John Deere 6076 Natural Gas Engines Components Technical Service Manual CTM82
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CONTENTS :
Group 00-Safety
General 00-1
Group 01-General Information
Unified Inch Bolt and Cap Screw Torque
Values 01-1
Metric Bolt and Cap Screw Torque
Values 01-2
Engine Model Designation 01-3
Engine Serial Number Plate Information 01-4
Group 02-Fuels, Lubricants, and Coolant
Engine Oil 02-1
Natural Gas Recommendations 02-2
Oil scan® and Cool scan TM •••••••••••••• 02-3
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-3
Engine Coolant Requirements 02-4
John Deere Engine Cooling Fluid 02-8
Check Effectiveness of Coolant Solution 02-9
Replenishing Supplemental Coolant
Additives 02-10
Flushing and Servicing Cooling System 02-11
Disposing of Coolant . . . . . . . . . . . . . . . . 02-12
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 03-3
Disconnect Turbocharger Oil Inlet Line 03-4
Mount Engine On Repair Stand 03-5
Group 04-Engine Rebuild Guide
Engine Disassembly Sequence 04-1
Sealant Application Guidelines 04-2
Engine Assembly Sequence 04-4
Group 05-Cylinder Head and Valves
Special or Essential Tools . . . . . . . . . . . . . . 05-1
Cylinder Head and Valves Specifications 05-4
Service Equipment and Tools 05-6
Other Material . . . . . . . . . . . . . . . . . . . . . . 05- 7
Check and Adjust Valve Clearance 05-7
Check Valve Lift 05-9
Remove Cylinder Head . . . . . . . . . . . . . . . 05-10
Disassemble and Inspect Rocker Arm
Shaft Assembly . . . . . . . . . . . . . . . . . . 05-12
Assemble Rocker Arm Shaft Assembly . . . . 05-13
Measure Valve Recess 05-14
Preliminary Cylinder Head and Valve
Checks . . . . . . . . . . . . . . . . . . . . . . . . 05-15
Remove Valve Assembly 05-16
Inspect and Measure Valve Springs 05-16
Inspect Valve Rotators and Wear Caps 05-17
Clean Valves 05-17
Inspect and Measure Valves 05-18
Grind Valves 05-19
Inspect and Clean Cylinder Head 05-19
Check Cylinder Head Combustion Face
Flatness . . . . . . . . . . . . . . . . . . . . . . . 05-20
Measure Cylinder Head Thickness 05-21
Clean Valve Guides 05-22
Measure Valve Guides 05-22
Knurl Valve Guides 05-23
Clean and Inspect Valve Seats 05-23
Measure Valve Seats 05-24
Grind Valve Seats 05-25
Remove Valve Seat Inserts 05-26
Measure Valve Seat Bore 05-27
Install Valve Seat Inserts 05-27
Inspect and Clean Cylinder Head Spark
Plug Bore . . . . . . . . . . . . . . . . . . . . . . 05-28
Clean and Inspect Push Rods 05-28
Inspect and Clean Ventilator Outlet Hose 05-29
Clean and Inspect Top Deck of Cylinder
Block . . . . . . . . . . . . . . . . . . . . . . . . . 05-29
Measure Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 05-30
Assemble Valve Assembly 05-31
Install Cylinder Head 05-32
Tighten Flanged-Head Cylinder Head Cap
Screws . . . . . . . . . . . . . . . . . . . . . . . . 05-34
TORQUE-TURN Flanged-Head Cap
Screws . . . . . . . . . . . . . . . . . . . . . . . . 05-35
Install Rocker Arm Assembly 05-36
Complete Final Assembly Of Water Pump
Side 05-37
Complete Final Assembly On Exhaust
Manifold Side . . . . . . . . . . . . . . . . . . . . 05-38
Perform Engine Break-In . . . . . . . . . . . . . . 05-40
Group 10-Cylinder Block, Liners, Pistons and
Rods
Special or Essential Tools 10-1
Service Equipment and Tools 10-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 10-4
Cylinder Block, Liners, Pistons, and Rods
Specifications . . . . . . . . . . . . . . . . . . . . . 10-5
Preliminary Liner, Piston, and Rod
Checks . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Remove Pistons and Connecting Rods .... 10-10
Measure Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 10-14
Remove Cylinder Liners 10-15
Remove Piston Rings . . . . . . . . . . . . . . . . 10-16
Clean Pistons 10-17
Clean Cylinder Liners . . . . . . . . . . . . . . . . 10-17
Visually Inspect Pistons 10-18
Check Piston Ring Groove Wear 10-18
Install Piston Pin in Piston 10-19
Visually Inspect Cylinder Liners 10-20
Measure Piston Skirt OD 10-21
Measure Oil Control Ring Groove 10-22
Measure Cylinder Liners 10-23
Deglazing Cylinder Liners . . . . . . . . . . . . . 10-24
Inspect and Measure Connecting Rod
Bearings . . . . . . . . . . . . . . . . . . . . . . . 10-25
Inspect Rod and Cap 10-26
Inspect Piston Pins and Bushings 10-27
Remove Piston Pin Bushing 10-29
Clean and Inspect Connecting Rod Pin
Bore 10-29
Install Piston Pin Bushing in Connecting
Rod 10-31
Remove and Clean Piston Cooling
Orifices 10-32
Inspect and Clean Cylinder Block . . . . . . . . 10-32
Clean Cylinder Liner 0-Ring Bore 10-34
Measure Cylinder Block 10-34
Install Piston Cooling Orifices and Gallery
Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Measure Liner Flange Thickness . . . . . . . . 10-37
Recheck Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 10-37
Install Liner Shims-If Required 10-38
Install Cylinder Liner 0-Rings and
Packings . . . . . . . . . . . . . . . . . . . . . . . 10-39
Cylinder Liner Manufacturing Date Code
Explanation . . . . . . . . . . . . . . . . . . . . . 10-40
Install Cylinder Liners . . . . . . . . . . . . . . . . 10-41
Install Pistons and Connecting Rods 10-43
Use TORQUE-TURN Method For Proper
Torque 10-45
Check Engine Rotation for Excessive
Tightness . . . . . . . . . . . . . . . . . . . . . . . 10-46
Complete Final Assembly . . . . . . . . . . . . . 10-46
Group 15-Crankshaft, Main Bearings and
Flywheel
Special or Essential Tools 15-1
Service Equipment and Tools 15-4
Other Material 15-4
Crankshaft, Main Bearings, and Flywheel
Specifications 15-5
Failure Analysis 15-7
Remove Crankshaft Rear Oil Seal
Housing
(With Oil Seal Housing Installed) 15-8
Install Crankshaft Rear Oil Seal and
Wear Sleeve
(Without Engine Disassembly) . . . . . . . . . 15-10
Inspect Vibration Damper . . . . . . . . . . . . . 15-11
Check Crankshaft End Play . . . . . . . . . . . . 15-12
Remove Damper Pulley . . . . . . . . . . . . . . 15-13
Remove Crankshaft Front Oil Seal
(With Timing Gear Cover Installed on
Engine) 15-14
Remove Crankshaft Front Wear Sleeve
(With Timing Gear Cover Installed or
Removed) . . . . . . . . . . . . . . . . . . . . . 15-15
Install Crankshaft Front Wear Sleeve 15-16
Install Crankshaft Front Oil Seal
(With Timing Gear Cover Installed) . . . . . 15-17
Remove Timing Gear Cover . . . . . . . . . . . 15-17
Inspect, Measure and Repair Flywheel .... 15-18
Check Flywheel Housing Face Run-Out . . . . 15-18
Check Flywheel Face Flatness . . . . . . . . . . 15-19
Check Pilot Bearing Bore Concentricity .... 15-19
Remove Flywheel . . . . . . . . . . . . . . . . . . 15-20
AND MORE ...
