group 10—Iskra Starter Motor Repair
SECTION 80—Valeo Starter Motors
Group 05—Starting Circuit Theory of Operation Group 10—Valeo Starter Motor Repair
Index
…

Pages from CTM42 (24MAR95) – John Deere Series 400 6076 Diesel Engines (SN 500000-) Component Technical Manual

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INSTANT DOWNLOAD

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Complete Component Technical Manual for John Deere Series 400 6076 Diesel Engines (SN 500000-). It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This John Deere Series 400 6076 Diesel Engines (SN 500000-) Component Technical Manual is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

CTM42 (24MAR95) – John Deere Series 400 6076 Diesel Engines (SN 500000-) Component Technical Manual.pdf; 456 pages (bookmarked, Searchable, Printable, high quality PDF)

EXCERPT:
TABLE OF CONTENTS
Group 00—Safety
Safety . . . 00-1
Group 01—General Information
Unified Inch Bolt and Cap Screw Torque
Values . . . 01-1
Metric Bolt and Cap Screw Torque
Values . . . 01-2
Engine Model Designation . . . . 01-3
Engine Serial Number Plate Information . . . 01-4
Engine Application Chart . . . 01-5
Engine Application Chart . . . 01-6
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . 02-1
Lubricity of Diesel Fuels . . . 02-1
Engine Break-In Oil . . . . 02-2
Engine Oil . . . . 02-3
Oilscan and Coolscan . . . 02-4
Grease . . . 02-4
Alternative and Synthetic Lubricants . . . 02-5
Engine Coolant Requirements . . . 02-5
Recommended Engine Coolant . . . 02-7
Engine Coolant Specifications . . . 02-8
Replenish Supplemental Coolant
Additives Between Coolant Changes . . . . 02-10
Operating in Tropical Conditions . . . 02-11
Flush and Service Cooling System . . . 02-12
Disposing of Coolant . . . . 02-13
Group 03—Engine Mounting
Engine Repair Stand . . . 03-1
Safety Precautions . . . 03-2
Install 400 Series Adapters on Repair
Stand . . . . 03-2
Engine Lifting Procedure . . . 03-3
Clean Engine . . . . 03-4
Disconnect Turbocharger Oil Inlet Line . . . 03-4
Mount Engine On Repair Stand . . . . 03-5
Group 04—Engine Rebuild Guide
6076 Engine Disassembly Sequence . . . 04-1
Sealant Application Guidelines . . . 04-2
6076 Engine Assembly Sequence . . . 04-4
Group 05—Cylinder Head and Valves
Special or Essential Tools . . . . 05-1
Service Equipment and Tools . . . . 05-3
Other Material . . . . 05-4
Cylinder Head and Valves Specifications . . . . 05-5
Check and Adjust Valve Clearance . . . . 05-7
Check Valve Lift . . . . 05-9
Remove Cylinder Head . . . 05-10
Disassemble and Inspect Rocker Arm
Shaft Assembly . . . . 05-12
Assemble Rocker Arm Shaft Assembly . . . . 05-14
Measure Valve Recess . . . 05-14
Preliminary Cylinder Head and Valve
Checks . . . . 05-15
Remove Valve Assembly . . . . 05-16
Inspect and Measure Valve Springs . . . . 05-17
Inspect Valve Rotators and Wear Caps . . . . 05-17
Clean Valves . . . . 05-18
Inspect and Measure Valves . . . 05-18
Grind Valves . . . . 05-19
Inspect and Clean Cylinder Head . . . . 05-19
Check Cylinder Head Combustion Face
Flatness . . . 05-20
Measure Cylinder Head Thickness . . . 05-21
Clean Valve Guides . . . 05-22
Measure Valve Guides . . . 05-22
Knurl Valve Guides . . . 05-23
Clean and Inspect Valve Seats . . . 05-23
Measure Valve Seats . . . . 05-24
Grind Valve Seats . . . . 05-25
Remove Valve Seat Inserts and Measure
Bores . . . 05-26
Install Valve Seat Inserts . . . . 05-27
Inspect and Clean Cylinder Head Nozzle
Bore . . . . 05-27
Clean and Inspect Push Rods . . . . 05-28
Inspect and Clean Ventilator Outlet Hose . . . 05-28
Clean and Inspect Top Deck of Cylinder
Block . . . 05-29
Measure Cylinder Liner Standout (Height
above Block) . . . . 05-30
Assemble Valve Assembly . . . 05-31
Install Cylinder Head . . . . 05-32
Cylinder Head Cap Screw Types . . . . 05-33
Clean, Inspect and Install Cylinder Head
Cap Screws . . . 05-34
Torque-To-Yield Special Flanged-Head
Cap Screws . . . 05-36
Install Rocker Arm Assembly . . . 05-37
Complete Final Assembly Of Injection
Pump Side . . . . 05-38
Complete Final Assembly On Exhaust
Manifold Side . . . . 05-39
Perform Engine Break-In . . . . 05-42
Group 10—Cylinder Block, Liners, Pistons and
Rods
Special or Essential Tools . . . . 10-1
Service Equipment and Tools . . . . 10-3
Other Material . . . . 10-3
Cylinder Block, Liners, Pistons, and Rods
Specifications . . . 10-4
Preliminary Liner, Piston, and Rod
Checks . . . 10-8
Remove Pistons and Connecting Rods . . . 10-9
Measure Cylinder Liner Standout (Height
above Block) . . . . 10-12
Remove Cylinder Liners . . . . 10-13
Deglazing Cylinder Liners . . . 10-14
Clean Cylinder Liners . . . . 10-15
Disassemble and Clean Piston . . . . 10-15
Visually Inspect Pistons . . . 10-16
Check Piston Ring Groove Wear . . . . 10-17
Measure Oil Control Ring Groove . . . . 10-18
Install Piston Pin in Piston Pin Bore . . . . 10-18
Visually Inspect Cylinder Liners . . . 10-19
Cylinder Liner Manufacturing Date Code
Explanation . . . 10-20
Measure Piston Skirt OD . . . . 10-21
Measure Cylinder Liner ID . . . 10-22
Measure Liner Flange Thickness . . . . 10-22
Inspect and Measure Connecting Rod
Bearings . . . 10-23
Inspect Rod and Cap . . . . 10-24
Inspect Piston Pins and Bushings . . . . 10-26
Remove Piston Pin Bushing . . . . 10-27
Clean and Inspect Piston Pin Bushing
Bore in Rod . . . 10-27
Install Piston Pin Bushing in Connecting
Rod . . . . 10-28
Complete Disassembly of Cylinder Block
(If Required) . . . 10-29
Remove and Clean Piston Cooling
Orifices . . . . 10-29
Inspect and Clean Cylinder Block . . . . 10-30
Clean O-Ring Bore . . . . 10-32
Measure Cylinder Block . . . . 10-32
Install Piston Cooling Orifices and Gallery
Plugs . . . 10-34
Recheck Cylinder Liner Standout (Height
above Block) . . . . 10-35
Install Liner Shims—If Required . . . 10-36
Install Cylinder Liner O-Rings and
Packings . . . 10-37
Install Cylinder Liners . . . . 10-38
Install Pistons and Connecting Rods . . . . 10-40
Torque-Turn Connecting Rod Cap Screws. . . 10-43
Check Engine Rotation for Excessive
Tightness . . . 10-43
Complete Final Assembly . . . 10-44
Group 15—Crankshaft, Main Bearings and
Flywheel
Special or Essential Tools . . . . 15-1
Service Equipment and Tools . . . . 15-4
Other Material . . . . 15-5
Crankshaft, Main Bearings, and Flywheel
Specifications . . . 15-6
Failure Analysis . . . 15-8
Remove Crankshaft Rear Oil Seal
Housing
(With Oil Seal Housing Installed) . . . . 15-9
Install Crankshaft Rear Oil Seal and
Wear Sleeve
(Without Engine Disassembly) . . . 15-11
Inspect Vibration Damper . . . 15-12
Check Crankshaft End Play . . . . 15-13
Remove Damper Pulley . . . . 15-14
Remove Front Oil Seal
(With Timing Gear Cover Installed on
Engine) . . . . 15-16
Remove Front Wear Sleeve
(With Timing Gear Cover Installed or
Removed) . . . 15-17
Install Front Wear Sleeve
(With Timing Gear Cover Installed) . . . 15-17
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . 15-18
Replace Timing Gear Cover
(6076HRW33, 34, and 35 Engines)
—Engine Installed in Vehicle . . . . 15-19
Remove Timing Gear Cover . . . 15-20
Inspect, Measure and Repair Flywheel . . . . 15-20
Check Flywheel Housing Face Run-Out . . . . 15-21
Check Flywheel Face Flatness . . . . 15-21
Check Pilot Bearing Bore Concentricity . . . . 15-22
Remove Flywheel . . . . 15-22
Remove SAE 1 and SAE 2 Flywheel
Housing . . . . 15-23
Remove SAE 3 Flywheel Housing . . . . 15-23
Replace Flywheel Ring Gear . . . 15-24
Replace Rear Oil Seal Housing
(6076HRW33, 34, and 35 Engines)
—Engines Installed in Vehicle . . . 15-25
Remove Rear Oil Seal Housing and
Wear Sleeve
(With Engine Disassembled) . . . . 15-26
Remove Crankshaft Main Bearings . . . 15-27
Check Main Bearing Clearance . . . 15-28
Remove Crankshaft . . . 15-29
Inspect Crankshaft . . . . 15-30
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals . . . 15-32
Main Bearing Cap Line Bore
Specifications . . . . 15-33
Crankshaft Grinding Guidelines . . . . 15-34
Thrust Bearing New Part Specifications . . . . 15-36
Crankshaft Grinding Specifications . . . 15-37
Replace Crankshaft Oil Pump Drive Gear . . . 15-38
Replace Crankshaft Gear . . . 15-39
Inspect Thrust Bearings . . . . 15-40
Remove and Clean Piston Cooling
Orifices . . . . 15-40
Install Main Bearings and Crankshaft . . . . 15-41
Install Crankshaft Rear Oil Seal Housing . . . 15-43
Check Oil Seal Housing Runout . . . 15-45
Crankshaft Rear Oil Seal And Wear
Sleeve Handling Precautions . . . . 15-46
Install Crankshaft Rear Oil Seal and
Wear Sleeve Assembly . . . 15-47
Install Timing Gear Cover . . . 15-48
Install Front Wear Sleeve . . . 15-48
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . 15-49
Install Damper Pulley Assembly . . . 15-49
Install SAE 3 Flywheel Housing . . . 15-50
Install Flywheel . . . . 15-51
Install SAE 1 and SAE 2 Flywheel
Housing . . . . 15-51
Complete Final Assembly . . . 15-52
Group 16—Camshaft and Timing Gear Train
Special or Essential Tools . . . . 16-1
Service Equipment and Tools . . . . 16-3
Other Material . . . . 16-3
Camshaft and Timing Gear Train
Specifications . . . 16-4
Check Valve Lift . . . . 16-6
Check Camshaft End Play . . . . 16-7
Remove Damper Pulley and Timing Gear
Cover . . . . 16-7
Measure Camshaft Drive
Gear-to-Crankshaft Gear Backlash . . . 16-8
Remove Camshaft . . . 16-9
Remove Camshaft Gears . . . 16-11
Measure Thrust Washer Thickness . . . 16-11
Inspect and Measure Camshaft Followers . . . 16-12
Visually Inspect Camshaft . . . 16-12
Measure Camshaft Journal OD and
Bushing ID . . . . 16-13
Measure Camshaft Lobe Lift . . . 16-13
Install Camshaft Gears . . . 16-14
Service Camshaft Bushings using
JDG602 Adapter Set . . . 16-15
Service Camshaft Bushings using
JDG606 Adapter Set . . . 16-17
Install Camshaft . . . . 16-18
Install Thrust Washer and Timing Gear
Cover . . . 16-20
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . 16-21
Complete Final Assembly . . . 16-22
Group 20—Lubrication System
Other Material . . . . 20-1
Lubrication System Specifications . . . 20-1
Drain Engine Oil and Remove Oil Pan . . . . 20-2
Oil Filter and Oil Conditioning Housing
Assembly . . . . 20-3
Remove Oil Filter and Oil Conditioning
Housing . . . 20-4
Inspect and Replace Oil Filter Adapter . . . . 20-4
Remove, Inspect, and Install Valves from
Oil Conditioning Housing . . . 20-5
Install Oil Filter and Oil Conditioning
Housing . . . 20-6
Remove Engine Oil Cooler . . . 20-7
Clean, Inspect, and Install Engine Oil
Cooler . . . . 20-8
Check Crankshaft Gear-To-Oil Pump
Drive Gear Backlash . . . . 20-9
Remove Engine Oil Pump . . . . 20-9
Inspect and Clean Oil Pump . . . 20-10
Check Drive Shaft End Play . . . 20-11
Check Drive Shaft Side Movement . . . 20-11
Check Pumping Gear Backlash . . . 20-12
Inspect Oil Pump Drive Gear . . . 20-12
Install Engine Oil Pump . . . 20-13
Install Oil Pan . . . 20-14
Tighten cap screws on front frame/oil
sump . . . 20-15
Group 25—Cooling System
Special or Essential Tools . . . . 25-1
Other Material . . . . 25-2
Cooling System Specifications . . . 25-3
Service Equipment and Tools . . . . 25-5
Replace Bearings in Standard Duty,
Adjustable Fan Drive Assembly . . . 25-6
Replace Bearings in Heavy Duty,
Adjustable Fan Drive Assembly . . . 25-8
Water Manifold Mounted Fixed Fan Drive
Assembly . . . 25-10
Replace Bearing in Injection Pump Drive
Gear Mounted Fan Drive . . . . 25-12
Inspect and Check Belt Tensioner Spring
Tension . . . . 25-13
Replace Belt Tensioner Assembly . . . . 25-14
Remove Water Pump . . . . 25-14
Disassemble Water Pump . . . 25-15
Inspect Water Pump Parts . . . 25-18
Assemble Water Pump . . . 25-19
Install Water Pump . . . . 25-21
Remove and Test Thermostats . . . . 25-22
Install Thermostats . . . . 25-23
Remove Water Manifold . . . . 25-23
Install Water Manifold . . . . 25-24
Remove Coolant Heater . . . . 25-24
Install Coolant Heater . . . . 25-25
Complete Final Assembly . . . 25-26
Fan Belt Tension Specifications . . . 25-26
Group 30—Air Intake And Exhaust System
Special or Essential Tools . . . . 30-1
Other Material . . . . 30-2
Air Intake and Exhaust System
Specifications . . . 30-2
Extending Turbocharger Life . . . . 30-4
Remove Turbocharger . . . . 30-6
Turbocharger Failure Analysis . . . 30-8
Turbocharger Seven-Step Inspection . . . . 30-10
Perform Radial Bearing Clearance Test . . . . 30-15
Perform Axial Bearing End Play Test . . . . 30-16
Repair Turbocharger . . . 30-16
Disassemble Turbocharger . . . . 30-17
Clean and Inspect Turbine and
Compressor Housings . . . . 30-18
Replace Center Housing Assembly and
Assemble Turbocharger . . . 30-19
Prelube Turbocharger . . . . 30-20
Install Turbocharger . . . 30-20
Remove, Inspect, and Install Intake
Manifold . . . 30-22
Remove Vertically-Mounted Aftercooler
and Intake Manifold . . . . 30-23
Remove and Disassemble
Horizontally-Mounted Aftercooler
Assembly . . . 30-25
Inspect and Repair Aftercooler . . . . 30-26
Inspect and Repair Intake Manifold and
Cover . . . 30-26
Install Intake Manifold and
Vertically-Mounted Aftercooler . . . 30-27
Assemble and Install
Horizontally-Mounted Aftercooler
Assembly . . . 30-29
Remove, Inspect, and Install Exhaust
Manifold . . . 30-31
Group 35—Fuel System
Special or Essential Tools . . . . 35-1
Other Material . . . . 35-4
Diesel Fuel System Specifications . . . 35-4
Relieve Fuel System Pressure . . . 35-6
Replace Rectangular Fuel Filter Element . . . . 35-6
Replace Fuel Check Valve . . . 35-7
Remove Round Fuel Filter Element . . . . 35-8
Identification of fuel supply and fuel
injection pumps . . . 35-9
Remove Mechanical Fuel Supply Pump . . . . 35-10
Test Mechanical Fuel Supply Pump for
Leaks . . . 35-11
Disassemble Mechanical Fuel Supply
Pump (Nippondenso) . . . 35-12
Inspect and Repair Mechanical Fuel
Supply Pump (Nippondenso) . . . . 35-14
Assemble Mechanical Fuel Supply Pump
(Nippondenso) . . . 35-15
Disassemble Mechanical Fuel Supply
Pump (Robert Bosch) . . . . 35-16
Inspect and Repair Mechanical Fuel
Supply Pump (Robert Bosch) . . . 35-17
Assemble Mechanical Fuel Supply Pump
(Robert Bosch) . . . 35-18
Install Mechanical Fuel Supply Pump . . . 35-18
Remove and Install Electric Fuel Supply
Pump . . . 35-19
Clean or Replace Electric Fuel Supply
Pump Filter Screen . . . . 35-20
Repair Aneroid . . . . 35-21
Remove Hydraulic Aneroid Activator . . . . 35-21
Disassemble and Clean Hydraulic
Aneroid Activator Parts . . . 35-22
Assemble and Install Hydraulic Aneroid
Activator . . . 35-22
Service Injection Pump Overflow Valve . . . . 35-22
Remove and Install Fuel Shutoff Solenoid . . . 35-24
Identification of In-Line Injection Pumps . . . . 35-25
Remove In-Line Fuel Injection Pump . . . . 35-26
Install In-Line Fuel Injection Pump . . . 35-29
Remove Rotary Fuel Injection
Pump—Stanadyne DB4 . . . 35-33
Install Rotary Fuel Injection
Pump—Stanadyne DB4 . . . 35-34
Remove Fuel Injection Nozzles . . . 35-37
Diagnose Injection Nozzle Malfunction . . . 35-40
Test Fuel Injection Nozzles . . . . 35-42
Perform Opening Pressure Test . . . 35-43
Injection Nozzle Specifications . . . . 35-44
Perform Nozzle Leakage Test . . . . 35-45
Perform Chatter and Spray Pattern Test . . . 35-46
Disassemble Fuel Injection Nozzle . . . 35-47
Clean and Inspect Fuel Injection Nozzle
Assembly . . . 35-49
Perform Nozzle Slide Test . . . 35-50
Clean Spray Orifices . . . 35-50
Inspect Nozzle Holder . . . . 35-51
Inspect Gland Nut . . . . 35-53
Assemble Fuel Injection Nozzle . . . 35-54
Adjust Injection Nozzles . . . . 35-57
Inspect and Clean Cylinder Head Nozzle
Bore . . . . 35-58
Inspect and Clean Nozzle Seating
Surface . . . . 35-59
Install Fuel Injection Nozzles . . . 35-59
Group 100—Engine Tune-Up and Break-In
Effects of Altitude and Temperature on
Engine Performance . . . 100-1
Preliminary Engine Testing . . . . 100-2
General Tune-Up Recommendations . . . . 100-3
Dynamometer Test . . . . 100-4
Engine Break-In Guidelines . . . . 100-5
Perform Engine Break-In . . . . 100-6
Check Crankcase Ventilation System . . . . 100-7
Check Air Intake System . . . . 100-7
Check Exhaust System . . . 100-8
Check and Service Cooling System . . . 100-8
Check Electrical System . . . 100-10
Group 105—Engine System Operation and Test
Special or Essential Tools . . . 105-1
Engine Test Specifications . . . 105-3
Engine—Sectional View . . . . 105-4
General Engine Description . . . . 105-5
How the Lubrication System Works . . . 105-6
How the Cooling System Works . . . . 105-10
Head Gasket Joint Construction and
Operation . . . 105-12
Diagnosing Head Gasket Joint Failures . . . 105-14
Head Gasket Inspection and Repair
Sequence **M:CTM42,G105,18 -19- . . . . 105-17
Diagnosing Engine Malfunctions . . . . 105-18
Test Engine Compression Pressure . . . . 105-21
Check Engine Oil Pressure . . . 105-22
Inspect Thermostat and Test Opening
Temperature . . . 105-24
Group 110—Air Intake System Operation and
Test
Special or Essential Tools . . . 110-1
Air Intake and Exhaust System Test
Specifications . . . . 110-2
Diagnosing Air Intake Malfunctions . . . 110-3
How the Air Intake and Exhaust System
Works . . . 110-4
Air Cleaner Operation . . . . 110-4
Diagnosing Turbocharger Malfunctions . . . 110-6
How The Turbocharger Works . . . . 110-7
How The Turbocharger is Lubricated . . . . 110-7
How The Aftercooler Works—6076A
Engines . . . . 110-8
Check Intake Manifold Pressure
(Turbocharger Boost) . . . 110-9
Group 115—Fuel System Operation and Test
Special or Essential Tools . . . 115-1
Fuel System Test Specifications . . . 115-2
Check and Adjust Rotary fuel pump
Dynamic Timing . . . . 115-2
Fuel System Operation—In-Line Fuel
Injection Pump . . . . 115-10
Fuel System Operation—Rotary Fuel
Injection Pump . . . . 115-11
Diagnose Fuel System Malfunctions . . . 115-12
Mechanical Fuel Supply Pump Operation
Operation . . . 115-16
Diagnosing Mechanical Fuel Supply
Pump Malfunctions . . . 115-18
Test Mechanical Fuel Supply Pump for
Leaks . . . . 115-19
Check Mechanical Fuel Supply Pump
Operation . . . 115-20
Service Mechanical Fuel Supply Pump . . . 115-22
Electric Fuel Supply Pump Operation . . . . 115-23
Diagnose Electric Fuel Supply Pump
Malfunction . . . . 115-24
Test Electric Fuel Supply Pump Output
Pressure and Flow . . . 115-25
Fuel Shut-Off Solenoid Resistance Test . . . 115-27
Rectangular Fuel Filter Operation . . . 115-28
Round (Final) Fuel Filter Operation . . . . 115-28
Bleed the Fuel System . . . . 115-29
Diagnose In-Line Fuel Injection Pump
Malfunctions . . . . 115-32
In-Line Fuel Injection Pump Operation . . . . 115-33
Check Fast Idle Speed—In-Line Fuel
Injection Pump . . . . 115-34
Check and Adjust Engine Slow Idle
Speed—In-Line Fuel Injection Pump . . . . 115-35
Rotary Fuel Injection Pump
Operation—Stanadyne DB4 . . . 115-38
Diagnose Rotary Fuel Injection Pump
Malfunctions . . . . 115-40
Check and Adjust Engine Speeds on
Rotary Pump . . . 115-41
How the Aneroid Works—In-Line Injection
Pumps . . . 115-42
Diagnose Aneroid Malfunctions . . . 115-43
How the Hydraulic Aneroid Activator
Works . . . . 115-44
Diagnose Malfunctions—Hydraulic
Aneroid Activator . . . . 115-45
Fuel Injection Nozzles—General
Information . . . 115-46
Fuel Injection Nozzle Operation . . . . 115-47
Diagnose Malfunctions—Fuel Injection
Nozzle . . . 115-48
Test Fuel Injection Nozzles (Engine
Running) . . . . 115-49
Fuel Drain Back Test Procedure . . . . 115-49
Group 199—Dealer Fabricated Tools
How to Make Tools . . . 199-1
Cylinder Liner Holding Fixture . . . . 199-1
Index

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INSTANT DOWNLOAD

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Pages from CTM6 (03OCT91) – John Deere 6076 Engines (SN -499999) Component Technical Manual

---

INSTANT DOWNLOAD

---

Complete Component Technical Manual for John Deere 6076 Engines (SN -499999). It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This John Deere 6076 Engines (SN -499999) Component Technical Manual is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

CTM6 (03OCT91) – John Deere 6076 Engines (SN -499999) Component Technical Manual.pdf; 437 pages (bookmarked, Searchable, Printable, high quality PDF)

EXCERPT:
TABLE OF CONTENTS
Group 00—Introduction and Safety Information
About This Manual . . . 00-1
Safety . . . 00-1
Group 01—General Information
Inch Series Torque Chart . . . . 01-1
Metric Series Torque Chart . . . 01-2
Bolt Identification Chart . . . . 01-3
Engine Model Designation . . . . 01-4
Engine Nameplate Information . . . 01-6
Option Code Label . . . 01-8
Engine Application Chart
Industrial Equipment . . . . 01-8
OEM . . . 01-9
Agricultural Equipment . . . 01-9
Basic 6076 Engine Specifications . . . . 01-10
General Engine Description . . . . 01-11
Engine-Sectional View . . . 01-12
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . 02-1
Diesel Engine Oil . . . . 02-2
General Purpose Grease . . . 02-3
Engine Coolant Recommendations . . . . 02-4
Engine Coolant Requirements . . . 02-5
Group 03—Engine Mounting
Engine Repair Stand . . . 03-1
Safety Precautions . . . 03-2
Install 400 Series Adapters on Repair
Stand . . . . 03-2
Engine Lifting Procedure . . . 03-3
Clean Engine . . . . 03-4
Disconnect Turbocharger Oil Inlet Line . . . 03-4
Mount Engine On Repair Stand . . . . 03-5
Group 04—Engine Rebuild Guide
6076 Engine Disassembly Sequence . . . 04-1
Sealant Application Guidelines . . . 04-2
6076 Engine Assembly Sequence . . . 04-3
Group 05—Cylinder Head and Valves
Essential Tools . . . 05-1
Service Equipment and Tools . . . . 05-3
Other Materials . . . 05-3
Cyl. Head and Valve Specifications . . . . 05-4
Diagnosing Malfunctions . . . 05-7
Check and Adjust Valve Clearance . . . . 05-8
Check Valve Lift . . . 05-10
Disconnect Turbocharger Oil Inlet Line . . . . 05-11
Remove Cylinder Head . . . 05-12
Disassemble and Inspect Rocker Arm
Shaft Assembly . . . . 05-14
Measure Valve Recess . . . 05-15
Remove Valve Assembly . . . . 05-16
Inspect and Measure valve Springs . . . 05-17
Inspect Valve Rotators and Wear Caps . . . . 05-17
Clean Valves . . . . 05-18
Inspect and Measure Valves . . . 05-18
Grind Valves . . . . 05-19
Inspect and Clean Cylinder Head . . . . 05-19
Check Cylinder Head Flatness . . . . 05-20
Measure Cylinder Head Thickness . . . 05-21
Clean Valve Guides . . . 05-21
Measure Valve Guides . . . 05-22
Knurl Guides . . . . 05-22
Clean Valve Seats . . . . 05-23
Measure Valve Seats . . . . 05-23
Grind Valve Seats . . . . 05-24
Replace Valve Inserts . . . . 05-25
Install Valves . . . . 05-26
Inspect and Clean Cylinder Head Nozzle
Bore . . . . 05-27
Clean and Inspect Push Rods . . . . 05-28
Clean and Inspect Cylinder Head Cap
Screws . . . . 05-28
Inspect and Clean Ventilator Outlet Hose . . . 05-28
Clean and Inspect Top Deck of Cylinder
Block . . . 05-29
Measure Cylinder Liner Standout . . . . 05-30
Protect Cylinder Block Top Deck . . . . 05-30
Assemble Valve Assembly . . . 05-31
Install Cylinder Head . . . . 05-32
Tighten Cylinder Head Cap Screws
(Grade 180 or 12.9) . . . 05-34
Tighten Flanged-Head Cylinder Head Cap
Screws . . . . 05-35
TORQUE-TURN Flanged-Head Cap
Screws . . . . 05-36
Install Rocker Arm Assembly . . . 05-37
Complete Final Assembly Of Injection
Pump Side . . . . 05-38
Complete Final Assembly On Exhaust
Manifold Side . . . . 05-38
Perform Engine Break-In . . . . 05-40
Group 10—Cylinder Block, Liners, Pistons and
Rods
Essential Tools . . . 10-1
Service Equipment and Tools . . . . 10-3
Specifications . . . . 10-4
Other Materials . . . 10-6
Diagnosing Malfunctions . . . 10-7
Disconnect Turbocharger Oil Inlet Line . . . 10-8
Remove Pistons and Connecting Rods . . . 10-9
Measure Cylinder Liner Standout . . . . 10-12
Remove Cylinder Liners . . . . 10-13
Inspect Pistons and Liners . . . 10-14
Measure Oil Control Ring Groove . . . . 10-21
Measure Cylinder Liners . . . . 10-22
Deglazing Cylinder Liners . . . 10-23
Inspect and Measure Connecting Rod
Bearings . . . 10-24
Inspect Rod and Cap . . . . 10-25
Inspect Piston Pins and Bushings . . . . 10-27
Remove Piston Pin Bushing . . . . 10-28
Clean and Inspect Rod Pin Bushing Bore . . . 10-29
Install Rod Pin Bushing . . . 10-30
Complete Disassembly of Cylinder Block
(If Required) . . . 10-31
Remove and Clean Piston Cooling
Orifices . . . . 10-31
Inspect and Clean Cylinder Block . . . . 10-32
Clean O-Ring Bore . . . . 10-34
Measure Cylinder Block . . . . 10-34
Install Piston Cooling Orifices and Gallery
Plugs . . . 10-36
Recheck Cylinder Liner Standout . . . . 10-37
Measure Liner Flange Thickness . . . . 10-38
Install Liner Shims—If Required . . . 10-38
Install Cylinder Liner O-Rings and
Packings . . . 10-39
Install Cylinder Liners . . . . 10-40
Install Pistons and Connecting Rods . . . . 10-43
Use TORQUE-TURN Method For Proper
Torque . . . . 10-45
Check Engine Rotation for Excessive
Tightness . . . 10-45
Complete Final Assembly . . . 10-46
Group 15—Crankshaft, Main Bearings and
Flywheel
Essential Tools . . . 15-1
Service Equipment and Tools . . . . 15-2
Other Materials . . . 15-2
Specifications . . . . 15-3
Diagnosing Malfunctions . . . 15-5
General Information . . . . 15-5
Disconnect Turbocharger Oil Inlet Line . . . 15-6
Remove Crankshaft Real Oil Seal and
Wear Sleeve . . . 15-6
/(Without Removing Oil Seal Housing)
Install Crankshaft Rear Oil Seal and
Wear Sleeve . . . 15-8
/(Without Engine Disassembly)
Inspect Vibration Damper . . . . 15-9
Remove Water Pump and Damper Pulley . . . 15-10
Remove Timing Gear
Cover—Non-Auxiliary Engines . . . 15-11
Remove Auxiliary Drive Gear and Timing
Gear Cover . . . 15-11
/—Auxiliary Drive Engines
Remove Front Oil Seal From Timing
Gear Cover . . . 15-13
Install Front Oil Seal In Timing Gear
Cover . . . 15-13
Check Crankshaft End Play . . . . 15-14
Remove Front Wear Sleeve . . . . 15-14
Remove and Inspect Crankshaft Gear . . . 15-15
Inspect, Measure and Repair Flywheel . . . . 15-15
Check Flywheel Housing Face Run-Out . . . . 15-16
Check Flywheel Face Flatness . . . . 15-16
Check Pilot Bearing Bore Concentricity . . . . 15-17
Remove Flywheel . . . . 15-17
Remove SAE 1 And SAE 2 Flywheel
Housing . . . . 15-18
Remove SAE 3 Flywheel Housing . . . . 15-18
Replace Flywheel Ring Gear . . . 15-19
Service Clutch Shaft Pilot Bushing-Quad
Range Transmissions . . . . 15-20
Remove Rear Oil Seal Housing And Wear
Sleeve . . . . 15-21
/(With Engine Disassembled)
Remove Crankshaft Main Bearings . . . 15-22
Check Main Bearing Clearance . . . 15-23
Remove Crankshaft . . . 15-24
Inspect Crankshaft . . . . 15-25
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals . . . 15-26
Main Bearing Cap Line Bore
Specifications . . . . 15-27
Thrust Bearing New Part Specifications . . . . 15-27
Crankshaft Grinding Guidelines . . . . 15-28
Crankshaft Grinding Specifications . . . 15-30
Replace Crankshaft Oil Pump Drive Gear . . . 15-31
Inspect Thrust Bearings . . . . 15-32
Remove and Clean Piston Cooling
Orifices . . . . 15-32
Install Main Bearings and Crankshaft . . . . 15-33
Install Oil Pump And Check Drive
Gear-To-Crankshaft Clearance . . . . 15-35
Install Rear Crankshaft Oil Seal Housing . . . 15-36
Check Oil Seal Housing Runout . . . 15-37
Crankshaft Rear Oil Seal And Wear
Sleeve Handling Precautions . . . . 15-38
Install Crankshaft Rear Oil Seal And
Wear Sleeve (With Engine Disassem . . . . 15-39
Install Crankshaft Gear . . . 15-40
Install Front Wear Sleeve . . . 15-40
Install SAE 3 Flywheel Housing . . . 15-41
Install Flywheel . . . . 15-41
Install SAE 1 And SAE 2 Flywheel
Housing . . . . 15-42
Install Timing Gear Cover—Non-Auxiliary
Drive Engines . . . . 15-42
Install Timing Gear Cover And Auxiliary
Drive Idler Gear—Auxiliary Dri . . . 15-43
Install Rear Auxiliary Drive Gear . . . 15-46
Install Damper Pulley Assembly . . . 15-46
Complete Final Assembly . . . 15-47
Group 16—Camshaft and Timing Gear Train
Essential Tools . . . 16-1
Service Equipment and Tools . . . . 16-2
Other Material . . . . 16-3
Specifications . . . . 16-4
General Information . . . . 16-5
Check Valve Lift . . . . 16-6
Disconnect Turbocharger Oil Inlet Line . . . 16-7
Prepare Engine For Camshaft Removal . . . 16-8
Remove Damper Pulley and Timing Gear
Cover—Non-Auxiliary Drive Engines . . . . 16-8
Remove Damper Pulley, Auxiliary Drive
Gear and Timing Gear Cover . . . 16-10
/—Auxiliary Drive Engines
Remove Front Oil Seal From Timing
Gear Cover . . . 16-12
Install Front Oil Seal In Timing Gear
Cover . . . 16-13
Check Camshaft End Play . . . 16-14
Measure Camshaft Drive
Gear-To-Crankshaft Gear Minimum
Backlash . . . 16-14
Remove Camshaft . . . . 16-15
Remove Camshaft Gear, Spacer, and
Thrust Plate . . . 16-16
Measure Thrust Plate and Spacer . . . . 16-17
Inspect And Measure Camshaft Followers . . . 16-17
Visually Inspect Camshaft . . . 16-17
Measure Camshaft Journal OD and
Bushing ID . . . . 16-18
Measure Camshaft Lobe Lift . . . 16-18
Assemble Camshaft . . . 16-19
Service Camshaft Bushings Using
JDG602 Adapter Set . . . 16-20
Service Camshaft Bushings Using
JDG606 Adapter Set . . . 16-22
Install Camshaft . . . . 16-23
Replace Auxiliary Drive Gear Bearings . . . . 16-25
Replace Auxiliary Drive Idler Gear
Bearings . . . 16-26
Install Timing Gear Cover—Non Auxiliary
Drive Engines . . . . 16-27
Install Timing Gear Cover and Auxiliary
Drive Gear . . . . 16-28
/—Auxiliary Drive Engines
Install Rear Auxiliary Drive Gear . . . 16-31
Complete Final Assembly . . . 16-32
Group 20—Lubrication System
Specifications . . . . 20-1
Engine Crankcase Oil Fill Quantities . . . 20-2
Other Material . . . . 20-4
How The Lubrication System Works . . . 20-5
Diagnosing Malfunctions . . . 20-6
Disconnect Turbocharger Oil Inlet Line . . . 20-7
Drain Engine Oil and Remove Oil Pan . . . . 20-7
Horizontal Oil Filter and Housing
Assembly . . . . 20-8
Remove Horizontal Oil Filter and Housing
Assembly . . . . 20-9
Vertical Oil Filter and Housing Assembly . . . 20-10
Remove Vertical Oil Filter and Housing
Assemblies . . . 20-11
Inspect Oil Pressure Regulating Valve . . . 20-12
Inspect Oil Filter Bypass Valve . . . . 20-13
Install Horizontal Oil Filter and Housing . . . . 20-14
Install Vertical Oil Filter and Housing
Assemblies . . . 20-15
Remove Engine Oil Cooler . . . . 20-15
Clean Inspect, and Install Engine Oil
Cooler . . . 20-17
Remove Oil Cooler Bypass Housing . . . . 20-18
Remove and Inspect Oil Cooler Bypass
Valve . . . 20-18
Engine Oil Pump Assembly—Deep Sump . . . 20-19
Engine Oil Pump Assembly—Standard
Sump . . . 20-20
Check Crankshaft Gear-To-Oil Pump
Drive Gear Backlash . . . 20-21
Remove Engine Oil Pump . . . 20-21
Inspect and Clean Oil Pump . . . 20-22
Check Drive Shaft End Play . . . 20-22
Check Drive Shaft Side Movement . . . 20-23
Check Pumping Gear Backlash . . . 20-23
Remove And Inspect Oil Pump Drive
Gear . . . . 20-24
Install Oil Cooler Bypass Valve And
Housing . . . . 20-25
Adjust Set Screw . . . 20-26
Install Engine Oil Pump . . . 20-27
Install Oil Pan . . . 20-29
Group 25—Cooling System
Essential Tools . . . 25-1
Other Materials . . . 25-2
Specifications . . . . 25-3
How The Cooling System Works . . . 25-5
Diagnosing Malfunctions . . . 25-6
Medium Duty, Adjustable Fan Drive
Assembly
Remove and Install . . . 25-6
Replace Bearings . . . . 25-7
Heavy Duty, Adjustable Fan Drive
Assembly
Remove and Install . . . 25-8
Replace Bearings . . . . 25-8
Replace Bearings In Water Manifold
Mounted, Fixed Fan Drive Assembly . . . . 25-10
Remove Water Pump . . . . 25-11
Disassemble Water Pump . . . 25-12
Inspect Water Pump Parts . . . 25-14
Assemble Water Pump . . . 25-15
Install Water Pump . . . . 25-17
Remove and Test Thermostats . . . . 25-17
Install Thermostats . . . . 25-18
Remove Water Manifold . . . . 25-19
Inspect and Clean Water Manifold . . . 25-19
Install Water Manifold . . . . 25-20
Remove Coolant Heater—If Equipped . . . 25-20
Install Coolant Heater—If Equipped . . . 25-21
Complete Final Assembly . . . 25-22
Inspect and Tension Fan and Alternator
V-Belts . . . . 25-23
Group 30—Air Intake And Exhaust System
Essential Tools . . . 30-1
Other Material . . . . 30-2
Specifications . . . . 30-2
How The Air Intake and Exhaust System
Works . . . . 30-3
How The Turbocharger Works . . . 30-3
How The Turbocharger is Lubricated . . . 30-4
Extending Turbocharger Life . . . . 30-4
Diagnosing Turbocharger Malfunctions . . . . 30-7
Remove Turbocharger . . . 30-10
Turbocharger Seven-Step Inspection . . . . 30-11
Perform Axial End Play Bearing Test
(Schwitzer 3LM) . . . . 30-17
Perform Radial Bearing Clearance Test
(Schwitzer) . . . . 30-17
Perform Raidal Bearing
Test—(AiResearch/Garrett T04E) . . . 30-18
Disassemble Turbocharger . . . . 30-19
Clean and Inspect Turbine and
Compressor Housings . . . . 30-21
Replace Center Housing and Rotating
Assembly . . . 30-22
Prelube Turbocharger . . . . 30-23
Install Turbocharger . . . 30-24
Remove and Inspect Intake Manifold
(6076T and 6076H Engines) . . . . 30-26
Install Intake Manifold (6076T and 6076H
Engines) . . . 30-27
How The Aftercooler Works—6076A
Engines . . . . 30-28
Single-Pass Aftercooler Assembly . . . . 30-29
Two-Pass Aftercooler Assembly . . . 30-30
Remove Aftercooler and Intake Manifold (6076A
Engines) . . . 30-31
Inspect and Repair Aftercooler (6076A
Engines) . . . 30-32
Inspect and Repair Intake Manifold
(6076A Engines) . . . . 30-33
Install Intake Manifold and Single-Pass
Aftercooler (6076A Engines) . . . . 30-34
Install Intake Manifold and Two-Pass
Aftercooler (6076A Engines) . . . . 30-37
Remove, Inspect, Install Exhaust Manifold
Assembly . . . 30-39
Group 35—Fuel System
Essential Tools . . . 35-1
Other Material . . . . 35-3
Specifications . . . . 35-4
Relieve System Pressure . . . . 35-5
Replace Dual Fuel Filters . . . . 35-5
Replace Single Fuel Filter . . . . 35-6
Remove and Inspect Fuel Check Valve
Assembly—Dual Fuel Filter Systems . . . 35-7
Inspect and Clean Dual Fuel Filter Base . . . . 35-8
Install Fuel Check Valve Assembly—Dual
Filter Fuel Systems . . . 35-9
Replace Fuel Check Valve
Assembly—Single Filter Fuel Systems . . . 35-10
Inspect and Clean Single Fuel Filter Base . . . 35-11
Bleed the Fuel System . . . 35-12
Diagnosing Fuel Supply Pump
Malfunctions . . . 35-14
Remove Fuel Supply Pump . . . . 35-15
Test Fuel Supply Pump For Leaks . . . 35-16
Disassemble Fuel Supply Pump . . . 35-17
Inspect and Repair Fuel Supply Pump . . . 35-19
Assemble Fuel Supply Pump . . . 35-20
Install Fuel Supply Pump . . . . 35-22
General Information For Aneroid—If
Equipped . . . 35-22
Repair Aneroid . . . . 35-23
Remove Hydraulic Aneroid Activator . . . . 35-23
Disassemble And Clean Hydraulic
Aneroid Activator Parts . . . 35-24
Assemble and Install Hydraulic Aneroid
Activator . . . 35-24
Service Overflow Valve . . . 35-25
Remove Fuel Shutoff Solenoid . . . . 35-26
Install Fuel Shutoff Solenoid . . . 35-27
Remove Fuel Injection Pump . . . 35-28
Install Fuel Injection Pump . . . 35-31
Remove Fuel Injection Nozzles . . . 35-35
Test Fuel Injection Nozzles . . . . 35-38
Make Opening Pressure Test . . . 35-39
Perform Leakage Test . . . 35-41
Make Chatter and Spray Pattern Test . . . 35-42
Disassemble Fuel Injection Nozzle . . . 35-43
Clean and Inspect Fuel Injection Nozzle
Assembly . . . 35-45
Perform Nozzle Slide Test . . . 35-46
Clean Spray Orifices . . . 35-46
Inspect Nozzle Holder . . . . 35-47
Inspect Gland Nut . . . . 35-49
Assemble Fuel Injection Nozzle . . . 35-50
Inspect and Clean Cylinder Head Nozzle
Bore . . . . 35-52
Inspect and Clean Nozzle Seating
Surface . . . . 35-53
Install Fuel Injection Nozzles . . . 35-53
Group 100—Tune-Up
Preliminary Engine Testing . . . . 100-1
General Tune-Up Recommendations . . . . 100-2
Check Crankcase Ventilation System . . . . 100-3
Check Air Intake System . . . . 100-3
Check Exhaust System . . . 100-3
Check and Service Entire Cooling System. . . 100-4
Inspect and Adjust V-Belts . . . 100-5
Check Electrical System . . . . 100-6
Group 105—Engine System Operation and Test
Essential Tools . . . . 105-1
Specifications . . . 105-3
Diagnose Malfunctions . . . 105-4
Dynamometer Test . . . . 105-6
Engine Break-In Instructions . . . 105-7
Test Engine Compression Pressure . . . 105-8
Check and Adjust Valve Clearance . . . 105-9
Check Valve Lift . . . . 105-11
Inspect Vibration Damper . . . . 105-12
Check Crankshaft End Play . . . 105-13
How the Lubrication System Works . . . . 105-14
Check Engine Oil Pressure . . . 105-15
How The Cooling System Works . . . 105-16
Pressure Test Cooling System and
Radiator Cap . . . 105-17
Inspect Thermostat and Test Opening
Temperature . . . 105-18
Group 110—Air Intake System Operation and
Test
Essential Tools . . . . 110-1
Specifications . . . 110-2
How the Air Intake and Exhaust System
Works . . . 110-2
Air Cleaner Operation . . . . 110-3
Diagnosing Malfunctions . . . . 110-4
How The Turbocharger Works . . . . 110-5
How The Turbocharger is Lubricated . . . . 110-5
Diagnosing Turbocharger Malfunctions . . . 110-6
How The Aftercooler Works—6076A
Engines . . . . 110-7
Check Intake Manifold Pressure At
Aneroid . . . . 110-8
Check Intake Manifold Pressure At Intake
Manifold . . . 110-9
Air Filter Restriction Indicator Switch Test . . 110-10
Group 115—Fuel System Operation and Tests
Essential Tools . . . . 115-1
Specifications . . . 115-1
Fuel System Operation . . . 115-2
Diagnose Fuel System Malfunctions . . . . 115-3
Supply Pump Operation . . . . 115-7
Diagnose Supply Pump Malfunction . . . . 115-9
Check Supply Pump Operation . . . 115-10
Service Supply Pump . . . 115-12
Bleed the Fuel System . . . . 115-13
Diagnose In-Line Type Injection Pump
Malfunctions . . . . 115-15
In-Line Type Fuel Injection Pump
Operation . . . 115-16
Check and Adjust Injection Pump Timing . . 115-16
Check Engine Fast Idle Speed . . . 115-19
Check and Adjust Engine Slow Idle
Speed . . . . 115-20
How The Aneroid Works (If Equipped) . . . . 115-22
Diagnose Aneroid Malfunctions . . . 115-23
How The Hydraulic Aneroid Activator
Works . . . . 115-24
Diagnose Malfunctions—Hydraulic
Aneroid Activator . . . . 115-25
Fuel Injection Nozzle—General
Information . . . 115-26
Fuel Injection Nozzle Operation . . . . 115-27
Diagnose Malfunctions—Fuel Injection
Nozzle . . . 115-28
Test Fuel Injection Nozzles (Engine
Running) . . . . 115-29
Fuel Drain Back Test Procedure . . . . 115-29
Group 199—Dealer Fabricated Tools
Fabricated Tools—Cylinder Liner Holding
Fixture . . . . 199-1
Index
…

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Pages from CTM4 (28OCT95) – Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual

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This John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

CTM4 (28OCT95) – John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual.PDF; 547 pages (bookmarked, Searchable, Printable, high quality PDF)

EXCERPT:
TABLE OF CONTENTS
Group 00—Safety
Group 01—General Information
Unified Inch Bolt and Cap Screw Torque Values . . . 01-1
Metric Bolt and Cap Screw Torque Values . . . 01-2
Engine Model Designation . . . 01-3
Engine Serial Number Plate Information . . . 01-5
Engine Application Chart . . . 01-7
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . 02-1
Lubricity of Diesel Fuels . . . 02-1
Engine Break-In Oil . . . 02-2
Diesel Engine Oil . . . 02-3
OILSCAN® and COOLSCAN™ . . . 02-4
Alternative and Synthetic Lubricants . . . 02-4
Grease . . . 02-5
Engine Coolant Requirements . . . 02-6
Recommended Engine Coolant . . . 02-7
Engine Coolant Specifications . . . 02-9
Replenishing Supplemental Coolant
Additives (SCA’s) . . . 02-11
Operating in Tropical Conditions . . . 02-12
Flush and Service Cooling System . . . 02-13
Disposing of Coolant . . . 02-14
Group 03—Engine Mounting
Engine Repair Stand . . . 03-1
Safety Precautions . . . 03-2
Install 300 Series Adapters on Repair Stand . . . 03-3
Engine Lifting Procedure . . . 03-3
Clean Engine . . . 03-4
Disconnect Turbocharger Oil Inlet Line . . . 03-4
Mount Engine on Repair Stand . . . 03-5
Engine Mounted on Repair Stand . . . 03-6
Group 04—Engine Rebuild Guide
Engine Disassembly Sequence . . . 04-1
Sealant Application Guidelines . . . 04-2
Engine Assembly Sequence . . . 04-4
Group 05—Cylinder Head and Valves
Special or Essential Tools . . . 05-1
Service Equipment and Tools . . . 05-4
Specifications . . . 05-5
Other Material . . . 05-9
Check and Adjust Valve Clearance . . . 05-10
Measure Valve Lift . . . 05-14
Remove Cylinder Head . . . 05-16
Disassemble and Inspect Rocker Arm Shaft Assembly . . . 05-19
Assemble Rocker Arms on Shaft . . . 05-21
Clean and Inspect Push Rods . . . 05-21
Make Preliminary Valve Checks . . . 05-22
Check Valve Recess in Cylinder Head . . . 05-23
Remove Valve Assembly . . . 05-23
Inspect and Measure Valve Springs . . . 05-24
Inspect Valve Rotators and Wear Caps . . . 05-24
Clean Valves . . . 05-25
Inspect and Measure Valves . . . 05-25
Grind Valves . . . 05-26
Inspect and Clean Cylinder Head . . . 05-27
Check Cylinder Head Flatness . . . 05-27
Measure Cylinder Head Thickness . . . 05-28
Clean Injection Nozzle Bores . . . 05-28
Clean Valve Guides . . . 05-29
Measure Valve Guides . . . 05-29
Knurl Valve Guides . . . 05-30
Clean and Inspect Valve Seats . . . 05-30
Grind Valve Seats . . . 05-31
Remove Valve Seat Inserts . . . 05-33
Measure Valve Seat Bore in Cylinder
Head . . . 05-34
Install Valve Seat Inserts . . . 05-35
Install Valves . . . 05-35
Valve Stem Seals—General Information . . . 05-36
Install Valve Stem O-Ring Seals . . . 05-36
Install Valve Stem Tower Seals . . . 05-37
Inspect and Clean Ventilator Outlet Hose . . . 05-38
Inspect and Clean Exhaust Manifold . . . 05-39
Clean and Inspect Top Deck of Cylinder Block . . . 05-39
Measure Cylinder Liner Standout (Height Above Block) . . . 05-40
Clean and Inspect Cylinder Head Cap Screws . . . 05-40
Install Cylinder Head . . . 05-41
Install Cylinder Head Cap Screws . . . 05-42
TORQUE-TURN Method for Proper Torque . . . 05-45
Install Rocker Arm Assembly . . . 05-45
Install Rocker Arm Cover . . . 05-47
Complete Final Assembly . . . 05-48
Perform Engine Break-In . . . 05-49
Group 10—Cylinder Block, Liners, Pistons, and Rods
Special or Essential Tools . . . 10-1
Service Equipment and Tools . . . 10-3
Other Material . . . 10-3
Specifications . . . 10-4
Remove Pistons and Connecting Rods . . . 10-8
Remove Cylinder Liners . . . 10-11
Complete Disassembly of Cylinder Block (If Required) . . . 10-13
Preliminary Liner, Piston and Rod Checks . . . 10-14
Disassemble Piston and Rod Assembly . . . 10-15
Clean Pistons . . . 10-16
Visually Inspect Pistons . . . 10-17
Install Piston Pin . . . 10-18
Clean Cylinder Liners . . . 10-19
Visually Inspect Cylinder Liners . . . 10-19
Check Piston Ring Groove Wear . . . 10-20
Measure Piston Skirt . . . 10-21
Determine Piston-to-Liner Clearance . . . 10-22
Deglaze Cylinder Liners . . . 10-23
Replace Piston and Liner Sets . . . 10-24
Determine Piston Type . . . 10-25
Measure Piston Protrusion . . . 10-26
Inspect and Measure Connecting Rod Bearings . . . 10-27
Inspect Rod and Cap . . . 10-29
Inspect Piston Pins and Bushings . . . 10-30
Remove Piston Pin Bushing . . . 10-31
Clean and Inspect Connecting Rod Pin Bore . . . 10-32
Install Piston Pin Bushing in Connecting Rod . . . 10-32
Inspect and Clean Cylinder Block . . . 10-33
Clean Cylinder Liner O-Ring Bore . . . 10-34
Measure Cylinder Block Main Bearing Bore . . . 10-34
Measure Camshaft Follower Bore . . . 10-35
Measure Camshaft Bearing Bore . . . 10-35
Measure Balancer Shaft Bore—4-Cylinder Engines . . . 10-36
Measure Cylinder Block Top Deck Flatness . . . 10-37
Inspect Piston Cooling Orifices . . . 10-38
Measure Liner Flange Thickness and Block Counterbore Depth . . . 10-38
Recheck Cylinder Liner Standout (Height Above Block) . . . 10-39
Install Steel Ball in Oil Passage of Service Cylinder Block . . . 10-41
Install Cylinder Liner O-Rings and Packings . . . 10-42
Install Cylinder Liner . . . 10-43
Assemble Piston and Connecting Rod . . . 10-44
Install Piston Rings . . . 10-45
Install Piston and Connecting Rod Assembly . . . 10-46
Check Engine Rotation For Excessive Tightness . . . 10-48
Measure Piston Protrusion . . . 10-49
Complete Final Assembly . . . 10-49
Group 15—Crankshaft, Main Bearings, and Flywheel Special or Essential Tools . . . 15-1
Service Equipment and Tools . . . 15-4
Specifications . . . 15-5
Other Material . . . 15-8
Crankshaft and Main Bearing Failure Analysis . . . 15-9
Inspect Vibration Damper (6-Cylinder Engine) . . . 15-10
Remove Pulley or Vibration Damper Pulley . . . 15-11
Install Pulley or Vibration Damper Pulley . . . 15-12
Checking Vibration Damper or Pulley (Front PTO) . . . 15-13
Removing Vibration Damper or Pulley (Front PTO) . . . 15-14
Install Vibration Damper or Pulley (Front PTO) . . . 15-15
Replace Front Crankshaft Oil Seal (Without Removing Cover) . . . 15-16
Check Crankshaft End Play . . . 15-19 Inspect Flywheel . . . 15-20
Check Flywheel Housing Face Runout . . . 15-20
Check Flywheel Face Flatness . . . 15-21
Remove Flywheel . . . 15-21
Replace Flywheel Ring Gear . . . 15-22
Install Flywheel . . . 15-23
Crankshaft Rear Oil Seal and Wear Sleeve General Information . . . 15-24
Remove Two-Piece Crankshaft Oil Seal and Wear Sleeve . . . 15-24
Remove Unitized Crankshaft Rear Oil Seal and Wear Sleeve . . . 15-27
Install Crankshaft Rear Oil Seal and Wear Sleeve . . . 15-28
Remove Flywheel Housing . . . 15-30
Remove Crankshaft Main Bearings . . . 15-30
Check Main Bearing Clearance . . . 15-31
Remove and Install Crankshaft Gear with Crankshaft Installed . . . 15-32
Remove Crankshaft . . . 15-33
Remove Crankshaft Rear Wear Sleeve with Crankshaft Removed . . . 15-34
Inspect Crankshaft . . . 15-35
Measure Assembled ID of Bearings and OD of Crankshaft Journal . . . 15-36
Measure Main Thrust Journal Width and Thrust Bearing Width . . . 15-37
Crankshaft Grinding Guidelines . . . 15-38
Crankshaft Grinding Specifications . . . 15-40
Measure Assembled ID of Main Bearing Caps . . . 15-40
Inspect Piston Cooling Orifices . . . 15-42
Install Main and Thrust Bearing Inserts in Block . . . 15-43
Install Crankshaft . . . 15-44
Install Flywheel Housing . . . 15-46
Complete Final Assembly . . . 15-48
Group 16—Camshaft, Balancer Shafts, and Timing Gear Train Special or Essential Tools . . . 16-1
Service Equipment and Tools . . . 16-3
Other Materials . . . 16-3
Specifications . . . 16-4
Auxiliary Gear Drive Specifications . . . 16-10
Measure Valve Lift . . . 16-11
Remove Timing Gear Cover . . . 16-13
Remove Auxiliary Drive Gears . . . 16-14
Measure Camshaft End Play . . . 16-14
Measure Balancer Shaft End Play—4-Cylinder Engines . . . 16-15
Measure Timing Gear Backlash . . . 16-16
Measure Idler Gear End Play . . . 16-17
Remove Camshaft . . . 16-17
Visually Inspect Camshaft . . . 16-18
Measure Camshaft Thrust Plate Clearance . . . 16-19
Inspect and Measure Camshaft Bearing Bore ID and Journal OD . . . 16-19
Measure Camshaft Lobe Height . . . 16-20
Remove and Install Camshaft Gear . . . 16-20
Inspect Camshaft Followers . . . 16-21
Replace Tachometer Drive Gear . . . 16-22
Remove Balancer Shafts—If Equipped (4-Cylinder Engines) . . . 16-23
Inspect and Measure Balancer Shaft Bushings and Journals . . . 16-24
Remove and Install Balancer Shaft
Bushings in Block . . . 16-25
Install Oversize Balancer Shaft Bushings in Block—4239 Engines . . . 16-26
Inspect Balancer Shaft Gears and Thrust Plates . . . 16-27
Remove and Install Balancer Shaft Gears . . . 16-28
Remove Balancer Shaft . . . 16-29
Remove Cylinder Block Front Plate . . . 16-29
Measure Idler Gear Bushing and Shaft . . . 16-31
Remove and Install Idler Gear Bushings . . . 16-31
Remove Lower and Upper Idler Shafts . . . 16-32
Clean and Inspect Front Plate . . . 16-33
Replace Engine Front Plate . . . 16-34
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate . . . 16-35
Install Idler Shaft Spring Pins . . . 16-35
Install Upper Idler Shaft in Front Plate . . . 16-36
Install Lower Idler Shaft in Front Plate . . . 16-36
Install Engine Front Plate . . . 16-38
Install and Time Balancer Shafts—If Equipped (4-Cylinder Engines) . . . 16-39
Install and Time Camshaft and Fuel Injection Pump . . . 16-42
Clean and Inspect Timing Gear Cover . . . 16-44
Install Ball Bearings and Dowels . . . 16-44
Install Drive Gear . . . 16-45
Install Timing Gear Cover . . . 16-46
Install Crankshaft Front Oil Seal . . . 16-49
Install Idler Gear and Output Gear . . . 16-50
Complete Final Assembly . . . 16-51
Group 20—Lubrication System Special or Essential Tools . . . 20-1
Service Equipment and Tools . . . 20-2
Other Material . . . 20-2
Specifications . . . 20-3
Engine Crankcase Oil Fill Quantities . . . 20-6
Identify Oil Cooler Type—3179, 4239, 6359 Engines . . . 20-14
Remove, Inspect, & Install Standard-Flow Oil Cooler (3179, 4239, 6359) . . . 20-14
Remove and Install High-Flow Oil Cooler (6359 Engines) . . . 20-15
Remove Distributor Base—High-Flow Cooler (6359) . . . 20-16
Inspect and Repair Distributor Base—High Flow Oil Cooler (6359) . . . 20-16
Install Distributor Base—High-Flow Oil Cooler (6359) . . . 20-17
Remove Oil Cooler (4276, 6414 Engines) . . . 20-17
Repair Oil Cooler (4276, 6414 Engines) . . . 20-17
Install Oil Cooler (4276, 6414 Engines) . . . 20-18
Remove and Inspect Oil Bypass Valve (3179, 4239, 6359 Engines) . . . 20-19
Measure Oil Bypass Valve Length and Cylinder Block Bore . . . 20-20
Install Oil Bypass Valve (3179, 4239, 6359 Engines) . . . 20-20
Remove and Install Oil Cooler/Filter Bypass Valve (4276, 6414 Engines) . . . 20-21
Remove & Install Oil Pressure Regulating Valve/Seat (3179, 4239, 6359) . . . 20-21
Remove, Inspect and Install Oil Pressure Regulating Valve (4276, 6414) . . . 20-22
Repair Oil Pressure Regulating Valve (4276, 6414 Engines) . . . 20-23
Remove Oil Filter Adapter (3179, 4239, 6359 Engines) . . . 20-24
Install Oil Filter Adapter (3179, 4239, 6359 Engines) . . . 20-25
Remove, Install, and Adjust Dipstick Tube . . . 20-26
General Oil Pump Information . . . 20-26
Replace Oil Pump Pick-Up Tube Assembly . . . 20-27
Remove Standard Capacity Oil Pump . . . 20-27
Inspect and Measure Clearances (Standard Capacity Oil Pump) . . . 20-28
Complete Standard Capacity Oil Pump
Disassembly . . . 20-29
Assemble Standard Capacity Oil Pump . . . 20-30
Install Standard Capacity Oil Pump . . . 20-31
Remove High Capacity Oil Pump . . . 20-33
Inspect and Measure Clearances (High Capacity Oil Pump) . . . 20-34
Complete High Capacity Oil Pump Disassembly . . . 20-35
Assemble High Capacity Oil Pump . . . 20-36
Install High Capacity Oil Pump . . . 20-36
Install Oil Pan . . . 20-38
Group 25—Cooling System Special or Essential Tools . . . 25-1
Service Equipment and Tools . . . 25-1
Other Material . . . 25-2
Specifications . . . 25-3
Remove, Test, and Install Thermostats . . . 25-10
Remove and Install Thermostat Housing/Water Manifold . . . 25-11
General Water Pump Information . . . 25-13
Remove Low Flow (Standard Duty) Water Pump . . . 25-14
Disassemble Low Flow (Standard Duty) Water Pump . . . 25-15
Inspect and Clean Low Flow (Standard Duty) Water Pump Parts . . . 25-17
Assemble Low Flow (Standard Duty) Water Pump . . . 25-18
Install Low Flow (Standard Duty) Water Pump . . . 25-21
Remove High Flow (Heavy-Duty) Water Pump . . . 25-22
Disassemble High Flow (Heavy-Duty) Water Pump . . . 25-22
Inspect and Clean High Flow (Heavy-Duty) Water Pump Parts . . . 25-26
Assemble High Flow (Heavy-Duty) Water Pump . . . 25-27
Checking Water Pump Cap Screw Protrusion . . . 25-31
Install High Flow (Heavy-Duty) Water Pump . . . 25-33
Inspect and Install Fan Blade Assembly . . . 25-34
Remove Coolant Heater—If Equipped . . . 25-34
Install Coolant Heater—If Equipped . . . 25-35
Group 30—Air Intake and Exhaust System Other Material . . . 30-1
Specifications . . . 30-1
Extending Turbocharger Life . . . 30-3
Remove Turbocharger—4239T and 6359T & A Engines . . . 30-5
Turbocharger Failure Analysis . . . 30-7
Turbocharger Seven-Step Inspection . . . 30-9
Perform Radial Bearing Clearance Test—K.K.K. . . 30-13
Perform Axial Bearing End Play Test—K.K.K. . . 30-14
Perform Radial Bearing Clearance Test—AiResearch/Garrett . . . 30-14
Perform Axial Bearing End Play
Test—AiResearch/Garrett . . . 30-15
Repair Turbocharger . . . 30-16
Disassemble and Inspect Turbocharger . . . 30-17
Replace Center Housing and Rotating Assembly . . . 30-18
Prelube Turbocharger . . . 30-19
Install K.K.K. and AiResearch/Garrett Turbocharger . . . 30-19
Turbocharger Break-In . . . 30-21
Remove, Inspect, and Install Intake Manifold . . . 30-22
Remove Cross-Over Tube Assembly—If Equipped . . . 30-23
Inspect and Repair Cross-Over Tube Assembly—If Equipped . . . 30-23
Install Cross-Over Tube Assembly—If Equipped . . . 30-24
Remove Aftercooler and Intake Manifold (6359A) . . . 30-25
Inspect and Repair Aftercooler (6359A) . . . 30-26
Inspect and Repair Intake Manifold (6359A) . . . 30-26
Install Intake Manifold and Aftercooler (6359A) . . . 30-27
Remove, Inspect, and Install Exhaust Manifold . . . 30-28
Group 35—Fuel System
Special or Essential Tools . . . 35-1
Service Equipment and Tools . . . 35-3
Other Material . . . 35-4
Specifications . . . 35-5
Relieve Fuel System Pressure . . . 35-8
Replace Fuel Filter . . . 35-9
Remove Fuel Supply Pump . . . 35-10
Bench Test Fuel Supply Pump . . . 35-11
Repair Sofabex and AC Fuel Supply Pumps . . . 35-13
Repair Corona Fuel Supply Pump . . . 35-13
Install Fuel Supply Pump . . . 35-15
Fuel Injection Pump Timing . . . 35-15
Fuel Injection Pump—General Information . . . 35-16
Remove Roto Diesel/Lucas CAV Fuel Injection Pump . . . 35-17
Repair Roto Diesel/Lucas CAV Fuel Injection Pump . . . 35-20
Install Roto Diesel/Lucas CAV Fuel Injection Pump . . . 35-21
Timing Roto Diesel/Lucas CAV Injection Pump (Front Plate Installed) . . . 35-24
Remove Stanadyne Pump—Model JDB & DB2 (Non-Retained Drive Shaft) . . . 35-27
Remove Stanadyne Model JDB & DB2 Pump with Non-Retained Drive Shaft . . . 35-28
Repair Stanadyne Model JDB and DB2 Fuel Injection Pump . . . 35-30
Install Non-Retained Drive Shaft in Stanadyne Model JDB & DB2 Pump . . . 35-30
Install Stanadyne Model JDB & DB2 Pump with Non-Retained Drive Shaft . . . 35-31
Remove Stanadyne Model DB2 (Retained Drive Shaft) & DB4 Injection Pump . . . 35-34
Inspect Injection Pump Drive Gear I.D. and Shaft O.D. . . 35-38
Repair Stanadyne Fuel Injection Pump . . . 35-38
Install Stanadyne Model DB2 (Retained Drive Shaft) and DB4 Pump . . . 35-39
Remove Stanadyne Model DM4 Fuel Injection Pump . . . 35-42
Repair Stanadyne Fuel Injection Pump . . . 35-43
Install Stanadyne Model DM4 Fuel Injection Pump . . . 35-44
Replace Engine Front Plate . . . 35-46
Transfer Fuel Injection Pump Timing Mark onto Replacement Front Plate . . . 35-47
Aneroid Replacement . . . 35-48
Aneroid Field Adjustment . . . 35-48
Aneroid Workshop Adjustment . . . 35-49
Remove Fuel Injection Nozzles . . . 35-50
Clean Fuel Injection Nozzle Bore . . . 35-51
Clean Injection Nozzles . . . 35-52
Diagnose Injection Nozzle Malfunction . . . 35-53
Test Injection Nozzles . . . 35-55
Disassemble Injection Nozzles . . . 35-58
Inspect and Clean Nozzle Body . . . 35-59
Inspect and Clean Valve and Valve Seat . . . 35-60
Inspect Valve Adjusting Mechanism . . . 35-62
Assemble Injection Nozzles . . . 35-63
Adjust Fuel Injection Nozzles . . . 35-63
Install Seals on Injection Nozzle . . . 35-66
Install Injection Nozzles . . . 35-66
Repair Leak-Off Line Assembly . . . 35-67
Group 100—Engine Tune-Up and Break-In
Special or Essential Tools . . . 100-1
Effects of Altitude and Temperature on Engine Performance . . . 100-1
Preliminary Engine Testing . . . 100-2
General Tune-Up Recommendations . . . 100-3
Dynamometer Test . . . 100-4
Dynamometer Test Specifications . . . 100-5
Engine Break-In Guidelines . . . 100-9
Perform Engine Break-In . . . 100-10
Check Crankcase Ventilation System . . . 100-11
Check Air Intake System . . . 100-11
Check Exhaust System . . . 100-11
Check and Service Cooling System . . . 100-12
Check Electrical System . . . 100-13
Group 105—Engine System Operation and Tests
Special or Essential Tools . . . 105-1
Engine Test Specifications . . . 105-3
Engine—Sectional View . . . 105-4
General Engine Description . . . 105-5
How the Lubrication System Works—4239T Shown . . . 105-6
Oil Cooler Operation—4276 and 6414 Engines . . . 105-8
How the Cooling System Works—Standard Flow Oil Cooler . . . 105-9
How the Cooling System
Works—High-Flow Oil Cooler . . . 105-10
How the Crankshaft Gear-Drive Auxiliary Drive Works . . . 105-11
Head Gasket Joint Construction and Operation . . . 105-13
Diagnosing Head Gasket Joint Failures . . . 105-14
Head Gasket Inspection and Repair Sequence . . . 105-17
Diagnosing Engine Malfunctions . . . 105-19
Test Engine Compression Pressure . . . 105-22
Check Engine Oil Pressure . . . 105-23
Measure Engine Crankcase Pressure (Blow-By) . . . 105-24
Pressure Test Cooling System and Radiator Cap . . . 105-25
Inspect Thermostat and Test Opening Temperature . . . 105-26
Group 110—Air Intake System Operation and Tests
Special or Essential Tools . . . 110-1
Service Equipment and Tools . . . 110-1
Test Specifications . . . 110-2
Diagnosing Air Intake Malfunctions . . . 110-3
How the Air Intake and Exhaust System Works . . . 110-4
Air Cleaner Operation . . . 110-5
Diagnosing Turbocharger Malfunctions . . . 110-6
How the Turbocharger is Lubricated . . . 110-7
Turbocharger Operation . . . 110-7
How the Aftercooler Works . . . 110-8
Check Intake Manifold Pressure (Turbo Boost) . . . 110-9
Air Filter Restriction Indicator Switch Test . . 110-10
Group 115—Fuel System Operation and Tests
Special or Essential Tools . . . 115-1
Service Equipment and Tools . . . 115-2
Fuel System Test Specifications . . . 115-3
Saran Fuel Injection Pump Specifications . . . 115-4
Dubuque Fuel Injection Pump Specifications . . . 115-7
Fuel Injection Pump Timing . . . 115-9
Check and Adjust Injection Pump Dynamic Timing . . . 115-9
Check Roto Diesel/Lucas CAV Injection Pump Static Timing . . . 115-17
Check Stanadyne DB2 Pump Static Timing . . . 115-20
Check Stanadyne JDB Injection Pump Static Timing . . . 115-21
Check Stanadyne DM4 Injection Pump Static Timing . . . 115-22
Fuel System Operation . . . 115-24
Diagnose Fuel System Malfunctions . . . 115-25
Fuel Supply Pump Operation—If Equipped . . . 115-29
Diagnose Supply Pump Malfunction . . . 115-30
Measure Fuel Supply Pump Pressure—If Equipped . . . 115-31
Rectangular Final Fuel Filter Operation . . . 115-32
Bleed the Fuel System . . . 115-33
Roto Diesel/Lucas CAV Fuel Injection Pump Operation . . . 115-36
Stanadyne DM4 Fuel Injection Pump Operation . . . 115-38
Stanadyne DB2/DB4 Fuel Injection Pump Operation . . . 115-40
Diagnose Fuel Injection Pump Malfunctions . . . 115-42
Check and Adjust Engine Speeds on
Lucas CAV Pump . . . 115-43
Adjust Variable Speed on Generator Set
Engines (Lucas CAV) . . . 115-44
Check and Adjust Engine Speeds on Stanadyne Pump . . . 115-45
Adjust Variable Speed on Generator Set
Engines—Stanadyne . . . 115-46
Changing Gen Set Engine Rated
Speed—Stanadyne . . . 115-47
Fuel Injection Nozzles—General Information/Operation . . . 115-49
Diagnose Malfunction—Fuel Injection
Nozzle . . . 115-50
Test Fuel Injection Nozzles (Engine Running) . . . 115-51
Fuel Drain Back Test Procedure . . . 115-51
Group 199—Dealer Fabricated Tools How to Make Tools . . . 199-1
DFRG2—Injection Pump Front Plate
Timing Mark Transfer Tool . . . 199-1
DFRG3—Cylinder Liner Holding Fixture . . . 199-2
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Pages from TM1419 – John Deere 210C, 310C, 315C Backhoe Loader Technical Manual – Operation and Test

Complete Technical Manual Operation and Test with electrical wiring diagrams for John Deere 210C, 310C, 315C Backhoe Loader. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This TM1419 – John Deere 210C, 310C, 315C Backhoe Loader Technical Manual – Operation and Test (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

TM1419 – John Deere 210C, 310C, 315C Backhoe Loader Technical Manual – Operation and Test.pdf

EXCERPT:
Electrical System Operation and Test/Display Module and Logic Module Circuit
LOGIC MODULE BENCH TEST
IMPORTANT: DO NOT allow wires to touch one another after bei~g connected to logic module.
1. Connect wires (A and B) from positive ( +) battery post to pins A and C in large connector.
2. Connect wire (C) from negative battery post to pin F in large connector.
3. Using a 12V indicator light with two wire leads, connect one lead to pin D in large connector, and one lead to pin A in small connector.
4. Connect wire (D) to pin E in large connector, and negative battery post. Light must come on. If it does, remove wire from pin E and go to next step. If light does not come on, replace module.
5. Connect wire (E) to pin B in small connector. Light must come on. If it does, remove wire (E) from pin 8 and go to next step. If light does not come on, replace module.
6. Remove the indicator light lead from pin D in large connector and connect to pin C in small connector.
Connect wire (D) to pin D in small connector. Light must pulse on and off. If it does not, replace module.
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