CTM42 - John Deere Series 400, 6076 Diesel Engines (SN 500000-) Component Technical Manual.pdf

Complete Component Technical Manual for John Deere Series 400 6076 Diesel Engines (SN 500000-), with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.

John Deere Series 400 Diesel Engines Component Technical Manual CTM includes:
* 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.

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

Main Sections

Foreword

About This Manual

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

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

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

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 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

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

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

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

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

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

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

Install Turbocharger

Remove, Inspect, and Install Intake Manifold (6076T and 6076H Engines)

Remove Vertically-Mounted Aftercooler and Intake Manifold (6076A Engines)

Remove and Disassemble Horizontally-Mounted Aftercooler Assembly (6076A Engines)

Inspect and Repair Aftercooler (6076A Engines)

Inspect and Repair Intake Manifold and Air Intake Cover (6076A Engines)

Install Intake Manifold and Vertically-Mounted Aftercooler (6076A Engines)

Assemble and Install Horizontally-Mounted Aftercooler Assembly (6076A Engines)

Remove, Inspect, and Install Exhaust Manifold

Fuel System

Essential Tools

Other Material

Diesel Fuel System Specifications

Relieve Fuel System Pressure

Replace Rectangular Fuel Filter Element

Replace Fuel Check Valve

Replace Round Fuel Filter Element

Identification of Mechanical Fuel Supply Pumps

Remove Mechanical Fuel Supply Pump

Test Mechanical Fuel Supply Pump for Leaks

Disassemble Mechanical (Roller Tappet) Fuel Supply Pump-Nippondenso

Inspect and Repair Mechanical (Roller Tappet) Fuel Supply Pump Components-Nippondenso

Assemble Mechanical (Roller Tappet) Fuel Supply Pump-Nippondenso

Disassemble Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch

Inspect and Repair Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch

Assemble Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch

Install Mechanical Fuel Supply Pump

Remove and Install Electric Fuel Supply Pump-6076TRW31 Engines

Clean or Replace Electric Fuel Supply Pump Filter Screen-6076TRW31 Engines

Repair Aneroid-If Equipped

Remove Hydraulic Aneroid Activator-If Equipped

Disassemble and Clean Hydraulic Aneroid Activator Parts-If Equipped

Assemble and Install Hydraulic Aneroid Activator-If Equipped

Service Injection Pump Overflow Valve

Remove and Install Fuel Shutoff Solenoid

Identification of In-Line Fuel Injection Pumps

Remove In-Line Fuel Injection Pump

Install In-Line Fuel Injection Pump

Remove Rotary Fuel Injection Pump-Stanadyne DB4

Install Rotary Fuel Injection Pump-Stanadyne DB4

Remove Fuel Injection Nozzles

Diagnose Engine Malfunction

Test Fuel Injection Nozzles

Perform Opening Pressure Test

Injection Nozzle Specifications

Perform Nozzle Leakage Test

Perform 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

Adjust Fuel Injection Nozzles

Inspect and Clean Cylinder Head Nozzle Bore

Inspect and Clean Nozzle Seating Surface

Install Fuel Injection Nozzles

Engine Tune-Up and Break-In

Effects of Altitude and Temperature on Engine Performance

Preliminary Engine Testing

General Tune-Up Recommendations

Dynamometer Test

Engine Break-In Guidelines

Perform Engine Break-In

Check Crankcase Ventilation System

Check Air Intake System

Check Exhaust System

Check and Service Cooling System

Check Electrical System

Engine System Operation and Test

Essential Tools

Engine Test Specifications

Engine-Sectional View

General Engine Description

How the Lubrication System Works

How the Cooling System Works

Head Gasket Joint Construction and Operation

Diagnosing Head Gasket Joint Failures

Head Gasket Inspection and Repair Sequence

Diagnosing Engine Malfunctions

Test Engine Compression Pressure

Check Engine Oil Pressure

Pressure Test Cooling System and Radiator Cap

Inspect Thermostat and Test Opening Temperature

Air Intake System Operation and Test

Essential Tools

Air Intake and Exhaust System Test Specifications

Diagnosing Air Intake Malfunctions

How the Air Intake and Exhaust System Works

Air Cleaner Operation

Air Filter Restriction Indicator Switch Test

Diagnosing Turbocharger Malfunctions

How the Turbocharger Works

How the Turbocharger is Lubricated

How the Aftercooler Works-6076A Engines

Check Intake Manifold Pressure (Turbocharger Boost)

Fuel System Operation and Test

Essential Tools

Fuel System Test Specifications

Check and Adjust Rotary Fuel Injection Pump Dynamic Timing Using JT07158 TIME TRAC TIME TRAC is a trademark of the Stanadyne Automotive Corp. Kit

Fuel System Operation-In-Line Fuel Injection Pump

Fuel System Operation-Rotary Fuel Injection Pump

Diagnose Fuel System Malfunctions

Mechanical Fuel Supply Pump Operation

Diagnosing Mechanical Fuel Supply Pump Malfunctions

Test Mechanical Fuel Supply Pump for Leaks

Check Mechancial Fuel Supply Pump Operation

Service Mechanical Fuel Supply Pump

Electric Fuel Supply Pump Operation

Diagnose Electric Fuel Supply Pump Malfunction

Test Electric Fuel Supply Pump for Output Pressure and Flow

Fuel Shut-Off Solenoid Operational Check

Fuel Shut-Off Solenoid Resistance Test

Fuel Shut-Off Solenoid Linkage Adjustment

Rectangular Fuel Filter Operation

Round (Final) Fuel Filter Operation

Bleed the Fuel System

Diagnose In-Line Fuel Injection Pump Malfunctions

In-Line Fuel Injection Pump Operation

Check Fast Idle Speed-In-Line Fuel Injection Pump

Check and Adjust Slow Idle Speed-In-Line Fuel Injection Pump

Rotary Fuel Injection Pump Operation-Stanadyne DB4

Diagnose Engine Malfunction

Check and Adjust Engine Speeds on Rotary Pump-Stanadyne DB4

How the Aneroid Works (If Equipped)-In-Line Injection Pumps

Diagnose Aneroid Malfunction

How the Hydraulic Aneroid Activator Works (If Equipped)

Diagnose Malfunctions-Hydraulic Aneroid Activator

Fuel Injection Nozzles-General Information

Fuel Injection Nozzle Operation

Diagnose Malfunctions-Fuel Injection Nozzle

Test Fuel Injection Nozzles (Engine Running)

Fuel Drain Back Test Procedure

Instructions for Changing 6076 Gen Set Engine Rated Speed from 1800 RPM (60 Hz) to 1500 RPM (50 Hz)-Mechanical Governor

Change Engine Rated Speed from 1800 RPM to 1500 RPM and Adjust Droop

Dealer Fabricated Tools

How to Make Tools

DFRG3-Cylinder Liner Holding Fixture

PRODUCT DETAILS:
Total Pages/Size: 689 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

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
Install Turbocharger
Remove, Inspect, and Install Intake Manifold (6076T and 6076H Engines)
Remove Vertically-Mounted Aftercooler and Intake Manifold (6076A Engines)
Remove and Disassemble Horizontally-Mounted Aftercooler Assembly (6076A Engines)
Inspect and Repair Aftercooler (6076A Engines)
Inspect and Repair Intake Manifold and Air Intake Cover (6076A Engines)
Install Intake Manifold and Vertically-Mounted Aftercooler (6076A Engines)
Assemble and Install Horizontally-Mounted Aftercooler Assembly (6076A Engines)
Remove, Inspect, and Install Exhaust Manifold
Section 35: Fuel System
Essential Tools
Other Material
Diesel Fuel System Specifications
Relieve Fuel System Pressure
Replace Rectangular Fuel Filter Element
Replace Fuel Check Valve
Replace Round Fuel Filter Element
Identification of Mechanical Fuel Supply Pumps
Remove Mechanical Fuel Supply Pump
Test Mechanical Fuel Supply Pump for Leaks
Disassemble Mechanical (Roller Tappet) Fuel Supply Pump-Nippondenso
Inspect and Repair Mechanical (Roller Tappet) Fuel Supply Pump Components-Nippondenso
Assemble Mechanical (Roller Tappet) Fuel Supply Pump-Nippondenso
Disassemble Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch
Inspect and Repair Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch
Assemble Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch
Install Mechanical Fuel Supply Pump
Remove and Install Electric Fuel Supply Pump-6076TRW31 Engines
Clean or Replace Electric Fuel Supply Pump Filter Screen-6076TRW31 Engines
Repair Aneroid-If Equipped
Remove Hydraulic Aneroid Activator-If Equipped
Disassemble and Clean Hydraulic Aneroid Activator Parts-If Equipped
Assemble and Install Hydraulic Aneroid Activator-If Equipped
Service Injection Pump Overflow Valve
Remove and Install Fuel Shutoff Solenoid
Identification of In-Line Fuel Injection Pumps
Remove In-Line Fuel Injection Pump
Install In-Line Fuel Injection Pump
Remove Rotary Fuel Injection Pump-Stanadyne DB4
Install Rotary Fuel Injection Pump-Stanadyne DB4
Remove Fuel Injection Nozzles
Diagnose Engine Malfunction
Test Fuel Injection Nozzles
Perform Opening Pressure Test
Injection Nozzle Specifications
Perform Nozzle Leakage Test
Perform 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
Adjust Fuel Injection Nozzles
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Nozzle Seating Surface
Install Fuel Injection Nozzles
Section 100: Engine Tune-Up and Break-In
Effects of Altitude and Temperature on Engine Performance
Preliminary Engine Testing
General Tune-Up Recommendations
Dynamometer Test
Engine Break-In Guidelines
Perform Engine Break-In
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check and Service Cooling System
Check Electrical System
Section 105: Engine System Operation and Test
Essential Tools
Engine Test Specifications
Engine-Sectional View
General Engine Description
How the Lubrication System Works
How the Cooling System Works
Head Gasket Joint Construction and Operation
Diagnosing Head Gasket Joint Failures
Head Gasket Inspection and Repair Sequence
Diagnosing Engine Malfunctions
Test Engine Compression Pressure
Check Engine Oil Pressure
Pressure Test Cooling System and Radiator Cap
Inspect Thermostat and Test Opening Temperature
Section 110: Air Intake System Operation and Test
Essential Tools
Air Intake and Exhaust System Test Specifications
Diagnosing Air Intake Malfunctions
How the Air Intake and Exhaust System Works
Air Cleaner Operation
Air Filter Restriction Indicator Switch Test
Diagnosing Turbocharger Malfunctions
How the Turbocharger Works
How the Turbocharger is Lubricated
How the Aftercooler Works-6076A Engines
Check Intake Manifold Pressure (Turbocharger Boost)
Section 115: Fuel System Operation and Test
Essential Tools
Fuel System Test Specifications
Check and Adjust Rotary Fuel Injection Pump Dynamic Timing Using JT07158 TIME TRAC TIME TRAC is a trademark of the Stanadyne Automotive Corp. Kit
Fuel System Operation-In-Line Fuel Injection Pump
Fuel System Operation-Rotary Fuel Injection Pump
Diagnose Fuel System Malfunctions
Mechanical Fuel Supply Pump Operation
Diagnosing Mechanical Fuel Supply Pump Malfunctions
Test Mechanical Fuel Supply Pump for Leaks
Check Mechancial Fuel Supply Pump Operation
Service Mechanical Fuel Supply Pump
Electric Fuel Supply Pump Operation
Diagnose Electric Fuel Supply Pump Malfunction
Test Electric Fuel Supply Pump for Output Pressure and Flow
Fuel Shut-Off Solenoid Operational Check
Fuel Shut-Off Solenoid Resistance Test
Fuel Shut-Off Solenoid Linkage Adjustment
Rectangular Fuel Filter Operation
Round (Final) Fuel Filter Operation
Bleed the Fuel System
Diagnose In-Line Fuel Injection Pump Malfunctions
In-Line Fuel Injection Pump Operation
Check Fast Idle Speed-In-Line Fuel Injection Pump
Check and Adjust Slow Idle Speed-In-Line Fuel Injection Pump
Rotary Fuel Injection Pump Operation-Stanadyne DB4
Diagnose Engine Malfunction
Check and Adjust Engine Speeds on Rotary Pump-Stanadyne DB4
How the Aneroid Works (If Equipped)-In-Line Injection Pumps
Diagnose Aneroid Malfunction
How the Hydraulic Aneroid Activator Works (If Equipped)
Diagnose Malfunctions-Hydraulic Aneroid Activator
Fuel Injection Nozzles-General Information
Fuel Injection Nozzle Operation
Diagnose Malfunctions-Fuel Injection Nozzle
Test Fuel Injection Nozzles (Engine Running)
Fuel Drain Back Test Procedure
Instructions for Changing 6076 Gen Set Engine Rated Speed from 1800 RPM (60 Hz) to 1500 RPM (50 Hz)-Mechanical Governor
Change Engine Rated Speed from 1800 RPM to 1500 RPM and Adjust Droop
Section 199: Dealer Fabricated Tools
How to Make Tools
DFRG3-Cylinder Liner Holding Fixture