John Deere Engines 6076 ctm6 Technical Manual EN

Description

John Deere Engines 6076 ctm6 Technical Manual EN

FILE DETAILS:

John Deere Engines 6076 ctm6 Technical Manual EN

Language : English
Pages : 437
Downloadable : Yes
File Type : PDF
Size: 12.9 MB

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere Engines 6076 ctm6 Technical Manual EN

Group 00—Introduction and Safety Information
About This Manual 00-1
Safety 00-1
Group 01—General Information
Inch Series Torque Chart01-1
Metric Series Torque Chart 01-2
Bolt Identification Chart 01-3
Engine Model Designation01-4
Engine Nameplate Information01-6
Option Code Label 01-8
Engine Application Chart
Industrial Equipment 01-8
OEM 01-9
Agricultural Equipment 01-9
Basic 6076 Engine Specifications01-10
General Engine Description 01-11
Engine-Sectional View 01-12
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel 02-1
Diesel Engine Oil02-2
General Purpose Grease 02-3
Engine Coolant Recommendations02-4
Engine Coolant Requirements02-5
Group 03—Engine Mounting
Engine Repair Stand03-1
Safety Precautions 03-2
Install 400 Series Adapters on Repair
Stand03-2
Engine Lifting Procedure 03-3
Clean Engine 03-4
Disconnect Turbocharger Oil Inlet Line03-4
Mount Engine On Repair Stand 03-5
Group 04—Engine Rebuild Guide
6076 Engine Disassembly Sequence 04-1
Sealant Application Guidelines04-2
6076 Engine Assembly Sequence 04-3
Page
Group 05—Cylinder Head and Valves
Essential Tools 05-1
Service Equipment and Tools 05-3
Other Materials 05-3
Cyl Head and Valve Specifications05-4
Diagnosing Malfunctions 05-7
Check and Adjust Valve Clearance05-8
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 Assembly05-16
Inspect and Measure valve Springs 05-17
Inspect Valve Rotators and Wear Caps 05-17
Clean Valves 05-18
Inspect and Measure Valves05-18
Grind Valves 05-19
Inspect and Clean Cylinder Head05-19
Check Cylinder Head Flatness 05-20
Measure Cylinder Head Thickness 05-21
Clean Valve Guides05-21
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
Bore05-27
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 Standout05-30
Protect Cylinder Block Top Deck05-30
Continued on next page
COPYRIGHT© 1991
DEERE & COMPANY
Moline, Illinois
Assemble Valve Assembly 05-31
Install Cylinder Head 05-32
Tighten Cylinder Head Cap Screws
(Grade 180 or 129) 05-34
Tighten Flanged-Head Cylinder Head Cap
Screws 05-35
TORQUE-TURN Flanged-Head Cap
Screws 05-36
Install Rocker Arm Assembly05-37
Complete Final Assembly Of Injection
Pump Side 05-38
Complete Final Assembly On Exhaust
Manifold Side05-38
Perform Engine Break-In05-40
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 Line10-8
Remove Pistons and Connecting Rods10-9
Measure Cylinder Liner Standout10-12
Remove Cylinder Liners10-13
Inspect Pistons and Liners 10-14
Measure Oil Control Ring Groove10-21
Measure Cylinder Liners10-22
Deglazing Cylinder Liners 10-23
Inspect and Measure Connecting Rod
Bearings10-24
Inspect Rod and Cap 10-25
Inspect Piston Pins and Bushings10-27
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 Block10-32
Clean O-Ring Bore 10-34
Measure Cylinder Block10-34
Install Piston Cooling Orifices and Gallery
Plugs 10-36
Recheck Cylinder Liner Standout10-37
Measure Liner Flange Thickness10-38
Install Liner Shims—If Required 10-38
Page
Install Cylinder Liner O-Rings and
Packings10-39
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
Tightness10-45
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 Line15-6
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 Damper15-9
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 Gear15-15
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 Housing15-18
Replace Flywheel Ring Gear15-19
Service Clutch Shaft Pilot Bushing-Quad
Range Transmissions15-20
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 Crankshaft15-24
Inspect Crankshaft 15-25
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals15-26
Main Bearing Cap Line Bore
Specifications15-27
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 Bearings15-32
Remove and Clean Piston Cooling
Orifices 15-32
Install Main Bearings and Crankshaft 15-33
Install Oil Pump And Check Drive
Gear-To-Crankshaft Clearance15-35
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 Flywheel15-41
Install SAE 1 And SAE 2 Flywheel
Housing 15-42
Install Timing Gear Cover—Non-Auxiliary
Drive Engines15-42
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 Lift16-6
Disconnect Turbocharger Oil Inlet Line16-7
Prepare Engine For Camshaft Removal16-8
Page
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
Backlash16-14
Remove Camshaft 16-15
Remove Camshaft Gear, Spacer, and
Thrust Plate 16-16
Measure Thrust Plate and Spacer16-17
Inspect And Measure Camshaft Followers 16-17
Visually Inspect Camshaft 16-17
Measure Camshaft Journal OD and
Bushing ID 16-18
Measure Camshaft Lobe Lift16-18
Assemble Camshaft16-19
Service Camshaft Bushings Using
JDG602 Adapter Set 16-20
Service Camshaft Bushings Using
JDG606 Adapter Set 16-22
Install Camshaft16-23
Replace Auxiliary Drive Gear Bearings 16-25
Replace Auxiliary Drive Idler Gear
Bearings16-26
Install Timing Gear Cover—Non Auxiliary
Drive Engines16-27
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 Line20-7
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 Valve20-12
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 Pump20-22
Check Drive Shaft End Play20-22
Check Drive Shaft Side Movement 20-23
Check Pumping Gear Backlash 20-23
Remove And Inspect Oil Pump Drive
Gear20-24
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 Install25-6
Replace Bearings 25-7
Heavy Duty, Adjustable Fan Drive
Assembly
Remove and Install25-8
Replace Bearings 25-8
Replace Bearings In Water Manifold
Mounted, Fixed Fan Drive Assembly 25-10
Remove Water Pump 25-11
Page
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 Manifold25-19
Inspect and Clean Water Manifold 25-19
Install Water Manifold 25-20
Remove Coolant Heater—If Equipped25-20
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
Works30-3
How The Turbocharger Works30-3
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 Housings30-21
Replace Center Housing and Rotating
Assembly30-22
Prelube Turbocharger 30-23
Install Turbocharger30-24
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 Assembly30-29
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
Assembly30-39
Group 35—Fuel System
Essential Tools 35-1
Other Material 35-3
Specifications 35-4
Relieve System Pressure35-5
Replace Dual Fuel Filters35-5
Replace Single Fuel Filter35-6
Remove and Inspect Fuel Check Valve
Assembly—Dual Fuel Filter Systems35-7
Inspect and Clean Dual Fuel Filter Base 35-8
Install Fuel Check Valve Assembly—Dual
Filter Fuel Systems35-9
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 Pump35-19
Assemble Fuel Supply Pump35-20
Install Fuel Supply Pump35-22
General Information For Aneroid—If
Equipped35-22
Repair Aneroid35-23
Remove Hydraulic Aneroid Activator 35-23
Disassemble And Clean Hydraulic
Aneroid Activator Parts 35-24
Assemble and Install Hydraulic Aneroid
Activator35-24
Service Overflow Valve 35-25
Remove Fuel Shutoff Solenoid 35-26
Install Fuel Shutoff Solenoid35-27
Remove Fuel Injection Pump35-28
Install Fuel Injection Pump 35-31
Remove Fuel Injection Nozzles 35-35
Page
Test Fuel Injection Nozzles 35-38
Make Opening Pressure Test35-39
Perform Leakage Test 35-41
Make Chatter and Spray Pattern Test35-42
Disassemble Fuel Injection Nozzle 35-43
Clean and Inspect Fuel Injection Nozzle
Assembly35-45
Perform Nozzle Slide Test 35-46
Clean Spray Orifices35-46
Inspect Nozzle Holder 35-47
Inspect Gland Nut 35-49
Assemble Fuel Injection Nozzle 35-50
Inspect and Clean Cylinder Head Nozzle
Bore35-52
Inspect and Clean Nozzle Seating
Surface 35-53
Install Fuel Injection Nozzles35-53
Group 100—Tune-Up
Preliminary Engine Testing 100-1
General Tune-Up Recommendations 100-2
Check Crankcase Ventilation System 100-3
Check Air Intake System100-3
Check Exhaust System 100-3
Check and Service Entire Cooling System100-4
Inspect and Adjust V-Belts 100-5
Check Electrical System100-6
Group 105—Engine System Operation and Test
Essential Tools105-1
Specifications 105-3
Diagnose Malfunctions 105-4
Dynamometer Test 105-6
Engine Break-In Instructions105-7
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 Play105-13
How the Lubrication System Works 105-14
Check Engine Oil Pressure105-15
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
Specifications 110-2
How the Air Intake and Exhaust System
Works 110-2
Air Cleaner Operation 110-3
Diagnosing Malfunctions110-4
How The Turbocharger Works 110-5
How The Turbocharger is Lubricated 110-5
Diagnosing Turbocharger Malfunctions110-6
How The Aftercooler Works—6076A
Engines 110-7
Check Intake Manifold Pressure At
Aneroid 110-8
Check Intake Manifold Pressure At Intake
Manifold110-9
Air Filter Restriction Indicator Switch Test110-10
Group 115—Fuel System Operation and Tests
Essential Tools115-1
Specifications 115-1
Fuel System Operation 115-2
Diagnose Fuel System Malfunctions 115-3
Supply Pump Operation115-7
Diagnose Supply Pump Malfunction 115-9
Check Supply Pump Operation 115-10
Service Supply Pump 115-12
Bleed the Fuel System115-13
Diagnose In-Line Type Injection Pump
Malfunctions115-15
In-Line Type Fuel Injection Pump
Operation 115-16
Check and Adjust Injection Pump Timing115-16
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 Operation115-27
Diagnose Malfunctions—Fuel Injection
Nozzle115-28
Test Fuel Injection Nozzles (Engine
Running) 115-29
Fuel Drain Back Test Procedure115-29
Page
Group 199—Dealer Fabricated Tools
Fabricated Tools—Cylinder Liner Holding
Fixture 199-1
Index

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.V