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