John Deere Series 400 6076 Diesel Engines (SN 500000-) Workshop Repair Service Manual (CTM42) PDF Download - MJODCTM42OPES.zip

The complete factory-level service reference covering John Deere Series 400 6076 diesel engines (serial numbers 500000 and up), packed with everything needed to service, troubleshoot, overhaul, and reassemble these units to a professional standard.

Inside the John Deere Series 400 diesel engine manual, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

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PRODUCT DETAILS:

Total Pages: 689 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English Spanish Portuguese French Russian German Italian

ctm42 - series 400, 6076 diesel engines (500000 - )

Table of Contents - Expanded View

Foreword

About This Manual

Section 00: 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

Dispose of Waste Properly

Live With Safety

Section 01: General Information

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Engine Model Designation

Engine Serial Number Plate Information

Engine Application Chart

OEM Applications

Section 02: Fuels, Lubricants, and Coolant

Diesel Fuel

Lubricity of Diesel Fuels

Engine Break-In Oil

Diesel Engine Oil

OILSCANOILSCAN is a trademark of Deere & Company. and CoolScanCoolScan is a trademark of Deere & Company.

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

Section 03: 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

Section 04: Engine Rebuild Guide

6076 Engine Disassembly Sequence

Sealant Application Guidelines

6076 Engine Assembly Sequence

Section 05: 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

Section 10: 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

Section 15: 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

Section 16: Camshaft and Timing Gear Train

Essential Tools

Service Equipment and Tools

Other Material

Camshaft and Timing Gear Train Specifications

Check Valve Lift

Check Camshaft End Play

Remove Damper Pulley and Timing Gear Cover

Measure Camshaft Drive Gear-to-Crankshaft Gear Backlash

Remove Camshaft

Remove Camshaft Gears

Measure Thrust Washer Thickness

Inspect and Measure Camshaft Followers

Visually Inspect Camshaft

Measure Camshaft Journal OD and Bushing ID

Measure Camshaft Lobe Lift

Install Camshaft Gears

Service Camshaft Bushings Using JDG602 Adapter Set

Service Camshaft Bushings Using JDG606 Adapter Set

Install Camshaft

Install Thrust Washer and Timing Gear Cover

Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed on Engine)

Complete Final Assembly

Section 20: Lubrication System

Other Material

Lubrication System Specifications

Drain Engine Oil and Remove Oil Pan

Oil Filter and Oil Conditioning Housing Assembly

Remove Oil Filter and Oil Conditioning Housing

Inspect and Replace Oil Filter Adapter

Remove, Inspect, and Install Oil Pressure Regulating Valve, Oil Filter Bypass Valve, and Oil Cooler Bypass Valve

Install Oil Filter and Oil Conditioning Housing

Remove Engine Oil Cooler

Clean, Inspect, and Install Engine Oil Cooler

Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash

Remove Engine Oil Pump

Inspect and Clean Oil Pump

Check Drive Shaft End Play

Check Drive Shaft Side Movement

Check Pumping Gear Backlash

Inspect Oil Pump Drive Gear

Install Engine Oil Pump

Install Oil Pan

Tighten Cap Screws on Front Frame/Oil Sump

Section 25: Cooling System

Essential Tools

Other Material

Cooling System Specifications

Service Equipment and Tools

Replace Bearings in Standard Duty, Adjustable Fan Drive Assembly

Replace Bearings in Heavy Duty, Adjustable Fan Drive Assembly

Replace Bearings in Water Manifold Mounted, Fixed Fan Drive Assembly

Replace Bearing in Injection Pump Drive Gear Cover Mounted, Fan Drive

Inspect and Check Belt Tensioner Spring Tension

Replace Belt Tensioner Assembly

Remove Water Pump

Disassemble Engine Water Pump

Inspect Water Pump Parts

Assemble Engine Water Pump

Install Engine Water Pump

Remove and Test Thermostats

Install Thermostats

Remove Water Manifold

Install Water Manifold

Remove Coolant Heater-If Equipped

Install Coolant Heater-If Equipped

Complete Final Assembly

Fan Belt Tension Specifications

Section 30: Air Intake and Exhaust System

Essential Tools

Other Material

Air Intake and Exhaust System Specifications

Extending Turbocharger Life

Remove Turbocharger

Diagnose Engine Malfunction

Turbocharger Seven-Step Inspection

Perform Radial Bearing Clearance Test

Perform Axial Bearing End Play Test

Repair Turbocharger

Disassemble Turbocharger

Clean and Inspect Turbine and Compressor Housings

Replace Center Housing Assembly and Assemble Turbocharger

Prelube Turbocharger