Factory Technical Manual For John Deere Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.

Format: PDF
Language: English
Pages: 437
Number: CTM6 (march 1997)

Model

John Deere Engine
6076
SN -499999

Contents

-INTRODUCTION AND SAFETY INFORMATION
Safety
-GENERAL INFORMATION
Inch Series Torque Chart
Metric Series Torque Chart
Bolt Identification Chart
Engine Model Designation
Engine Nameplate Information
Option Code Label
Engine Application Chart
Basic 6076 Engine Specifications
General Engine Description
Engine-Sectional View
-FUELS, LUBRICANTS, AND COOLANT
Diesel Fuel
Diesel Engine Oil
General Purpose Grease
Engine Coolant Recommendations
Engine Coolant Requirements
-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 Materials
Cyl Head and Valve Specifications
Diagnosing Malfunctions
Check and Adjust Valve Clearance
Check Valve Lift
Disconnect Turbocharger Oil Inlet Line
Remove Cylinder Head
Disassemble and Inspect Rocker Arm Shaft Assembly
Measure Valve Recess
Remove Valve Assembly
Inspect and Measure valve Springs
Inspect Valve Rotators and Wear Caps
Clean Valves
Inspect and Measure Valves
Grind Valves
Inspect and Clean Cylinder Head
Check Cylinder Head Flatness
Measure Cylinder Head Thickness
Clean Valve Guides
Measure Valve Guides
Knurl Guides
Clean Valve Seats
Measure Valve Seats
Grind Valve Seats
Replace Valve Inserts
Install Valves
Inspect and Clean Cylinder Head Nozzle Bore
Clean and Inspect Push Rods
Clean and Inspect Cylinder Head Cap Screws
Inspect and Clean Ventilator Outlet Hose
Clean and Inspect Top Deck of Cylinder Block
Measure Cylinder Liner Standout
Protect Cylinder Block Top Deck
Assemble Valve Assembly
Install Cylinder Head
Tighten Cylinder Head Cap Screws (Grade 180 or 129)
Tighten Flanged-Head Cylinder Head Cap Screws
TORCUE-TURN Flanged-Head Cap Screws
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
Specifications
Other Materials
Diagnosing Malfunctions
Disconnect Turbocharger Oil Inlet Line
Remove Pistons and Connecting Rods
Measure Cylinder Liner Standout
Remove Cylinder Liners
Inspect Pistons and Liners
Measure Oil Control Ring Groove
Measure Cylinder Liners
Deglazing Cylinder Liners
Inspect and Measure Connecting Rod Bearings
Inspect Rod and Cap
Inspect Piston Pins and Bushings
Remove Piston Pin Bushing
Clean and Inspect Rod Pin Bushing Bore
Install Rod Pin Bushing
Complete Disassembly of Cylinder Block (If Required)
Remove and Clean Piston Cooling Orifices
Inspect and Clean Cylinder Block
Clean O-Ring Bore
Measure Cylinder Block
Install Piston Cooling Orifices and Gallery Plugs
Recheck Cylinder Liner Standout
Measure Liner Flange Thickness
Install Liner Shims—If Required
Install Cylinder Liner O-Rings and Packings
Install Cylinder Liners
Install Pistons and Connecting Rods
Use TORQUE-TURN Method For Proper Torque
Check Engine Rotation for Excessive Tightness
Complete Final Assembly
-CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
Essential Tools
Service Equipment and Tools
Other Materials
Specifications
Diagnosing Malfunctions
General Information
Disconnect Turbocharger Oil Inlet Line
Remove Crankshaft Real Oil Seal and Wear Sleeve Without Removing Oil Seal Housing
Install Crankshaft Rear Oil Seal and
Wear Sleeve Without Engine Disassembly
Inspect Vibration Damper
Remove Water Pump and Damper Pulley
Remove Timing Gear Cover—Non-Auxiliary Engines
Remove Auxiliary Drive Gear and Timing Gear Cover
Auxiliary Drive Engines Remove Front Oil Seal From Timing Gear Cover
Install Front Oil Seal In Timing Gear Cover
Check Crankshaft End Play
Remove Front Wear Sleeve
Remove and Inspect Crankshaft Gear
Inspect, Measure and Repair Flywheel
Check Flywheel Housing Face Run-Out
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
Service Clutch Shaft Pilot Bushing-Quad Range Transmissions
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 Specifications
Thrust Bearing New Part Specifications
Crankshaft Grinding Guidelines
Crankshaft Grinding Specifications
Replace Crankshaft Oil Pump Drive Gear
Inspect Thrust Bearings
Remove and Clean Piston Cooling Orifices
Install Main Bearings and Crankshaft
Install Oil Pump And Check Drive Gear-To-Crankshaft Clearance
Install Rear Crankshaft 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 (With Engine Disassem
Install Crankshaft Gear
Install Front Wear Sleeve
Install SAE 3 Flywheel Housing
Install Flywheel
Install SAE 1 And SAE 2 Flywheel Housing
Install Timing Gear Cover—Non-Auxiliary Drive Engines
Install Timing Gear Cover And Auxiliary Drive Idler Gear
Auxiliary Drive Engine
Install Rear Auxiliary Drive Gear
Install Damper Pulley Assembly
Complete Final Assembly
-LUBRICATION SYSTEM
Specifications
Engine Crankcase Oil Fill Quantities
Other Material
How The Lubrication System Works
Diagnosing Malfunctions
Disconnect Turbocharger Oil Inlet Line
Drain Engine Oil and Remove Oil Pan
Horizontal Oil Filter and Housing Assembly
Remove Horizontal Oil Filter and Housing Assembly
Vertical Oil Filter and Housing Assembly
Remove Vertical Oil Filter and Housing Assemblies
Inspect Oil Pressure Regulating Valve
Inspect Oil Filter Bypass Valve
Install Horizontal Oil Filter and Housing
Install Vertical Oil Filter and Housing Assemblies
Remove Engine Oil Cooler
Clean Inspect, and Install Engine Oil Cooler
Remove Oil Cooler Bypass Housing
Remove and Inspect Oil Cooler Bypass Valve
Engine Oil Pump Assembly—Deep Sump
Engine Oil Pump Assembly—Standard Sump
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
Remove And Inspect Oil Pump Drive Gear
Install Oil Cooler Bypass Valve And Housing
Adjust Set Screw
Install Engine Oil Pump
Install Oil Pan
-COOLING SYSTEM
Essential Tools
Other Materials
Specifications
How The Cooling System Works Diagnosing Malfunctions
Medium Duty, Adjustable Fan Drive
Heavy Duty, Adjustable Fan Drive
Replace Bearings In Water Manifold
Remove Water Pump
Disassemble Water Pump
Inspect Water Pump Parts
Assemble Water Pump
Install Water Pump
Remove and Test Thermostats
Install Thermostats
Remove Water Manifold
Inspect and Clean Water Manifold
Install Water Manifold
Remove Coolant Heater—If Equipped
Install Coolant Heater—If Equipped
Complete Final Assembly
Inspect and Tension Fan and Alternator V-Belts
Group 30—Air Intake And Exhaust System
Essential Tools
Other Material
Specifications
How The Air Intake and Exhaust System Works
How The Turbocharger Works
How The Turbocharger is Lubricated
Extending Turbocharger Life
Diagnosing Turbocharger Malfunctions
Remove Turbocharger
Turbocharger Seven-Step Inspection
Perform Axial End Play Bearing Test (Schwitzer 3LM)
Perform Radial Bearing Clearance Test (Schwitzer)
Perform Raidal Bearing Test—(AiResearch/Garrett T04E)
Disassemble Turbocharger
Clean and Inspect Turbine and Compressor Housings
Replace Center Housing and Rotating Assembly
Prelube Turbocharger
Install Turbocharger
Remove and Inspect Intake Manifold (6076T and 6076H Engines)
Install Intake Manifold (6076T and 6076H Engines)
How The Aftercooler Works—6076A Engines
Single-Pass Aftercooler Assembly
Two-Pass Aftercooler Assembly
Remove Aftercooler and Intake Manifold (6076A Engines)
Inspect and Repair Aftercooler (6076A Engines)
Inspect and Repair Intake Manifold (6076A Engines)
Install Intake Manifold and Single-Pass Aftercooler (6076A Engines)
Install Intake Manifold and Two-Pass Aftercooler (6076A Engines)
Remove, Inspect, Install Exhaust Manifold Assembly
-FUEL SYSTEM
Essential Tools
Other Material
Specifications
Relieve System Pressure
Replace Dual Fuel Filters
Replace Single Fuel Filter
Remove and Inspect Fuel Check Valve Assembly—Dual Fuel Filter Systems
Inspect and Clean Dual Fuel Filter Base
Install Fuel Check Valve Assembly—Dual Filter Fuel Systems
Replace Fuel Check Valve Assembly—Single Filter Fuel Systems
Inspect and Clean Single Fuel Filter Base
Bleed the Fuel System
Diagnosing Fuel Supply Pump Malfunctions
Remove Fuel Supply Pump
Test Fuel Supply Pump For Leaks
Disassemble Fuel Supply Pump
Inspect and Repair Fuel Supply Pump
Assemble Fuel Supply Pump
Install Fuel Supply Pump
General Information For Aneroid—If Equipped
Repair Aneroid
Remove Hydraulic Aneroid Activator
Disassemble And Clean Hydraulic Aneroid Activator Parts
Assemble and Install Hydraulic Aneroid Activator
Service Overflow Valve
Remove Fuel Shutoff Solenoid
Install Fuel Shutoff Solenoid
Remove Fuel Injection Pump
Install Fuel Injection Pump
Remove Fuel Injection Nozzles
Test Fuel Injection Nozzles
Make Opening Pressure Test
Perform Leakage Test
Make Chatter and Spray Pattern Test
Disassemble Fuel Injection Nozzle
Clean and Inspect Fuel Injection Nozzle Assembly
Perform Nozzle Slide Test
Clean Spray Orifices
Inspect Nozzle Holder
Inspect Gland Nut
Assemble Fuel Injection Nozzle
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Nozzle Seating Surface
Install Fuel Injection Nozzles
-TUNE-UP
Preliminary Engine Testing
General Tune-Up Recommendations
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check and Service Entire Cooling System
Inspect and Adjust V-Belts
Check Electrical System
-ENGINE SYSTEM OPERATION AND TEST
Essential Tools
Specifications
Diagnose Malfunctions
Dynamometer Test
Engine Break-In Instructions
Test Engine Compression Pressure
Check and Adjust Valve Clearance
Check Valve Lift
Inspect Vibration Damper
Check Crankshaft End Play
How the Lubrication System Works
Check Engine Oil Pressure
How The Cooling System Works
Pressure Test Cooling System and Radiator Cap
Inspect Thermostat and Test Opening Temperature
-AIR INTAKE SYSTEM OPERATION AND TEST
Essential Tools
Specifications
How the Air Intake and Exhaust System Works
Air Cleaner Operation
Diagnosing Malfunctions
How The Turbocharger Works
How The Turbocharger is Lubricated
Diagnosing Turbocharger Malfunctions
How The Aftercooler Works—6076A Engines
Check Intake Manifold Pressure At Aneroid
Check Intake Manifold Pressure At Intake Manifold
Air Filter Restriction Indicator Switch Test
-FUEL SYSTEM OPERATION AND TESTS
Essential Tools
Specifications
Fuel System Operation
Diagnose Fuel System Malfunctions
Supply Pump Operation
Diagnose Supply Pump Malfunction
Check Supply Pump Operation
Service Supply Pump
Bleed the Fuel System
Diagnose In-Line Type Injection Pump Malfunctions
In-Line Type Fuel Injection Pump Operation
Check and Adjust Injection Pump Timing
Check Engine Fast Idle Speed
Check and Adjust Engine Slow Idle Speed
How The Aneroid Works (If Equipped)
Diagnose Aneroid Malfunctions
How The Hydraulic Aneroid Activator Works
Diagnose Malfunctions—Hydraulic Aneroid Activator
Fuel Injection Nozzle—General Information
Fuel Injection Nozzle Operation
Diagnose Malfunctions—Fuel Injection Nozzle
Test Fuel Injection Nozzles (Engine Running)
Fuel Drain Back Test Procedure
-DEALER FABRICATED TOOLS
Fabricated Tools—Cylinder Liner Holding Fixture