Pages from CTM6 (03OCT91) – John Deere 6076 Engines (SN -499999) Component Technical Manual
Complete Component Technical Manual for John Deere 6076 Engines (SN -499999). It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This John Deere 6076 Engines (SN -499999) 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.
CTM6 (03OCT91) – John Deere 6076 Engines (SN -499999) Component Technical Manual.pdf; 437 pages (bookmarked, Searchable, Printable, high quality PDF)
EXCERPT:
TABLE OF CONTENTS
Group 00—Introduction and Safety Information
About This Manual . . . 00-1
Safety . . . 00-1
Group 01—General Information
Inch Series Torque Chart . . . . 01-1
Metric Series Torque Chart . . . 01-2
Bolt Identification Chart . . . . 01-3
Engine Model Designation . . . . 01-4
Engine Nameplate Information . . . 01-6
Option Code Label . . . 01-8
Engine Application Chart
Industrial Equipment . . . . 01-8
OEM . . . 01-9
Agricultural Equipment . . . 01-9
Basic 6076 Engine Specifications . . . . 01-10
General Engine Description . . . . 01-11
Engine-Sectional View . . . 01-12
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . 02-1
Diesel Engine Oil . . . . 02-2
General Purpose Grease . . . 02-3
Engine Coolant Recommendations . . . . 02-4
Engine Coolant Requirements . . . 02-5
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 . . . 04-3
Group 05—Cylinder Head and Valves
Essential Tools . . . 05-1
Service Equipment and Tools . . . . 05-3
Other Materials . . . 05-3
Cyl. Head and Valve Specifications . . . . 05-4
Diagnosing Malfunctions . . . 05-7
Check and Adjust Valve Clearance . . . . 05-8
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 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 Flatness . . . . 05-20
Measure Cylinder Head Thickness . . . 05-21
Clean Valve Guides . . . 05-21
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
Bore . . . . 05-27
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 Standout . . . . 05-30
Protect Cylinder Block Top Deck . . . . 05-30
Assemble Valve Assembly . . . 05-31
Install Cylinder Head . . . . 05-32
Tighten Cylinder Head Cap Screws
(Grade 180 or 12.9) . . . 05-34
Tighten Flanged-Head Cylinder Head Cap
Screws . . . . 05-35
TORQUE-TURN 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 . . . . 05-38
Perform Engine Break-In . . . . 05-40
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 Line . . . 10-8
Remove Pistons and Connecting Rods . . . 10-9
Measure Cylinder Liner Standout . . . . 10-12
Remove Cylinder Liners . . . . 10-13
Inspect Pistons and Liners . . . 10-14
Measure Oil Control Ring Groove . . . . 10-21
Measure Cylinder Liners . . . . 10-22
Deglazing Cylinder Liners . . . 10-23
Inspect and Measure Connecting Rod
Bearings . . . 10-24
Inspect Rod and Cap . . . . 10-25
Inspect Piston Pins and Bushings . . . . 10-27
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 Block . . . . 10-32
Clean O-Ring Bore . . . . 10-34
Measure Cylinder Block . . . . 10-34
Install Piston Cooling Orifices and Gallery
Plugs . . . 10-36
Recheck Cylinder Liner Standout . . . . 10-37
Measure Liner Flange Thickness . . . . 10-38
Install Liner Shims—If Required . . . 10-38
Install Cylinder Liner O-Rings and
Packings . . . 10-39
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
Tightness . . . 10-45
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 Line . . . 15-6
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 Damper . . . . 15-9
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 Gear . . . 15-15
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 Housing . . . . 15-18
Replace Flywheel Ring Gear . . . 15-19
Service Clutch Shaft Pilot Bushing-Quad
Range Transmissions . . . . 15-20
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 Crankshaft . . . 15-24
Inspect Crankshaft . . . . 15-25
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals . . . 15-26
Main Bearing Cap Line Bore
Specifications . . . . 15-27
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 Bearings . . . . 15-32
Remove and Clean Piston Cooling
Orifices . . . . 15-32
Install Main Bearings and Crankshaft . . . . 15-33
Install Oil Pump And Check Drive
Gear-To-Crankshaft Clearance . . . . 15-35
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 Flywheel . . . . 15-41
Install SAE 1 And SAE 2 Flywheel
Housing . . . . 15-42
Install Timing Gear Cover—Non-Auxiliary
Drive Engines . . . . 15-42
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 Lift . . . . 16-6
Disconnect Turbocharger Oil Inlet Line . . . 16-7
Prepare Engine For Camshaft Removal . . . 16-8
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
Backlash . . . 16-14
Remove Camshaft . . . . 16-15
Remove Camshaft Gear, Spacer, and
Thrust Plate . . . 16-16
Measure Thrust Plate and Spacer . . . . 16-17
Inspect And Measure Camshaft Followers . . . 16-17
Visually Inspect Camshaft . . . 16-17
Measure Camshaft Journal OD and
Bushing ID . . . . 16-18
Measure Camshaft Lobe Lift . . . 16-18
Assemble Camshaft . . . 16-19
Service Camshaft Bushings Using
JDG602 Adapter Set . . . 16-20
Service Camshaft Bushings Using
JDG606 Adapter Set . . . 16-22
Install Camshaft . . . . 16-23
Replace Auxiliary Drive Gear Bearings . . . . 16-25
Replace Auxiliary Drive Idler Gear
Bearings . . . 16-26
Install Timing Gear Cover—Non Auxiliary
Drive Engines . . . . 16-27
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 Line . . . 20-7
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 Valve . . . 20-12
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 Pump . . . 20-22
Check Drive Shaft End Play . . . 20-22
Check Drive Shaft Side Movement . . . 20-23
Check Pumping Gear Backlash . . . 20-23
Remove And Inspect Oil Pump Drive
Gear . . . . 20-24
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 Install . . . 25-6
Replace Bearings . . . . 25-7
Heavy Duty, Adjustable Fan Drive
Assembly
Remove and Install . . . 25-8
Replace Bearings . . . . 25-8
Replace Bearings In Water Manifold
Mounted, Fixed Fan Drive Assembly . . . . 25-10
Remove Water Pump . . . . 25-11
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 Manifold . . . . 25-19
Inspect and Clean Water Manifold . . . 25-19
Install Water Manifold . . . . 25-20
Remove Coolant Heater—If Equipped . . . 25-20
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
Works . . . . 30-3
How The Turbocharger Works . . . 30-3
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 Housings . . . . 30-21
Replace Center Housing and Rotating
Assembly . . . 30-22
Prelube Turbocharger . . . . 30-23
Install Turbocharger . . . 30-24
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 Assembly . . . . 30-29
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
Assembly . . . 30-39
Group 35—Fuel System
Essential Tools . . . 35-1
Other Material . . . . 35-3
Specifications . . . . 35-4
Relieve System Pressure . . . . 35-5
Replace Dual Fuel Filters . . . . 35-5
Replace Single Fuel Filter . . . . 35-6
Remove and Inspect Fuel Check Valve
Assembly—Dual Fuel Filter Systems . . . 35-7
Inspect and Clean Dual Fuel Filter Base . . . . 35-8
Install Fuel Check Valve Assembly—Dual
Filter Fuel Systems . . . 35-9
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 Pump . . . 35-19
Assemble Fuel Supply Pump . . . 35-20
Install Fuel Supply Pump . . . . 35-22
General Information For Aneroid—If
Equipped . . . 35-22
Repair Aneroid . . . . 35-23
Remove Hydraulic Aneroid Activator . . . . 35-23
Disassemble And Clean Hydraulic
Aneroid Activator Parts . . . 35-24
Assemble and Install Hydraulic Aneroid
Activator . . . 35-24
Service Overflow Valve . . . 35-25
Remove Fuel Shutoff Solenoid . . . . 35-26
Install Fuel Shutoff Solenoid . . . 35-27
Remove Fuel Injection Pump . . . 35-28
Install Fuel Injection Pump . . . 35-31
Remove Fuel Injection Nozzles . . . 35-35
Test Fuel Injection Nozzles . . . . 35-38
Make Opening Pressure Test . . . 35-39
Perform Leakage Test . . . 35-41
Make Chatter and Spray Pattern Test . . . 35-42
Disassemble Fuel Injection Nozzle . . . 35-43
Clean and Inspect Fuel Injection Nozzle
Assembly . . . 35-45
Perform Nozzle Slide Test . . . 35-46
Clean Spray Orifices . . . 35-46
Inspect Nozzle Holder . . . . 35-47
Inspect Gland Nut . . . . 35-49
Assemble Fuel Injection Nozzle . . . 35-50
Inspect and Clean Cylinder Head Nozzle
Bore . . . . 35-52
Inspect and Clean Nozzle Seating
Surface . . . . 35-53
Install Fuel Injection Nozzles . . . 35-53
Group 100—Tune-Up
Preliminary Engine Testing . . . . 100-1
General Tune-Up Recommendations . . . . 100-2
Check Crankcase Ventilation System . . . . 100-3
Check Air Intake System . . . . 100-3
Check Exhaust System . . . 100-3
Check and Service Entire Cooling System. . . 100-4
Inspect and Adjust V-Belts . . . 100-5
Check Electrical System . . . . 100-6
Group 105—Engine System Operation and Test
Essential Tools . . . . 105-1
Specifications . . . 105-3
Diagnose Malfunctions . . . 105-4
Dynamometer Test . . . . 105-6
Engine Break-In Instructions . . . 105-7
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 Play . . . 105-13
How the Lubrication System Works . . . . 105-14
Check Engine Oil Pressure . . . 105-15
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
Test
Essential Tools . . . . 110-1
Specifications . . . 110-2
How the Air Intake and Exhaust System
Works . . . 110-2
Air Cleaner Operation . . . . 110-3
Diagnosing Malfunctions . . . . 110-4
How The Turbocharger Works . . . . 110-5
How The Turbocharger is Lubricated . . . . 110-5
Diagnosing Turbocharger Malfunctions . . . 110-6
How The Aftercooler Works—6076A
Engines . . . . 110-7
Check Intake Manifold Pressure At
Aneroid . . . . 110-8
Check Intake Manifold Pressure At Intake
Manifold . . . 110-9
Air Filter Restriction Indicator Switch Test . . 110-10
Group 115—Fuel System Operation and Tests
Essential Tools . . . . 115-1
Specifications . . . 115-1
Fuel System Operation . . . 115-2
Diagnose Fuel System Malfunctions . . . . 115-3
Supply Pump Operation . . . . 115-7
Diagnose Supply Pump Malfunction . . . . 115-9
Check Supply Pump Operation . . . 115-10
Service Supply Pump . . . 115-12
Bleed the Fuel System . . . . 115-13
Diagnose In-Line Type Injection Pump
Malfunctions . . . . 115-15
In-Line Type Fuel Injection Pump
Operation . . . 115-16
Check and Adjust Injection Pump Timing . . 115-16
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 Operation . . . . 115-27
Diagnose Malfunctions—Fuel Injection
Nozzle . . . 115-28
Test Fuel Injection Nozzles (Engine
Running) . . . . 115-29
Fuel Drain Back Test Procedure . . . . 115-29
Group 199—Dealer Fabricated Tools
Fabricated Tools—Cylinder Liner Holding
Fixture . . . . 199-1
Index
…