John Deere 6076 Natural GAS Engines workshop manual pdf

John Deere 6076 Natural Gas Engines Serial Number (500000— ) Deere Power Systems Group CTM82 (11JUN93) workshop manual

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components. This manual is divided in two parts: repair and operation and tests. Repair sections contain necessary instructions to repair the component. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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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
Oilscan® and Coolscan™ 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
Page
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 O-Ring Bore 10-34
Measure Cylinder Block 10-34
Page
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 O-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
Remove SAE 1 and SAE 2 Flywheel
Housing 15-20
Remove SAE 3 Flywheel Housing 15-21
Replace Flywheel Ring Gear . 15-21
Remove Rear Oil Seal Housing and
Wear
Sleeve (With Engine Disassembled) . 15-22
Remove Crankshaft Main Bearings . 15-23
Check Main Bearing Clearance . 15-24
Remove Crankshaft . 15-25
Remove and Inspect Crankshaft Gear . 15-26
Inspect Crankshaft 15-27
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals . 15-28
Main Bearing Cap Line Bore
Specifications 15-30
Crankshaft Grinding Guidelines 15-31
Thrust Bearing New Part Specifications 15-33
Crankshaft Grinding Specifications . 15-34
Replace Crankshaft Oil Pump Drive Gear . 15-35
Inspect Thrust Bearings 15-36
Remove and Clean Piston Cooling
Orifices 15-36
Install Main Bearings 15-37
Install Crankshaft Gear . 15-38
Install Crankshaft . 15-39
Install Crankshaft Rear Oil Seal Housing . 15-40
Check Oil Seal Housing Runout . 15-41
Crankshaft Rear Oil Seal And Wear
Sleeve Handling Precautions 15-42
Install Crankshaft Rear Oil Seal and
Wear Sleeve Assembly . 15-43
Install Timing Gear Cover . 15-44
Install SAE 3 Flywheel Housing . 15-45
Install Flywheel 15-46
Install SAE 1 and SAE 2 Flywheel
Housing 15-47
Install Damper Pulley Assembly . 15-48
Complete Final Assembly . 15-48
Group 16—Camshaft and Timing Gear Train
Special or Essential Tools 16-1
Other Material 16-3
Camshaft and Timing Gear Train
Specifications . 16-4
Check Valve Lift 16-5
Check Camshaft End Play 16-6
Measure Camshaft Drive
Gear-to-Crankshaft Gear Backlash . 16-6
Remove Timing Gear Cover 16-7
Remove Camshaft . 16-8
Page
Remove Camshaft Gear and Ignition
Timing Wheel 16-10
Measure Thrust Washer Thickness . 16-10
Inspect and Measure Camshaft Followers . 16-11
Visually Inspect Camshaft . 16-11
Measure Camshaft Journal OD and
Bushing ID 16-12
Measure Camshaft Lobe Lift . 16-12
Install Camshaft Gear and Ignition Timing
Wheel . 16-13
Service Camshaft Bushings using
JDG602 Adapter Set . 16-14
Service Camshaft Bushings using
JDG606 Adapter Set . 16-16
Install Camshaft 16-17
Install Thrust Washer and Timing Gear
Cover . 16-19
Complete Final Assembly . 16-20
Group 20—Lubrication System
Other Material 20-1
Lubrication System Specifications . 20-1
Drain Engine Oil and Remove Oil Pan 20-2
Oil Filter and Oil Conditioning Housing
Assembly 20-3
Remove Oil Filter and Oil Conditioning
Housing . 20-4
Remove, Inspect, and Install Valves from
Oil Conditioning Housing . 20-5
Install Oil Filter and Oil Conditioning
Housing . 20-6
Remove Engine Oil Cooler . 20-7
Clean, Inspect, and Install Engine Oil
Cooler 20-8
Engine Oil Pump Assembly—Deep and
Standard Sump . 20-9
Check Crankshaft Gear-To-Oil Pump
Drive Gear Backlash . 20-10
Remove Engine Oil Pump . 20-10
Inspect and Clean Oil Pump . 20-11
Check Drive Shaft End Play . 20-11
Check Drive Shaft Side Movement . 20-12
Check Pumping Gear Backlash . 20-12
Inspect Oil Pump Drive Gear . 20-13
Install Engine Oil Pump . 20-13
Install Oil Pan . 20-15
Group 25—Cooling System
Special or Essential Tools 25-1
Other Material 25-2
Cooling System Specifications . 25-3
Service Equipment and Tools 25-4
Remove Engine Water Pump 25-5
Disassemble Engine Water Pump . 25-6
Inspect Water Pump Parts 25-8
Assemble Engine Water Pump . 25-9
Install Engine Water Pump 25-11
Remove and Install Auxiliary Water Pump . 25-12
Inspect and Clean Aftercooler Orifice
Fitting . 25-13
Remove and Test Thermostats 25-13
Install Thermostats 25-14
Remove Water Manifold 25-15
Water Manifold Mounted Fixed Fan Drive
Assembly . 25-16
Install Water Manifold 25-17
Remove Coolant Heater 25-17
Install Coolant Heater 25-18
Complete Final Assembly . 25-19
Group 30—Air Intake And Exhaust System
Special or Essential Tools 30-1
Other Material 30-1
Air Intake and Exhaust System
Specifications . 30-1
Extending Turbocharger Life 30-3
Remove Turbocharger 30-6
Turbocharger Failure Analysis . 30-7
Turbocharger Seven-Step Inspection . 30-9
Perform Radial Bearing Clearance Test 30-13
Perform Axial Bearing End Play Test 30-14
Repair Turbocharger . 30-14
Prelube Turbocharger 30-15
Install Turbocharger . 30-16
Remove Aftercooler Assembly 30-17
Inspect and Repair Aftercooler 30-18
Inspect and Repair Intake Manifold and
Aftercooler Cover . 30-19
Assemble and Install Aftercooler
Assembly . 30-20
Remove, Inspect, and Install Exhaust
Manifold . 30-22
Group 35—Fuel System
Other Material 35-1
Fuel System Specifications . 35-1
Replace Natural Gas Filter . 35-2
Remove and Install 20 PSI Carburetor 35-3
Remove and Install 4 PSI Carburetor 35-4
Replace Diaphragm(s) in Carburetor . 35-5
Service Natural Gas Regulator . 35-6
Page
Group 40—Ignition System and Electronic
Governor
Special or Essential Tools 40-1
Other Materials . 40-2
Ignition System and Electronic Governor
Specifications . 40-2
Check Ignition Timing Indicator
Alignments . 40-3
Remove and Install Spark Plugs 40-4
Inspect, Clean, and Adjust Spark Plugs . 40-4
Remove and Install Ignition Timing
Sensor . 40-5
Remove and Install Ignition Sensor Plate 40-5
Remove and Install Manifold Absolute
Pressure Sensor . 40-6
Remove and Install Charge Air
Temperature Switch . 40-6
Remove and Install Ignition Coils . 40-7
Remove and Install Ignition Control Unit 40-7
Remove and Install Ignition System
Mounting Plate 40-8
Remove and Install Electronic Governor . 40-8
Remove and Install Throttle Actuator . 40-9
Remove and Install Electronic Governor
Speed Sensor . 40-10
Remove and Install Governor and Ignition
System Wiring Harness . 40-11
Replace Weather Pack™ Connector 40-12
Install Weather Pack™ Contact . 40-13
Group 100—Engine Tune-Up and Break-In
Altitude Compensation Guideline . 100-1
Preliminary Engine Testing 100-1
General Tune-Up Recommendations 100-2
Dynamometer Test 100-3
Engine Break-In Guidelines 100-3
Engine Break-In Instructions . 100-4
Check Crankcase Ventilation System 100-4
Check Air Intake System 100-5
Check Exhaust System . 100-5
Check and Service Cooling System . 100-6
Check Electrical System 100-8
Group 105—Engine System Operation and Test
Special or Essential Tools . 105-1
Engine Test Specifications . 105-2
Engine—Sectional View 105-4
General Engine Description 105-5
How the Lubrication System Works . 105-6
How the Cooling System Works 105-10
Head Gasket Joint Construction and
Operation . 105-14
Diagnosing Head Gasket Joint Failures . 105-16
Head Gasket Inspection and Repair
Sequence . 105-19
Test Engine Compression Pressure 105-21
Check Engine Oil Pressure . 105-22
Pressure Test Cooling System and
Radiator Cap . 105-23
Inspect Thermostat and Test Opening
Temperature . 105-24
Group 110—Air Intake System Operation and
Test
Special or Essential Tools . 110-1
Service Equipment and Tools . 110-1
Air Intake and Exhaust System Test
Specifications 110-1
How the Air Intake and Exhaust System
Works . 110-2
Air Cleaner Operation 110-2
Diagnosing Turbocharger Malfunctions . 110-3
How The Turbocharger Works 110-4
How The Turbocharger is Lubricated 110-4
How The Aftercooler Works 110-5
Check Intake Manifold Pressure . 110-6
Troubleshoot Charge Air Temperature
Switch (CATS) . 110-7
How the Pyrometer Shutdown Works . 110-8
Adjust Pyrometer Shutdown Temperature . 110-9
Group 115—Fuel System Operation and Test
Service Equipment and Tools . 115-1
Fuel System Test Specifications . 115-1
How the Fuel System Works . 115-2
Adjust Low Idle Speed . 115-6
Adjust Low Idle Fuel Mixture . 115-6
Adjust Air/Fuel Mixture . 115-7
Adjust Regulator Differential Gas
Pressure . 115-8
Group 120—Ignition System Operation and Test
Special or Essential Tools . 120-1
Service Equipment and Tools . 120-1
How the Ignition System Works . 120-2
Ignition Control Unit (ICU) Self-Diagnostic
Test 120-4
Troubleshoot Manifold Absolute Pressure
(MAP) Sensor . 120-5
Page
Troubleshoot Primary and Secondary
Ignition System . 120-6
Troubleshoot Ignition Timing and
Governor Speed Sensors 120-8
Adjust Overspeed Shutdown . 120-9
Adjust Ignition Timing . 120-10
How the Electronic Governor Works . 120-11
Troubleshoot Remote Speed
Potentiometer . 120-12
Troubleshoot Throttle Actuator . 120-13
Adjust Electronic Governor . 120-14
Wiring Diagrams
Instrument Panel/Engine 120-16
Reading a Wiring Diagram 120-17
Wiring Harness Connectors 120-18
Ignition System and Electronic
Governor 120-19
Primary Ignition System 120-20
Group 125—Engine Diagnostics
Diagnose Engine Malfunctions 125-1
Group 199—Dealer Fabricated Tools
How to Make Tools . 199-1
Cylinder Liner Holding Fixture 199-1
and more

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