DOWNLOAD PDF FOR CTM42 - JOHN DEERE SERIES 400 6076 DIESEL ENGINE (SERIAL NUMBER 500000)COMPONENT TECHNICAL MANUAL

PUBLICATION DATE : 01 DEC 18

MODEL COVERED :
SERIES 400 6076 DIESEL ENGINE

TABLE OF CONTENTS :
INTRODUCTION
NOT A REAL STANDARD BLOCK
ABOUT THIS MANUAL
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
PREVENT BATTERY EXPLOSIONS
PREPARE FOR EMERGENCIES
PREVENT ACID BURNS
AVOID HIGH-PRESSURE FLUIDS
WEAR PROTECTIVE CLOTHING
SERVICE MACHINES SAFELY
WORK IN VENTILATED AREA
WORK IN CLEAN AREA
REMOVE PAINT BEFORE WELDING OR HEATING
AVOID HEATING NEAR PRESSURIZED FLUID LINES
ILLUMINATE WORK AREA SAFELY
USE PROPER LIFTING EQUIPMENT
PRACTICE SAFE MAINTENANCE
USE PROPER TOOLS
DECOMMISSIONING - PROPER RECYCLING AND DISPOSAL OF FLUIDS AND COMPONENTS
LIVE WITH SAFETY
GENERAL INFORMATION
UNIFIED INCH BOLT AND SCREW TORQUE VALUES
METRIC BOLT AND SCREW TORQUE VALUES
ENGINE MODEL DESIGNATION
ENGINE SERIAL NUMBER PLATE INFORMATION
ENGINE APPLICATION CHART
OEM APPLICATIONS
FUELS, LUBRICANTS, AND COOLANT
DIESEL FUEL
LUBRICITY OF DIESEL FUELS
DIESEL ENGINE BREAK-IN OIL - NON-EMISSIONS CERTIFIED AND CERTIFIED TIER 1, TIER 2, TIER 3, STAGE I, STAGE II, AND STAGE III
DIESEL ENGINE OIL
OILSCAN AND COOLSCAN
GREASE
ALTERNATIVE AND SYNTHETIC LUBRICANTS
ENGINE COOLANT REQUIREMENTS
RECOMMENDED ENGINE COOLANT
ENGINE COOLANT SPECIFICATIONS
REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCA`S) BETWEEN COOLANT CHANGES
OPERATING IN TROPICAL CONDITIONS
FLUSH AND SERVICE COOLING SYSTEM
DISPOSING OF COOLANT
ENGINE MOUNTING
ENGINE REPAIR STAND
SAFETY PRECAUTIONS
INSTALL 400 SERIES ADAPTERS ON REPAIR STAND
ENGINE LIFTING PROCEDURE
CLEAN ENGINE
DISCONNECT TURBOCHARGER OIL INLET LINE
MOUNT ENGINE ON REPAIR STAND
ENGINE REBUILD GUIDE
6076 ENGINE DISASSEMBLY SEQUENCE
SEALANT APPLICATION GUIDELINES
6076 ENGINE ASSEMBLY SEQUENCE
CYLINDER HEAD AND VALVES
ESSENTIAL TOOLS
SERVICE EQUIPMENT AND TOOLS
OTHER MATERIAL
CYLINDER HEAD AND VALVES SPECIFICATIONS
CHECK AND ADJUST VALVE CLEARANCE
CHECK VALVE LIFT
REMOVE CYLINDER HEAD
DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY
ASSEMBLE ROCKER ARM SHAFT ASSEMBLY
MEASURE VALVE RECESS
PRELIMINARY CYLINDER HEAD AND VALVE CHECKS
REMOVE VALVE ASSEMBLY
INSPECT AND MEASURE VALVE SPRINGS
INSPECT VALVE ROTATORS AND WEAR CAPS
CLEAN VALVES
INSPECT AND MEASURE VALVES
GRIND (REFACE) VALVES
INSPECT AND CLEAN CYLINDER HEAD
CHECK CYLINDER HEAD COMBUSTION FACE FLATNESS
MEASURE CYLINDER HEAD THICKNESS
CLEAN VALVE GUIDES
MEASURE VALVE GUIDES
KNURL VALVE GUIDES
CLEAN AND INSPECT VALVE SEATS
MEASURE VALVE SEATS
GRIND VALVE SEATS
REMOVE VALVE SEAT INSERTS AND MEASURE BORES IN CYLINDER HEAD
INSTALL VALVE SEAT INSERTS
INSPECT AND CLEAN CYLINDER HEAD NOZZLE BORE
CLEAN AND INSPECT PUSH RODS
INSPECT AND CLEAN VENTILATOR OUTLET HOSE
CLEAN AND INSPECT TOP DECK OF CYLINDER BLOCK
MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)
ASSEMBLE VALVE ASSEMBLY
INSTALL CYLINDER HEAD
CYLINDER HEAD CAP SCREW TYPES
CLEAN, INSPECT AND INSTALL CYLINDER HEAD CAP SCREWS
TORQUE-TURN FLANGED-HEAD CAP SCREWS-GRADE 180
TORQUE-TO-YIELD FLANGED-HEAD CAP SCREWS-GRADE 180 MARKED “SPECIAL”
INSTALL ROCKER ARM ASSEMBLY
COMPLETE FINAL ASSEMBLY OF INJECTION PUMP SIDE
COMPLETE FINAL ASSEMBLY ON EXHAUST MANIFOLD SIDE
PERFORM ENGINE BREAK-IN
CYLINDER BLOCK, LINERS, PISTONS AND RODS
ESSENTIAL TOOLS
SERVICE EQUIPMENT AND TOOLS
OTHER MATERIAL
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS
PRELIMINARY LINER, PISTON AND ROD CHECKS
REMOVE PISTONS AND CONNECTING RODS
MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)
REMOVE CYLINDER LINERS
DEGLAZE CYLINDER LINERS
CLEAN CYLINDER LINERS
DISASSEMBLE PISTON/ROD ASSEMBLY AND CLEAN PISTON
VISUALLY INSPECT PISTONS
CHECK PISTON COMPRESSION RING GROOVE WEAR
MEASURE OIL CONTROL RING GROOVE
INSTALL PISTON PIN IN PISTON PIN BORE
VISUALLY INSPECT CYLINDER LINERS
CYLINDER LINER MANUFACTURING DATE CODE EXPLANATION
MEASURE PISTON SKIRT OD
MEASURE CYLINDER LINER ID
MEASURE CYLINDER LINER FLANGE THICKNESS
INSPECT AND MEASURE CONNECTING ROD BEARINGS
INSPECT CONNECTING ROD AND CAP
INSPECT PISTON PINS AND BUSHINGS
REMOVE PISTON PIN BUSHING
CLEAN AND INSPECT CONNECTING ROD PIN BORE
INSTALL PISTON PIN BUSHING IN ROD
COMPLETE DISASSEMBLY OF CYLINDER BLOCK (IF REQUIRED)
REMOVE AND CLEAN PISTON COOLING ORIFICES
INSPECT AND CLEAN CYLINDER BLOCK
CLEAN CYLINDER LINER O-RING BORE
MEASURE CYLINDER BLOCK
INSTALL PISTON COOLING ORIFICES AND GALLERY PLUGS
RECHECK CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)
INSTALL LINER SHIMS-IF REQUIRED
INSTALL CYLINDER LINER O-RINGS AND PACKINGS
INSTALL CYLINDER LINERS
INSTALL PISTONS AND CONNECTING RODS
TORQUE-TURN CONNECTING ROD CAP SCREWS
CHECK ENGINE ROTATION FOR EXCESSIVE TIGHTNESS
COMPLETE FINAL ASSEMBLY
CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
ESSENTIAL TOOLS
SERVICE EQUIPMENT AND TOOLS
OTHER MATERIAL
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS
CRANKSHAFT AND MAIN BEARING FAILURE ANALYSIS
REMOVE CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE (WITH OIL SEAL HOUSING INSTALLED)
INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE (WITHOUT ENGINE DISASSEMBLY)
INSPECT VIBRATION DAMPER
CHECK CRANKSHAFT END PLAY
REMOVE DAMPER PULLEY
REMOVE CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
REMOVE CRANKSHAFT FRONT WEAR SLEEVE (WITH TIMING GEAR COVER INSTALLED OR REMOVED)
INSTALL CRANKSHAFT FRONT WEAR SLEEVE
INSTALL CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
REPLACE TIMING GEAR COVER (6076HRW33, 34, AND 35 ENGINES)-ENGINE INSTALLED IN VEHICLE
REMOVE TIMING GEAR COVER
INSPECT AND MEASURE FLYWHEEL
CHECK FLYWHEEL HOUSING FACE RUNOUT
CHECK FLYWHEEL FACE FLATNESS
CHECK PILOT BEARING BORE CONCENTRICITY
REMOVE FLYWHEEL
REMOVE SAE 1 AND SAE 2 FLYWHEEL HOUSING
REMOVE SAE 3 FLYWHEEL HOUSING
REPLACE FLYWHEEL RING GEAR
REPLACE REAR OIL SEAL HOUSING (6076HRW33, 34, AND 35 ENGINES)-ENGINE INSTALLED IN VEHICLE
REMOVE REAR OIL SEAL HOUSING AND WEAR SLEEVE (WITH ENGINE DISASSEMBLED)
REMOVE CRANKSHAFT MAIN BEARINGS
CHECK MAIN BEARING CLEARANCE
REMOVE CRANKSHAFT
INSPECT CRANKSHAFT
MEASURE ASSEMBLED ID OF BEARINGS AND OD OF CRANKSHAFT JOURNALS
MAIN BEARING CAP LINE BORE SPECIFICATION
CRANKSHAFT GRINDING GUIDELINES
THRUST BEARING NEW PART SPECIFICATIONS
CRANKSHAFT GRINDING SPECIFICATIONS
REPLACE (CRANKSHAFT) OIL PUMP DRIVE GEAR
REPLACE CRANKSHAFT GEAR
INSPECT THRUST BEARINGS
REMOVE AND CLEAN PISTON COOLING ORIFICES
INSTALL MAIN BEARINGS AND CRANKSHAFT
INSTALL CRANKSHAFT
INSTALL CRANKSHAFT REAR OIL SEAL HOUSING
CHECK OIL SEAL HOUSING RUNOUT
CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE HANDLING PRECAUTIONS
INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE ASSEMBLY
INSTALL TIMING GEAR COVER
INSTALL FRONT WEAR SLEEVE
INSTALL CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
INSTALL DAMPER PULLEY ASSEMBLY
INSTALL SAE 3 FLYWHEEL HOUSING
INSTALL FLYWHEEL
INSTALL SAE 1 AND SAE 2 FLYWHEEL HOUSING
COMPLETE FINAL ASSEMBLY 

FILE SIZE : 5.80 MB
TOTAL PAGE : 456
LANGUAGE : ENGLISH

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