Series 400 6076 Diesel Engines Serial Number (500000

T
C
D
Series 400
6076
Diesel Engines
Serial Number
(500000- )
COMPONENT TECHNICAL MANUAL
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Deere Power Systems Group
CTM42 (24MAR95)
LITHO IN U.S.A.
ENGLISH
C T M 4 2
2 4 M A R 9 5
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Introduction
FOREWORD
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.
N
This is the safety-alert symbol. When you see
this symbol on the machine or in this manual,
be alert to the potential for personal injury.
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.
DX,CTMIFC
CTM42 (24MAR95)
-19-22MAY92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=3
Dealer Presentation Sheet
JOHN DEERE DEALERS
IMPORTANT: The changes listed below make your
current CTM obsolete. Discard
CTM42, dated 02 NOV 92. Please
copy this page and route through
your service department.
• Recommendation against disassembly of the engine
oil pump added to Group 20.
• Instructions for installation of structural front
frame/oil sump on engines used in 8000 series
tractors added to Group 20.
• Engine application charts updated to include the
latest product models. See ENGINE APPLICATION
CHART in Group 01.
• Information and specifications for fan drive assembly
with press-fit fan spacer added to Group 25.
• Engine coolant information revised. See ENGINE
COOLANT RECOMMENDATIONS in Group 02.
• Torque specifications for turbocharger oil inlet line
added to Group 30.
• Recommendation to use ONLY JDG23 Lifting Sling
and Deere provided lifting straps for lifting engines.
Also recommend the use of SAE Grade 8 or higher
grade cap screws and Loctite 242 when installing
engine lifting straps added to Group 03.
• Information to help identify A-Series and P-Series
fuel injection pumps and fuel supply pumps added to
Group 35.
• New “TORQUE-TO-YIELD” instructions for tightening
cylinder head cap screws marked “SPECIAL” added
to Group 05.
• Valve lift specifications revised in Group 05 and
Group 16.
• Piston ring end gap specifications for new pistons
have been added to Group 10.
• A revised (longer) JDG681A Tap for cleaning
deeper tapped cylinder head cap screw holes in block
added to Group 10.
• Use of JDG796 Alignment Tool for installing
crankshaft rear oil seal housing added to Group 15.
• Detailed instructions for inspection of the vibration
damper and the crankshaft dowel pin added to Group
15.
• Timing gear cover and rear oil seal housing
replacement procedures for 6076HRW33, 34, and 35
Engines (equipped with structural front frame/oil
sump), with engine installed in vehicle added to
Group 15.
• Instructions for disassembly and assembly of the
fuel check valve deleted from Group 35. The check
valve has been replaced by a non-serviceable
assembly.
• In Group 100 — Engine Tune-Up and Break-In, the
paragraph titled ALTITUDE COMPENSATION
GUIDELINE changed to EFFECTS OF
TEMPERATURE AND ALTITUDE ON ENGINE
PERFORMANCE.
• In Group 105, the recommended temperatures and
engine speeds for checking engine oil pressure
revised. The procedure to pressure test the cooling
system and radiator cap also revised.
• Dynamic timing procedure using TIME TRAC®
timing kit to accurately check and adjust (rotary)
injection pump-to-engine timing added to Group 115.
• Instructions and specifications for check and
adjustment of the fuel shut-off solenoid added to
Group 115.
• Instructions for changing 6076 generator set
engines with mechanical governor from rated speed
of 1800 RPM (60 Hz) to 1500 RPM (50 Hz) added to
Group 115.
• Camshaft lobe lift specifications and valve lift
specifications revised in Group 16.
TIME TRAC® is a registered trademark of Stanadyne Automotive Corp.
CTM42 (24MAR95)
RG,CTM42,DPS
-19-21MAR95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=4
ABOUT THIS MANUAL
This component technical manual covers the
recommended repair procedure for 6076, 7.6 L (466
cu. in.) diesel engines produced in Waterloo, Iowa
beginning with Engine Serial No. (500000—
).
Before beginning repair of an engine, clean the
engine and mount on a repair stand. (See Group 03 Engine Mounting.)
Direction of engine crankshaft rotation in this manual
is referenced facing the flywheel looking toward the
fan. Front of engine is fan drive end.
Some components of this engine may be serviced
without removing the engine from the machine. Refer
to the specific machine technical manuals for
information on components that can be serviced
without removing the engine from the machine and
for engine removal and installation procedures.
Read each module completely before performing any
service.
RG,CTM42,G0,1 -19-14FEB95
CTM42 (24MAR95)
6076 Diesel Engines—S.N. (500000—
)
160101
PN=5
Contents
Page
Page
00
Group 00—Safety
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Group 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 . . . . . . . . . . .
Engine Application Chart . . . . . . . . . . .
. . . . 01-1
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Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . .
Lubricity of Diesel Fuels . . . . . . . . . . . . . .
Engine Break-In Oil . . . . . . . . . . . . . . . . .
Engine Oil . . . . . . . . . . . . . . . . . . . . . . .
Oilscan and Coolscan . . . . . . . . . . . . . . . .
Grease . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternative and Synthetic Lubricants . . . . . .
Engine Coolant Requirements . . . . . . . . . .
Recommended Engine Coolant . . . . . . . . . .
Engine Coolant Specifications . . . . . . . . . .
Replenish Supplemental Coolant
Additives Between Coolant Changes . . . .
Operating in Tropical Conditions . . . . . . . . .
Flush and Service Cooling System . . . . . . .
Disposing of Coolant . . . . . . . . . . . . . . . .
Group 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 . . . .
Group 04—Engine Rebuild Guide
6076 Engine Disassembly Sequence . . . . . . . 04-1
Sealant Application Guidelines . . . . . . . . . . . 04-2
6076 Engine Assembly Sequence . . . . . . . . . 04-4
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Group 05—Cylinder Head and Valves
Special or 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 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 . . . . . . . . . . . . . . . . . . . . . .
Install Valve Seat Inserts . . . . . . . . . . .
01-2
01-3
01-4
01-5
01-6
02-1
02-1
02-2
02-3
02-4
02-4
02-5
02-5
02-7
02-8
02-10
02-11
02-12
02-13
. . . . . . 03-1
. . . . . . 03-2
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03-2
03-3
03-4
03-4
03-5
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01
02
. 05-1
. 05-3
. 05-4
. 05-5
. 05-7
. 05-9
05-10
03
04
. . . 05-12
. . . 05-14
. . . 05-14
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05-15
05-16
05-17
05-17
05-18
05-18
05-19
05-19
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05-20
05-21
05-22
05-22
05-23
05-23
05-24
05-25
05
10
15
16
20
25
. . . 05-26
. . . 05-27
30
Continued on next page
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
35
CTM42-19-24MAR95
100
COPYRIGHT© 1995
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION™ Manual
Previous Editions
Copyright 1992, 1991 Deere & Company
CTM42 (24MAR95)
i
105
6076 Diesel Engines—S.N. (500000—
)
160101
PN=438
Contents
Page
Page
00
01
02
03
04
05
10
15
16
20
25
30
35
100
105
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-To-Yield Special 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 . . . . . . . . . . .
. . . 05-27
. . . 05-28
. . . 05-28
Inspect Piston Pins and Bushings . . . . . .
Remove Piston Pin Bushing . . . . . . . . . .
Clean and Inspect Piston Pin Bushing
Bore in Rod . . . . . . . . . . . . . . . . . . .
Install Piston Pin Bushing in Connecting
Rod . . . . . . . . . . . . . . . . . . . . . . . .
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 (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 . . . . . . . . . . .
. . . 05-29
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05-30
05-31
05-32
05-33
. . . 05-34
. . . 05-36
. . . 05-37
. . . 05-38
. . . 05-39
. . . 05-42
Group 10—Cylinder Block, Liners, Pistons and
Rods
Special or Essential Tools . . . . . . . . . . . . . . 10-1
Service Equipment and Tools . . . . . . . . . . . . 10-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 10-3
Cylinder Block, Liners, Pistons, and Rods
Specifications . . . . . . . . . . . . . . . . . . . . . 10-4
Preliminary Liner, Piston, and Rod
Checks . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Remove Pistons and Connecting Rods . . . . . 10-9
Measure Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 10-12
Remove Cylinder Liners . . . . . . . . . . . . . . 10-13
Deglazing Cylinder Liners . . . . . . . . . . . . . 10-14
Clean Cylinder Liners . . . . . . . . . . . . . . . . 10-15
Disassemble and Clean Piston . . . . . . . . . . 10-15
Visually Inspect Pistons . . . . . . . . . . . . . . . 10-16
Check Piston Ring Groove Wear . . . . . . . . 10-17
Measure Oil Control Ring Groove . . . . . . . . 10-18
Install Piston Pin in Piston Pin Bore . . . . . . 10-18
Visually Inspect Cylinder Liners . . . . . . . . . 10-19
Cylinder Liner Manufacturing Date Code
Explanation . . . . . . . . . . . . . . . . . . . . . 10-20
Measure Piston Skirt OD . . . . . . . . . . . . . . 10-21
Measure Cylinder Liner ID . . . . . . . . . . . . . 10-22
Measure Liner Flange Thickness . . . . . . . . 10-22
Inspect and Measure Connecting Rod
Bearings . . . . . . . . . . . . . . . . . . . . . . . 10-23
Inspect Rod and Cap . . . . . . . . . . . . . . . . 10-24
CTM42 (24MAR95)
. . 10-26
. . 10-27
. . 10-27
. . 10-28
. . 10-29
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10-29
10-30
10-32
10-32
. . 10-34
. . 10-35
. . 10-36
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10-37
10-38
10-40
10-43
. . 10-43
. . 10-44
Group 15—Crankshaft, Main Bearings and
Flywheel
Special or Essential Tools . . . . . . . . . . . . .
Service Equipment and Tools . . . . . . . . . . .
Other Material . . . . . . . . . . . . . . . . . . . . .
Crankshaft, Main Bearings, and Flywheel
Specifications . . . . . . . . . . . . . . . . . . . .
Failure Analysis . . . . . . . . . . . . . . . . . . . .
Remove Crankshaft Rear Oil Seal
Housing
(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 Front Oil Seal
(With Timing Gear Cover Installed on
Engine) . . . . . . . . . . . . . . . . . . . . . .
. 15-1
. 15-4
. 15-5
. 15-6
. 15-8
. 15-9
15-11
15-12
15-13
15-14
15-16
Continued on next page
ii
6076 Diesel Engines—S.N. (500000—
)
160101
PN=439
Contents
Page
Remove Front Wear Sleeve
(With Timing Gear Cover Installed or
Removed) . . . . . . . . . . . . . . . . . .
Install Front Wear Sleeve
(With Timing Gear Cover Installed) . .
Install Front Oil Seal
(With Timing Gear Cover Installed) . .
Replace Timing Gear Cover
(6076HRW33, 34, and 35 Engines)
—Engine Installed in Vehicle . . . . . . .
Remove Timing Gear Cover . . . . . . . .
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 . . . . . . . .
Replace Rear Oil Seal Housing
(6076HRW33, 34, and 35 Engines)
—Engines 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
Specifications . . . . . . . . . . . . . . . . .
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 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 . . . . . . . . . .
CTM42 (24MAR95)
Page
Install Front Wear Sleeve . . . . . . .
Install Front Oil Seal
(With Timing Gear Cover Installed)
Install Damper Pulley Assembly . . .
Install SAE 3 Flywheel Housing . . .
Install Flywheel . . . . . . . . . . . . . .
Install SAE 1 and SAE 2 Flywheel
Housing . . . . . . . . . . . . . . . . . .
Complete Final Assembly . . . . . . .
. . . 15-17
. . . 15-17
. . . 15-18
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15-19
15-20
15-20
15-21
15-21
15-22
15-22
. . . 15-25
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15-26
15-27
15-28
15-29
15-30
. . . 15-32
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15-33
15-34
15-36
15-37
15-38
15-39
15-40
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15-40
15-41
15-43
15-45
110
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15-49
15-49
15-50
15-51
115
. . . . . . 15-51
. . . . . . 15-52
199
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Group 16—Camshaft and Timing Gear Train
Special or Essential Tools . . . . . . . . . . . . . . 16-1
Service Equipment and Tools . . . . . . . . . . . . 16-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 16-3
Camshaft and Timing Gear Train
Specifications . . . . . . . . . . . . . . . . . . . . . 16-4
Check Valve Lift . . . . . . . . . . . . . . . . . . . . 16-6
Check Camshaft End Play . . . . . . . . . . . . . . 16-7
Remove Damper Pulley and Timing Gear
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Measure Camshaft Drive
Gear-to-Crankshaft Gear Backlash . . . . . . . 16-8
Remove Camshaft . . . . . . . . . . . . . . . . . . . 16-9
Remove Camshaft Gears . . . . . . . . . . . . . 16-11
Measure Thrust Washer Thickness . . . . . . . 16-11
Inspect and Measure Camshaft Followers . . . 16-12
Visually Inspect Camshaft . . . . . . . . . . . . . 16-12
Measure Camshaft Journal OD and
Bushing ID . . . . . . . . . . . . . . . . . . . . . . 16-13
Measure Camshaft Lobe Lift . . . . . . . . . . . 16-13
Install Camshaft Gears . . . . . . . . . . . . . . . 16-14
Service Camshaft Bushings using
JDG602 Adapter Set . . . . . . . . . . . . . . . 16-15
Service Camshaft Bushings using
JDG606 Adapter Set . . . . . . . . . . . . . . . 16-17
Install Camshaft . . . . . . . . . . . . . . . . . . . . 16-18
Install Thrust Washer and Timing Gear
Cover . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . . . 16-21
Complete Final Assembly . . . . . . . . . . . . . 16-22
. . . 15-23
. . . 15-23
. . . 15-24
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. . . . . . 15-48
Group 20—Lubrication System
Other Material . . . . . . . . . . . . . . . .
Lubrication System Specifications . . .
Drain Engine Oil and Remove Oil Pan
Oil Filter and Oil Conditioning Housing
Assembly . . . . . . . . . . . . . . . . . .
. . . 15-46
. . . 15-47
. . . 15-48
INDX
. . . . . . 20-1
. . . . . . 20-1
. . . . . . 20-2
. . . . . . 20-3
Continued on next page
iii
6076 Diesel Engines—S.N. (500000—
)
160101
PN=440
Contents
Page
110
115
199
INDX
Remove Oil Filter and Oil Conditioning
Housing . . . . . . . . . . . . . . . . . . . . .
Inspect and Replace Oil Filter Adapter . .
Remove, Inspect, and Install Valves from
Oil Conditioning Housing . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . .
Group 25—Cooling System
Special or 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 . . . . .
Water Manifold Mounted Fixed Fan Drive
Assembly . . . . . . . . . . . . . . . . . . . .
Replace Bearing in Injection Pump Drive
Gear Mounted Fan Drive . . . . . . . . .
Inspect and Check Belt Tensioner Spring
Tension . . . . . . . . . . . . . . . . . . . . .
Replace Belt Tensioner Assembly . . . . .
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 . . . . . . . . . . .
Install Water Manifold . . . . . . . . . . . . .
Remove Coolant Heater . . . . . . . . . . .
Install Coolant Heater . . . . . . . . . . . . .
Complete Final Assembly . . . . . . . . . .
CTM42 (24MAR95)
Page
Fan Belt Tension Specifications . . . . . . . . .
Group 30—Air Intake And Exhaust System
Special or Essential Tools . . . . . . . . . . . . .
Other Material . . . . . . . . . . . . . . . . . . . . .
Air Intake and Exhaust System
Specifications . . . . . . . . . . . . . . . . . . . .
Extending Turbocharger Life . . . . . . . . . . .
Remove Turbocharger . . . . . . . . . . . . . . .
Turbocharger Failure Analysis . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . .
Remove Vertically-Mounted Aftercooler
and Intake Manifold . . . . . . . . . . . . . . . .
Remove and Disassemble
Horizontally-Mounted Aftercooler
Assembly . . . . . . . . . . . . . . . . . . . . . . .
Inspect and Repair Aftercooler . . . . . . . . . .
Inspect and Repair Intake Manifold and
Cover . . . . . . . . . . . . . . . . . . . . . . . . .
Install Intake Manifold and
Vertically-Mounted Aftercooler . . . . . . . . .
Assemble and Install
Horizontally-Mounted Aftercooler
Assembly . . . . . . . . . . . . . . . . . . . . . . .
Remove, Inspect, and Install Exhaust
Manifold . . . . . . . . . . . . . . . . . . . . . . .
. . . . 20-4
. . . . 20-4
. . . . 20-5
. . . . 20-6
. . . . 20-7
. . . . 20-8
.
.
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.
.
.
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.
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.
.
.
.
.
.
.
. 20-9
. 20-9
20-10
20-11
20-11
20-12
20-12
20-13
20-14
. . . 20-15
.
.
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.
.
.
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.
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25-1
25-2
25-3
25-5
. . . . 25-6
. . . . 25-8
. . . 25-10
. . . 25-12
.
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.
.
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.
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25-13
25-14
25-14
25-15
25-18
25-19
25-21
25-22
25-23
25-23
25-24
25-24
25-25
25-26
Group 35—Fuel System
Special or Essential Tools . . . . . . . . . .
Other Material . . . . . . . . . . . . . . . . . .
Diesel Fuel System Specifications . . . . .
Relieve Fuel System Pressure . . . . . . .
Replace Rectangular Fuel Filter Element
Replace Fuel Check Valve . . . . . . . . .
Remove Round Fuel Filter Element . . . .
Identification of fuel supply and fuel
injection pumps . . . . . . . . . . . . . . .
Remove Mechanical Fuel Supply Pump .
.
.
.
.
.
.
.
.
.
.
.
.
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.
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.
.
.
.
.
.
25-26
. 30-1
. 30-2
. 30-2
. 30-4
. 30-6
. 30-8
30-10
30-15
30-16
30-16
30-17
30-18
30-19
30-20
30-20
30-22
30-23
30-25
30-26
30-26
30-27
30-29
30-31
.
.
.
.
.
.
.
35-1
35-4
35-4
35-6
35-6
35-7
35-8
. . . . 35-9
. . . 35-10
Continued on next page
iv
6076 Diesel Engines—S.N. (500000—
)
160101
PN=441
Contents
Page
Test Mechanical Fuel Supply Pump for
Leaks . . . . . . . . . . . . . . . . . . . . . . .
Disassemble Mechanical Fuel Supply
Pump (Nippondenso) . . . . . . . . . . . . .
Inspect and Repair Mechanical Fuel
Supply Pump (Nippondenso) . . . . . . . .
Assemble Mechanical Fuel Supply Pump
(Nippondenso) . . . . . . . . . . . . . . . . .
Disassemble Mechanical Fuel Supply
Pump (Robert Bosch) . . . . . . . . . . . .
Inspect and Repair Mechanical Fuel
Supply Pump (Robert Bosch) . . . . . . .
Assemble Mechanical Fuel Supply Pump
(Robert Bosch) . . . . . . . . . . . . . . . . .
Install Mechanical Fuel Supply Pump . . .
Remove and Install Electric Fuel Supply
Pump . . . . . . . . . . . . . . . . . . . . . . .
Clean or Replace Electric Fuel Supply
Pump Filter Screen . . . . . . . . . . . . . .
Repair Aneroid . . . . . . . . . . . . . . . . . .
Remove Hydraulic Aneroid Activator . . . .
Disassemble and Clean Hydraulic
Aneroid Activator Parts . . . . . . . . . . .
Assemble and Install Hydraulic Aneroid
Activator . . . . . . . . . . . . . . . . . . . . .
Service Injection Pump Overflow Valve . .
Remove and Install Fuel Shutoff Solenoid .
Identification of In-Line 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 Injection Nozzle 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 Injection Nozzles . . . . . . . . . . . .
CTM42 (24MAR95)
Page
Inspect and Clean Cylinder Head Nozzle
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 35-58
Inspect and Clean Nozzle Seating
Surface . . . . . . . . . . . . . . . . . . . . . . . . 35-59
Install Fuel Injection Nozzles . . . . . . . . . . . 35-59
. . 35-11
. . 35-12
. . 35-14
Group 100—Engine Tune-Up and Break-In
Effects of Altitude and Temperature on
Engine Performance . . . . . . . . . . . . . . . 100-1
Preliminary Engine Testing . . . . . . . . . . . . 100-2
General Tune-Up Recommendations . . . . . . 100-3
Dynamometer Test . . . . . . . . . . . . . . . . . . 100-4
Engine Break-In Guidelines . . . . . . . . . . . . 100-5
Perform Engine Break-In . . . . . . . . . . . . . . 100-6
Check Crankcase Ventilation System . . . . . . 100-7
Check Air Intake System . . . . . . . . . . . . . . 100-7
Check Exhaust System . . . . . . . . . . . . . . . 100-8
Check and Service Cooling System . . . . . . . 100-8
Check Electrical System . . . . . . . . . . . . . 100-10
. . 35-15
. . 35-16
. . 35-17
. . 35-18
. . 35-18
. . 35-19
. . 35-20
. . 35-21
. . 35-21
Group 105—Engine System Operation and Test
Special or Essential Tools . . . . . . . . . . . . . 105-1
Engine Test Specifications . . . . . . . . . . . . . 105-3
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 . . . . . . . . . . . . . . . . . . . . . 105-12
Diagnosing Head Gasket Joint Failures . . . 105-14
Head Gasket Inspection and Repair
Sequence **M:CTM42,G105,18 -19- . . . . 105-17
Diagnosing Engine Malfunctions . . . . . . . . 105-18
Test Engine Compression Pressure . . . . . . 105-21
Check Engine Oil Pressure . . . . . . . . . . . 105-22
Inspect Thermostat and Test Opening
Temperature . . . . . . . . . . . . . . . . . . . 105-24
. . 35-22
.
.
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35-22
35-22
35-24
35-25
35-26
35-29
. . 35-33
.
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35-34
35-37
35-40
35-42
35-43
35-44
35-45
35-46
35-47
.
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.
35-49
35-50
35-50
35-51
35-53
35-54
35-57
Group 110—Air Intake System Operation and
Test
Special or Essential Tools . . . . . . . . . . . . . 110-1
Air Intake and Exhaust System Test
Specifications . . . . . . . . . . . . . . . . . . . . 110-2
Diagnosing Air Intake Malfunctions . . . . . . . 110-3
How the Air Intake and Exhaust System
Works . . . . . . . . . . . . . . . . . . . . . . . . . 110-4
Air Cleaner Operation . . . . . . . . . . . . . . . . 110-4
Diagnosing Turbocharger Malfunctions . . . . . 110-6
How The Turbocharger Works . . . . . . . . . . 110-7
How The Turbocharger is Lubricated . . . . . . 110-7
Continued on next page
v
6076 Diesel Engines—S.N. (500000—
)
160101
PN=442
Contents
Page
Page
How the Hydraulic Aneroid Activator
Works . . . . . . . . . . . . . . . . . . . .
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 . . . .
How The Aftercooler Works—6076A
Engines . . . . . . . . . . . . . . . . . . . . . . . . 110-8
Check Intake Manifold Pressure
(Turbocharger Boost) . . . . . . . . . . . . . . . 110-9
Group 115—Fuel System Operation and Test
Special or Essential Tools . . . . . . . . . . . . . 115-1
Fuel System Test Specifications . . . . . . . . . 115-2
Check and Adjust Rotary fuel pump
Dynamic Timing . . . . . . . . . . . . . . . . . . 115-2
Fuel System Operation—In-Line Fuel
Injection Pump . . . . . . . . . . . . . . . . . . 115-10
Fuel System Operation—Rotary Fuel
Injection Pump . . . . . . . . . . . . . . . . . . 115-11
Diagnose Fuel System Malfunctions . . . . . 115-12
Mechanical Fuel Supply Pump Operation
Operation . . . . . . . . . . . . . . . . . . . . . 115-16
Diagnosing Mechanical Fuel Supply
Pump Malfunctions . . . . . . . . . . . . . . . 115-18
Test Mechanical Fuel Supply Pump for
Leaks . . . . . . . . . . . . . . . . . . . . . . . . 115-19
Check Mechanical Fuel Supply Pump
Operation . . . . . . . . . . . . . . . . . . . . . 115-20
Service Mechanical Fuel Supply Pump . . . 115-22
Electric Fuel Supply Pump Operation . . . . 115-23
Diagnose Electric Fuel Supply Pump
Malfunction . . . . . . . . . . . . . . . . . . . . 115-24
Test Electric Fuel Supply Pump Output
Pressure and Flow . . . . . . . . . . . . . . . 115-25
Fuel Shut-Off Solenoid Resistance Test . . . 115-27
Rectangular Fuel Filter Operation . . . . . . . 115-28
Round (Final) Fuel Filter Operation . . . . . . 115-28
Bleed the Fuel System . . . . . . . . . . . . . . 115-29
Diagnose In-Line Fuel Injection Pump
Malfunctions . . . . . . . . . . . . . . . . . . . . 115-32
In-Line Fuel Injection Pump Operation . . . . 115-33
Check Fast Idle Speed—In-Line Fuel
Injection Pump . . . . . . . . . . . . . . . . . . 115-34
Check and Adjust Engine Slow Idle
Speed—In-Line Fuel Injection Pump . . . . 115-35
Rotary Fuel Injection Pump
Operation—Stanadyne DB4 . . . . . . . . . 115-38
Diagnose Rotary Fuel Injection Pump
Malfunctions . . . . . . . . . . . . . . . . . . . . 115-40
Check and Adjust Engine Speeds on
Rotary Pump . . . . . . . . . . . . . . . . . . . 115-41
How the Aneroid Works—In-Line Injection
Pumps . . . . . . . . . . . . . . . . . . . . . . . 115-42
Diagnose Aneroid Malfunctions . . . . . . . . . 115-43
CTM42 (24MAR95)
. . . . 115-44
. . . . 115-45
. . . . 115-46
. . . . 115-47
. . . . 115-48
. . . . 115-49
. . . . 115-49
Group 199—Dealer Fabricated Tools
How to Make Tools . . . . . . . . . . . . . . . . . 199-1
Cylinder Liner Holding Fixture . . . . . . . . . . 199-1
Index
vi
6076 Diesel Engines—S.N. (500000—
)
160101
PN=443
Group 00
Safety
HANDLE FLUIDS SAFELY—AVOID FIRES
00
1
-UN-23AUG88
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
TS227
Do not store oily rags; they can ignite and burn
spontaneously.
DX,FLAME
-19-04JUN90
DX,SPARKS
-19-03MAR93
DX,FIRE2
-19-03MAR93
PREVENT BATTERY EXPLOSIONS
-UN-23AUG88
Keep sparks, lighted matches, and open flame away
from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
TS204
Do not charge a frozen battery; it may explode. Warm
battery to 16˚C (60˚F).
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
-UN-23AUG88
Keep a first aid kit and fire extinguisher handy.
TS291
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
CTM42 (24MAR95)
00-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=6
Safety/Safety
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
-UN-23AUG88
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 2 L (2 quarts).
3. Get medical attention immediately.
TS203
00
2
DX,POISON
CTM42 (24MAR95)
00-2
-19-21APR93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=7
Safety/Safety
AVOID HIGH-PRESSURE FLUIDS
00
3
-UN-23AUG88
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere & Company Medical Department in
Moline, Illinois, U.S.A.
DX,FLUID
-19-03MAR93
DX,WEAR
-19-10SEP90
WEAR PROTECTIVE CLOTHING
-UN-23AUG88
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
TS206
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
CTM42 (24MAR95)
00-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=8
Safety/Safety
SERVICE MACHINES SAFELY
-UN-23AUG88
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
TS228
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
DX,LOOSE
-19-04JUN90
DX,AIR
-19-04JUN90
DX,CLEAN
-19-04JUN90
WORK IN VENTILATED AREA
-UN-23AUG88
Engine exhaust fumes can cause sickness or death. If it
is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
exhaust pipe extension.
TS220
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
WORK IN CLEAN AREA
-UN-18OCT88
Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
00
4
CTM42 (24MAR95)
00-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=9
Safety/Safety
REMOVE PAINT BEFORE WELDING OR
HEATING
00
5
-UN-23AUG88
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
TS220
Do all work outside or in a well ventilated area. Dispose
of paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT
-19-03MAR93
DX,TORCH
-19-03MAR93
DX,LIGHT
-19-04JUN90
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
TS953
-UN-15MAY90
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
ILLUMINATE WORK AREA SAFELY
TS223
-UN-23AUG88
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
CTM42 (24MAR95)
00-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=10
Safety/Safety
USE PROPER LIFTING EQUIPMENT
-UN-23AUG88
Lifting heavy components incorrectly can cause severe
injury or machine damage.
TS226
Follow recommended procedure for removal and
installation of components in the manual.
DX,LIFT
-19-04JUN90
DX,SERV
-19-03MAR93
PRACTICE SAFE MAINTENANCE
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow
machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
-UN-23AUG88
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on
machine.
TS218
00
6
CTM42 (24MAR95)
00-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=11
Safety/Safety
USE PROPER TOOLS
00
7
-UN-08NOV89
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
TS779
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere
specifications.
DX,REPAIR
-19-04JUN90
DX,DRAIN
-19-03MAR93
DISPOSE OF WASTE PROPERLY
-UN-26NOV90
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil,
fuel, coolant, brake fluid, filters, and batteries.
TS1133
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
CTM42 (24MAR95)
00-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=12
Safety/Safety
LIVE WITH SAFETY
-19-07OCT88
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
TS231
00
8
DX,LIVE
CTM42 (24MAR95)
00-8
-19-25SEP92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=13
Group 01
General Information
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
TS1162
-19-04MAR91
01
1
Grade 2b
Grade 1
Size
Lubricateda
Drya
Lubricateda
Grade 5, 5.1, or 5.2
Drya
Lubricateda
Grade 8 or 8.2
Drya
Lubricateda
Drya
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
1/4
5/16
3/8
3.7
7.7
14
2.8
5.5
10
4.7
10
17
3.5
7
13
6
12
22
4.5
9
16
7.5
15
27
5.5
11
20
9.5
20
35
7
15
26
12
25
44
9
18
33
13.5
28
50
10
21
36
17
35
63
12.5
26
46
7/16
1/2
9/16
22
33
48
16
25
36
28
42
60
20
31
45
35
53
75
26
39
56
44
67
95
32
50
70
55
85
125
41
63
90
70
110
155
52
80
115
80
120
175
58
90
130
100
150
225
75
115
160
5/8
3/4
7/8
67
120
190
50
87
140
85
150
240
62
110
175
105
190
190
78
140
140
135
240
240
100
175
175
170
300
490
125
225
360
215
375
625
160
280
450
240
425
700
175
310
500
300
550
875
225
400
650
1
1-1/8
1-1/4
290
400
570
210
300
425
360
510
725
270
375
530
290
400
570
210
300
425
360
510
725
270
375
530
725
900
1300
540
675
950
925
1150
1650
675
850
1200
1050
1450
2050
750
1075
1500
1300
1850
2600
975
1350
1950
1-3/8
1-1/2
750
1000
550
725
950
1250
700
925
750
990
550
725
950
1250
700
930
1700
2250
1250
1650
2150
2850
1550
2100
2700
3600
2000
2650
3400
4550
2550
3350
DO NOT use these values if a different torque value
or tightening procedure is given for a specific
application. Torque values listed are for general use
only. Check tightness of fasteners periodically.
Fasteners should be replaced with the same or
higher grade. If higher grade fasteners are used,
these should only be tightened to the strength of the
original.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Make sure fasteners threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
a
“Lubricated” means coated with a lubricant such as engine oil, or
fasteners with phosphate and oil coatings. “Dry” means plain or zinc
plated without any lubrication.
Tighten plastic insert or crimped steel-type lock nuts
to approximately 50 percent of the dry torque shown
in the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
b
Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm
(6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws of any length.
CTM42 (24MAR95)
01-1
DX,TORQ1
-19-20JUL94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=14
General Information/Metric Bolt and Cap Screw Torque Values
METRIC BOLT AND CAP SCREW TORQUE VALUES
TS1163
-19-04MAR91
01
2
Class 4.8
Size
Lubricateda
Class 8.8 or 9.8
Drya
Lubricateda
Class 10.9
Drya
Lubricateda
Class 12.9
Drya
Lubricateda
Drya
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
N·m
lb-ft
M6
M8
M10
4.8
12
23
3.5
8.5
17
6
15
29
4.5
11
21
9
22
43
6.5
16
32
11
28
55
8.5
20
40
13
32
63
9.5
24
47
17
40
80
12
30
60
15
37
75
11.5
28
55
19
47
95
14.5
35
70
M12
M14
M16
40
63
100
29
47
73
50
80
125
37
60
92
75
120
190
55
88
140
95
150
240
70
110
175
110
175
275
80
130
200
140
225
350
105
165
255
130
205
320
95
150
240
165
260
400
120
190
300
M18
M20
M22
135
190
260
100
140
190
175
240
330
125
180
250
260
375
510
195
275
375
330
475
650
250
350
475
375
530
725
275
400
540
475
675
925
350
500
675
440
625
850
325
460
625
560
800
1075
410
580
800
M24
M27
M30
330
490
675
250
360
490
425
625
850
310
450
625
650
950
1300
475
700
950
825
1200
1650
600
875
1200
925
1350
1850
675
1000
1350
1150
1700
2300
850
1250
1700
1075
1600
2150
800
1150
1600
1350
2000
2700
1000
1500
2000
M33
M36
900
1150
675
850
1150
1450
850
1075
1750
2250
1300
1650
2200
2850
1650
2100
2500
3200
1850
2350
3150
4050
2350
3000
2900
3750
2150
2750
3700
4750
2750
3500
DO NOT use these values if a different torque value
or tightening procedure is given for a specific
application. Torque values listed are for general use
only. Check tightness of fasteners periodically.
Make sure fasteners threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts
to approximately 50 percent of the dry torque shown
in the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical
property class.
Fasteners should be replaced with the same or
higher property class. If higher property class
fasteners are used, these should only be tightened to
the strength of the original.
a
“Lubricated” means coated with a lubricant such as engine oil, or
fasteners with phosphate and oil coatings. “Dry” means plain or zinc
plated without any lubrication.
CTM42 (24MAR95)
01-2
DX,TORQ2
-19-20JUL94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=15
General Information/Engine Model Designation
ENGINE MODEL DESIGNATION
JOHN DEERE ENGINE MODEL—6076
John Deere engine model designation includes number
of cylinders, displacement in liters, aspiration, user code,
and application code. For example:
01
3
6076HH030 Engine
6 .....
076 . . .
H .
H
...
...
...
...
030
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Number of cylinders
. Liter displacement
. . . Aspiration code
. . . . End user code
. . Application code
Aspiration Code
A . . . . . . . . . . . . . . . . . Turbocharged and air-to-coolant aftercooled
H . . . . . . . . . . . . . . . . . . . . Turbocharged and air-to-air aftercooled
T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
End User Code
DW
F .
H .
N .
RW
T .
Z .
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.
. . Davenport
. . . . . OEM
. . Harvester
Des Moines
. . . . Tractor
. . Dubuque
Zweibrucken
Application Code
30, 31, etc.
RG,CTM42,G1,1 -19-14FEB95
CTM42 (24MAR95)
01-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=16
General Information/Engine Serial Number Plate Information
ENGINE SERIAL NUMBER PLATE
INFORMATION
-UN-12AUG91
• Engine Serial Number (A)
RG5804
01
4
IMPORTANT: The engine serial number plate can be
easily destroyed. Remove the plate or
record the information elsewhere,
before “hot tank” cleaning the block.
Each engine has a 13-digit John Deere engine serial
number identifying the producing factory, engine model
designation, and a 6-digit sequential number. The
following is an example:
RG6076H000000
RG . . . . . . . . . . . . . . Factory code producing engine
6076H . . . . . . . . . . Engine Model Designation
000000 . . . . . Sequential Number
Factory Code Producing Engine
RG . . . . . . . . Waterloo Engine Works
Engine Model Designation
6076H . . . . . . Definition explained previously. (See
ENGINE MODEL DESIGNATION.)
Sequential Number
000000
. . . . . 6-digit sequential number.
The engine serial number plate is located either on the
right-hand side of engine between the oil conditioning
housing and fuel injection pump (viewed from flywheel
end) or on the left-hand side of the block directly above
the starting motor.
• Engine Application Data (B)
The second line of information on the engine serial
number plate identifies the engine/Deere machine or
OEM relationship. See ENGINE APPLICATION CHART
later in this group.
RG,CTM42,G1,2 -19-14FEB95
CTM42 (24MAR95)
01-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=17
General Information/Engine Application Chart
ENGINE APPLICATION CHART
John Deere Agricultural Equipment Applications
Machine Model No.
Engine Model
01
5
COMBINES—HARVESTER WORKS
CTS Rice
2056 . .
2058 . .
2064 . .
2066 . .
9500* .
9600* .
Combine*
.......
.......
.......
.......
.......
.......
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6076HH030
6076AZ031
6076AZ030
6076AZ030
6076HZ031
6076HH031, 6076HH032
6076HH030, 6076HH031
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6076AZ031
6076AZ030
6076AZ030
6076HZ031
COMBINES—ZWEIBRUCKEN
2056
2058
2064
2066
Hillmaster
Hillmaster
Hillmaster
Hillmaster
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FORAGE HARVESTERS—ZWEIBRUCKEN
6610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HZ030
COTTON PICKER—DES MOINES
9960** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AN030
9965 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6067AN031
TRACTORS—WATERLOO
7700
7800
8100
8200
8300
8560
8570
............
............
............
............
............
4-Wheel Drive***
4-Wheel Drive . .
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* Beginning with combine serial number (645000—
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6076TRW31
6076TRW30
6076HRW33
6076HRW34
6076HRW35
6076HRW30
6076HRW32
)
** Above P.I.N. 4001
*** Beginning with tractor serial number (5000—
CTM42 (24MAR95)
)
RG,CTM42,G1,3 -19-16AUG94
01-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=18
General Information/Engine Application Chart
ENGINE APPLICATION CHART—CONTINUED
John Deere Industrial Equipment Applications
Machine Model No.
01
6
Engine Model
LOADERS—DUBUQUE
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076ADW30
644GH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076ADW32
644G Dual Power . . . . . . . . . . . . . . . . . . . . . . . . 6076ADW33
MOTOR GRADERS—DUBUQUE
770B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076TDW30
770BH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076ADW31
772BH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076ADW31
EXCAVATORS—DUBUQUE
892E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AT030
BULLDOZERS—DUBUQUE
850C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AT032
RG,CTM42,G1,3B -19-16AUG94
OEM APPLICATIONS
Machine Model No.
Engine Model
Marine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AFM030
OEM Repower . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AF030
6076HF030
6076TF030
RG,CTM42,G1,3A -19-16AUG94
CTM42 (24MAR95)
01-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=19
Group 02
Fuels, Lubricants, and Coolant
DIESEL FUEL
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
• Sulfur Content
— Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
— If diesel fuel with sulfur content greater than 0.5%
is used, reduce the service interval for engine oil and
filter changes by 50%.
— DO NOT use diesel fuel with sulfur content greater
than 1.0%.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
02
1
Bio-diesel fuels meeting DIN 51606 or equivalent
specification may be used.
In all cases, the fuel must meet the following
properties:
• Cetane Number 40 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20˚ C (-4˚ F) or elevations
above 1500 m (5000 ft).
• Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5˚ C (9˚ F) below the expected low temperature.
RG,FUEL1
-19-22FEB95
LUBRICITY OF DIESEL FUELS
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components.
Diesel fuels for highway use in the United States now
require sulfur content less than 0.05%. Diesel fuel in
the European Union will require sulfur content less
than 0.05% by 1 October 1996.
Experience shows that some low sulfur diesel fuels
may have inadequate lubricity and their use may
reduce performance in fuel injection systems due to
inadequate lubrication of injector components. The
lower concentration of aromatic compounds in these
fuels also adversely affects injection pump seals and
may result in leaks.
Fuel lubricity should pass a minimum of 3300 gram
load level as measured by the BOCLE scuffing test.
ASTM D975 and EN 590 specifications do not require
fuels to pass a fuel lubricity test. Diesel fuels meeting
U.S. Military Specification VV—F—800E pass a fuel
lubricity test.
If fuel of low or unknown lubricity is used, add John
Deere ALL-SEASON DIESEL FUEL CONDITIONER
or equivalent at the specified concentration.
Use of low lubricity diesel fuels may also cause
accelerated wear, injection nozzle erosion or
corrosion, engine speed instability, hard starting, low
power, and engine smoke.
RG,FUEL5
CTM42 (24MAR95)
02-1
-19-22FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=20
Fuels, Lubricants, and Coolant/Engine Break-In Oil
ENGINE BREAK-IN OIL
New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL. During the break-in period,
add John Deere ENGINE BREAK-IN OIL as needed
to maintain the specified oil level.
02
2
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
IMPORTANT: Do not use John Deere PLUS-50 oil
or engine oils meeting API CG4,
API CF4, or CCMC D5 performance
levels during the first 100 hours of
operation of a new or rebuilt engine.
These oils will not allow the engine
to break-in properly.
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not
available, use a diesel engine oil meeting one of the
following during the first 100 hours of operation:
• API Service Classification CE
• CCMC Specification D4
After the break-in period, use John Deere PLUS-50®
or other diesel engine oil as recommended in this
manual.
DX,ENOIL4
CTM42 (24MAR95)
02-2
-19-17OCT94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=21
Fuels, Lubricants, and Coolant/Engine Oil
DIESEL ENGINE OIL
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oil is preferred.
• John Deere PLUS-50®
02
3
If John Deere PLUS-50 engine oil and a John Deere oil
filter are used, the service interval for oil and filter
changes may be extended by 50 hours.
The following oil is also recommended:
• John Deere TORQ-GARD SUPREME®
John Deere UNI-GARD™
API Service Classification CG-4
API Service Classification CF-4
API Service Classification CE
CCMC Specification D5 and Mercedes Benz MB228.3
CCMC Specification D4 and Mercedes Benz MB228.1
TS1619
•
•
•
•
•
•
-UN-12SEP94
Other oils may be used if they meet one or more of the
following:
Viscosity grade SAE 15W-40 is preferred.
If diesel fuel with sulfur content greater than 0.5% is
used, reduce the service interval by 50%.
DX,ENOIL
CTM42 (24MAR95)
02-3
-19-16SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=22
Fuels, Lubricants, and Coolant/Grease
OILSCAN® AND COOLSCAN™
T6828AB
Oil and coolant samples should be taken from each
system prior to its recommended change interval.
T6829AB
-UN-18OCT88
Check with your John Deere dealer for the availability of
OILSCAN and COOLSCAN kits.
DX,OILSCAN
-19-16APR92
DX,GREA1
-19-02NOV94
GREASE
Use grease based on the expected air temperature
range during the service interval.
The following greases are preferred:
• John Deere MOLY HIGH TEMPERATURE EP
GREASE
• John Deere HIGH TEMPERATURE EP GREASE
• John Deere GREASE-GARD™
Other greases may be used if they meet one of the
following:
• SAE Multipurpose EP Grease with a maximum of
5% molybdenum disulfide
• SAE Multipurpose EP Grease
-UN-02NOV94
Greases meeting Military Specification MIL-G-10924F
may be used as arctic grease.
TS1622
02
4
-UN-15JUN89
OILSCAN and COOLSCAN are John Deere sampling
programs to help you monitor machine performance and
identify potential problems before they cause serious
damage.
CTM42 (24MAR95)
02-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=23
Fuels, Lubricants, and Coolant/Engine Coolant Requirements
ALTERNATIVE AND SYNTHETIC LUBRICANTS
Conditions in certain geographical areas may require
lubricant recommendations different from those
printed in this manual. Some John Deere lubricants
may not be available in your location. Consult your
John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements listed in this manual.
02
5
DX,ALTER
-19-01FEB94
RG6258
-UN-22APR92
ENGINE COOLANT REQUIREMENTS
A—Quality Water
B—Ethylene Glycol Concentrate
(Antifreeze)
C—Supplemental Coolant Additives
(SCA’s)
Engine Coolant
IMPORTANT: Supplemental coolant additives
MUST be added to the coolant
solution. Ethylene glycol concentrate
(antifreeze) DOES NOT contain
chemical inhibitors needed to
control liner pitting or erosion, rust,
scale, and acidity.
To meet cooling system protection requirements, the
coolant MUST consist of a 50/50 mixture of quality
water and ethylene glycol concentrate (antifreeze).
Supplemental coolant additives (SCA’s) must be
added to this mixture. Add 3% (by volume) TY16004
or TY16005 Liquid Coolant Conditioner. If an
equivalent product is used, always follow the
supplier’s recommendations printed on the container.
See ENGINE COOLANT SPECIFICATIONS, later in
this section, for further definition.
Makeup of the coolant between changes MUST
consist of the same requirements as during a
complete change. Performing a CoolScan analysis is
the recommended method for determining the amount
of quality water, ethylene glycol concentrate, and
supplemental coolant additives that should be added.
RG,COOL1
CTM42 (24MAR95)
02-5
-19-10OCT94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=24
Fuels, Lubricants, and Coolant/Engine Coolant Requirements
ENGINE COOLANT REQUIREMENTS—CONTINUED
RG6263
-UN-22APR92
02
6
A—Cylinder Liner Walls
B—Engine Coolant
Coolant solutions of ethylene glycol concentrate
(antifreeze), quality water, and supplemental coolant
additives (SCA’s) MUST be used year-round to
protect against freezing, boil-over, liner erosion or
pitting, and to provide a stable, non-corrosive
environment for seals, hoses, and metal engine parts.
Water pump impellers and cylinder liner walls (A)
which are in contact with engine coolant (B) can be
eroded or pitted unless the proper concentration and
type of SCA’s are present in the coolant solution.
Vapor bubbles (C) are formed when piston impacts
against liner ID causing walls to vibrate; sending
compression waves into the coolant.
C—Vapor Bubbles
Erosion or pitting is caused by the formation and
collapse of tiny vapor bubbles in the coolant on the
surface of metal parts. Over a period of time, this
pitting will progress completely through the metal.
Generally, the most critical erosion occurs in the
cylinder liner area of wet-sleeve, heavy-duty engines.
If coolant is allowed to enter the combustion
chamber, engine failure or other serious damage will
result.
Use of SCA’s will reduce the effects of erosion and
pitting. The chemicals in the additives form a
protective film on cylinder liner surface. This film acts
as a barrier against collapsing vapor bubbles and
also reduces the quantity of bubbles formed.
RG,COOL1A
CTM42 (24MAR95)
02-6
-19-10OCT94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=25
Fuels, Lubricants, and Coolant/Recommended Engine Coolant
RECOMMENDED ENGINE COOLANT
Solutions of antifreeze and supplemental coolant
additives MUST be used year-round for freeze
protection, boil-over protection, and to provide a
stable, non-corrosive environment for seals, hoses
and metal engine parts.
John Deere Prediluted Antifreeze/Summer Coolant is
preferred. John Deere Antifreeze/Summer Coolant
Concentrate and John Deere COOL-GARD™, where
available, are also recommended.
Refer to your vehicle operator’s manual for the
service life of these products.
• JOHN DEERE PREDILUTED
ANTIFREEZE/SUMMER COOLANT
This product contains all the necessary ingredients
that make up the proper coolant solution: chemically
pure water, ethylene glycol (low silicate antifreeze),
and supplemental coolant additives (SCA’s). It is
ready to use; no mixing is required.
John Deere Prediluted Antifreeze/Summer Coolant
permits extended service life.
• JOHN DEERE ANTIFREEZE/SUMMER COOLANT
CONCENTRATE
This product contains ethylene glycol (low silicate
antifreeze) and supplemental coolant additives
(SCA’s). It must be mixed with quality water, as
described later in this section, before adding to the
engine cooling system. The proportion of water to be
used depends upon the lowest freeze protection
temperature desired according to the following table:
% CONCENTRATE
40
50
60
FREEZE PROTECTION LIMIT
-24˚ C (-12˚ F)
-37˚ C (-34˚ F)
-52˚ C (-62˚ F)
• JOHN DEERE COOL-GARD™
In certain geographical areas, John Deere
COOL-GARD is marketed for use in the engine
cooling system. This product contains all the
necessary ingredients that make up the proper
coolant solution: chemically pure water, ethylene
glycol (low silicate antifreeze), and supplemental
coolant additives (SCA’s). It is ready to add to cooling
system as is; no mixing or supplemental coolant
additives required. Contact your John Deere Parts
Network for local availability.
RG,COOL2,CTM
CTM42 (24MAR95)
02
7
02-7
-19-23FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=26
Fuels, Lubricants, and Coolant/Engine Coolant Specifications
ENGINE COOLANT SPECIFICATIONS
Contact your authorized servicing dealer or engine
distributor to determine what the cooling system of
this engine is filled with and the winter freeze
protection level.
02
8
If John Deere coolant products are not used, other
low silicate ethylene glycol base coolants for
heavy-duty diesel engines may be used when mixed
with quality water and supplemental coolant additives
(SCA’s), if they meet one of the following
specifications:
• ASTM D5345 (prediluted coolant)
• ASTM D4985 (coolant concentrate) in a 40 to 60%
mixture of concentrate with quality water.
Coolants meeting these specifications require addition
of supplemental coolant additives (SCA’s), formulated
for heavy-duty diesel engines, for protection against
corrosion and cylinder liner erosion and pitting.
Water Quality:
Distilled, de-ionized, or demineralized water is
preferred for use in cooling systems. Mineral
(hard/tap) water should NEVER be put in a cooling
system unless first tested. However, water that meets
the following water quality specifications is
acceptable.
Water Quality Specifications
Item
Chlorides (maximum) . . . . . . . .
Sulfates (maximum) . . . . . . . . .
Total Dissolved Solids (maximum)
Total Hardness (maximum) . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Parts
Per
Million
40
100
340
170
pH Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5—9.0
If Chlorides, Sulfates, or Total Dissolved Solids are
higher than the above given specifications, the water
must be distilled, de-mineralized, or de-ionized before
using in cooling system.
If Total Hardness is higher than the above given
specification and all other parameters are within the
given specifications, the water must be softened
before using in cooling system.
Ethylene Glycol Concentrate (Antifreeze):
IMPORTANT: DO NOT use ethylene glycol
concentrate containing sealer or
stop-leak additives.
RG,COOL3
CTM42 (24MAR95)
Grains
Per
Gallon
2.5
5.9
20
10
02-8
-19-23FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=27
Fuels, Lubricants, and Coolant/Engine Coolant Specifications
-UN-13FEB95
ENGINE COOLANT SPECIFICATIONS—CONTINUED
RG7298
02
9
Supplemental Coolant Additives (SCA’s):
IMPORTANT: DO NOT over-inhibit antifreeze
solutions, as this can cause
silicate-dropout. When this happens,
a gel-type deposit is created which
retards heat transfer and coolant
flow.
IMPORTANT: Check inhibitors between drain
intervals. Replenish inhibitors by the
addition of a supplemental coolant
additive as necessary. See your
vehicle operator’s manual for
details.
DO NOT use soluble oil.
NOTE: John Deere Prediluted Antifreeze/Summer
Coolant, John Deere Antifreeze/Summer
Coolant Concentrate, and John Deere
COOL-GARD contain supplemental coolant
additives (SCA’s). However, as the coolant
solution loses its effectiveness, additives will
need to be added.
Additives eventually lose their effectiveness and must
be recharged with additional liquid coolant conditioner.
See label on container for recommended service
intervals and concentration rates. See
REPLENISHING SUPPLEMENTAL COOLANT
ADDITIVES (SCA’S) BETWEEN COOLANT
CHANGES, later in this group.
Inhibit the antifreeze-coolant mix with a non-chromate
inhibitor such as John Deere Liquid Coolant
Conditioner. SCA’s guard against rust, corrosion, and
liner pitting. ALWAYS follow the supplier’s
recommendations printed on the container.
Contact your authorized servicing dealer or engine
distributor, if there are further questions.
John Deere Liquid Coolant Conditioner is available in
the following sizes:
—TY16004 473 mL (16 oz) container
—TY16005 3.8 L (1 US gal) container
RG,COOL3A,CTM -19-23FEB95
CTM42 (24MAR95)
02-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=28
Fuels, Lubricants, and Coolant/Replenish Supplemental Coolant Additives Between Coolant Changes
REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCA’S) BETWEEN COOLANT
CHANGES
RG6262
-UN-22APR92
RG6261
-UN-22APR92
02
10
Through time and use, original additives eventually
lose their effectiveness and must be recharged with
additional supplemental coolant additives available in
the form of liquid coolant conditioner.
IMPORTANT: ALWAYS maintain coolant at correct
level and concentration. DO NOT
operate engine without coolant for
even a few minutes.
Maintaining the correct coolant conditioner
concentration (SCA’s) and freeze point is essential in
your cooling system to protect against liner pitting,
corrosion, and freeze-ups due to incorrect coolant
solution.
A coolant strip test, available from your dealer,
provides a simple, effective way to check freeze point
and molybdate/nitrite levels. These results can be
compared to the SCA chart to determine the amount
of coolant conditioner in your system.
If frequent coolant make-up is
required, the glycol concentration
should be checked with JT05460
Refractometer to assure that the
desired freeze point is maintained.
Follow manufacturer’s instructions
provided with refractometer.
See ENGINE COOLANT SPECIFICATIONS earlier in
this group for proper mixing of coolant ingredients
before adding to the cooling system.
NOTE: Refer to your vehicle operator’s manual for
specific service intervals for checking and
charging your coolant.
For a more thorough evaluation of your coolant,
perform a CoolScan analysis. If a CoolScan analysis
is not available, recharge system per instructions
printed on label of TY16004 or TY16005 John Deere
Liquid Coolant Conditioner.
RG,COOL4,CTM
CTM42 (24MAR95)
02-10
-19-23FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=29
Fuels, Lubricants, and Coolant/Operating in Tropical Conditions
OPERATING IN TROPICAL CONDITIONS
Always use a recommended glycol base engine
coolant, even when operating in geographical areas
where freeze protection is not required.
Only when no glycol base engine coolant (antifreeze)
is available, use distilled, deionized, or demineralized
water meeting the quality specifications on the
previous page. Add to the water an initial charge of
supplemental coolant additives, such as John Deere
Liquid Coolant Conditioner or equivalent. The
recommended concentration of John Deere Liquid
Coolant Conditioner must be doubled to 6% (60 mL
per Liter of cooling system capacity) by volume when
used with water only (no antifreeze). Double other
manufacturer’s recommended concentration.
IMPORTANT: Never use water as the engine
coolant without an initial charge of
supplemental coolant additives.
Using water alone will cause severe
corrosion and pitting damage to
vital engine parts. Drain system and
refill cooling system as specified in
your vehicle operator’s manual.
RG,COOL6,CTM
CTM42 (24MAR95)
02-11
02
11
-19-23FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=30
Fuels, Lubricants, and Coolant/Flush and Service Cooling System
-UN-23AUG88
FLUSH AND SERVICE COOLING SYSTEM
TS281
02
12
N
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
Flush cooling system and replace thermostats as
described in your operator’s manual. Clean cooling
system with clean water and TY15979 John Deere
Heavy-Duty Cooling System Cleaner or an equivalent
cleaner such as FLEETGUARD® RESTORE™. Follow
the instructions provided with the cleaner. Refill
cooling system with the appropriate coolant solution.
See ENGINE COOLANT SPECIFICATIONS, earlier in
this group.
Shut off engine. Only remove filler cap
when cool enough to touch with bare
hands. Slowly loosen cap to first stop to
relieve pressure before removing cap
completely.
IMPORTANT: Air must be expelled from cooling
system when system is refilled.
Follow procedure given in your
operator’s manual.
The ethylene glycol base (antifreeze) can become
depleted of SCA’s allowing various acids to form that
will damage engine components. In addition, heavy
metals, such as lead, copper and zinc, accumulate in
the ethylene glycol base. The heavy metals come
from corrosion that occurs to some degree within a
cooling system. When a coolant is saturated to the
point where it can no longer hold heavy metals and
other dissolved solids, they settle out and act as
abrasives on engine parts.
IMPORTANT: NEVER overfill the system. A
pressurized system needs space for
heat expansion without overflowing
at the top of the radiator. Coolant
level should be at bottom of radiator
filler neck.
After adding new coolant solution, run engine until it
reaches operating temperature. This mixes the
coolant solution uniformly and circulates it through the
entire system. After running engine, check coolant
level and entire cooling system for leaks.
Contact your authorized servicing dealer or engine
distributor, if there are further questions.
NOTE: Refer to your operator’s manual for a specific
service interval.
FLEETGUARD® is a registered trademark of Cummins Engine
Company.
RESTORE™ is a trademark of FLEETGUARD®.
CTM42 (24MAR95)
RG,COOL,REQ8B -19-17AUG94
02-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=31
Fuels, Lubricants, and Coolant/Disposing of Coolant
DISPOSING OF COOLANT
-UN-26NOV90
Improperly disposing of engine coolant can threaten the
environment and ecology.
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or
into any water source.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
RG,COOL5
CTM42 (24MAR95)
02-13
-19-01SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=32
02
13
Fuels, Lubricants, and Coolant/Disposing of Coolant
02
14
CTM42 (24MAR95)
02-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=33
Group 03
Engine Mounting
ENGINE REPAIR STAND
RG4929
-UN-15DEC88
NOTE: Only the 2722 kg (6000 lb) heavy duty engine
repair stand (A) No. D05223ST manufactured by
Owatonna Tool Co., Owatonna, Minnesota is
referenced in this manual. When any other repair
stand is used, consult the manufacturer’s
instructions for mounting the engine.
S11,2000,EM
CTM42 (24MAR95)
03-1
-19-08MAR94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=34
03
1
Engine Mounting/Install 400 Series Adapters on Repair Stand
SAFETY PRECAUTIONS
• The engine repair stand should be used only by
qualified service technicians familiar with this
equipment.
• To maintain shear strength specifications, alloy steel
SAE Grade 8 or higher cap screws must be used to
mount adapters and engine to repair stand. Use
LOCTITE® 242 Thread Lock and Sealer on cap
screws when installing lifting straps on engine.
Tighten cap screws to 170 N·m (125 lb-ft).
• For full thread engagement, be certain that tapped
holes in adapters and engine blocks are clean and
not damaged. A thread length engagement equal to
1-1/2 screw diameters minimum is required to
maintain strength requirements.
• To prevent possible personal injury due to engine
slippage, recheck to make sure engine is solidly
mounted before releasing support from engine lifting
device.
• Never permit any part of the body to be positioned
under a load being lifted or suspended. Accidental
slippage may result in personal injury.
• To avoid structural or personal injury, do not exceed
the maximum capacity rating of 2722 kg (6000 lb).
Maximum capacity is determined with the center of
the engine located not more than 330 mm (13 in.)
from the mounting hub surface of the engine stand.
• The lifting jack is to be used when it is necessary to
lift the engine for rotation. When working on the
engine, the jack should be at its lowest position to
keep the center of gravity low and the possibility of
tipping low.
• To prevent possible personal injury due to sudden
engine movement, lower engine by operating jack
release valve slowly. Do not unscrew release valve
knob more than two turns from its closed position.
LOCTITE® is a registered trademark of Loctite Corporation.
S11,2000,DZ
-19-21MAR95
S11,2000,FB
-19-08MAR94
INSTALL 400 SERIES ADAPTERS ON
REPAIR STAND
-UN-15DEC88
1. Attach the No. 60581 Engine Adapter (A) to mounting
hub of the engine repair stand using SAE Grade 8
socket head screws. Tighten screws to 135 N·m (100
lb-ft).
2. Attach the No. 51400 end adapter (B) to the engine
adapter, using four 5/8-11 x 2 in. SAE Grade 8 cap
screws. Tighten screws to 135 N·m (100 lb-ft).
CTM42 (24MAR95)
03-2
RG4930
03
2
• To avoid an unsafe off-balance load condition, the
center of balance of an engine must be located within
51 mm (2 in.) of the engine stand rotating shaft.
Engine center of balance is generally located a few
millimeters above the crankshaft.
6076 Diesel Engines—S.N. (500000—
)
160101
PN=35
Engine Mounting/Engine Lifting Procedure
ENGINE LIFTING PROCEDURE
RG5788
-UN-09AUG91
03
3
N
CAUTION: Use of JDG23 Engine Lifting
Sling (A) is the ONLY APPROVED method
for lifting engine. Use extreme caution when
lifting and NEVER permit any part of the
body to be positioned under an engine
being lifted or suspended.
NOTE: If engine does not have lifting straps, they can
be procured through service parts network.
USE ONLY lifting straps supplied by DEERE.
2. Carefully lift engine and slowly lower to desired
location.
1. Attach the JDG23 Engine Lifting Sling to engine
lifting straps (B) and overhead hoist or floor crane.
IMPORTANT: Ensure that engine lifting straps are
secured to engine with SAE Grade 8
(or higher) cap screws. Apply
LOCTITE 242 Thread Lock and
Sealer and tighten cap screws to
170 N·m (125 lb-ft).
RG,CTM42,G3,1 -19-23MAR95
CTM42 (24MAR95)
03-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=36
Engine Mounting/Disconnect Turbocharger Oil Inlet Line
CLEAN ENGINE
1. Cap or plug all openings on engine. If electrical
components (starter, alternator, etc.) are not removed
prior to cleaning, cover with plastic and tape securely to
prevent moisture from entering.
2. Steam-clean engine thoroughly.
S11,2000,EC
-19-20AUG92
DISCONNECT TURBOCHARGER OIL INLET
LINE
-UN-06DEC88
1. Drain all engine oil and coolant, if not previously done.
IMPORTANT: When servicing 6076 Engines on a
rollover stand, disconnect turbocharger
oil inlet line (A) from oil conditioning
housing or turbocharger before rolling
engine over. Failure to do so may
cause a hydraulic lock upon starting
engine. Hydraulic lock may cause
possible engine failure.
RG5323
03
4
IMPORTANT: Never steam clean or pour cold water
on an injection pump while it is still
warm. To do so may cause seizure of
pump parts.
Hydraulic lock occurs when trapped oil
in the oil filter housing drains through
the turbocharger, the exhaust and
intake manifolds, and then into the
cylinder head.
After starting the engine, the trapped
oil in the manifold and head is released
into the cylinder(s) filling them with oil
causing hydraulic lock and possible
engine failure.
2. Disconnect turbocharger oil inlet line at turbocharger
or oil conditioning housing.
RG,CTM42,G03,3 -19-24SEP91
CTM42 (24MAR95)
03-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=37
Engine Mounting/Mount Engine On Repair Stand
-UN-05SEP91
MOUNT ENGINE ON REPAIR STAND
RG5965
03
5
NOTE: If starting motor is to be removed from
engine, remove before mounting engine onto
repair stand.
N
1. Mount the starter side of the engine to the engine
adapter with four 5/8-11UNC Flanged-head, SAE
Grade 8 or higher grade cap screws (A).
CAUTION: Never remove the overhead
lifting equipment from the equipment until
the engine is securely mounted to the stand
and all mounting hardware is tightened to
specified values. Always release the
overhead lifting equipment slowly.
2. Tighten cap screws to 203 N·m (150 lb-ft).
3. Carefully remove lift sling from engine.
RG,CTM42,G3,2 -19-21MAR95
CTM42 (24MAR95)
03-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=38
Engine Mounting/Mount Engine On Repair Stand
03
6
CTM42 (24MAR95)
03-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=39
Group 04
Engine Rebuild Guide
6076 ENGINE DISASSEMBLY SEQUENCE
The following sequence is suggested when complete
disassembly for overhaul is required. Refer to the
appropriate repair group when removing individual
engine components.
15. Remove exhaust manifold and air intake manifold.
16. Remove turbocharger oil return line.
17. Remove cylinder head with valve assembly.
Remove head gasket.
NOTE: Remove starting motor before mounting
engine into repair stand.
18. On SAE No. 3 flywheel housings, remove
flywheel then remove flywheel housing.
1. Drain all coolant and engine oil. Check engine oil
for metal contaminates.
19. On SAE No. 1 and 2 flywheel housings, remove
flywheel housing and then remove flywheel.
2. Remove turbocharger oil inlet line.
20. Roll engine over and remove oil pan and engine
oil pump assembly.
3. Remove breather hose.
04
1
4. Remove fan pulley and water manifold assembly.
21. Remove front timing gear cover.
5. Remove turbocharger exhaust elbow and
connector. Remove turbocharger.
22. Rotate engine to vertical position. Remove pistons
and connecting rods. Identify for re-assembly. Perform
wear checks with PLASTIGAGE™.
NOTE: DO NOT damage option code label (if
equipped), when removing rocker arm cover.
NOTE: Perform wear check on main bearing surfaces
with PLASTIGAGE, when removing main
bearing caps.
6. Remove rocker arm cover.
7. Remove rocker arm assembly and push rods.
Identify parts for re-assembly.
23. Remove main bearing caps. Remove crankshaft
and main bearings. Identify for re-assembly.
8. Remove alternator and mounting brackets.
24. Remove camshaft and cam followers. Identify for
re-assembly.
9. Remove front crankshaft pulley and damper
assembly.
25. Rotate engine and remove liners and their O-ring
seals. Mark liners for reassembly in same bore from
which removed.
10. Remove fuel injection lines and injection nozzles.
11. Remove water pump.
26. Remove piston cooling orifices.
12. Remove engine oil filter and oil conditioning
housing.
27. Remove cylinder block plugs and engine serial
number plate, if block is to be put in a “hot tank”.
13. Remove injection pump gear cover and remove
injection pump. Remove fuel filter and mounting base.
28. Refer to appropriate group for inspection and
repair of engine components.
14. On 6076A Engines, remove aftercooler cover and
aftercooler assembly.
PLASTIGAGE™ is a trademark of the Perfect Circle Division of Dana
Corp.
CTM42 (24MAR95)
04-1
RG,CTM42,G4,1 -19-24SEP91
6076 Diesel Engines—S.N. (500000—
)
160101
PN=40
Engine Rebuild Guide/Sealant Application Guidelines
SEALANT APPLICATION GUIDELINES
Listed below are sealants which have been tested
and are used by the John Deere factory to control
leakage and assure hardware retention. ALWAYS use
the following recommended sealants when
assembling your John Deere Diesel Engine to assure
quality performance.
LOCTITE® products are designed to perform to
sealing standards with machine oil residue present. If
excessive machine oil or poor cleanliness quality
exist, clean with solvent. Refer to John Deere
Merchandise and Parts Sales Manual for ordering
information.
04
2
• LOCTITE 592 Pipe Sealant with TEFLON® (white):
TY9374 6 ml. (0.2 oz) tube
TY9375 50 ml. (1.7 oz) bottle
—Pipe plugs: cylinder block (water manifold),
thermostat housing, air intake manifold, tachometer
drive, water pump, fan drive, fuel filter drain and
bleed.
—Drain valves: water pump and block
—Injection pump governor cover fitting (fuel return)
• LOCTITE 242 Thread Lock & Sealer (Medium
Strength) (blue):
—Threaded nipples and elbows in water pump
housing
TY9370 6 ml. (0.2 oz) tube
oz) bottle
—Temperature sending unit
T43512 50 ml. (1.7
—Oil pan (drain hose and drain valve)
—Plugs and fittings: fuel filter base, intake manifold,
cylinder block (oil galley).
—Cap Screws: injection pump access cover,
tachometer drive, oil filler inlet, flywheel, water outlet
manifold, engine lifting straps.
—Connectors: turbocharger oil supply and drain lines.
—Adapter fitting for turbocharger oil inlet line
• LOCTITE 609 Retaining Compound (green):
T43515 50 ml. (1.7 oz) bottle
—Oil pressure sending unit
• LOCTITE 271 Thread Lock & Sealer (High
Strength) (clear):
—Crankshaft rear oil seal/wear sleeve, crankshaft
front wear sleeve
TY9371 6 ml. (0.2 oz) tube
oz) bottle
• PERMATEX® AVIATION (Form-A-Gasket No. 3):
T43513 50 ml. (1.7
TY6299 227 g (8 oz) container
—Studs: Injection pump-to-block and exhaust
manifold-to-turbocharger.
—Timing gear cover-to oil pan
—Oil filter adapter.
—Flywheel housing-to-oil pan
—Steel cap plugs: cylinder block, cylinder head, and
water pump
—Camshaft bore steel cap plug
• LOCTITE 515 Flexible Sealant:
TY6304 50 ml. (1.7 oz) bottle
—Water pump and water manifold gaskets
RG,CTM42,G4,2 -19-17MAR95
CTM42 (24MAR95)
04-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=41
Engine Rebuild Guide/Sealant Application Guidelines
SEALANT APPLICATION GUIDELINES—CONTINUED
• PT569 NEVER-SEEZ® COMPOUND:
• AR31790 SCOTCH-GRIP® EC-1099 Plastic
Adhesive:
PT569 227 g (8 oz) Brush
PT506 453 g (16 oz) Spray
AR31790 118 ml (4 oz)
—Rocker arm cover gasket
—Cap Screws: exhaust manifold,
turbocharger-to-exhaust manifold.
• FEL-PRO® C-670 Molybdenum Disulfide Paste
—Gland nut threads and fuel injection nozzle barrel.
—Camshaft nose (gear installation)
LOCTITE®
and
Corporation.
PERMATEX®
04
3
are registered trademarks of Loctite
NEVER-SEEZ® is a registered trademark of the Emhart Chemical
Group.
TEFLON® is a registered trademark of DuPont Co.
SCOTCH-GRIP® is a registered trademark of 3M Company.
FEL-PRO® is a registered trademark of FEL-PRO.
CTM42 (24MAR95)
RG,CTM42,G4,5 -19-16AUG94
04-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=42
Engine Rebuild Guide/6076 Engine Assembly Sequence
6076 ENGINE ASSEMBLY SEQUENCE
The following assembly sequence is suggested when
engine has been completely disassembled. Be sure to
check run-out specifications, clearance tolerances,
torques, etc., as engine is assembled. Refer to the
appropriate repair group when assembling engine
components.
12. Install flywheels:
1. Install all plugs in cylinder block that were removed
to service block. Install engine serial number plate.
13. Install cylinder head, push rods, and rocker arm
assembly. Measure valve lift and adjust valve
clearance.
SAE 1 or SAE 2: Flywheel goes on before
housing.
SAE 3: Housing goes on before flywheel.
2. Install clean piston cooling orifices.
14. Install rocker arm cover. Install breather hose.
04
4
3. Install cylinder liners without O-rings and measure
liner stand-out. Install liner O-rings in block and
packings on liners. Install liners.
NOTE: If new piston and liner kit assemblies are
being installed, install the crankshaft first.
15. Install exhaust manifold and water manifold.
16. Install timing gear cover. Install front crankshaft
wear sleeve and oil seal.
17. Install air intake manifold.
4. Install main bearings and crankshaft. Rotate
crankshaft to assure correct assembly. Check
crankshaft end play.
18. Install aftercooler assembly on 6076A Engines.
19. Install turbocharger with elbow and oil lines.
5. If installing new piston/liner kits, assemble the
respective connecting rods.
20. Install water pump.
6. Install engine oil pump assembly.
21. Install injection nozzles and line assembly.
7. Install crankshaft rear oil seal housing, oil seal,
and wear sleeve.
22. Install front pulley and damper as an assembly.
23. Install alternator. Install fan pulley assembly.
8. Install cam followers in hole from which originally
removed.
9. Install camshaft. Align timing marks (camshaft to
crankshaft gears) with No. 1 piston at TDC
compression stroke.
10. Install fuel injection pump and drive gear.
24. Install fuel filter base, supply lines, and filter.
25. Fill engine with clean oil and the proper coolant.
Install dipstick.
26. Perform engine break-in and normal standard
performance checks.
11. Install engine oil conditioning assembly, if
removed.
RG,CTM42,G4,3 -19-14FEB95
CTM42 (24MAR95)
04-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=43
Group 05
Cylinder Head and Valves
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
RG5061
-19-05JUN91
-UN-23AUG88
Spring Compression Tester . . . . . . . . . D01168AA
Test valve spring compression.
S53,D01168,AA -19-13MAR92
RG5062
Valve Inspection Center . . . . . . . . . . . .
-UN-23AUG88
D05058ST
Check valves for out-of round.
S53,D05058,ST -19-02APR87
RG5063
05
1
-UN-23AUG88
End Brush . . . . . . . . . . . . . . . . . . . . . D17024BR
Clean valve seat and bores.
S53,D17024,BR -19-26JAN87
RG5099
-UN-23AUG88
Nozzle Thread Cleaning Brush . . . . . . . . . D17030BR
Used to clean nozzle threads in cylinder head.
S53,D17030,BR -19-16FEB87
-UN-27MAR92
Dial Indicator . . . . . . . . . . . . . (English, in.) D17526CI
or (Metric, mm ) D17527CI
RG6246
Use with JDG451 to measure valve recess and cylinder
liner height-to-cylinder block top deck.
RG,D17526CI
RG5064
Valve Guide Knurler Kit
-19-29OCT92
-UN-23AUG88
. . . . . . . . . . . . . . . JT05949
Knurl valve guides.
S53,D20002,WI -19-16SEP92
CTM42 (24MAR95)
05-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=44
Cylinder Head and Valves/Special or Essential Tools
RG5065
-UN-23AUG88
Valve Seat Pilot Driver . . . . . . . . . . . . . . . . JDE7
Install replacement valve seat inserts. Use with JDG605.
S53,JDE7A
-19-04FEB93
RG,JDG820
-19-14FEB95
RG,JDE814,86
-19-14FEB95
-UN-10AUG94
Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820
RG7056
Used to rotate engine to check damper radial runout and
time engine. JDE81-1 may be used also if JDG820 is
not available.
05
2
RG5068
-UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train, adjusting
valve clearance, and installing fuel injection pump. Use
with JDG820 and JDE81-1 Flywheel Turning Tools.
RG5071
-UN-23AUG88
Valve Seat Puller . . . . . . . . . . . . . . . . . JDE41296
Remove valve seats.
S53,JDE,41296 -19-26JAN87
RG5100
-UN-23AUG88
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDF5
Used to restore nozzle threads in cylinder head.
RG5100
S53,JDF5
-19-08MAR94
RG,JDG681A
-19-17MAR95
-UN-23AUG88
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG681A
Used to restore threaded holes in cylinder block for
cylinder head cap screws.
CTM42 (24MAR95)
05-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=45
Cylinder Head and Valves/Service Equipment and Tools
Valve Seat Installer
. . . . . . . . . . . . . . . . JDG605
RG5240
-UN-23AUG88
Install intake and exhaust valve seat inserts. Use with
JDE7.
RG5289
S53,JDG605
-19-25MAR91
S53,JDG609
-19-02DEC87
-UN-23AUG88
Nozzle Seat Reamer . . . . . . . . . . . . . . . . . . JDG609
Used to clean carbon from nozzle seats in cylinder head.
05
3
SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from your SERVICE-GARD™
Catalog. Some tools may be available from a
local supplier.
Name
Use
JDE138 Valve Spring Compressor
Compress valve springs when removing and
installing valves
D05012ST Precision “Bevelled Edge” Straightedge
Check cylinder head flatness
Plastic Brush
Clean valve guides
D11010KW Eccentrimeter
Measure valve seat-to-stem runout
JT05893 Heavy-Duty Seat Grinder Set
Grind valve seats
S55,2505,AH
CTM42 (24MAR95)
05-3
-19-08FEB94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=46
Cylinder Head and Valves/Other Material
OTHER MATERIAL
Name
Use
AR44402 Valve Stem Lubricant
Lubricate valve stems.
PT569 NEVER-SEEZ Compound
Exhaust manifold and cylinder head front plate
cap screws.
AR31790 SCOTCH-GRIP Plastic Adhesive
Rocker arm cover gasket.
S11,2505,BW
-19-30MAR93
05
4
CTM42 (24MAR95)
05-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=47
Cylinder Head and Valves/Cylinder Head and Valves Specifications
CYLINDER HEAD AND VALVES SPECIFICATIONS
ITEM
SPECIFICATION
WEAR LIMIT
Valve Lift at 0.00 mm (in.) Clearance
Intake . . . . . . . . . . . . . . . . . . . 13.53—13.71 mm (0.533—0.540 in.)
Exhaust . . . . . . . . . . . . . . . . . . 14.52—14.70 mm (0.572—0.579 in.)
12.65 mm (0.498 in.)
13.64 mm (0.537 in.)
Valve Clearance With Engine Cold
(Rocker Arm-to-Valve Tip):
Intake . . . . . . . . . . . . . . . . . . . 0.331—0.431 mm (0.013—0.017 in.)
Exhaust . . . . . . . . . . . . . . . . . . 0.457—0.559 mm (0.018—0.022 in.)
Valve Spring Compressed Height:
Valve Closed-Intake . . . . . . . .
Exhaust . . . . . . . .
Valve Open-Intake . . . . . . . . .
Exhaust . . . . . . . .
.
.
.
.
.
.
.
.
52.5
54.5
38.1
38.5
mm
mm
mm
mm
@
@
@
@
345—399
284—338
810—880
797—867
N
N
N
N
(2.07
(2.15
(1.50
(1.52
in.
in.
in.
in.
@
@
@
@
——
——
78—90 lb-force)
64—76 lb-force)
182—198 lb-force)
179—195 lb-force)
——
——
——
——
Valve Head OD:
Intake . . . . . . . . . . . . . . . . . . . 50.87—51.13 mm (2.003—2.013 in.)
Exhaust . . . . . . . . . . . . . . . . . . 46.87—47.13 mm (1.845—1.856 in.)
——
——
Valve Stem OD:
Exhaust . . . . . . . . . . . . . . . . . . 9.44—9.46 mm (0.3717—0.3724 in.)
Intake . . . . . . . . . . . . . . . . . . . 9.46—9.49 mm (0.3724—0.3736 in.)
——
——
Oversize Valve (Stem) Available . . . 0.08, 0.38, 0.76 mm (0.003, 0.015, 0.030 in.)
——
Valve Guide ID
. . . . . . . . . . . . . . 9.51—9.54 mm (0.3745—0.3755 in.)
——
Valve Stem-to-Guide Clearance:
Exhaust . . . . . . . . . . . . . . . . . . 0.051—0.102 mm (0.002—0.004 in.)
Intake . . . . . . . . . . . . . . . . . . . 0.025—0.076 mm (0.001—0.003 in.)
——
——
Valve Face Angle . . . . . . . . . . . . . 29.25˚ ±0.25˚
——
Valve Seat Angle . . . . . . . . . . . . . 30˚ ±0.50˚
——
Valve Seat Width:
Exhaust . . . . . . . . . . . . . . . . . . 2.0—3.8 mm (0.79—0.150 in.)
Intake . . . . . . . . . . . . . . . . . . . 1.4—3.8 mm (0.055—0.150 in.)
——
——
Valve Seat Concentricity
with Guide . . . . . . . . . . . . . . . . 0.051 mm (0.0020 in.)
——
Valve Recess in Cylinder Head:
Intake . . . . . . . . . . . . . . . . . . . 3.35—3.86 mm (0.132—0.152 in.)
Exhaust . . . . . . . . . . . . . . . . . . 1.19—1.70 mm (0.047—0.067 in.)
05
5
4.62 mm (0.182 in.)
2.46 mm (0.097 in.)
Maximum Valve Seat Runout . . . . . 0.051 mm (0.0020 in.)
——
Maximum Valve Face Runout . . . . . 0.051 mm (0.0020 in.)
——
RG,CTM42,G5,1 -19-14FEB95
CTM42 (24MAR95)
05-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=48
Cylinder Head and Valves/Cylinder Head and Valves Specifications
CYLINDER HEAD AND VALVES SPECIFICATIONS—CONTINUED
ITEM
05
6
SPECIFICATION
WEAR LIMIT
Cylinder Firing Order . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
——
Rocker Arm ID . . . . . . . . . . . . . . . . . . . . . 19.07—19.10 mm (0.7507—0.7520 in.)
——
Rocker Arm Shaft OD . . . . . . . . . . . . . . . . 19.01—19.05 mm (0.7484—0.7500 in.)
——
Cylinder Liner Height Above Block . . . . . . . . 0.050—0.127 mm (0.002—0.005 in.)
——
Cylinder Head Reconditioning:
Thickness of Head
(Rocker Arm Cover Gasket Rail-toCombustion Face) . . . . . . . . . . . . .
Minimum Acceptable Thickness . . . . .
Maximum Acceptable Head Out-of-Flat
(Entire Length or Width) . . . . . . . . .
Combustion Face Surface
Finish (Surface Grind Only) . . . . . . .
Maximum Wave Depth . . . . . . . . . .
Maximum Material Removal for
Resurfacing Head . . . . . . . . . . . . .
. . . 155.45—155.71 mm (6.120—6.130 in.)
. . . 154.69 mm (6.09 in.)
——
——
. . . 0.102 mm (0.0040 in.)
——
. . . 60—110AA
. . . 0.008 mm (0.0003 in.)
——
——
. . . 0.762 mm (0.0300 in.)
——
RG,CTM42,G5,2 -19-14FEB95
CYLINDER HEAD AND VALVES SPECIFICATIONS—CONTINUED
TORQUES
Cylinder Head-to-Cylinder Block:
Refer to TORQUE-TURN FLANGED-HEAD CAP SCREWS—GRADE 180
and TORQUE-TO-YIELD FLANGED-HEAD CAP SCREWS—GRADE 180
MARKED “SPECIAL”, later in this group.
Rocker Arm Shaft Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N·m (55 lb-ft)
Rocker Arm Cover-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N·m (6 lb-ft) (72 lb-in.)
Intake Manifold-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
Exhaust Manifold-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
Valve Adjusting Screw Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
RG,CTM42,G5,33A-19-14FEB95
CTM42 (24MAR95)
05-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=49
Cylinder Head and Valves/Check and Adjust Valve Clearance
CHECK AND ADJUST VALVE CLEARANCE
RG5790
-UN-09AUG91
Too little valve clearance throws valves out of time.
Valves open too early and close too late. This causes
the valves to overheat due to hot combustion gases
rushing past valves when out of time. Overheating
lengthens valve stems which prevents proper seating of
valves. The valves seat so briefly or poorly that normal
heat transfer into the cooling system does not have time
to take place, causing burned valves and low power.
Too much valve clearance causes a lag in valve timing
causing engine valve train imbalance. The fuel-air
mixture enters the cylinders late during intake stroke.
The exhaust valve closes early and prevents waste
gases from being completely removed from cylinders.
Also, the valves close with a great deal of impact, which
may crack or break the valves and scuff the camshaft
and followers.
05
7
NOTE: Valve clearance should be checked with engine
cold.
1. Remove rocker arm cover and ventilator hose (A).
2. Remove plastic plugs (B).
IMPORTANT: Visually inspect contact surfaces of
valve tips or wear caps and rocker arm
wear pads. Check all parts for
excessive wear, breakage, or cracks.
Replace parts that show visible
damage.
RG,CTM42,G5,5 -19-03MAY93
3. Rotate engine with the JDE81-1 or JDG820 Flywheel
Turning Tool (A) until JDE81-4 Timing Pin (B) engages
timing hole in flywheel.
RG5791
-UN-09AUG91
If the rocker arms for No. 1 cylinder are loose, the
engine is at No. 1 “TDC-Compression.” If the rocker
arms for No. 6 cylinder are loose, the engine is at No. 6
“TDC-Compression.” Rotate the engine one full revolution
to No. 1 “TDC-Compression.”
RG,CTM42,G5,26 -19-14FEB95
CTM42 (24MAR95)
05-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=50
Cylinder Head and Valves/Check and Adjust Valve Clearance
-UN-06DEC88
4. With engine lock-pinned at “TDC” of No. 1 piston’s
compression stroke, check and adjust (as needed) valve
clearance on Nos. 1, 3 and 5 exhaust valves and Nos.
1, 2 and 4 intake valves.
VALVE CLEARANCE SPECIFICATIONS
Intake Valves . . . . . . . . . . . . . . . . 0.331-0.431 mm (0.013-0.017 in.)
Exhaust Valves . . . . . . . . . . . . . . . 0.457-0.559 mm (0.018-0.022 in.)
-19-21AUG91
6. Rotate flywheel 360˚ until No. 6 piston is at “TDC” of
its compression stroke. Rocker arms for No. 6 piston
should be loose.
7. Check and adjust (as needed) valve clearance to the
same specifications on Nos. 2, 4 and 6 exhaust and
Nos. 3, 5, and 6 intake valves. Tighten valve adjusting
screw locknut to 27 N·m (20 lb-ft).
RG4295
05
8
RG5241
5. If valve clearance needs to be adjusted, loosen the
locknut on rocker arm adjusting screw. Turn adjusting
screw until feeler gauge slips with a slight drag. Hold the
adjusting screw from turning with screwdriver and tighten
locknut to 27 N·m (20 lb-ft). Recheck clearance again
after tightening locknut. Readjust clearance as
necessary.
8. Recheck clearance on all valves again after locknut is
tightened.
S11,2005,NB
CTM42 (24MAR95)
05-8
-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=51
Cylinder Head and Valves/Check Valve Lift
CHECK VALVE LIFT
NOTE: Measuring valve lift can give an indication of
wear on camshaft lobes and cam followers or
bent push rods.
IMPORTANT: For a more accurate measurement, it is
recommended that valve lift be
measured at 0.00 mm (in.) valve
clearance and with engine cold.
-UN-09AUG91
1. Remove turbocharger oil inlet line clamp and rocker
arm cover. Loosen locknut on rocker arm. Set valve
clearance at 0.00 mm (in.). Tighten locknut.
2. Put dial indicator tip on valve rotator. Be sure that
valve is fully closed.
RG5789
3. Check pre-set on dial indicator. Set dial indicator
pointer at zero.
4. Manually turn engine in running direction, using the
engine rotation tools previously mentioned for checking
valve clearance.
5. Observe dial indicator reading as valve is moved to
fully open position.
VALVE LIFT SPECIFICATION AT 0.00 MM (IN.) CLEARANCE
Intake . . . . . . . . . . . . . . . . . . 13.53—13.71 mm (0.533—0.540 in.)
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.)
Exhaust . . . . . . . . . . . . . . . . . 14.52—14.70 mm (0.572—0.579 in.)
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . 13.64 mm (0.537 in.)
6. Adjust valve clearance to specification after measuring
lift. (See CHECK AND ADJUST VALVE CLEARANCE,
earlier in this group.)
7. Repeat procedure on all remaining valves.
RG,CTM42,G5,4 -19-14FEB95
CTM42 (24MAR95)
05-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=52
05
9
Cylinder Head and Valves/Remove Cylinder Head
REMOVE CYLINDER HEAD
N
-UN-23AUG88
It is not necessary to remove engine from machine to
service cylinder head on all applications. Refer to your
Machine Technical Manual for engine removal procedure,
if required.
CAUTION: After operating engine, allow
exhaust system to cool before removal.
TS281
DO NOT drain coolant until the coolant is
below operating temperature. Always loosen
drain valve slowly to relieve any excess
pressure.
Remove rocker arm cover, if not previously done.
2. Remove water manifold (A) and all coolant piping.
(See Cooling System, Group 25.)
3. Remove turbocharger (B) and exhaust elbow (E). (See
Air Intake and Exhaust System, Group 30.)
4. On 6076A Engines, remove aftercooler assembly (D).
-UN-09AUG91
NOTE: Remove exhaust manifold before removing intake
manifold on 6076HRW33, 34, and 35 engines.
5. Remove air intake manifold (C). (Group 30.)
6. Remove exhaust manifold. (Group 30.)
RG5792
05
10
1. Drain all engine oil and coolant. Disconnect
turbocharger oil inlet line at turbocharger or oil
conditioning housing. (See DISCONNECT
TURBOCHARGER OIL INLET LINE in Group 03.)
A—Water Manifold
B—Turbocharger
C—Intake Manifold
D—Aftercooler Assembly
E—Exhaust Elbow
RG,CTM42,G5,6 -19-17MAR95
CTM42 (24MAR95)
05-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=53
Cylinder Head and Valves/Remove Cylinder Head
7. Remove fuel injection lines (A) and nozzles (B). (See
Fuel System, Group 35.)
RG5887
-UN-13AUG91
8. Remove rocker arm cover (C) and ventilator outlet
hose assembly.
RG,CTM42,G5,7 -19-22AUG91
RG5793
-UN-09AUG91
9. Remove six cap screws (A) and remove all four
clamps (B). Lift rocker arm assembly up and remove.
Remove wear caps from valve stems.
10. Remove all 12 push rods and identify for
reassembly.
05
11
RG5794
-UN-09AUG91
NOTE: Clean and inspect push rods as explained later in
this group.
RG,CTM42,G5,8 -19-28OCT92
CTM42 (24MAR95)
05-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=54
Cylinder Head and Valves/Disassemble and Inspect Rocker Arm Shaft Assembly
11. Remove all 26 cylinder head cap screws.
RG5245
-UN-06DEC88
NOTE: If cylinder head gasket failed, check and record
each cylinder head cap screw torque before
removing. Make a reference mark (in-line) on
socket and cylinder head surface. Loosen cap
screw at least 1/2 turn. Retighten cap screw
(using torque wrench) until reference marks align,
and record torque.
IMPORTANT: DO NOT use screwdrivers or pry bars
between cylinder block and cylinder
head to loosen head-to-block gasket
seal.
Lift cylinder head from block. If
cylinder head sticks, use a soft
hammer to tap the cylinder head.
12. Remove cylinder head gasket. Inspect possible oil,
coolant, or combustion chamber leaks. Also, check for
evidence of incorrect or defective head gasket being
used.
NOTE: Do not rotate crankshaft with cylinder head
removed unless all cylinder liners are secured
with cap screws and large flat washers as
described later in this group.
S11,2005,MT
-19-16AUG94
S11,2005,HY1
-19-07AUG91
DISASSEMBLE AND INSPECT ROCKER ARM
SHAFT ASSEMBLY
-UN-23FEB89
NOTE: Make preliminary inspection during disassembly.
Look for:
—Worn or scored rocker arms, shaft, and shaft
support.
—Weak or broken springs
—Lube oil restriction
RG3801
05
12
1. Remove plugs (A) and washers (B) from ends of
rocker arm shaft.
2. Slide springs, rocker arms, and rocker arm supports
off rocker arm shaft identifying their parts for reassembly
in the same sequence they were in before disassembly.
CTM42 (24MAR95)
05-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=55
Cylinder Head and Valves/Disassemble and Inspect Rocker Arm Shaft Assembly
-UN-23FEB89
3. Inspect rocker arm shaft (A) for severe scratching,
scoring, or excessive wear at points of rocker arm
contact. Measure rocker arm and shaft. Compare with
specifications given below.
NOTE: Wear could indicate weak valve springs, bent
push rods, or loose rocker arm shaft clamps.
RG3802
ROCKER ARM ASSEMBLY SPECIFICATIONS
Rocker Arm I.D. . . . . . . . . . . 19.07—19.10 mm (0.7507—0.7520 in.)
Rocker Arm Shaft O.D . . . . . . 19.01—19.05 mm (0.7484—0.7500 in.)
4. Check rocker arm adjusting nut (C) and screw (B) for
damage. Visually inspect rocker arm for hairline cracks.
Replace if necessary.
IMPORTANT: Be sure all oil holes in rocker arm
shaft are clean and open.
05
13
5. Clean all rocker arm parts with clean solvent. Dry with
compressed air.
S11,2005,MB
-19-28OCT92
NOTE: If the rocker arm has been damaged by a valve
failure, replace it and the push rods when
replacing valves.
8. Roll rocker arm shaft and push rods on a flat surface
to check for bends or distortion. Replace parts as
necessary.
R26131
7. Examine spacer springs on shaft between rocker
arms. Be sure they are strong enough to exert a positive
pressure on rocker arms.
-UN-09DEC88
6. Check for cups or concave wear (A) on ends of
rocker arms where they contact wear caps.
S11,0401,N
CTM42 (24MAR95)
05-13
-19-05FEB85
6076 Diesel Engines—S.N. (500000—
)
160101
PN=56
Cylinder Head and Valves/Measure Valve Recess
ASSEMBLE ROCKER ARM SHAFT
ASSEMBLY
-UN-23FEB89
1. Assemble parts on rocker arm shaft opposite removal
procedure.
RG3801
Make sure rocker arm shaft end plugs (A) are firmly
seated against end of shaft, and washers (B) are
installed on shaft.
S11,0401,O
-19-08MAR94
MEASURE VALVE RECESS
-UN-06DEC88
NOTE: Thoroughly clean all gasket material from cylinder
head combustion face before measuring.
VALVE RECESS SPECIFICATIONS
Valve Recess Below Cylinder Head:
Exhaust . . . . . . . . . . . . . . . . . . 1.19—1.70 mm (0.047—0.067 in.)
—Maximum Recess . . . . . . . . . . . . . . . . . . . 2.46 mm (0.097 in.)
RG5250
05
14
1. Measure and record valve recess dimensions for all
valves using JDG451 Gauge with D17526CI (English, in.)
or D17527CI (Metric, mm) Dial Indicator or KJD10123
Gauge and compare measurements to specifications
given below.
Intake . . . . . . . . . . . . . . . . . . . 3.35—3.86 mm (0.132—0.152 in.)
—Maximum Recess . . . . . . . . . . . . . . . . . . . 4.62 mm (0.182 in.)
NOTE: If measurement does not meet specifications,
check valve face angle and valve seat angle. If
valve is recessed beyond the maximum
specification, install either new valves, valve seat
inserts, or both to obtain proper valve recess.
(See REMOVE VALVE SEAT INSERTS AND
MEASURE BORES IN CYLINDER HEAD, later in
this group.)
RG,CTM42,G5,10 -19-28OCT92
CTM42 (24MAR95)
05-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=57
Cylinder Head and Valves/Preliminary Cylinder Head and Valve Checks
PRELIMINARY CYLINDER HEAD AND VALVE CHECKS
Make preliminary inspection of cylinder head and
valve assembly during disassembly.
• Worn or Broken Valve Seats:
Misaligned valves.
Distorted cylinder head.
Carbon deposits on seats due to incomplete
combustion.
Valve spring tension too weak.
Excessive heat.
Improper valve clearance.
Improper valve timing.
Incorrect valve or seat installed.
Look for the following conditions:
• Sticking Valves:
Carbon deposits on valve stem.
Worn valve guides.
Scored valve stems.
Warped valve stems.
Cocked or broken valve springs.
Worn or distorted valve seats.
Insufficient lubrication.
• Burned, Pitted, Worn, or Broken Valves:
Worn or distorted valve seats.
Loose Valve Seats
Worn valve guides.
Insufficient cooling.
Cocked or broken valve springs.
Improper engine operation.
Improper valve train timing.
Faulty valve rotators.
Warped or distorted valve stems.
“Stretched” valves due to excessive spring tension.
Warped cylinder head.
Bent push rods.
Carbon build-up on valve seats.
Rocker arm failure.
Incorrect valve or seat installed.
Incorrect piston-to-valve clearance.
• Warped, Worn, or Distorted Valve Guides:
Lack of lubrication.
Cylinder head distortion.
Excessive heat.
Unevenly tightened cylinder head cap screws.
• Distorted Cylinder Head and Gasket Leakage:
Loss of cylinder head cap screw torque.
Broken cylinder head cap screw.
Overheating from low coolant level operation.
Insufficient liner standout.
Coolant leakage into cylinder causing hydraulic
failure of gasket.
Leaking aftercooler.
Cracked cylinder head.
Cracked cylinder liner.
Damaged or incorrect gasket.
Overpowering or overfueling.
Damaged cylinder head or block surfaces.
Improper surface finish on cylinder head.
Improperly tightened cylinder head cap screws.
Faulty gasket installation (misaligned).
05
15
• Improper Valve Clearance:
Inefficient use of fuel.
Engine starts harder.
Maximum engine power will not be achieved.
Shorter service life of valve train.
Greater chance for engine to overheat.
• Excessive Recession:
Worn valve guides.
Bent valves.
Debris passed through valve train.
RG,CTM8,G05,28 -19-08MAR94
CTM42 (24MAR95)
05-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=58
Cylinder Head and Valves/Remove Valve Assembly
REMOVE VALVE ASSEMBLY
-UN-23FEB89
NOTE: Refer to PRELIMINARY CYLINDER HEAD AND
VALVE CHECKS earlier in this group.
NOTE: Identify all parts for proper assembly in same
location as removed.
RG3803
1. Compress JDE138 Valve Spring Compressor (A) over
valve.
2. Remove retaining locks (B).
3. Remove valve spring compressor.
S11,0401,Q
-19-14FEB95
4. Remove valve rotators (A) and valve springs (B).
-UN-23FEB89
5. Remove exhaust valve stem shields.
6. Remove valves (C) from cylinder head.
RG3804
05
16
RG,CTM42,G5,27 -19-28OCT92
CTM42 (24MAR95)
05-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=59
Cylinder Head and Valves/Inspect Valve Rotators and Wear Caps
INSPECT AND MEASURE VALVE SPRINGS
-UN-23FEB89
1. Inspect valve springs for alignment, wear and
damage.
2. Put springs on a flat surface to see that they are
square and parallel.
RG2732
3. Check valve spring tension using D01168AA Spring
Compression Tester.
NOTE: Free spring length of 65 mm (2.56 in.) springs
differ slightly, but compressed height must be the
same.
-UN-08NOV88
VALVE SPRING SPECIFICATIONS
Spring Load
Height
Intake:
Open: 810—880 N (182—198 lb-force) . . . . . . . 38.1 mm (1.50 in.)
Closed: 345—399 N (78—90 lb-force) . . . . . . . . 52.5 mm (2.07 in.)
T82054
Exhaust:
Open: 797—867 N (179—195 lb-force) . . . . . . . 38.5 mm (1.52 in.)
Closed: 284—338 N (64—76 lb-force) . . . . . . . . 54.5 mm (2.15 in.)
RG,CTM42,G5,11 -19-06SEP94
INSPECT VALVE ROTATORS AND WEAR
CAPS
-UN-23FEB89
1. Insure that valve rotators (A), if equipped, will turn
freely. Replace if defective.
2. Replace valve wear caps (B) if pitted or worn.
RG3491
3. Inspect valve retainer locks for excessive wear.
Replace as needed.
S11,0401,T
CTM42 (24MAR95)
05-17
-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=60
05
17
Cylinder Head and Valves/Inspect and Measure Valves
CLEAN VALVES
1. Hold each valve firmly against a soft wire wheel on a
bench grinder.
2. Make sure all carbon is removed from valve head,
face and unplated portion of stem.
IMPORTANT: Any carbon left on the stem will affect
alignment in valve refacer if valves
need to be refaced. Do not use wire
wheel on plated portion of valve stem.
S11,0401,U
-19-13MAR92
INSPECT AND MEASURE VALVES
1. Thoroughly clean and inspect valves to help determine
if they can be restored to a serviceable condition.
Replace valves that are burned, cracked, eroded, or
chipped.
2. Inspect valve retainer lock groove (C) on valve stem
for damage. Also inspect stems for signs of scuffing,
which may indicate insufficient valve guide-to-valve stem
clearance. Replace if defects are evident.
3. Measure valve head OD (A). Compare valve stem OD
(B) with guide ID to determine clearance, as outlined
later in this group.
VALVE HEAD AND STEM SPECIFICATIONS
-UN-12AUG91
A—Valve Head OD:
Exhaust . . . . . . . . . . . . . . . . 46.87—47.13 mm (1.845—1.856 in.)
Intake . . . . . . . . . . . . . . . . . . 50.87—51.13 mm (2.003—2.013 in.)
B—Valve Stem OD:
Exhaust . . . . . . . . . . . . . . . . 9.44—9.46 mm (0.3717—0.3724 in.)
Intake . . . . . . . . . . . . . . . . . . 9.46—9.49 mm (0.3724—0.3736 in.)
RG5795
05
18
RG,CTM42,G5,12 -19-03MAY93
CTM42 (24MAR95)
05-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=61
Cylinder Head and Valves/Inspect and Clean Cylinder Head
4. Use D05058ST Valve Inspection Center to determine
if valves are out of round, bent or warped.
-UN-23FEB89
VALVE FACE RUNOUT SPECIFICATION
RG4234
Maximum permissible runout of
valve face . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
S11,2005,IZ
-19-14FEB95
GRIND (REFACE) VALVES
-UN-12AUG91
IMPORTANT: Valve grinding should only be done by
experienced personnel familiar with
equipment and capable of maintaining
required specifications.
RG5247
If necessary to reface valve, grind valve face to an angle
of 29.25˚ ± 0.25˚ (A).
IMPORTANT: When valve faces are ground, it is
important not to nick valve
head-to-stem radius with facing stone.
A nick could cause the valve to break.
Radius all sharp edges after grinding.
S11,2005,MG
-19-20JUL94
INSPECT AND CLEAN CYLINDER HEAD
Inspect all cylinder head passages for restrictions. Heads
with restricted or clogged passages can be cleaned by
soaking them in a tank of hot caustic solution.
Scrape all old gasket material from head. Use a powered
wire brush to clean sealing surfaces.
If cylinder head is not put in a chemical hot tank for
cleaning, clean with solvent and a brush. Dry with
compressed air and be sure to blow out all passages.
S11,2005,KW
CTM42 (24MAR95)
05-19
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=62
05
19
Cylinder Head and Valves/Check Cylinder Head Combustion Face Flatness
CHECK CYLINDER HEAD COMBUSTION
FACE FLATNESS
-UN-07SEP94
Check cylinder head flatness using D05012ST Precision
Straightedge and feeler gauge. Check lengthwise,
crosswise, and diagonally in several places.
RG7231
If any measurement exceeds this specification, the
cylinder head must be either resurfaced or replaced.
(See MEASURE CYLINDER HEAD THICKNESS, later in
this group.)
CYLINDER HEAD TOP DECK FLATNESS SPECIFICATION
-UN-07SEP94
Maximum Out-of-Flat
(Over Entire Length or Width) . . . . . . . . . . . 0.102 mm (0.0040 in.)
Straightness per any 305 mm
(12 in.) Length . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)
RG4629
-UN-06DEC88
RG7232
05
20
S11,2005,KY
CTM42 (24MAR95)
05-20
-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=63
Cylinder Head and Valves/Measure Cylinder Head Thickness
MEASURE CYLINDER HEAD THICKNESS
-UN-23FEB89
Measure head thickness (A) from valve cover gasket
rail-to-combustion face.
If cylinder head thickness is less than wear limit. DO
NOT attempt to resurface. Install a new cylinder head.
RG4421
NOTE: If necessary to resurface cylinder head, a
MAXIMUM of 0.762 mm (0.030 in.) can be
ground from new part dimension. Remove ONLY
what is necessary to restore flatness.
IMPORTANT: After resurfacing, check flatness as
described earlier and check surface
finish on combustion face of head.
Check valve recess after grinding. (See
MEASURE VALVE RECESS, earlier in
this group.) Valve seat or valve face
may be ground to bring this
characteristic within specification.
05
21
CYLINDER HEAD SPECIFICATIONS
Thickness . . . . . . . . . . . . . . 155.45—155.71 mm (6.120—6.130 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . 154.69 mm (6.09 in.)
Combustion Face Surface Finish (AA) . . . . . . . . . 0.015—0.0028 mm
(60—110 micro-in.)
Maximum Wave Depth . . . . . . . . . . . . . . . . . 0.008 mm (0.0003 in.)
S11,2005,KZ
CTM42 (24MAR95)
05-21
-19-14SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=64
Cylinder Head and Valves/Measure Valve Guides
CLEAN VALVE GUIDES
1. Use a D17011BR Valve Guide Cleaning Brush to
clean valve guides before inspection or repair.
RG5346
-UN-06DEC88
NOTE: A few drops of light oil or kerosene will help to
fully clean the guide.
S11,2005,MY
-19-28OCT92
S11,2005,MH
-19-03MAY93
MEASURE VALVE GUIDES
-UN-09DEC88
1. Measure valve guides (A) for wear using a telescope
gauge (B) and micrometer.
VALVE GUIDE SPECIFICATIONS
I.D. Guide in a New Head . . . . . . . . . . . . . . . . . . . 9.51—9.54 mm
(0.3745—0.3755 in.)
New Guide-to-Valve Stem Clearance:
Exhaust . . . . . . . . . . . . . . . . . 0.051—0.102 mm (0.002—0.004 in.)
Intake . . . . . . . . . . . . . . . . . . 0.025—0.076 mm (0.001—0.003 in.)
R23984
05
22
NOTE: Worn guides can allow a clearance of 0.15 mm
(0.006 in.) and still be acceptable. Worn guides
may be knurled to return them to specified
clearance if valve-to-guide clearance is 0.25 mm
(0.010 in.) or less. If clearance exceeds 0.25 mm
(0.010 in.), install oversize valves.
IMPORTANT: ALWAYS knurl exhaust valve guides
before reaming to assure proper valve
guide-to-stem clearance.
CTM42 (24MAR95)
05-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=65
Cylinder Head and Valves/Clean and Inspect Valve Seats
KNURL VALVE GUIDES
1. Use JT05949 (formerly D20002) Valve Guide Knurler
Kit to knurl valve guides.
NOTE: Use tool set exactly as directed by the
manufacturer.
2. After knurling, ream valve guide to finished size to
provide specified stem-to-guide clearance.
R26141
-UN-09DEC88
A—Knurler
B—Reamer
C—Speed Reducer
D—Lubricant
S11,0401,Z
-19-08MAR94
05
23
CLEAN AND INSPECT VALVE SEATS
-UN-09DEC88
1. Use an electric hand drill with D17024BR Wire
Cleaning Brush or equivalent brush to remove all carbon
on valve seats.
2. Check seats for cracks, pits, or excessive wear.
R26142N
3. Check entire combustion face for rust, scoring, pitting
or cracks.
S11,0401,AA
CTM42 (24MAR95)
05-23
-19-28OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=66
Cylinder Head and Valves/Measure Valve Seats
MEASURE VALVE SEATS
1. Measure valve seats for proper specifications listed
below.
2. Using D11010KW Eccentrimeter, measure valve seat
runout (D).
3. If valve seat is not within specification, recondition
valve seat by grinding or replace valve seat inserts (A) if
reconditioning is not possible. (See GRIND VALVE
SEATS or INSTALL VALVE SEAT INSERTS, later in this
group.)
VALVE SEAT SPECIFICATIONS
Valve Seat Width (C):
—Exhaust . . . . . . . . . . . . . . . . . . 2.0—3.8 mm (0.079—0.150 in.)
—Intake . . . . . . . . . . . . . . . . . . . . 1.4—3.8 mm (0.055—0.150 in.)
Maximum Valve Seat Runout . . . . . . . . . . . . 0.051 mm (0.0020 in.)
A—Valve
B—Valve
C—Valve
D—Valve
Seat
Seat
Seat
Seat
RG5248
05
24
30˚ ±0.50˚
-UN-06DEC88
Valve Seat Angle (B) . . . . . . . . . . . . . . . . . . . . . . . . . .
Insert
Angle
Width
Runout
S11,2005,MI
CTM42 (24MAR95)
05-24
-19-16SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=67
Cylinder Head and Valves/Grind Valve Seats
GRIND VALVE SEATS
IMPORTANT: Valve seat grinding should only be
done by experienced personnel familiar
with equipment and capable of
maintaining required specifications.
ALWAYS keep work area clean when
grinding valve seats.
R26143N
-UN-09DEC88
Using JT05893 Heavy-Duty Seat Grinder
Set, grind valve seats to obtain correct
valve recess in cylinder head. (See
MEASURE VALVE RECESS earlier in
this group.) Be sure valve guide bores
are clean before grinding valve seats.
(See CLEAN VALVE GUIDES earlier in
this group.)
If valve seats need grinding, do not grind too long. Only
a few seconds are required to recondition the average
valve seat. Avoid the tendency to grind off too much. Do
not use too much pressure. While grinding, support the
weight of the dresser to avoid excessive pressure on the
stone.
05
25
1. Check the seat width and contact pattern between the
seat and valve with bluing. Seat width MUST BE
maintained within specification. Use a vernier caliper or
scale to measure seat width. Thoroughly clean seat area
after grinding and replace valves and valve seat inserts
as necessary.
-UN-06DEC88
NOTE: Valve seat width can be reduced with a
narrowing stone. This will change the angle at
the top of the seat and increase the diameter. If
valve seat width is too narrow, valve may burn or
erode. Varying the width changes the fine contact
between valve face and seat.
RG5248
2. ALWAYS measure valve seat runout after grinding
using D11010KW Eccentrimeter.
VALVE SEAT SPECIFICATIONS
A—Valve Seat Insert
B—Valve Seat Angle . . . . . . . .
C—Valve Seat Width
—Exhaust . . . . . . . . . . . . . .
—Intake . . . . . . . . . . . . . . .
D—Maximum Valve Seat Runout
..................
30˚ ±0.50˚
. . . . 2.0—3.8 mm (0.079—0.150 in.)
. . . . 1.4—3.8 mm (0.055—0.150 in.)
. . . . . . . . . . 0.051 mm (0.0020 in.)
IMPORTANT: Blend or radius all sharp edges after
grinding valve seats. Always check
valve recess in cylinder head after
grinding as described later.
S11,2005,MJ
CTM42 (24MAR95)
05-25
-19-28OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=68
Cylinder Head and Valves/Remove Valve Seat Inserts and Measure Bores
REMOVE VALVE SEAT INSERTS AND
MEASURE BORES IN CYLINDER HEAD
-UN-06DEC88
In some cases the inside diameter of the valve seat bore
may become damaged or oversized and require
machining. In this case, oversize inserts are available in
0.25 mm (0.010 in.) oversize only.
RG5306
IMPORTANT: Be careful not to damage cylinder head
when removing seats.
1. Remove valve seat insert (if necessary) with
JDE41296 Valve Seat Puller (A). Adjusting screw on
puller may need to be retightened during removal of
inserts.
05
26
NOTE: On some engines, removal of valve seat inserts
with the JDE41296 Puller may not be possible.
An alternate removal method is to weld two or
three short beads (use an arc welder) equidistant
from each other around the face of insert. Allow
seat to cool and carefully pry out the insert(s)
with a screwdriver.
IMPORTANT: If an arc welder is used to remove
valve seat inserts, protect entire
combustion face and valve throat area
from weld spatter.
2. After removal of inserts, thoroughly clean area around
valve seat bore and inspect for damage or cracks.
S11,2005,ML
CTM42 (24MAR95)
05-26
-19-28OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=69
Cylinder Head and Valves/Inspect and Clean Cylinder Head Nozzle Bore
INSTALL VALVE SEAT INSERTS
-UN-06DEC88
1. Use the JDE7 Driver (A) along with the JDG605 Valve
Seat Installer (B) to drive inserts into place. The larger
end of JDG605 Installer is used to install intake valves
and the smaller end is used to install exhaust valves.
RG5249
2. Install new or refaced valves and check valve recess.
(See MEASURE VALVE RECESS, earlier in this group.)
3. Grind valve seats as required to maintain correct
valve recess and valve-to-seat seal. (See GRIND VALVE
SEATS, earlier in this group.)
S11,2005,MM
-19-28OCT92
05
27
INSPECT AND CLEAN CYLINDER HEAD
NOZZLE BORE
-UN-14DEC88
1. Inspect condition of threads for gland nut. Threads are
metric (M28 x 1.5).
2. Inspect condition of nozzle seating surface in cylinder
head.
RG5251
Cylinder head threads and nozzle seating surface must
be free of debris and carbon deposits.
IMPORTANT: If the injection nozzle gland nut threads
are not clean, a false torque reading
may be obtained when the injection
nozzle is installed. This may prevent
the injection nozzle from seating
properly in the cylinder head.
3. Clean threads which have light foreign deposits using
a drill and the D17030BR Thread Cleaning Brush. Work
brush up and down several times to clean threads.
RG,CTM42,G5,14 -19-08FEB94
CTM42 (24MAR95)
05-27
6076 Diesel Engines—S.N. (500000—
)
160101
PN=70
Cylinder Head and Valves/Inspect and Clean Ventilator Outlet Hose
RG5252
-UN-06DEC88
4. Clean threads with heavy foreign deposits or clean up
damaged threads using the JDF5 Tap (M28 x 1.5 mm)
or an equivalent M28 x 1.5 mm (metric) tap (A). Be sure
to start tap straight to avoid possible cross-threading. A
light coat of grease on tap will help collect foreign
deposits on tap and prevent them from falling into the
nozzle bore.
RG,CTM42,G5,15 -19-22AUG91
5. Clean nozzle seating surface by using the JDG609
Nozzle Seat Reamer (A) to remove carbon.
-UN-06DEC88
6. Blow out debris with compressed air and thoroughly
clean all nozzle bores.
RG5253
05
28
S11,2005,NU
-19-23AUG91
S11,2005,JN
-19-24APR92
CLEAN AND INSPECT PUSH RODS
1. Clean push rods with solvent and compressed air.
-UN-01NOV88
2. Check push rods for straightness by rolling on a flat
surface.
3. Inspect contact ends for wear and damage.
T81233
4. Replace defective push rods.
INSPECT AND CLEAN VENTILATOR OUTLET
HOSE
-UN-12AUG91
1. Check ventilator outlet hose (A) on rocker arm cover
for bent or damaged condition. Replace if necessary.
RG5797
2. Clean ventilator hose if restricted.
RG,CTM42,G5,9 -19-28OCT92
CTM42 (24MAR95)
05-28
6076 Diesel Engines—S.N. (500000—
)
160101
PN=71
Cylinder Head and Valves/Clean and Inspect Top Deck of Cylinder Block
CLEAN AND INSPECT TOP DECK OF
CYLINDER BLOCK
-UN-12AUG91
1. Remove gasket material, rust, carbon, and other
foreign material from top deck. Gasket surface must be
clean.
RG5796
2. Use compressed air to remove all loose foreign
material from cylinders and top deck.
3. Remove cylinder head locating dowels.
4. Clean all cylinder head mounting cap screw holes
using JDG681A or an equivalent 9/16-12 UNC-2A tap
about 114.3 mm (4.5 in.) long. Use compressed air to
remove debris and any fluids which may be present in
the cap screw holes.
5. Measure top deck flatness. See MEASURE
CYLINDER BLOCK in Group 10.
05
29
6. Install new cylinder head locating dowel pins in
cylinder block.
RG,CTM42,G5,17 -19-17MAR95
CTM42 (24MAR95)
05-29
6076 Diesel Engines—S.N. (500000—
)
160101
PN=72
Cylinder Head and Valves/Measure Cylinder Liner Standout (Height above Block)
-UN-12AUG91
MEASURE CYLINDER LINER STANDOUT
(HEIGHT ABOVE BLOCK)
RG5829
1. Bolt down liners using cap screws and flat washers in
the seven locations as shown. Flat washers should be at
least 3.18 mm (1/8 in.) thick. Tighten cap screws to 68
N·m (50 lb-ft) to achieve an accurate standout reading.
NOTE: Liners having obvious defects must be replaced.
2. Using JDG451 Gauge along with D17526CI (English)
or D17527CI (Metric scale) Dial Indicator (B) or
KJD10123 Gauge to measure the height (C) of bolted
down liners (A) that are not obviously defective before
removal from block (D).
3. Measure each liner in four places, approximately at 1,
5, 7 and 11 O’clock positions as viewed from the rear of
the engine (flywheel end). Record all measurements by
cylinder number.
4. Remove any liner that does not meet standout
specification at any location and install liner shims or
replace piston/liner sets as necessary, as outlined in
Group 10. See INSTALL LINER SHIMS—IF REQUIRED.
LINER HEIGHT SPECIFICATIONS
Liner Height Above Block . . . . . . . . . . . . . . . . . .
RG5813
05
30
-UN-08MAR94
NOTE: Variations in measurement readings may occur
within one cylinder and/or between adjacent
cylinders.
A—Cylinder Liner
B—Dial Indicator
C—Liner Height
D—Cylinder Block
0.050—0.127 mm
(0.002—0.005 in.)
RG,CTM42,G5,31 -19-16AUG94
CTM42 (24MAR95)
05-30
6076 Diesel Engines—S.N. (500000—
)
160101
PN=73
Cylinder Head and Valves/Assemble Valve Assembly
ASSEMBLE VALVE ASSEMBLY
-UN-23FEB89
1. Apply AR44402 Valve Stem Lubricant or clean engine
oil to valve stems and guides.
RG3806
NOTE: Exhaust valve stem shields will not seat on valve
guide tower; they ride up and down with valve
stem.
2. Install reconditioned or new valves (A) in head. If
valves are reused, install in same location from which
removed.
NOTE: Valves must move freely and seat properly.
S11,0401,AK
-19-28OCT92
05
31
NOTE: There is no top or bottom to valve springs; they
may be installed either way.
-UN-23FEB89
3. Position valve springs (B). End of spring must be in
machined counterbore of head. Do not mix valve springs.
See INSPECT AND MEASURE VALVE SPRINGS,
earlier in this group.
RG3804
4. Install valve rotators (A) on springs and valves (C).
5. Install valve stem shields on exhaust valve stems.
RG,CTM42,G5,28 -19-28OCT92
6. Compress valve springs with JDE138 Valve Spring
Compressor (A) and install retainer locks (B).
RG3803
-UN-23FEB89
NOTE: Install wear caps just before installing rocker arm
assembly.
RG,CTM42,G5,29 -19-28OCT92
CTM42 (24MAR95)
05-31
6076 Diesel Engines—S.N. (500000—
)
160101
PN=74
Cylinder Head and Valves/Install Cylinder Head
7. Strike end of each valve with a soft mallet (A) three or
four times to insure proper seating of the retainer locks.
-UN-23FEB89
Repeat procedure for all remaining valves. Remember
valve stem seals are installed onto exhaust valve stems
only.
RG3807
8. Measure valve recess as directed earlier in this group.
RG,CTM42,G5,30 -19-28OCT92
INSTALL CYLINDER HEAD
-UN-06DEC88
Be sure cylinder head and block gasket
surfaces are clean, dry, and free of any
oil.
RG5245
05
32
IMPORTANT: ALWAYS thoroughly inspect new
cylinder head gasket for possible
manufacturing imperfections. Return
any gasket that does not pass
inspection.
1. Put a new head gasket on cylinder block. Do not use
sealant on gasket; install dry.
IMPORTANT: If cylinder head is lowered onto
cylinder block and you discover that
the head is not positioned correctly on
locating dowels, remove cylinder head
and install a new gasket. DO NOT try
to reposition cylinder head on the same
gasket again since the fire ring will
possibly be damaged.
2. Lower cylinder head everly to correct position on block
using appropriate lifting equipment. Make sure that head
is positioned correctly over dowels.
RG,CTM42,G5,40 -19-14FEB95
CTM42 (24MAR95)
05-32
6076 Diesel Engines—S.N. (500000—
)
160101
PN=75
Cylinder Head and Valves/Cylinder Head Cap Screw Types
RG7226
-UN-22JUL94
CYLINDER HEAD CAP SCREW TYPES
A—ASTM Grade 180 Flanged-Head
One of the two cylinder head cap screws shown will
be found on the engine, depending upon when the
engine was built.
IMPORTANT: Cylinder head cap screw torque
specifications and tightening
procedures vary depending upon the
grade or type of cap screw used,
and the cylinder block casting
number.
Cylinder block casting numbers R116070, R119995,
R119996, R119997, R119998 and R119999 use
Grade 180 flanged-head cylinder head cap screws.
These cap screws must be tightened using the
“Torque-Turn” method. See TIGHTEN
FLANGED-HEAD CYLINDER HEAD CAP SCREWS
later in this group.
B—Flanged-Head Marked
“SPECIAL”
Grade 180 flanged-head cylinder head cap screws
must be tightened using the “TORQUE-TURN”
method. See TIGHTEN FLANGED-HEAD CYLINDER
HEAD CAP SCREWS — GRADE 180, later in this
group.
05
33
Cylinder head cap screws marked “SPECIAL” must
be tightened using the “TORQUE-TO-YIELD” method.
See TORQUE-TO-YIELD FLANGED-HEAD CAP
SCREWS—GRADE 180 MARKED “SPECIAL” later in
this group.
IMPORTANT: DO NOT re-use cylinder head cap
screws marked “SPECIAL”, they
may be used only one time.
For cylinder blocks with casting numbers R122736,
R122737, R122738, R122739, R122740 and
R122741, the early engines were built with Grade
180 flanged-head cylinder head cap screws, and later
engines are built with cylinder head cap screws
marked “SPECIAL”. For service of these engines,
either type of cylinder head cap screw can be used,
although use of “SPECIAL” cylinder head cap screws
is recommended.
RG,CTM42,G5,41 -19-14FEB95
CTM42 (24MAR95)
05-33
6076 Diesel Engines—S.N. (500000—
)
160101
PN=76
Cylinder Head and Valves/Clean, Inspect and Install Cylinder Head Cap Screws
-UN-28FEB94
CLEAN, INSPECT AND INSTALL CYLINDER
HEAD CAP SCREWS
RG4471
IMPORTANT: All SAE Grade 180 flanged-head cap
screws can be reused if they pass
inspection EXCEPT for the
flanged-head cap screws marked
“SPECIAL”. These cap screws can be
used only one time and only on
cylinder blocks with casting numbers
R116070, R119995, R119996, R119997,
R119998, and R119999.
1. Clean entire length of cap screws (if reusing) to
remove rust and scale using a wire brush and solvent.
Dry cap screws with compressed air.
05
34
2. Inspect cap screws for corrosion damage and
condition of threads. ANY CAP SCREW WITH
CORROSION OR OTHER IMPERFECTIONS MUST BE
REPLACED.
IMPORTANT: DO NOT use multi-viscosity oils
tolubricate cap screws. Only SAE30
engine oil may be used.
3. Dip entire cap screw in clean SAE30 engine oil. Allow
excess oil to drip off.
Arrow (A) points toward front of engine.
4. Install cap screws in proper location.
Use the following cap screws in location as shown:
Cap Screw Length
134
149
175
203
mm
mm
mm
mm
(5.2
(5.9
(6.9
(8.0
in.)
in.)
in.)
in.)
.
.
.
.
.
.
.
.
Location on Cylinder Head
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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.
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.
.
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.
.
.
.
.
.
.
. . . . . . . . . 2, 3, 4, 5, 6, 7
. . . . . . 23, 25, 17, 21, 19
1, 15, 14, 13, 12, 11, 10, 8
. . 16, 20, 22, 18, 26, 24, 9
RG,CTM42,G5,42 -19-17MAR95
CTM42 (24MAR95)
05-34
6076 Diesel Engines—S.N. (500000—
)
160101
PN=77
Cylinder Head and Valves/Clean, Inspect and Install Cylinder Head Cap Screws
RG7136
-UN-21FEB94
TORQUE-TURN FLANGED-HEAD CAP
SCREWS—GRADE 180
Arrow (A) points toward front of engine.
-UN-28FEB94
• Using line scribe method to TORQUE-TURN
cylinder head cap screws:
IMPORTANT: DO NOT use multi-viscosity oils to
lubricate cap screws.
RG4471
1. Lubricate cap screws with clean SAE30 engine oil and
install in their proper locations as outlined previously.
2. Tighten cap screw No. 17 to 100 N·m (75 lb-ft) first.
Tighten all remaining cap screws to 100 N·m (75 lb-ft),
beginning with No. 1 and proceed sequentially.
3. Retighten all cap screws to 125 N·m (95 lb-ft)
beginning with No. 1.
05
35
4. Make 90˚ reference marks (A,B) on socket.
5. Install socket on cap screw No. 1 and make a
reference mark on cylinder head that aligns with
reference mark (A) on socket.
6. Turn cap screw 90˚—100˚ until reference mark on
cylinder head aligns with reference mark (B) on socket.
7. Repeat Steps 5 and 6 on all remaining cap screws.
• Using JT05993 Torque Angle Gauge:
RG7138
-UN-28FEB94
After lubricating and tightening cylinder head cap screws
(in proper sequence) according to steps 1, 2, and 3
listed above, follow directions provided with gauge and
TORQUE-TURN each cap screw 90˚—100˚, beginning
with cap screw No. 1 and sequentially proceed thru to
No. 26.
RG,CTM42,G5,36 -19-14FEB95
CTM42 (24MAR95)
05-35
6076 Diesel Engines—S.N. (500000—
)
160101
PN=78
Cylinder Head and Valves/Torque-To-Yield Special Flanged-Head Cap Screws
-UN-28FEB94
TORQUE-TO-YIELD FLANGED-HEAD CAP
SCREWS—GRADE 180 MARKED “SPECIAL”
RG4471
Arrow (A) points toward front of engine.
IMPORTANT: DO NOT use multi-viscosity oils to
lubricate cap screws.
1. Lubricate cap screws with clean SAE30 engine oil and
install in their proper locations as outlined previously.
2. Tighten cap screw No. 17 to 80 N·m (60 lb-ft).
Sequentially (start at cap screw No. 1 and proceed
through cap screw No. 26) tighten all cap screws to 80
N·m (60 lb-ft).
IMPORTANT: If a cap screw is accidentally tightened
more than 90˚ in any one sequence, DO
NOT loosen cap screw but make
adjustments in the next tightening
sequence.
4. Sequentially (start at cap screw No. 1 and proceed
through cap screw No. 26) turn each cap screw 90˚.
Line on top of cap screw will be perpendicular to
crankshaft.
5. Again, sequentially (start at cap screw No. 1 and
proceed through cap screw No. 26) turn each cap screw
90˚. Line on top of cap screw will now be parallel to
crankshaft.
IMPORTANT: Cap screws MUST NOT be tightened
more than a total of 270˚ ±5˚.
-UN-01MAY94
6. Finally, sequentially (start at cap screw No. 1 and
proceed through cap screw No. 26) turn each cap screw
90˚, SO THAT LINE ON TOP OF CAP SCREW IS AS
CLOSE AS POSSIBLE TO BEING PERPENDICULAR
TO THE CRANKSHAFT. It is not necessary to obtain the
final turn in one swing of the wrench. TOTAL AMOUNT
OF TURN FROM STEPS 4, 5, AND 6 IS 270˚ ±5˚.
RG7139
05
36
3. Using an oil proof pen, pencil, or marker, draw a line
parallel to the crankshaft across the entire top of each
cap screw head. This line will be used as a reference
mark.
RG,CTM1,G5,4
CTM42 (24MAR95)
05-36
-19-09AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=79
Cylinder Head and Valves/Install Rocker Arm Assembly
INSTALL ROCKER ARM ASSEMBLY
-UN-23FEB89
1. Install push rods (A) in holes from which removed.
RG3809
2. Install wear caps (B) on valves, making certain caps
rotate freely.
S11,2005,HT
-19-12JUL94
RG3810
-UN-23FEB89
3. Make sure spring pin (A) engages with hole (B) in
shaft.
RG5793
-UN-09AUG91
4. Install shaft clamps (B) and all six cap screws (A).
Tighten cap screws to 75 N·m (55 lb-ft).
RG,CTM42,G5,20 -19-07AUG91
CTM42 (24MAR95)
05-37
6076 Diesel Engines—S.N. (500000—
)
160101
PN=80
05
37
Cylinder Head and Valves/Complete Final Assembly Of Injection Pump Side
COMPLETE FINAL ASSEMBLY OF
INJECTION PUMP SIDE
1. Adjust valve clearance as directed earlier in this
group.
-UN-12AUG91
2. Apply AR31790 SCOTCH-GRIP Adhesive or
equivalent to new gasket, and seal gasket to rocker arm
cover (B). Be sure to follow the manufacturer’s directions
on the package for correct application procedures and
curing times.
3. Install cover and tighten cap screws to 8 N·m (6 lb-ft)
(72 lb-in.).
05
38
5. Connect ventilator outlet hose to adapter on rocker
arm cover and tighten clamp securely.
6. Install water manifold (A). (See INSTALL WATER
MANIFOLD in Group 25.)
RG5798
4. Install fuel injection nozzles (E), leak-off lines (D) and
fuel injection lines (C). (See INSTALL FUEL INJECTION
NOZZLES in Group 35.)
A—Water Manifold
B—Rocker Arm Cover
C—Fuel Injection Lines
D—Leak-off Lines
E—Fuel Injection Nozzles
RG,CTM42,G5,21 -19-28OCT92
CTM42 (24MAR95)
05-38
6076 Diesel Engines—S.N. (500000—
)
160101
PN=81
Cylinder Head and Valves/Complete Final Assembly On Exhaust Manifold Side
COMPLETE FINAL ASSEMBLY ON EXHAUST
MANIFOLD SIDE
-UN-12AUG91
NOTE: Apply PT569 NEVER-SEEZ Compound or
equivalent to all exhaust manifold cap screws,
except 6076 HRW 33, 34, and 35 engines. Also,
intake manifold is installed before exhaust
manifold on these engines.
RG5799
1. Install front exhaust manifold using new gaskets. Do
not tighten cap screws until sealing ring (A) and rear
exhaust manifold is installed.
RG5800
-UN-12AUG91
2. Install rear exhaust manifold using new gaskets and
sealing ring.
3. Tighten cap screws in sequence shown in bottom
illustration to 47 N·m (35 lb-ft).
RG6338
-UN-03AUG92
4. Install turbocharger oil return pipe, using a new
O-ring.
RG,CTM42,G5,22 -19-14FEB95
CTM42 (24MAR95)
05-39
6076 Diesel Engines—S.N. (500000—
)
160101
PN=82
05
39
Cylinder Head and Valves/Complete Final Assembly On Exhaust Manifold Side
5. On 6076T and 6076H Engines, using new gaskets
install intake manifold (A). Tighten cap screws to 47 N·m
(35 lb-ft).
-UN-12AUG91
6. On 6076T Engines, install intake coupling (B). Do not
tighten clamps.
RG5801
7. On 6076T and 6076H Engines, install turbocharger
(C), adapter (D), and exhaust elbow (E). (See INSTALL
TURBOCHARGER in Group 30.)
8. Position intake adapter with turbocharger and intake
manifold and tighten clamps securely.
A—Intake Manifold
B—Intake Coupling
C—Turbocharger
D—Turbocharger Adapter
E—Exhaust Elbow
RG,CTM42,G5,23 -19-16AUG94
RG5802
-UN-13AUG91
9. On 6076A Engines, use new gaskets (A) and install
intake manifold (B). Tighten cap screws to 47 N·m (35
lb-ft).
RG,CTM42,G5,24 -19-22AUG91
-UN-13AUG91
10. On 6076A Engines, using new gaskets and O-rings,
install aftercooler and cover (A). (See INSTALL INTAKE
MANIFOLD AND AFTERCOOLER in Group 30.)
RG5803
05
40
RG,CTM42,G5,25 -19-06SEP91
CTM42 (24MAR95)
05-40
6076 Diesel Engines—S.N. (500000—
)
160101
PN=83
Cylinder Head and Valves/Complete Final Assembly On Exhaust Manifold Side
11. Install water inlet (A) and water outlet (C) hoses.
Tighten hose clamps securely.
12. Install aneroid line (B), if equipped, and tighten
securely.
13. Install turbocharger (D) with couplings. Tighten cap
screws to 47 N·m (35 lb-ft). (See INSTALL
TURBOCHARGER in Group 30.)
-UN-13AUG91
14. If engine oil was drained from crankcase, install new
oil filter and fill with clean oil of correct grade and
viscosity. (See DIESEL ENGINE OIL in Group 02.)
RG5885
15. Fill cooling system with clean coolant. (See ENGINE
COOLANT SPECIFICATIONS in Group 02.)
16. Perform engine break-in as outlined later in this
group. (See PERFORM ENGINE BREAK-IN.)
05
41
A—Water Inlet Hose
B—Aneroid Line
C—Water Outlet Tube and Hose
D—Turbocharger
RG,CTM42,G5,32 -19-28OCT92
CTM42 (24MAR95)
05-41
6076 Diesel Engines—S.N. (500000—
)
160101
PN=84
Cylinder Head and Valves/Perform Engine Break-In
PERFORM ENGINE BREAK-IN
1. Run engine at slow idle no load for 2 minutes. Check
for liquid leaks.
2. Increase RPM to fast idle, then load down to 50 rpm
above rated speed for 20 minutes.
NOTE: Dynamometer is the preferred load control, but
engine can be loaded by matching drag loads to
gear selection.
3. Recheck valve clearance and adjust as necessary.
(See CHECK AND ADJUST VALVE CLEARANCE,
earlier in this group.)
05
42
4. Install rocker arm cover gasket and cover. Tighten
rocker arm cover cap screws to 8 N·m (6 lb-ft) (72
lb-in.). (See COMPLETE FINAL ASSEMBLY OF
INJECTION PUMP SIDE OF ENGINE, earlier in this
group.)
Retorque of cylinder head cap screws after engine
break-in is not required.
IMPORTANT: After engine break-in, follow ALL
recommended hourly service intervals
outlined in your Operator’s Manual.
RG,CTM6,G05,5 -19-14SEP94
CTM42 (24MAR95)
05-42
6076 Diesel Engines—S.N. (500000—
)
160101
PN=85
Group 10
Cylinder Block, Liners, Pistons and Rods
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
-19-05JUN91
Cylinder Liner Puller . . . . . . . . . . . . . . D01062AA
(or D01073AA)
RG5019
-UN-23AUG88
Remove cylinder liners.
S53,D01062,AA -19-07AUG91
RG5074
-UN-23AUG88
Flexible Cylinder Hone . . . . . . . . . . . . D17005BR
10
1
Hone cylinder liners.
S53,D17005,BR -19-07APR88
O-Ring Groove Cleaning Brush . . . . . . . D17015BR
RG5075
-UN-23AUG88
Clean cylinder liner O-ring groove in block.
S53,D17015,BR -19-25MAR91
-UN-27MAR92
Dial Indicator . . . . . . . . . . . . . (English, in.) D17526CI
or (Metric, mm ) D17527CI
RG6246
Use with JDG451 to measure valve recess and cylinder
liner height-to-cylinder block top deck.
RG,D17526CI
CTM42 (24MAR95)
10-1
-19-29OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=86
Cylinder Block, Liners, Pistons and Rods/Special or Essential Tools
RG5076
-UN-23AUG88
Ring Groove Wear Gauge . . . . . . . . . . . . . JDE55
Check wear of keystone ring groove on pistons.
RG5077
S53,JDE55
-19-25MAR91
S53,JDE93
-19-17FEB87
S53,JDE96
-19-25MAR87
S53,JDE98A
-19-16AUG94
-UN-23AUG88
Piston Ring Expander . . . . . . . . . . . . . . . . JDE93
Remove and install piston rings.
RG5031
-UN-23AUG88
Piston Ring Compressor . . . . . . . . . . . . . . JDE96
Compress rings while installing pistons.
Connecting Rod Bushing Service Set . . . . . JDE98A
Set consists of:
1—Cup . . . . . . . . . .
2—Driver . . . . . . . . .
3—Pilot . . . . . . . . . .
4—Driver . . . . . . . . .
5—Driver . . . . . . . . .
6—Pilot . . . . . . . . . .
7—Driver . . . . . . . . .
8—Cup . . . . . . . . . .
9—Pilot . . . . . . . . . .
10—Remover Bushing
Forcing Screw . . . . .
.
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-UN-16FEB94
Remove and install connecting rod bushings.
.
.
.
.
.
.
.
.
.
JDE98-1
JDE98-2
JDE98-3
JDE98-4
JDE98-5
JDE98-6
JDE98-7
JDE98-8
JDE98-9
JDE98-10
STD36104
RG5078
10
2
RG5079
-UN-25JUN94
Connecting Rod Bushing Service Set . . . . . JDG337
Use with JDE98A Bushing Service Set to remove and
install connecting rod bushings.
S53,JDG337,A
CTM42 (24MAR95)
10-2
-19-29JUL94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=87
Cylinder Block, Liners, Pistons and Rods/Other Material
RG5100
-UN-23AUG88
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG681A
Used to restore threaded holes in cylinder block for
cylinder head cap screws.
RG,JDG681A
-19-17MAR95
RG,JT05993
-19-22AUG91
Torque Angle Gauge . . . . . . . . . . . . . . . . . . JT05993
RG5698
-UN-27AUG90
Used to TORQUE-TURN flanged-head cylinder head and
connecting rod cap screws.
SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog
(MTC). Some tools may be available from a local supplier.
Name
Use
D05012ST Precision “Bevelled Edge” Straightedge
Check cylinder block flatness
Piston Ring Groove Cleaner
Clean piston ring grooves
Cylinder Bore Ridge Reamer
Remove carbon from liner bore
10
3
RG,CTM61,G10,6 -19-04AUG94
OTHER MATERIAL
Name
Use
AR54749 Soap Lubricant
Coat O-rings on cylinder liners.
PLASTIGAGE
Determine connecting rod bearing-to-journal
oil clearance.
S11,2010,BS
CTM42 (24MAR95)
10-3
-19-08AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=88
Cylinder Block, Liners, Pistons and Rods/Cylinder Block, Liners, Pistons, and Rods Specifications
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS
ITEM
SPECIFICATION
WEAR LIMIT
0.050—0.127 mm
(0.002—0.005 in.)
——
——
0.051—0.787 mm
(0.002—0.031 in.)
——
——
0.064—0.102 mm
(0.0025—0.0040 in.)
0.165 mm
(0.0065 in.)
0.43—0.69 mm
(0.017—0.027 in.)
0.63—0.89 mm
(0.025—0.035 in.)
——
——
——
——
0.43—0.69 mm
0.017—0.027 in.)
1.27—1.52 mm
(0.050—0.060 in.)
——
——
——
——
115.771—115.789 mm
(4.5579—4.5586 in.)
——
0.076—0.124 mm
(0.0030—0.0049 in.)
0.152 mm
(0.0060 in.)
115.865—115.895 mm
(4.5616—4.5628 in.)
127.94—128.24 mm
(5.037—5.049 in.)
——
——
——
——
.....................
6.05—6.15 mm
(0.238—0.242 in.)
——
——
Cylinder Liner Packing Step Dimension . . . . . . . . . . . .
1.45—1.55 mm
(0.057—0.061 in.)
——
——
Cylinder Liner Maximum Taper . . . . . . . . . . . . . . . . .
0.051 mm
(0.0020 in.)
——
——
Cylinder Liner Height
Above Block . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Piston Protrusion Above Block . . . . . . . . . . .
Piston Oil Control Ring-toGroove Clearance . . . . . . . . . . . . . . . . . . . . . . . .
Piston Compression Ring End Gap:
Pistons Stamped RE50868
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons Stamped RE57512
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
4
Piston OD:
—19.1 mm (0.75 in.) from Bottom of Skirt
Engine Serial No. . . . . . . . . . . . . . . . . . . . . . . . .
Piston-to-Liner Clearance at Bottom of Skirt:
Engine Serial No. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner ID . . . . . . . . . . . . . . . . . . . . . . . . . . .
OD . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Thickness
RG,CTM42,G10,25-19-17MAR95
CTM42 (24MAR95)
10-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=89
Cylinder Block, Liners, Pistons and Rods/Cylinder Block, Liners, Pistons, and Rods Specifications
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS—CONTINUED
ITEM
SPECIFICATION
WEAR LIMIT
0.051 mm
(0.0020 in.)
——
——
8.105—8.155 mm
(0.319—0.321 in.)
8.175—8.225 mm
(0.322—0.324 in.)
——
——
——
——
135.105—135.130 mm
(5.319—5.321 in.)
——
——
129.085—129.135 mm
(5.082—5.084 in.)
125.042—125.122 mm
(4.923—4.926 in.)
——
——
——
——
129.155—129.205 mm
(5.085—5.087 in.)
——
——
125.133—125.183 mm
(4.9265—4.9285 in.)
——
——
0.026—0.126 mm
(0.001—0.005 in.)
0.012—0.140 mm
(0.0005—0.0055 in.)
——
——
——
——
Liner Shim Thickness . . . . . . . . . . . . . . . . . . . . .
0.05 mm
(0.002 in.)
——
——
Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . .
47.597—47.613 mm
(1.8739—1.8745 in.)
——
——
Piston Pin Bore ID in Piston . . . . . . . . . . . . . . . .
47.620—47.630 mm
(1.8748—1.8752 in.)
——
——
Rod Pin Bushing ID (Before Honing) . . . . . . . . . . .
47.579—47.628 mm
1.8732—1.8751 in.)
——
——
Rod Pin Bushing ID (After Honing) . . . . . . . . . . . .
47.655—47.681 mm
(1.8762—1.8772 in.)
——
——
Rod Pin Bore Diameter Without Bushing . . . . . . . .
52.354—52.380 mm
(2.0612—2.0622 in.)
——
——
Cylinder Liner Maximum
Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Counterbore Depth . . . . . . . . . . . . .
Cylinder Liner Flange Thickness . . . . . . . . . . . . . .
Cylinder Liner Flange OD . . . . . . . . . . . . . . . . . .
Outer Diameter of Liner:
at Upper Bore . . . . . . . . . . . . . . . . . . . . . . . .
at Lower Bore
........................
Upper Bore Diameter in Block For
Seating Liners . . . . . . . . . . . . . . . . . . . . . . . .
Lower Bore Diameter in Block for
Seating Liners . . . . . . . . . . . . . . . . . . . . . . . .
Liner-to-Block Clearance:
at Upper Bore . . . . . . . . . . . . . . . . . . . . . . . .
at Lower Bore
........................
10
5
RG,CTM42,G10,29-19-16AUG94
CTM42 (24MAR95)
10-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=90
Cylinder Block, Liners, Pistons and Rods/Cylinder Block, Liners, Pistons, and Rods Specifications
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS—CONTINUED
10
6
ITEM
SPECIFICATION
WEAR LIMIT
Rod Pin-to-Bushing Oil Clearance . . . . . . . . . . . . .
0.042—0.084 mm
(0.0017—0.0033 in.)
0.102 mm
(0.0040 in.)
Rod-to-Pin Bushing Press Fit Specification . . . . . . .
0.084—0.147 mm
(0.0033—0.0058 in.)
——
——
Connecting Rod Bore Without Bearings . . . . . . . . .
81.051—81.077 mm
(3.191—3.192 in.)
——
——
Connecting Rod Bearing Assembled ID . . . . . . . . .
76.21—76.26 mm
(3.0004—3.0024 in.)
——
——
Crankshaft Rod Journal OD . . . . . . . . . . . . . . . . .
76.15—76.18 mm
(2.9980—2.9992 in.)
——
——
Bearing-to-Journal Clearance . . . . . . . . . . . . . . . .
0.030—0.110 mm
(0.0012—0.0044 in.)
——
——
Maximum Connecting Rod/Cap Gap . . . . . . . . . . .
0.254 mm (0.0100 in.)
——
Maximum Connecting Rod Out-of-Round . . . . . . . .
0.025 mm (0.0010 in.)
——
352.35—352.50 mm
(13.872—13.878 in.)
——
——
69.987—70.013 mm
(2.7554—2.7564 in.)
——
——
0.038 mm (0.0015 in.)
——
New Camshaft Bushing-to-Journal Clearance . . . . .
0.063—0.115 mm
(0.0025—0.0045 in.)
——
——
Camshaft Bushing ID . . . . . . . . . . . . . . . . . . . . .
67.076—67.102 mm
(2.6408—2.6418 in.)
——
——
0.10 mm (0.004 in.)
——
0.025 mm (0.001 in.)
——
222.20—222.30 mm
(8.748—8.752 in.)
——
——
Centerline of Main Bearing Bore-toTop Deck of Cylinder Block . . . . . . . . . . . . . . .
Camshaft Bushing Bore in Block . . . . . . . . . . . . . .
Maximum Runout of Camshaft Bushing
Bore in Block . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Top Deck:
Maximum Out-of-Flat Over Entire
Length or Width . . . . . . . . . . . . . . . . . . . . . .
Straightness per Any 305 mm (12 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centerline of Rod Pin Bore-to-Centerline
of Crankshaft Journal Bore . . . . . . . . . . . . . . . .
RG,CTM42,G10,20-19-14FEB95
CTM42 (24MAR95)
10-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=91
Cylinder Block, Liners, Pistons and Rods/Cylinder Block, Liners, Pistons, and Rods Specifications
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS—CONTINUED
TORQUES
Connecting Rod Cap Screws:
Initial * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final (All Cap Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Cooling Orifices into Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Cap Screws
(for Checking Liner Standout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* See INSTALL PISTONS AND CONNECTING RODS, later in this
group, before tightening cap screws.
27 N·m (20 lb-ft)
75 N·m (55 lb-ft)
Plus 90—100˚
9.6—12.4 N·m
(85—110 lb-in.)
68 N·m (50 lb-ft)
RG,CTM42,G10,39-19-16AUG94
10
7
CTM42 (24MAR95)
10-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=92
Cylinder Block, Liners, Pistons and Rods/Preliminary Liner, Piston, and Rod Checks
PRELIMINARY LINER, PISTON AND ROD CHECKS
• Scuffed or Scored Pistons:
• Stuck Rings:
Insufficient lubrication.
Insufficient cooling.
Improper piston-to-liner clearance.
Coolant leakage in crankcase.
Misaligned or bent connecting rod.
Improperly installed piston.
Low oil level.
Improper operation.
Incorrect connecting rod bearing clearance.
Carbon build-up in ring groove.
Improper break-in.
Worn piston.
Contaminated oil.
Distorted cylinder liner.
Improper oil classification.
Improper periodic service.
Poor operating conditions.
Coolant leakage in crankcase.
Excessive cylinder liner taper.
• Cylinder Liner Wear and Distortion:
Incorrectly installed compression rings.
Insufficient lubrication.
Uneven cooling around liner.
Improper piston-to-liner clearance.
Liner bore damage.
• Warped Cylinder Block:
• Worn or Broken Compression Rings:
Insufficient cooling.
10
8
Insufficient lubrication.
Insufficient cooling.
Improper ring installation.
Improper combustion.
Improper timing.
Abrasives in combustion chamber.
• Broken Connecting Rod:
Inadequate piston-to-liner clearance.
Worn connecting rod bearing.
Distorted cylinder liner.
Piston pin failure.
• Clogged Oil Control Ring:
• Piston Pin and Snap Ring Failure:
Improper oil.
Excessive Blow-by.
Contaminated oil.
Improper periodic service.
Low operating temperature.
Misaligned connecting rod.
Excessive crankshaft end play.
Incorrect snap rings.
• Mottled, Grayish or Pitted Compression Rings:
• Dull Satin Finish and Fine Vertical Scratches on
Rings:
Internal coolant leaks.
Dirt and abrasive in air intake system.
CTM8,GR10,37
CTM42 (24MAR95)
10-8
-19-17AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=93
Cylinder Block, Liners, Pistons and Rods/Remove Pistons and Connecting Rods
REMOVE PISTONS AND CONNECTING
RODS
CAUTION: DO NOT drain engine coolant until
the temperature is below operating
temperature. Then slowly loosen water pump
drain valve (A) and block drain valve (B) to
relieve any pressure.
RG5836
N
-UN-28AUG91
The engine does not always have to be removed from
the machine to service the pistons and connecting rods.
If engine is to be removed, see your Machine Technical
Manual.
IMPORTANT: Both water pump drain valve and block
drain valve must be opened to
completely drain both sides of the
engine.
1. Drain all coolant and engine oil.
10
9
RG,CTM42,G10,19-19-29OCT92
NOTE: If engine is to be completely disassembled, follow
DISASSEMBLY SEQUENCE in Group 04.
2. Remove cylinder head. (See REMOVE CYLINDER
HEAD in Group 05.)
3. Remove oil pan and oil pump. (See REMOVE
ENGINE OIL PUMP in Group 20.)
RG3657
-UN-13DEC88
A—#1 Keystone Compression Ring
B—#2 Keystone Compression Ring
C—Oil Control Ring with Expander
D—Snap Ring (2 used)
E—Piston
F—Piston Pin
G—Piston Pin Bushing
H—Connecting Rod
I—Bearings
J—Connecting Rod Cap
K—Special Cap Screw
RG,CTM42,G10,30-19-14FEB95
CTM42 (24MAR95)
10-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=94
Cylinder Block, Liners, Pistons and Rods/Remove Pistons and Connecting Rods
-UN-07DEC88
4. Use approximately 51 mm (2.0 in.) long cap screws
(A) and 5/8 in. ID x 1-3/4 in. OD x 3.18 mm (1/8 in.)
thick washers (B) to bolt down cylinder liners (C) in the
seven locations as shown. Tighten cap screws to 68 N·m
(50 lb-ft).
RG3819
NOTE: Do not rotate crankshaft with cylinder head
removed unless liners are bolted down. Bolt
liners down before removing pistons.
IMPORTANT: Cap screws and washers must be
tightened to the above specification to
achieve an accurate reading when
checking liner standout (height above
block).See MEASURE LINER
STANDOUT (HEIGNT ABOVE BLOCK),
later in this group.
As the cylinder liner wears, a ridge is formed at the top
of piston ring travel zone. If this ridge gets too high,
pistons and rings can be damaged when they are
removed. Remove any ridge from liner bores with a
scraper or ridge reamer before removing pistons.
10
10
5. Before removing pistons, visually inspect condition of
cylinder liners with pistons at bottom dead center “BDC”.
Liners will require replacement if:
—The crosshatch honing pattern is not visible
immediately below the top ring turn around area.
—Liners are pitted or contain deep vertical scratches that
can be detected by the fingernail.
No further inspection is required if any one of the above
conditions are found.
RG,CTM42,G10,41-19-14FEB95
CTM42 (24MAR95)
10-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=95
Cylinder Block, Liners, Pistons and Rods/Remove Pistons and Connecting Rods
NOTE: Connecting rod bearing-to-journal oil clearance
should be measured before removing piston/rod
assembly.
RG5807
-UN-12AUG91
6. Rod bearing-to-journal oil clearance can be checked
with PLASTIGAGE if rod is connected to crankshaft. If
rod is out of engine, measure ID of assembled
connecting rod bearings and compare with OD of
crankshaft journal.
NOTE: Use PLASTIGAGE as directed by the
manufacturer. Remember, the use of
PLASTIGAGE will determine bearing journal
clearance, but will not indicate the condition of
either surface.
-UN-12AUG91
IMPORTANT: DO NOT use pneumatic wrench to
tighten connecting rod cap screws.
Using pneumatic wrenches may cause
thread damage.
RG5806
Keep bearing inserts with their
respective rods and caps. Mark rods,
pistons, and caps to insure correct
assembly in same location.
7. Remove rod cap screws and rod caps (A) with
bearings (B).
RG,CTM42,G10,2 -19-14FEB95
8. Gently tap piston (A) through top of cylinder block
from the bottom. (Crankshaft shown removed.)
-UN-12AUG91
NOTE: Once piston rings have cleared cylinder liner,
hold on to piston to prevent piston from dropping.
RG5808
IMPORTANT: If liners are to be reused, be extremely
careful not to let connecting rod hit
liner bore when removing piston/liner
assembly.
Pistons and liners are selectively fitted
to maintain piston-to-liner clearance.
Always keep matched pistons and
liners together as a set and each set
MUST BE installed in the same cylinder
as removed.
RG,CTM42,G10,3 -19-29OCT92
CTM42 (24MAR95)
10-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=96
10
11
Cylinder Block, Liners, Pistons and Rods/Measure Cylinder Liner Standout (Height above Block)
-UN-12AUG91
MEASURE CYLINDER LINER STANDOUT
(HEIGHT ABOVE BLOCK)
RG5829
IMPORTANT: Remove all old gasket material, rust,
carbon, and other foreign material from
top deck of block. Gasket surface must
be clean. Use compressed air to
remove all loose foreign material from
cylinders and top deck.
NOTE: Liners having obvious defects must be replaced
as a matched piston and liner set.
1. Bolt liners down using cap screws and flat washers.
Flat washers should be at least 3.18 mm (1/8 in.) thick.
Tighten cap screws to 68 N·m (50 lb-ft).
RG5813
10
12
-UN-08MAR94
2. Use JDG451 Gauge along with D17526CI (English,
in.) or D17527CI (Metric, mm) Dial Indicator (B) or
KJD10123 Gauge to measure the height (C) of bolted
down liners (A) that are not obviously defective before
removal from block (D). Cap screws must be tightened
to 68 N·m (50 lb-ft) to achieve an accurate reading.
NOTE: Variations in measurement readings may occur
within one cylinder and/or between adjacent
cylinders.
3. Measure each liner in four places, approximately at 1,
5, 7 and 11 O’clock positions as viewed from the rear of
the engine (flywheel end). Record all measurements.
A—Cylinder Liner
B—Dial Indicator
C—Liner Height
D—Cylinder Block
4. Remove any liner that does not meet standout
specification at any location and measure liner flange
thickness, as explained later in this group. Use liner
shims or replace piston/liner sets as necessary.
LINER HEIGHT SPECIFICATIONS
New Liner Height Above Block . . . . . . . . . . . . . .
0.051—0.127 mm
(0.002—0.005 in.)
RG,CTM42,G10,21-19-14FEB95
CTM42 (24MAR95)
10-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=97
Cylinder Block, Liners, Pistons and Rods/Remove Cylinder Liners
REMOVE CYLINDER LINERS
-UN-12AUG91
1. Remove cap screws and washers securing liners to
cylinder block.
2. Number cylinder liners and mark fronts to assure
correct assembly.
RG5809
IMPORTANT: Keep matched pistons and liners
together. Liners must be reinstalled in
same cylinder bore.
3. Use D01062AA or D01073AA Cylinder Liner Puller (B)
to remove cylinder liner (A).
RG,CTM42,G10,4 -19-12APR93
IMPORTANT: When using D01062AA (or D01073AA)
Cylinder Liner Puller (B) to remove
liners (A), be sure jaw (C) of puller is
correctly positioned before attempting
to remove liner.
10
13
RG1179
-UN-13DEC88
DO NOT over-tighten liner puller to
remove liners. Doing so could easily
break liners.
S11,0402,AK
CTM42 (24MAR95)
10-13
-19-02APR93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=98
Cylinder Block, Liners, Pistons and Rods/Deglazing Cylinder Liners
4. Remove the cylinder liner square packing (A) from
liner (E).
5. Remove red O-ring (B) and black O-ring (C) from
cylinder block (D).
RG3825
-UN-13DEC88
A—Square Packing (Neoprene)
B—Red O-Ring (Silicone)
C—Black O-Ring (Viton)
D—Cylinder Block
E—Liner
RG,CTM42,G10,5 -19-07AUG91
DEGLAZE CYLINDER LINERS
1. Secure cylinder liner in a holding fixture. (See Dealer
Fabricated Tools, Group 199 for assembly of holding
fixture.)
2. Use D17004BR Flexible Cylinder Hone to deglaze
cylinder liner.
R26164
-UN-13DEC88
NOTE: Use honing oil along with flex hone when
deglazing liners.
S11,0402,AS
-19-08FEB95
S11,0402,AT
-19-12APR93
3. Use D17005BR Hone according to instructions
supplied with tool to obtain a 45˚ cross-hatch pattern.
-UN-13DEC88
Thoroughly clean liners after deglazing. See CLEAN
CYLINDER LINERS, earlier in this group.
R26165
10
14
CTM42 (24MAR95)
10-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=99
Cylinder Block, Liners, Pistons and Rods/Disassemble and Clean Piston
CLEAN CYLINDER LINERS
1. Use a stiff bristle brush to remove all debris, rust, and
scale from O.D. of liners, under liner flange, and in
O-ring packing areas. Make certain there are no nicks or
burrs in areas where packings will seat.
IMPORTANT: Do not use gasoline, kerosene, or
commercial solvents to clean liners.
Solvents will not remove all the
abrasives from liner walls.
2. Thoroughly clean liner I.D. with a 50 per cent solution
of hot water and liquid detergent.
3. Rinse thoroughly and wipe dry with a clean rag.
4. Swab out liner as many times as necessary with clean
SAE 10W oil.
5. Clean liner until a white rag shows no discoloration.
10
15
RG,CTM61,G10,9 -19-02APR93
DISASSEMBLE PISTON/ROD ASSEMBLY
AND CLEAN PISTON
-UN-13DEC88
1. Remove piston snap rings. Remove piston pin and
connecting rod from piston.
RG5228
NOTE: Discard snap rings, DO NOT reuse.
RG,CTM86,G10,11-19-14FEB95
RG5229
-UN-13DEC88
2. Remove piston rings (B) using the JDE93 Piston Ring
Expander (A). Discard rings.
RG,CTM86,G10,12-19-14FEB95
CTM42 (24MAR95)
10-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=100
Cylinder Block, Liners, Pistons and Rods/Visually Inspect Pistons
3. Clean piston ring grooves using a piston ring groove
cleaning tool.
N
CAUTION: Always follow manufacturer’s
instructions, and safety steps exactly. When
washing pistons, always use a stiff bristle
brush—NOT A WIRE BRUSH—to loosen carbon
residue. DO NOT bead blast ring groove areas.
4. Clean pistons by any of the following methods:
-UN-27JAN92
• Immersion-Solvent “D-Part”
• Hydra-Jet Rinse Gun
• Hot water with liquid detergent soap.
RG6088
If cleaning with hot water and liquid detergent, soak
pistons in a 50 per cent solution of liquid household
detergent and hot water for 30 to 60 minutes. Use a stiff
bristle brush—NOT A WIRE BRUSH—to loosen carbon
residue. Dry with compressed air.
10
16
RG,CTM86,G10,13-19-14FEB95
VISUALLY INSPECT PISTONS
1. Carefully inspect clean pistons under magnification.
Check for:
• Signs of fatigue
• Fine cracks in piston head (A)
• Bent or broken ring lands (B)
• Cracks in the skirt (C) at the inner and outer ends of
the piston pin bore
• Original machining marks must be visible
• Excessive piston skirt wear
RG3326
-UN-13DEC88
If any defects are found, replace the piston and liner as
a set.
(Defects Exaggerated)
RG,CTM61,G10,10-19-29OCT92
CTM42 (24MAR95)
10-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=101
Cylinder Block, Liners, Pistons and Rods/Check Piston Ring Groove Wear
CHECK PISTON COMPRESSION RING
GROOVE WEAR
RG5230
-UN-13DEC88
1. Use the JDE55 Ring Groove Wear Gauge to check
wear of keystone ring grooves. Check each groove at
several locations.
10
17
RG,CTM42,G10,32-19-14FEB95
Gauge shoulders should not contact ring land (D) of
piston. If ring grooves are worn, replace piston and liner
as a set. If ring grooves are good, proceed to next step.
R24201
-UN-13DEC88
A—Piston with Worn Ring Groove
B—Keystone Ring Groove
C—JDE55 Ring Groove Wear Gauge
D—Ring Land
E—Gauge Shoulder
F—Piston with Good Ring Groove
S11,2010,DG
CTM42 (24MAR95)
10-17
-19-17FEB87
6076 Diesel Engines—S.N. (500000—
)
160101
PN=102
Cylinder Block, Liners, Pistons and Rods/Install Piston Pin in Piston Pin Bore
MEASURE OIL CONTROL RING GROOVE
-UN-13DEC88
1. Check oil control ring-to-groove clearance by installing
a new ring in groove.
2. Measure clearance with a feeler gauge at several
points. Compare measurements with specifications given
below.
RG5234
OIL CONTROL RING-TO-GROOVE CLEARANCE SPECIFICATIONS
New Part Clearance . . . . . . . . . . . . . . . . . . . . . 0.064—0.102 mm
(0.0025—0.0040 in.)
Maximum Serviceable Clearance . . . . . . . . . . . . . . . . . . 0.165 mm
(0.0065 in.)
NOTE: Replace piston and liner (as a set) if oil control
ring clearance exceeds specifications given.
S11,2010,JF
-19-29OCT92
INSTALL PISTON PIN IN PISTON PIN BORE
-UN-13DEC88
NOTE: Piston pin must be in good condition and not
worn beyond specification given below.
1. Dip piston pin in clean engine oil.
2. Install pin (A) through piston.
RG5231
Pin should pass through piston using only light thumb
pressure. Check taper in piston pin bore by inserting pin
from both sides. If pin enters freely, but binds in the
center, the bore could be tapered (B). If bore is not
tapered, insert pin to check for bore alignment. Pin
should not “click” or need to be forced into bore on
opposite side (C).
-UN-26JUL94
3. Check piston pin and piston bore specifications. If
either are not within specification, replace pin, piston,
and liner.
PISTON PIN/BORE SPECIFICATIONS
RG4984
10
18
Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . 47.60—47.61 mm
(1.8739—1.8745 in.)
Piston Pin Bore ID . . . . . . . . . . . . . . . . . . . . . . 47.62—47.63 mm
(1.8748—1.8752 in.)
RG,CTM42,G10,33-19-14FEB95
CTM42 (24MAR95)
10-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=103
Cylinder Block, Liners, Pistons and Rods/Visually Inspect Cylinder Liners
VISUALLY INSPECT CYLINDER LINERS
IMPORTANT: If pitting has occurred, check condition
of coolant.
1. Inspect exterior length of liner for pitting (A). Check
packing step for erosion (B). If pitting or erosion is
observed, measure the depth of pits and erosion with a
fine wire or needle.
Replace piston and liner if:
—Pitting depth is one-half liner thickness (C) or more.
—Erosion depth is one-half packing step (D) or more.
CYLINDER LINER SPECIFICATIONS
-UN-13DEC88
Cylinder Liner Thickness . . . . . . . . . . . . . . . . . . 6.05—6.15 mm
(0.238—0.242 in.)
Packing Step Dimension . . . . . . . . . . . . . . . . . . 1.45—1.55 mm
(0.057—0.061 in.)
RG4643
NOTE: Liners are reusable if the depth of pits or erosion
is less than one-half the amount specified. When
installing these liners, rotate 90˚ from original
position. The liners should be deglazed and ring
sets installed on pistons.
A—Liner Pitting
B—Liner Erosion
C—Liner Thickness
D—Packing Step
RG,CTM42,G10,34-19-22JUL94
2. Visually examine liner ID. Replace piston and liner if:
— The crosshatch honing pattern is not visible
immediately below the top ring turn-around area.
— Liners are pitted or contain deep vertical scratches
that can be detected by the fingernail.
-UN-13DEC88
3. Carefully examine liner for signs of fatigue, such as
fine cracks in the flange area (A) and cracks in the ring
travel area (B).
RG1188
NOTE: Inspect block for cracks or erosion in the O-ring
packing areas. See INSPECT AND CLEAN
CYLINDER BLOCK, later in this group.
(Exaggerated defects)
RG,CTM61,G10,14-19-22JUL94
CTM42 (24MAR95)
10-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=104
10
19
Cylinder Block, Liners, Pistons and Rods/Cylinder Liner Manufacturing Date Code Explanation
RG5944
-UN-30AUG91
CYLINDER LINER MANUFACTURING DATE CODE EXPLANATION
10
20
A manufacturing four-digit date code will appear on
the liner. The following is an example of this four-digit
date code:
HL90
H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner Material Type
L . . . . . . . . . . . . . . . . . . . . . Month Liner was Manufactured
90 . . . . . . . . . . . . . . . . . . . . Year Liner was Manufactured
When installing new liners, the liner manufacturing
date code should be toward the front of the engine.
This will help with future repairs in knowing whether
the liners have been moved or not during a previous
repair.
Liner Material Specification
H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardened Bore
Month Liner
A .......
B .......
C .......
D .......
E .......
F .......
G .......
H .......
I ........
J ........
K .......
L .......
was Manufactured
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
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. January
. February
. . March
. . . . April
. . . . May
. . . June
. . . . July
. . August
September
. . October
. November
. December
Year Liner Was Manufactured
90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990
91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1991
etc.
RG,CTM42,G10,11-19-08MAR94
CTM42 (24MAR95)
10-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=105
Cylinder Block, Liners, Pistons and Rods/Measure Piston Skirt OD
MEASURE PISTON SKIRT OD
1. Measure piston skirt diameter (B) at right angles to
piston pin bore (C) 19.1 mm (0.75 in.) from the bottom
of the piston (A).
2. Measure cylinder liner as directed later in this group
and compare with piston measurement.
-UN-13DEC88
PISTON SKIRT DIAMETER SPECIFICATION
RG5232
Piston OD: 19.1 mm (0.75 in.) from
Bottom of Skirt . . . . . . . . . . . . . . . . . . 115.771—115.789 mm
(4.5579—4.5586 in.)
RG,CTM42,G10,35-19-17MAR95
3. Place piston (without rings) in matched liner.
10
21
4. Compare liner ID measurement with piston skirt OD
measurement to determine piston-to-liner clearance (A).
Piston-to-liner clearance specifications are:
PISTON-TO-LINER CLEARANCE
New Part . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.076—0.124 mm
(0.0030—0.0049 in.)
Maximum Wear Tolerance . . . . . . . . . . . . . . . . . . . . . 0.152 mm
(0.0060 in.)
Replace piston and liner as a matched set if clearance
exceeds limit.
RG5233
-UN-13DEC88
NOTE: Pistons and liners require replacement if liner
taper or out-of-roundness (top-to-bottom in ring
travel area) is more than 0.051 mm (0.0020 in).
See MEASURE CYLINDER LINERS, later in this
group.
RG,CTM42,G10,36-19-17MAR95
CTM42 (24MAR95)
10-21
6076 Diesel Engines—S.N. (500000—
)
160101
PN=106
Cylinder Block, Liners, Pistons and Rods/Measure Liner Flange Thickness
MEASURE CYLINDER LINER ID
IMPORTANT: ALWAYS measure liners at room
temperature.
A—Measure liner bore parallel to piston pin at top end of
ring travel.
D—Measure bore in same position at bottom end of ring
travel.
R25922
C—Measure bore at right angle to piston pin at top end
of ring travel.
-UN-13DEC88
B—Measure bore in same position at bottom end of ring
travel.
Compare measurements A, B, C, and D to determine if
liner is tapered or out-of-round.
Compare liner ID with piston OD.
CYLINDER LINER SPECIFICATIONS
Maximum Wear or Taper in
Ring Travel Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 mm
(0.002 in)
Maximum Liner Out-of-Round . . . . . . . . . . . . . . . . . . . . . 0.051 mm
(0.002 in.)
Maximum Piston-to-Liner Clearance . . . . . . . . . . . . . . . . . . 0.15 mm
(0.006 in.)
NOTE: Replace piston and liner (as a set) if they exceed
wear specifications given.
S11,2010,JQ
-19-14FEB95
S11,2510,AV
-19-16AUG94
MEASURE CYLINDER LINER FLANGE
THICKNESS
-UN-13DEC88
Measure cylinder liner flange thickness at several
locations. If liner flange is not within specifications,
replace piston and liner set.
LINER FLANGE SPECIFICATIONS
Flange Thickness . . . . . . . . . . . 8.175—8.225 mm (0.322—0.324 in.)
RG4727
10
22
CTM42 (24MAR95)
10-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=107
Cylinder Block, Liners, Pistons and Rods/Inspect and Measure Connecting Rod Bearings
INSPECT AND MEASURE CONNECTING
ROD BEARINGS
IMPORTANT: Never use new connecting rod cap
screws when checking rod bearing ID.
Use new cap screws only for final
assembly of connecting rods.
Rod bearing-to-journal oil clearance can be checked with
PLASTIGAGE, if rod is connected to crankshaft. If rod is
out of engine, measure ID of connecting rod bearings
and compare with OD of crankshaft journal.
2. Install connecting rod cap (A) on rod (B) with bearings
(C) in correct position.
-UN-01APR91
3. Tighten rod cap-to-rod using TORQUE-TURN method.
(See USE TORQUE-TURN METHOD FOR PROPER
TORQUE, described later in this group.)
RG5705
1. With crankshaft removed, measure connecting rod
journal OD at several points.
10
23
RG,CTM42,G10,40-19-29OCT92
4. Using an inside micrometer (A) measure ID of
bearing.
-UN-13DEC88
5. Subtract OD of crankshaft journals from ID of rod
bearings to obtain oil clearance.
6. Compare measurements with the following
specifications.
RG3824
CONNECTING ROD BEARING AND JOURNAL SPECIFICATIONS
Crankshaft Journal OD . . . . . . . . . . . . . . . . . . . 76.150—76.180 mm
(2.9980—2.9992 in.)
Assembled Rod Bearing ID . . . . . . . . . . . . . . . . 76.210—76.260 mm
(3.0005—3.0025 in.)
Oil Clearance (new parts) . . . . . . . . . . . . . . . . . . 0.030—0.110 mm
(0.0012—0.0044 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.152 mm
(0.0060 in.)
7. Inspect connecting rod bearings for wear or damage.
If bearings are worn or not within specification, replace
both connecting rod bearing and rod pin bearing.
S11,2010,JR
CTM42 (24MAR95)
10-23
-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=108
Cylinder Block, Liners, Pistons and Rods/Inspect Rod and Cap
INSPECT CONNECTING ROD AND CAP
-UN-13DEC88
1. Inspect rod and cap for wear or damage, such as
chips or cracks in the area of the tongue-and-groove
joints (A).
RG3749
2. Inspect in and around cap screw holes (B) in cap. If
any defects are found, replace rod and cap.
S11,0402,AE
-19-08MAR94
S11,2010,JS
-19-14FEB95
3. Carefully clamp rod in a soft-jawed vise (cap end
upward).
-UN-13DEC88
4. Install cap WITHOUT bearing inserts.
10
24
RG4982
IMPORTANT: Never use new connecting rod cap
screws when checking rod bore ID. Use
new cap screws only for final assembly
of connecting rods.
5. Initially tighten blind hole cap screw to 27 N·m (20
lb-ft), then tighten open hole cap screw to same torque.
6. Tighten cap screws to 75 N·m (55 lb-ft), then tighten
each cap screw an additional 90˚—100˚. (See
TORQUE-TURN CONNECTING ROD CAP SCREWS,
later in this group.)
CTM42 (24MAR95)
10-24
6076 Diesel Engines—S.N. (500000—
)
160101
PN=109
Cylinder Block, Liners, Pistons and Rods/Inspect Rod and Cap
6. Using an inside micrometer, measure rod bore at
center of bore and record measurements as follows:
A. At right angle to rod/cap joint.
B. At 45˚ left of measurement “A”.
C. At 45˚ right of measurement “A”.
ROD BORE SPECIFICATIONS
-UN-11MAR93
Rod Bore ID . . . . . . . . . . . . . . . . . . . . . . . . . . 81.051—81.077 mm
(3.191—3.192 in.)
RG6661
7. Compare the measurements. If difference between the
greatest and least measurement is more than 0.04 mm
(0.0016 in.), the rod and cap are out-of-round. Replace
both connecting rod and cap.
8. Remove cap screw (D). Using a feeler gauge,
measure gap at rod/cap joint (E). If gap is excessive,
mating surfaces of rod and cap are worn and must be
replaced.
ROD CAP SPECIFICATION
Maximum End Gap . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
10
25
S11,2010,JU
-19-12APR93
9. Measure connecting rod pin bore-to-crankshaft bore
center-to-center dimension (A) and compare with
specification given. If measurement is not within
specification, replace rod.
CENTERLINE OF PISTON BORE-TO-CRANKSHAFT BORE
. . . . . . . . . . . . . . 222.20—222.30 mm (8.748—8.752 in.)
RG6455
-UN-22OCT92
New part
RG,CTM42,G10,37-19-16AUG94
CTM42 (24MAR95)
10-25
6076 Diesel Engines—S.N. (500000—
)
160101
PN=110
Cylinder Block, Liners, Pistons and Rods/Inspect Piston Pins and Bushings
INSPECT PISTON PINS AND BUSHINGS
-UN-13DEC88
1. Insert piston pin (A) through piston pin bushing and
carefully clamp in a soft-jawed vise.
RG3172
2. Rotate connecting rod (B) back and forth several
times to make sure connecting rod moves freely on
piston pin.
3. Remove piston pin from vise and connecting rod.
S11,2010,DM
-19-08MAR94
S11,2010,JG
-19-14SEP94
-UN-13DEC88
4. Insert pin from either side of rod bushing. If pin is free
on one end, but tight on the other, the bore could be
tapered (A). If pin enters freely from both sides, but is
tight in the center, bore is bellmouthed (B).
5. Measure ID of rod pin bushing and OD of piston pin.
Compare measurements with specifications given below:
10
26
RG4983
PISTON PIN BORE SPECIFICATIONS
OD of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . 47.597—47.613 mm
(1.8739—1.8745 in.)
ID of Pin Bore in Piston . . . . . . . . . . . . . . . . . . 47.620—47.630 mm
(1.8748—1.8752 in.)
ID of Installed Rod Pin Bushing
(After Boring) . . . . . . . . . . . . . . . . . . . . . . . . . 47.655—47.681 mm
(1.8762—1.8772 in.)
Rod Pin-to-Bushing Oil Clearance . . . . . . . . . . . . 0.042—0.084 mm
(0.0017—0.0033 in.)
Maximum Serviceable . . . . . . . . . . . . . . . . . . . . . . . . . 0.102 mm
(0.0040 in.)
6. If necessary, remove and replace piston pin bushing.
See REMOVE PISTON PIN BUSHING, CLEAN AND
INSPECT PIN BORE, later in this group.
CTM42 (24MAR95)
10-26
6076 Diesel Engines—S.N. (500000—
)
160101
PN=111
Cylinder Block, Liners, Pistons and Rods/Clean and Inspect Piston Pin Bushing Bore in Rod
REMOVE PISTON PIN BUSHING
IMPORTANT: Do not use any power tool to remove
or install piston pin bushing.
1. If necessary, remove pin bushing with the JDG337
Connecting Rod Bushing Service Set.
Use the following tools from the service set:
A—JDG339 Cup
B—JDG338 Adapter
C—JDE98-4 Driver
D—STD36104 Forcing Screw with Washer
RG4985
-UN-13DEC88
IMPORTANT: Use care to properly align the JDE98-4
Driver with bushing so that the
connecting rod bushing bore is not
damaged.
S11,2010,J1
-19-12APR93
S11,2010,JJ
-19-12APR93
CLEAN AND INSPECT CONNECTING ROD
PIN BORE
-UN-13DEC88
1. Clean rod bushing bore using a medium grit emery
cloth, as burrs will distort bushing. Install bushing on
opposite side of rod burr.
RG5227
2. If necessary, file a slight chamfer (A) around bore to
remove any sharp edges. Chamfer will also aid in
bushing installation.
3. Measure rod pin bore in three places approximately
45˚ apart. Compare the measurements with the
specifications given below:
CONNECTING ROD PIN BORE SPECIFICATIONS
(Bushing Removed)
ID of Rod Pin Bore . . . . . . . . . . . . . . . . . . . . . 52.354—52.380 mm
(2.0612—2.0622 in.)
IMPORTANT: If connecting rod pin bore diameter is
not within specification or bushing has
spun in rod, discard rod and replace
with a new one.
CTM42 (24MAR95)
10-27
6076 Diesel Engines—S.N. (500000—
)
160101
PN=112
10
27
Cylinder Block, Liners, Pistons and Rods/Install Piston Pin Bushing in Connecting Rod
INSTALL PISTON PIN BUSHING IN ROD
1. Lubricate rod bushing bore and bushing with clean
engine oil. Install bushing using the JDG337 and
JDE98A Connecting Rod Bushing Service Sets.
Use the following tools from the above sets and
assemble in sequence as shown:
A—STD36104 Forcing Screw With Washer
B—JDE98A Driver
C—JDG338 Adapter
D—Service Bushing
E—JDE98-3 Pilot
F—JDE339 Cup
IMPORTANT: Be sure oil hole in service bushing and
connecting rod are properly aligned.
2. Precision bore and hone bushing to the specified
dimensions.
RG4986
10
28
-UN-13DEC88
Boring the piston pin bushing should
be done ONLY by experienced
personnel on equipment capable of
maintaining bushing specification.
CONNECTING ROD PIN BORE AND BUSHING SPECIFICATIONS
Rod Pin Bore-to-Bushing Press Fit
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.084—0.147 mm
(0.0033—0.0058 in.)
ID of Installed Service Rod Pin
Bushing (Before Honing) . . . . . . . . . . . . . . . . . . 47.579—7.628 mm
(1.8732—1.8751 in.)
ID of Installed Rod Pin Bushing
(After Honing) . . . . . . . . . . . . . . . . . . . . . . . . . 47.655—47.681 mm
(1.8762—1.8772 in.)
Bearing Bore-to-Pin Bushing
Bore (Center-to-Center) Length . . . . . . . . . . . . 222.20—222.30 mm
(8.748—8.752 in.)
3. Check piston pin-to-rod pin bushing clearance. See
INSPECT PISTON PINS AND BUSHINGS, earlier in this
group. Replace piston pin as required.
S11,2010,JK
CTM42 (24MAR95)
10-28
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=113
Cylinder Block, Liners, Pistons and Rods/Remove and Clean Piston Cooling Orifices
COMPLETE DISASSEMBLY OF CYLINDER BLOCK (IF REQUIRED)
If complete inspection and “Hot Tank” cleaning of
cylinder block is required, refer to the appropriate
group for removal of all external and internal mounted
components listed below:
1. Remove crankshaft and pulley if not previously
removed. (Group 15)
4. Remove timing gear train and camshaft. (Group
16)
5. Remove fuel injection pump and fuel filter
assembly. (Group 35)
6. If necessary to “Hot Tank” the block, remove oil
gallery plugs, water gallery plugs, piston cooling
orifices and the engine serial number plate. (See
REMOVE AND CLEAN PISTON COOLING
ORIFICES, later in this group.)
2. Remove all remaining lubrication system
components. (Group 20) Remove starting motor.
3. Remove water pump and all remaining cooling
system components. (Group 25)
RG,CTM42,G10,6 -19-22JUL94
REMOVE AND CLEAN PISTON COOLING
ORIFICES
10
29
1. Remove all six piston cooling orifices (A) and inspect
each cooling orifice to make sure it is not plugged or
damaged.
2. Use a soft wire and compressed air to clean orifice.
Replace, if condition is questionable.
RG5811
-UN-12AUG91
IMPORTANT: A piston cooling orifice failure could
cause damage to pistons, piston pins,
rod pin bushings, and liners. If a piston
cooling orifice is left out, low or no oil
pressure will result.
RG,CTM42,G10,7 -19-29OCT92
CTM42 (24MAR95)
10-29
6076 Diesel Engines—S.N. (500000—
)
160101
PN=114
Cylinder Block, Liners, Pistons and Rods/Inspect and Clean Cylinder Block
INSPECT AND CLEAN CYLINDER BLOCK
NOTE: All components (including piston cooling orifices),
water gallery plugs and oil gallery plugs must be
removed from the cylinder block for inspection
and cleaning. Refer to the proper group for
removal of all external and internal mounted
components.
1. Clean block thoroughly using cleaning solvent,
pressure steam, or a hot tank.
IMPORTANT: If cylinder block is cleaned in a hot
tank, be sure to remove any aluminum
parts. Aluminum parts can be damaged
or destroyed by hot tank solutions.
Remove all serial number plates.
RG,CTM42,G10,38-19-29OCT92
10
30
CTM42 (24MAR95)
10-30
6076 Diesel Engines—S.N. (500000—
)
160101
PN=115
Cylinder Block, Liners, Pistons and Rods/Inspect and Clean Cylinder Block
2. Be sure liner support flange (A) is free of any burrs. If
burrs are present, use a small half-moon file and
LIGHTLY file (in a circular motion) burr off at
approximately a 60˚ angle. DO NOT let file hit top of
cylinder block while filing.
-UN-13DEC88
NOTE: DO NOT file liner support flange excessively.
Excess filing can damage liner support flange
and allow an improper liner fitting. Thoroughly
clean all filings from cylinder block (B).
RG3329
3. Carefully inspect block for cracks or damage. If a
cracked block is suspected, pressure-test the block. A
procedure for pressure testing is outlined in FOS
(Fundamentals of Service) Manual-ENGINES. Replace
cracked or damaged block.
Cylinder Liner Counterbore Depth . . . . . . . . . . . .
8.105—8.155 mm
(0.319—0.321 in.)
Liner Flange Thickness . . . . . . . . . . . . . . . . . . .
8.175—8.225 mm
(0.322—0.324 in.)
-UN-12AUG91
COUNTERBORE DEPTH AND LINER FLANGE SPECIFICATIONS
RG5796
4. When determined that the cylinder block is
serviceable, remove cylinder head locating dowels. Clean
out all threaded holes for cylinder head cap screws in
top deck of cylinder block. Use JDG681A Tap or an
equivalent 9/16-12 UNC-2A tap approximately 114.3 mm
(4.5 in.) long. Use compressed air to remove any debris
or fluid which may be present in the cap screw hole.
5. Install new locating dowel pins in cylinder block.
RG,CTM42,G10,8 -19-17MAR95
CTM42 (24MAR95)
10-31
6076 Diesel Engines—S.N. (500000—
)
160101
PN=116
10
31
Cylinder Block, Liners, Pistons and Rods/Measure Cylinder Block
CLEAN CYLINDER LINER O-RING BORE
1. Use D17015BR O-Ring Bore Cleaning Brush to
thoroughly clean all debris from O-ring bore.
RG5812
-UN-12AUG91
NOTE: Use brush exactly as directed by the
manufacturer.
10
32
RG,CTM42,G10,9 -19-12APR93
MEASURE CYLINDER BLOCK
1. Assemble and measure main and thrust bearing
bores. Compare measurements with specifications given
below:
MAIN AND THRUST BEARING SPECIFICATIONS
Main and Thrust Bearing Bore ID
Without Bearing . . . . . . . . . . . . . . . . . . . . . . . 92.125—92.151 mm
(3.627—3.628 in.)
Main Bearing Surface Width . . . . . . . . . . . . . . . .
Thrust Bearing (No. 5 Main)
Surface Width . . . . . . . . . . . . . . . . . . . . . . . . .
Overall Thrust Bearing Cap Width . . . . . . . . . . . .
36.28—36.78 mm
(1.428—1.448 in.)
37.44—37.54 mm
(1.474—1.478 in.)
39.16—39.66 mm
(1.542—1.561 in.)
If any main or thrust bearing cap assembled ID is not
within specification, blank (generic) bearing caps are
available and must be lined bored to specification. (See
Group 15-Crankshaft, Main Bearings, and Flywheel.)
S11,2010,JH
CTM42 (24MAR95)
10-32
-19-29OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=117
Cylinder Block, Liners, Pistons and Rods/Measure Cylinder Block
2. Measure cam follower bore diameter at all bore
locations. Record measurements by bore location.
CAMSHAFT FOLLOWER AND BORE SPECIFICATIONS
Cam Follower Bore ID . . . . . . . . . . . . . . . . . . . 17.384—17.440 mm
(0.6845—0.6865 in.)
Cam Follower OD . . . . . . . . . . . . . . . . . . . . . . .
17.33—17.35 mm
(0.682—0.683 in.)
Maximum Cam Follower-to-Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.114 mm
(0.0045 in.)
If any one cam follower bore is not within specification,
install a new cylinder block.
S11,2010,JV
-19-12APR93
3. Measure camshaft bore diameter at all locations and
record readings. Compare measurements with
specifications given in chart below:
10
33
CAMSHAFT BUSHING AND BORE SPECIFICATION
Camshaft Bushing Installed ID
. . . . . . . . . . . . . 67.076—67.102 mm
(2.6408—2.6418 in.)
RG5830
-UN-12AUG91
Camshaft Bushing Bore in Block . . . . . . . . . . . . 69.987—70.013 mm
(2.7554—2.7564 in.)
Maximum Runout of Camshaft Bushing
Bore in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 mm
(0.0015 in.)
New Camshaft Bushing-to-Journal
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063—0.115 mm
(0.0025—0.0045 in.)
If camshaft bushing bore diameter in block is more than
specified, install a new cylinder block.
RG,CTM42,G10,22-19-14FEB95
CTM42 (24MAR95)
10-33
6076 Diesel Engines—S.N. (500000—
)
160101
PN=118
Cylinder Block, Liners, Pistons and Rods/Install Piston Cooling Orifices and Gallery Plugs
4. Measure cylinder block top deck flatness using
D05012ST Precision Straightedge and feeler gauge.
Resurface as required.
CYLINDER BLOCK TOP DECK SPECIFICATIONS
Maximum Out-of-Flat
(Over Entire Length or Width) . . . . . . . . . . . . . . . . . . . . . 0.10 mm
(0.004 in.)
Straightness per Any 305 mm
(12 in.) Length . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)
Minimum Main Bearing Bore Centerline-toTop Deck Distance . . . . . . . . . . . . . . . . . . . . . . . . . . 352.35 mm
(13.872 in.)
IMPORTANT: The centerline of the main bearing
bore-to-top deck of cylinder block
MUST be 352.35—352.50 mm
(13.872—13.878 in.). If not, replace
cylinder block.
10
34
S11,2010,JW
-19-16AUG94
INSTALL PISTON COOLING ORIFICES AND
GALLERY PLUGS
IMPORTANT: A piston cooling orifice failure could
cause damage to pistons, piston pins,
rod pin bushings, and liners. If a piston
cooling orifice is left out, low or no oil
pressure will result.
1. Install all six piston cooling orifices (A) and tighten to
11 N·m (97 lb-in.).
RG5811
-UN-12AUG91
2. Install new oil and water gallery plugs as required, if
removed.
RG,CTM42,G10,10-19-29OCT92
CTM42 (24MAR95)
10-34
6076 Diesel Engines—S.N. (500000—
)
160101
PN=119
Cylinder Block, Liners, Pistons and Rods/Recheck Cylinder Liner Standout (Height above Block)
RECHECK CYLINDER LINER STANDOUT
(HEIGHT ABOVE BLOCK)
NOTE: If a new liner assembly is being installed in a
new or used cylinder block, liner height must be
checked.
Be sure liner bore in cylinder block and top deck of
block are clean.
1. Install liners without O-ring. Secure with cap screws
and washers and measure liner standout. See
MEASURE CYLINDER LINER STANDOUT (HEIGHT
ABOVE BLOCK), earlier in this group.
Liner shims may be used to bring to bring standout
within specification. (See INSTALL LINER SHIMS—IF
REQUIRED, later in this group.)
10
35
RG,CTM42,G10,23-19-22JUL94
CTM42 (24MAR95)
10-35
6076 Diesel Engines—S.N. (500000—
)
160101
PN=120
Cylinder Block, Liners, Pistons and Rods/Install Liner Shims—If Required
INSTALL LINER SHIMS—IF REQUIRED
If the liner flange thickness is within specification, but
recorded standout was no more than 0.08 mm (0.003
in.) BELOW top deck of block, install liner shims on
bottom of liner flange.
The liner shim is 0.05 mm (0.002 in.) thick. A maximum
of two liner shims may be used per cylinder, as required.
Shims have tangs in the I.D. to help hold them in place
against bottom of liner flange during liner installation.
1. Make sure counterbore in block is clean and free of
burrs. Install liner(s), and shim(s), in block bore without
O-rings. Secure liners with cap screws and washers as
done previously. Tighten cap screws to 68 N·m (50 lb-ft).
Liner standout MUST NOT exceed 0.102 mm (0.004 in.)
after shim installation.
2. Measure liner standout again at 1, 5, 7, and 11
O’clock positions. Record measurements.
10
36
If standout is still not within specification, remove liner
and determine cause.
If standout is within specification, proceed to next step.
RG,CTM6,G10,2 -19-08MAR94
CTM42 (24MAR95)
10-36
6076 Diesel Engines—S.N. (500000—
)
160101
PN=121
Cylinder Block, Liners, Pistons and Rods/Install Cylinder Liner O-Rings and Packings
INSTALL CYLINDER LINER O-RINGS AND
PACKINGS
IMPORTANT: DO NOT use oil on cylinder liner
packing or O-rings. Oil can cause the
red packing to swell, which squeezes
liner and could possibly cause a
scored piston.
1. Pour AR54749 Soap Lubricant into a suitable
container.
2. Dip new packings and O-rings in soap before
installation. Do not leave packings or O-rings in soap to
soak.
-UN-13DEC88
3. Install the black viton O-ring (A) in the lower O-ring
groove of the cylinder block (C).
RG3826
4. Install the red silicone O-ring (B) in the upper O-ring
groove of the cylinder block.
S11,0402,BA
-19-16AUG94
S11,2010,JT
-19-29OCT92
5. Turn cylinder liner (B) upside-down and install the
square neoprene packing (A) over outside of liner.
6. Slide packing down firmly against second shoulder of
the liner.
-UN-13DEC88
NOTE: Make sure the square packing is not twisted.
RG3827
7. Coat the liner packings sealing area of the cylinder
liner and cylinder block O-rings with liquid soap.
CTM42 (24MAR95)
10-37
6076 Diesel Engines—S.N. (500000—
)
160101
PN=122
10
37
Cylinder Block, Liners, Pistons and Rods/Install Cylinder Liners
INSTALL CYLINDER LINERS
IMPORTANT: Install cylinder liners into same cylinder
block bore as removed.
DO NOT scuff liner packing across
upper counterbore.
-UN-12AUG91
Pitted or eroded liners that meet reuse
guidelines should be rotated 90˚ from
their removed position. See VISUALLY
INSPECT CYLINDER LINERS, earlier in
this group for reuse guidelines.
RG5814
1. Install liner and packing in block bore with mark
toward front of engine, unless liner OD is pitted or
eroded.
If liner OD is pitted or eroded, but still within acceptable
service limits, rotate liner 90˚ from it’s removed position.
Pitted sections of the liner should be facing the front or
rear of engine.
10
38
2. A resistance will be felt when cylinder liner is aligned
in pilot bore.
3. Using only the pressure of both palms, the cylinder
liner should drop to a point nearly flush with the upper
flange of the cylinder liner and cylinder block.
RG,CTM42,G10,12-19-12APR93
CTM42 (24MAR95)
10-38
6076 Diesel Engines—S.N. (500000—
)
160101
PN=123
Cylinder Block, Liners, Pistons and Rods/Install Cylinder Liners
4. Finish seating cylinder liners using a clean, hardwood
block and hammer.
5. Gently tap hardwood block over top of cylinder liner
with mallet.
NOTE: Cylinder liner will protrude over top of cylinder
block more than normal due to uncompressed
packings and O-rings.
-UN-12AUG91
IMPORTANT: If you suspect that a packing may have
sheared or displaced liner installation,
remove liner and packing assembly. If
no damage is found, check packing
and O-rings for proper position.
Re-soap packings and reinstall liner
assembly.
RG5815
6. Hold liners in place with large flat washers and cap
screws. Turn cap screws snug but do not tighten.
7. Clean cylinder liner bores with waterless hand cleaner
after installation. Wipe dry with clean towels.
10
39
8. Apply clean engine oil to liner bores immediately to
prevent corrosion.
RG,CTM42,G10,13-19-14FEB95
CTM42 (24MAR95)
10-39
6076 Diesel Engines—S.N. (500000—
)
160101
PN=124
Cylinder Block, Liners, Pistons and Rods/Install Pistons and Connecting Rods
INSTALL PISTONS AND CONNECTING
RODS
IMPORTANT: Pistons must be installed on same
connecting rod from which they were
removed.
-UN-13DEC88
If a new piston and liner assembly is to
be installed, DO NOT remove piston
from liner. Push piston out of liner
bottom only far enough to install piston
pin.
RG5239
1. Use the JDE93 Ring Expander to install piston rings
(F) and oil control ring with expander ring (E).
NOTE: New rings are furnished with the correct end gap,
therefore, fitting to the liner is not usually
necessary.
“Pip” marks on No. 1 and No. 2 compression
rings must face top of piston.
10
40
2. Lubricate piston pin (A) and bushing with clean engine
oil.
A—Piston Pin
B—Piston
C—Connecting Rod
D—Snap Rings (2 used)
E—Oil Control Ring with Expander Ring
F—Piston Rings
3. Install piston pin through piston (B) and connecting
rod (C). Be sure front of rod aligns with front of piston.
4. Install NEW piston pin snap rings (D) in grooves.
Make certain snap rings have expanded in grooves of
piston.
PISTON COMPRESSION RING END GAP SPECIFICATIONS
Pistons Stamped RE50868:
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.43—0.69 mm
(0.017—0.027 in.)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.63—0.89 mm
(0.025—0.035 in.)
Pistons Stamped RE57512:
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.43—0.69 mm
(0.017—0.027 in.)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27—1.52 mm
(0.050—0.060 in.)
S11,2010,JO
CTM42 (24MAR95)
10-40
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=125
Cylinder Block, Liners, Pistons and Rods/Install Pistons and Connecting Rods
5. Stagger ring gap on pistons as shown.
NOTE: If crankshaft was removed, see INSTALL
CRANKSHAFT in Group 15.
-UN-13DEC88
6. Coat pistons, liners and ID of JDE96 Piston Ring
Compressor with clean engine oil.
R31127
A—Top of Piston
B—Top Compression Ring Gap
C—Oil Control Ring Gap
D—Expander Ring Gap
E—Bottom Compression Ring Gap
F—Front of Engine
S11,2010,JW1
-19-07AUG91
7. Carefully place ring compressor with piston and rod
over liner.
10
41
IMPORTANT: Be sure crankshaft journals and liner
walls are not damaged when installing
piston and rod in liner.
NOTE: Be sure the word “FRONT” on piston and rod
face toward the front of the engine.
RG5816
-UN-12AUG91
8. With piston centered in ring compressor and rings
staggered correctly, push piston into liner.
RG,CTM42,G10,14-19-02NOV92
CTM42 (24MAR95)
10-41
6076 Diesel Engines—S.N. (500000—
)
160101
PN=126
Cylinder Block, Liners, Pistons and Rods/Install Pistons and Connecting Rods
9. Apply clean engine oil to bearing inserts (B) and
crankshaft rod journals (A).
IMPORTANT: NEVER use connecting rod cap screws
more than once for final engine
assembly. Once rod cap screws have
been tightened, they cannot be reused
for final asssembly.
RG5817
-UN-12AUG91
10. Install connecting rod caps.
RG,CTM42,G10,15-19-12APR93
11. Dip NEW cap screws and washers in clean engine
oil. Make sure top of cap screws have oil on them also.
IMPORTANT: Using pneumatic wrenches to install
cap screws may cause damage to the
threads.
-UN-12AUG91
12. Initially tighten cap screw (A) to 27 N·m (20 lb-ft)
before tightening the other cap screw.
13. Secondly, tighten all cap screws to 75 N·m (55 lb-ft).
14. Finally TORQUE-TURN all cap screws 90—100˚.
(See USE TORQUE-TURN METHOD FOR PROPER
TORQUE, described next in this group.)
RG5818
10
42
RG,CTM42,G10,16-19-29OCT92
CTM42 (24MAR95)
10-42
6076 Diesel Engines—S.N. (500000—
)
160101
PN=127
Cylinder Block, Liners, Pistons and Rods/Check Engine Rotation for Excessive Tightness
TORQUE-TURN CONNECTING ROD CAP
SCREWS
• Using engine axis method to TORQUE-TURN
connecting rod cap screws:
1. After tightening cap screws to 75 N·m (55 lb-ft), mark
connecting rod cap and socket.
2. Position handle of wrench parallel to centerline of
engine crankshaft axis (A).
RG7047
-UN-28JUL94
3. Tighten 1/4 turn (90—100˚) clockwise until handle of
wrench is perpendicular to centerline of engine
crankshaft axis (B) as shown.
RG,CTM86,G10,41-19-14FEB95
• Using JT05993 Torque Angle Gauge to
TORQUE-TURN connecting rod cap screws:
RG5698
-UN-27AUG90
1. After tightening cap screws to 75 N·m (55 lb-ft), follow
directions provided with gauge and TORQUE-TURN each
cap screw 90˚—100˚.
JT05993 Torque Angle Gauge
RG,CTM6,G10,4 -19-22AUG91
CHECK ENGINE ROTATION FOR
EXCESSIVE TIGHTNESS
1. Rotate crankshaft several revolutions to be sure
engine rotates without excessive tightness.
2. Check liners for deep scratches caused by an
improperly installed or broken piston ring.
3. Check side clearance of rods. Must have slight
side-to-side movement.
S11,0402,BK
CTM42 (24MAR95)
10-43
-19-08MAR94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=128
10
43
Cylinder Block, Liners, Pistons and Rods/Complete Final Assembly
COMPLETE FINAL ASSEMBLY
NOTE: Refer to the proper group for installation of
components.
6. Install crankshaft pulley. (Group 15)
1. Install camshaft and timing gear cover. (Group 16)
2. Install oiling system components. (Group 20)
7. Install alternator, fan, and fan belts. (Machine
Technical Manual)
8. Install exhaust manifold and intake assembly.
(Group 30)
3. Install cylinder head with new head gasket. Install
valve train. (Group 05)
9. Install starting motor, if removed.
4. Install fuel injection system components. (Group
35)
10. Fill engine with clean oil and proper coolant.
(Group 02)
5. Install water bypass pipe. (Group 25)
11. Perform engine break-in. (Group 05)
RG,CTM42,G10,17-19-14FEB95
10
44
CTM42 (24MAR95)
10-44
6076 Diesel Engines—S.N. (500000—
)
160101
PN=129
Group 15
Crankshaft, Main Bearings and Flywheel
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
-19-05JUN91
RG,D17526CI
-19-29OCT92
S53,JDE3A
-19-16AUG94
-UN-27MAR92
Dial Indicator . . . . . . . . . . . . . (English, in.) D17526CI
or (Metric, mm ) D17527CI
RG6246
Use with JDG451 to measure valve recess and cylinder
liner height-to-cylinder block top deck.
RG5080
-UN-23AUG88
Front Wear Sleeve Installer . . . . . . . . . . . . . . . JDE3
Install front oil seal in timing gear cover.
RG5108
15
1
-UN-23AUG88
Gear Driver . . . . . . . . . . . . . . . . . . . . . . . . . . JDH7
Install crankshaft drive gear.
S53,JDH7
-19-04AUG94
RG,JDG820
-19-14FEB95
-UN-10AUG94
Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820
RG7056
Used to rotate engine to check damper radial runout and
time engine. JDE81-1 may be used also if JDG820 is
not available.
CTM42 (24MAR95)
15-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=130
Measure piston and liner heights.
NOTE: A dial indicator is not supplied with JDG451. Use
D17526CI (English, in.) or D17527CI (Metric,
mm) Dial Indicator with JDG451.
Seal and Wear Sleeve Installer . . . . . . . .
RG7029
Piston and Liner Height Gauge . . . . . . . . . . . JDG451
-UN-30SEP94
Crankshaft, Main Bearings and Flywheel/Special or Essential Tools
RG,JDG451
-19-28SEP94
S11,2515,BW
-19-03MAY93
RG,JDG719
-19-29OCT92
RG,JDG720
-19-01APR93
JDG476(85)
-UN-23AUG88
Used to simultaneously install the new teflon unitized oil
seal and wear sleeve on the rear crankshaft flange. Use
with JDG796 Alignment Tool to install rear oil seal
housing eliminating need for dial indicator to measure
runout.
-UN-06MAR92
Seal Puller Adapter . . . . . . . . . . . . . . . . . . . JDG719
RG6214
Used with a standard metal screw, JDE38-2 Shank, and
JDE38-3 Slide Handle to remove front crankshaft oil seal
with timing gear cover installed. Also used to remove
rear crankshaft oil seal with seal housing installed.
Set consists of:
1—Adapter . . . . . . . . . . . . . . . . . . . . . . JDG719-1
2—Screw (not shown) . . . . . . . . . . . . . . . . 11200
Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG720
Set consists of:
1—Forcing Screw . . . . . . . .
2—Seal Protector . . . . . . . .
3—Seal Installer . . . . . . . . .
4—Ring (500 Series Engines)
CTM42 (24MAR95)
.
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.
.
.
.
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-UN-06MAR92
Used to install front crankshaft oil seal with timing
gear cover installed.
JDG720-1
JDG720-2
JDG720-3
JDG720-4
15-2
RG6215
15
2
RG5106
Consists of:
JDG477(85) Pilot
JDG478 Driver
6076 Diesel Engines—S.N. (500000—
)
160101
PN=131
Crankshaft, Main Bearings and Flywheel/Special or Essential Tools
Hub Puller Kit
. . . . . . . . . . . . . . . . . . . . . . JDG721
RG5763
-UN-06AUG91
Used with JDG787 Thread Protector to remove vibration
damper pulley assembly on some engine applications.
RG,JDG721
-19-03MAY93
RG,JDG786
-19-29OCT92
Front Wear Sleeve Puller . . . . . . . . . . . . . . . JDG786
RG6428
-UN-13OCT92
Used to remove front crankshaft wear sleeve with timing
gear cover installed.
15
3
Thread Protector . . . . . . . . . . . . . . . . . . . . . JDG787
RG6429
-UN-13OCT92
Used with any puller set to remove vibration damper
pulley assembly.
RG,JDG787
CTM42 (24MAR95)
15-3
-19-03FEB93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=132
Crankshaft, Main Bearings and Flywheel/Service Equipment and Tools
Rear Wear Sleeve Puller Kit . . . . . . . . . . . . . JDG790
Used to remove rear wear sleeve with oil seal housing
installed on 400, 450, and 500 Series Engines.
Set consists of:
.
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.
.
.
.
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.
.
. . 219469
JDG790-1
. . 35945
JDG790-2
. . 13876
. . 215177
JDG790-3
. . 19311
-UN-22OCT92
.
.
.
.
.
.
.
.
RG6457
A—Hose Clamp (500 Series) . . . . . . .
B—Collet Halves (400/450 Series) . . . .
C—Forcing Screw (400/450/500 Series)
D—Pulling Plate (400/450/500 Series) .
E—Retainer Clip (400/450/500 Series) .
F—Shaft Protector (400/450/500 Series)
G—Collet Halves (500 Series) . . . . . .
H—Hose Clamp (400/450 Series) . . . .
RG6590
RG,JDG790
-19-03OCT94
RG,JDG796
-19-08AUG94
-UN-18FEB93
Oil Seal Housing Alignment Tool . . . . . . . . . . JDG796
Use with oil seal housing casting numbers R115050 and
R125027.
15
4 SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog
(MTC). Some tools may be available from a local supplier.
Name
Use
D01251AA Puller*
Used to remove crankshaft gear.
*Part of D01047AA 17-1/2 and 30-Ton Puller Set
CTM42 (24MAR95)
RG,CTM42,G15,32-19-11JUN93
15-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=133
Crankshaft, Main Bearings and Flywheel/Other Material
OTHER MATERIAL
Name
Use
LOCTITE 242 (TY9370)
Thread Lock and Sealer
Coat threads of flywheel mounting cap screws.
LOCTITE 515 (TY6304) Flexible
Sealant (General Purpose)
Coat trimmed flywheel housing-to-cylinder block
gasket.
LOCTITE 609 (TY15969) Retaining Compound
Coat OD of crankshaft flange for installation of rear
oil seal/wear sleeve.
PLASTIGAGE
Check main bearing-to-crankshaft journal oil clearance
during engine disassembly.
Brake Kleen or Ignition Cleaner and Drier
Remove sealant from crankshaft flange.
S11,2015,EE
-19-11OCT94
15
5
CTM42 (24MAR95)
15-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=134
Crankshaft, Main Bearings and Flywheel/Crankshaft, Main Bearings, and Flywheel Specifications
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS
ITEM
SPECIFICATION
WEAR LIMIT
Crankshaft Fillet Radius:
Pin Journal . . . . . . . . . . . . . . . . . . . . 3.94—4.44 mm (0.156—0.175 in.)
Thrust Journal . . . . . . . . . . . . . . . . . . 3.56—4.06 mm (0.140—0.160 in.)
Main Journal . . . . . . . . . . . . . . . . . . . 3.94—4.44 mm (0.156—0.175 in.)
——
——
——
Engine Stroke . . . . . . . . . . . . . . . . . . . . 121 mm (4.75 in.)
15
6
Crankshaft End Play . . . . . . . . . . . . . . . 0.038—0.380 mm (0.0015—0.0150 in.)
——
Main Bearing Journal OD . . . . . . . . . . . . 85.65—85.67 mm (3.372—3.373 in.)
——
Main Bearing Assembled ID . . . . . . . . . . 85.705—85.755 mm (3.3742—3.3762 in.)
——
Main Bearing-to-Journal Clearance . . . . . . 0.030—0.108 mm (0.0012—0.0042 in.)
——
Connecting Rod Journal OD . . . . . . . . . . 76.15—76.18 mm (2.9980—2.9990 in.)
——
Crankshaft Rear Oil Sealto-Housing Maximum Runout . . . . . . . . 0.152 mm (0.0060 in.)
——
Journal Taper per 25.4 mm
(1.00 in.) Length . . . . . . . . . . . . . . . . . 0.0025 mm (0.0001 in.)
——
Journal Out-of-Roundness . . . . . . . . . . . . 0.025 mm (0.0010 in.)
——
Undersized Bearings Available . . . . . . . . . 0.05, 0.25, 0.51 and 0.76 mm
(0.002, 0.010, 0.020, and 0.030 in.)
——
Oversize Thrust Washer Available . . . . . . 0.18 mm (0.007 in.)
——
Main Bearing Cap Bore Specifications:
ID without Bearing Inserts . . . . . . .
Maximum Bore Diameter Taper . . . .
Maximum Bore Diameter Variation . .
Maximum Straightness Variation
(Any Bore-to-Adjacent Bores) . . . .
Maximum Straightness Variation
(5 Center Bores-to-End Bores) . . .
Centerline of Bore-to-Top
Deck of Block . . . . . . . . . . . . . .
. . . 92.125—92.151 mm (3.6270—3.6280 in.)
. . . 0.008 mm (0.0003 in.)
. . . 0.013 mm (0.0005 in.)
——
——
——
. . . 0.038 mm (0.0015 in.)
——
. . . 0.076 mm (0.0030 in.)
——
. . . 352.35—352.50 mm (13.872—13.878 in.)
——
Main Bearing Cap Surface Width . . . . . . . 36.28—36.78 mm (1.428—1.448 in.)
——
RG,CTM42,G15,37-19-14FEB95
CTM42 (24MAR95)
15-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=135
Crankshaft, Main Bearings and Flywheel/Crankshaft, Main Bearings, and Flywheel Specifications
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS—CONTINUED
ITEM
SPECIFICATION
WEAR LIMIT
No. 5 Main (Thrust) Bearing:
Surface Width
(Thrust Washer Clearance) . . . . . 37.44—37.54 mm (1.474—1.478 in.)
Overall Cap Width . . . . . . . . . . . . 39.16—39.66 mm (1.542—1.561 in.)
Base Circle OD for Thrust
Washer Clearance* . . . . . . . . . . 123.70—125.30 mm (4.87—4.93 in.)
——
Crankshaft OD for Front Pulley . . . . . 47.650—47.676 mm (1.8785—1.876 in.)
——
Front Pulley ID
——
. . . . . . . . . . . . . . . 47.594—47.630 mm (1.8738—1.8752 in.)
——
——
Damper Pulley
Radial Runout (Maximum) . . . . . . . 1.02 mm (0.040 in.)
——
Front Oil Seal Housing
Install Below Front of
Timing Gear Cover (Maximum) . . . 8.4 mm (0.33 in.)
——
Oil Pump Drive Gear-to-Crankshaft
Clearance . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
——
Maximum Rear Oil Seal
Housing Runout . . . . . . . . . . . . . 0.15 mm (0.006 in.)
——
Flywheel Housing Face Runout
Maximum Variation . . . . . . . . . . . 0.20 mm (0.008 in.)
——
Flywheel Face Flatness
Maximum Variation . . . . . . . . . . . 0.23 mm (0.009 in.)
Maximum Variation per
25 mm (1.0 in.) of travel . . . . . . 0.013 mm (0.0005 in.)
——
Flywheel Bearing Bore Concentricity
Maximum Variation . . . . . . . . . . . 0.127 mm (0.005 in.)
——
* Thrust (washer) surfaces on bearing cap must be flat in respect to
mating thrust (washer) surfaces in cylinder block.
CTM42 (24MAR95)
15-7
15
7
——
RG,CTM42,G15,1 -19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=136
Crankshaft, Main Bearings and Flywheel/Failure Analysis
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS—CONTINUED
TORQUES
Flywheel Housing-to-Cylinder Block . . . . . . . . .
Damper Pulley-to-Crankshaft . . . . . . . . . . . . . .
Main Bearing Caps . . . . . . . . . . . . . . . . . . . .
Rear Crankshaft Oil Seal Housing . . . . . . . . . .
Flywheel-to-Crankshaft . . . . . . . . . . . . . . . . . .
Piston Cooling Orifices . . . . . . . . . . . . . . . . . .
Damper Assembly-to-Pulley . . . . . . . . . . . . . .
Injection Pump Gear Cover-to-Timing Gear Cover
Timing Gear Cover-to-Cylinder Block* . . . . . . . .
Hub Drive-to-Flywheel . . . . . . . . . . . . . . . . . .
Magnetic Pickup-to-Timing Gear Cover . . . . . . .
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* See INSTALL TIMING GEAR COVER—NON-AUXILIARY DRIVE
ENGINES, later in this group, for proper cap screw tightening
sequence.
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407 N·m (300
230 N·m (170
203 N·m (150
. 27 N·m (20
115 N·m (85
. . 11 N·m (8
. 41 N·m (30
. 27 N·m (20
. 27 N·m (20
115 N·m (85
. 14 N·m (10
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
RG,CTM42,G15,47-19-24MAR95
CRANKSHAFT AND MAIN BEARING FAILURE ANALYSIS
• Scored Main Bearing:
(Diagnosis also applies to connecting rod bearing.)
15
8
Oil starvation.
Contaminated oil.
Engine parts failure.
Excessive heat.
Poor periodic service.
• Galled or “Wiped” Bearings:
Fuel in lubricating oil (incomplete combustion).
Coolant in lubrication system (cracked block,
liner seal failure, or leaking water pump
seal with plugged hole).
Insufficient bearing oil clearance.
Parts not lubricated prior to engine operation.
Wrong bearing size.
• Inconsistent Wear Pattern:
Misaligned or bent connecting rod.
Warped or bowed crankshaft.
Distorted cylinder block.
• Broken Main Bearing Caps:
Improper installation.
Dirt between bearing and crankshaft journal.
Low oil pressure.
Oil pump failure.
• Cracked, Chipped or Broken Bearings:
Overspeeding.
Excessive idling.
Lugging.
Excessive oil clearance.
Improper installation.
S11,2015,C
CTM42 (24MAR95)
15-8
-19-29SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=137
Crankshaft, Main Bearings and Flywheel/Remove Crankshaft Rear Oil Seal Housing
REMOVE CRANKSHAFT REAR OIL SEAL
AND WEAR SLEEVE (WITH OIL SEAL
HOUSING INSTALLED)
Using JDG719 Seal Puller Adapter along with JDE38-2
Shank and JDE38-3 Slide Handle is the preferred
method for removing the crankshaft rear oil seal. If
JDG719, JDE38-2, and JDE38-3 are not available,
JDG22 Seal Remover can be used to remove the seal.
Follow same procedure for both pullers.
-UN-12AUG91
IMPORTANT: If rear oil seal is replaced, also replace
rear wear sleeve (as a matched set).
RG5819
NOTE: If oil seal housing is to be removed, remove seal
and wear sleeve after housing is removed. See
REMOVE REAR OIL SEAL HOUSING AND
WEAR SLEEVE (WITH ENGINE
DISASSEMBLED), later in this group.
1. Remove rear drive hub (if equipped) and flywheel.
See REMOVE FLYWHEEL later in this group.
2. Drill two small holes approximately 20˚ apart in bottom
of seal casing. Install sheet metal screws in seal casing
with JDG22 Seal Remover attached.
NOTE: It may be necessary to drill a small hole in seal
at one or two other locations to aid in removal.
15
9
RG6467
-UN-26OCT92
3. Cock seal at 6 O’clock position (180˚ opposite drilled
hole) using a small punch and carefully pull seal from
housing.
RG,CTM42,G15,2 -19-03MAY93
CTM42 (24MAR95)
15-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=138
Crankshaft, Main Bearings and Flywheel/Remove Crankshaft Rear Oil Seal Housing
4. Assemble JDG790 Rear Wear Sleeve Puller and
position onto crankshaft flange with wear sleeve seated
in jaws.
5. Securely tighten band clamp in groove on OD of jaws.
RG6468
-UN-26OCT92
6. Tighten forcing screw with disc centered in crankshaft
flange until wear sleeve is removed from crankshaft.
RG,CTM42,G15,50-19-29OCT92
Clean OD of crankshaft flange with cleaning solvent,
acetone, or any other suitable cleaner that will remove
sealant. (Brake Kleen, Ignition Cleaner and Drier are
examples of commercially available solvents that will
remove sealant from flange.)
-UN-12AUG91
Look for nicks or burrs on wear ring surface and bore in
flywheel housing. If necessary, use a polishing cloth.
Finish cleaning by wiping flange with a clean rag. Any
small nicks should be removed with 180-grit or finer
polishing cloth.
Check oil seal housing runout as explained later in this
group.
RG5822
15
10
RG,CTM42,G15,4 -19-29OCT92
CTM42 (24MAR95)
15-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=139
Crankshaft, Main Bearings and Flywheel/Install Crankshaft Rear Oil Seal and Wear Sleeve
INSTALL CRANKSHAFT REAR OIL SEAL
AND WEAR SLEEVE (WITHOUT ENGINE
DISASSEMBLY)
RG4639
-UN-14DEC88
NOTE: These instructions are for use when the oil seal
housing and oil pan would not be removed. Refer
to INSTALL CRANKSHAFT REAR OIL SEAL
AND WEAR SLEEVE (WITH ENGINE
DISASSEMBLED), later in this group, for
instructions with oil seal housing and oil pan
removed.
1. Apply a light coating of LOCTITE 609 Retaining
Compound, or equivalent, completely around the leading
edge of crankshaft flange. Wipe away any sealant that
may have gotten on ID of seal housing bore.
2. Install JDG477 (85) Pilot (A) on end of crankshaft
using the Allen head cap screws (B) supplied with tool
set. Tighten cap screws securely.
IMPORTANT: Handle seal and wear sleeve assembly
carefully. If assembly becomes
separated, discard these parts and
install a new assembly. (See
CRANKSHAFT REAR OIL SEAL AND
WEAR SLEEVE HANDLING
PRECAUTIONS, later in this group.)
15
11
3. Carefully start oil seal/wear sleeve assembly (C) over
JDG477 (85) Pilot and crankshaft flange with open side
of seal toward engine.
IMPORTANT: When installing the JDG478 Driver on
JDG477 (85) Pilot and crankshaft flange
to position oil seal/wear sleeve
assembly, locate crossbar of installer at
right angle (90˚) to Allen head cap
screws. This allows the crossbar to
bottom on pilot, not head of cap
screws, assuring correct installation.
S11,2015,GQ
CTM42 (24MAR95)
15-11
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=140
Crankshaft, Main Bearings and Flywheel/Inspect Vibration Damper
4. Position JDG478 Driver (A) so that hole in the cross
plate goes over threaded stud of pilot. Install washer and
nut on stud.
-UN-14DEC88
5. Tighten nut to draw JDG478 Driver in until crossbar
bottoms on JDG477(85) Pilot. When the tool bottoms,
seal and wear ring assembly (B) will be correctly
positioned.
RG4640
6. Remove JDG476(85) Tool Set from engine.
S11,2015,GR
-19-11JUN93
INSPECT VIBRATION DAMPER
-UN-05SEP91
IMPORTANT: Do not immerse the vibration damper
or the damper pulley in cleaning
solvent. Doing so may damage the
rubber portions of these components.
15
12
RG5823
Never apply thrust on outer ring of
damper. Damper is sensitive to impact
damage, such as being dropped or
struck with a hammer.
The damper assembly is not repairable
and should be replaced every 5 years
or 4500 hours, whichever occurs first,
or whenever crankshaft is replaced.
1. Remove fan belts (shown removed).
2. Inspect damper for torn or split rubber protruding from
damper, ring shift toward front or back of damper, or
slippage of the ring (reference chisel marks). Replace
damper if any defects are found.
3. Grasp vibration damper (A) with both hands and
attempt to turn it in both directions. If rotation is felt,
damper is defective and should be replaced.
RG,CTM42,G15,5 -19-16AUG94
CTM42 (24MAR95)
15-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=141
Crankshaft, Main Bearings and Flywheel/Check Crankshaft End Play
4. Check vibration damper radial runout by positioning a
dial indicator (A) so probe (B) contacts damper O.D.
-UN-12AUG91
5. Rotate crankshaft using JDE81-1 Flywheel Turning
Tool.
6. Note dial indicator reading.
DAMPER RADIAL RUNOUT SPECIFICATION
RG5824
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 mm (0.040 in.)
If runout exceeds specifications, replace vibration
damper.
RG,CTM42,G15,6 -19-16AUG94
CHECK CRANKSHAFT END PLAY
1. Completely engage then release the clutch lever.
2. Place a dial indicator on damper face.
15
13
-UN-28AUG91
IMPORTANT: Use care not to damage or distort the
timing gear cover or bearing inserts
when prying. Do not pry on outer
interia ring of damper.
3. Pry with flat bar between the damper pulley and
timing gear cover.
RG5934
CRANKSHAFT END PLAY SPECIFICATIONS
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038—0.380 mm
(0.0015—0.0150 in.)
NOTE: New thrust bearings will usually restore proper
end play.
RG,CTM42,G105,8-19-29OCT92
CTM42 (24MAR95)
15-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=142
Crankshaft, Main Bearings and Flywheel/Remove Damper Pulley
REMOVE DAMPER PULLEY
1. Drain oil (if not previously done), and remove oil pan.
Remove oil pump if crankshaft is to be removed.
RG5827
-UN-12AUG91
2. Remove cap screw (B) and washer on damper pulley
(A).
RG,CTM42,G15,7 -19-29OCT92
15
14
CTM42 (24MAR95)
15-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=143
Crankshaft, Main Bearings and Flywheel/Remove Damper Pulley
-UN-06AUG91
IMPORTANT: DO NOT use a jaw-type puller to
remove vibration damper. Damage
could result to the damper. Never apply
thrust on outer ring of damper. Do not
drop or hammer on damper.
RG5765
NOTE: On some applications, it may be necessary to
remove the pulley from the damper before pulling
damper from crankshaft flange.
3. Remove pulley and damper from crankshaft using
D01207AA(OTC518) Puller Set (upper photo).
RG6470
-UN-26OCT92
RG6469
-UN-26OCT92
On certain applications, it may be necessary to use
JDG721 Hub Puller (B) and JDG787 Thread Protector
(A) (lower photos) to remove damper pulley.
RG,CTM42,G15,33-19-16AUG94
CTM42 (24MAR95)
15-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=144
15
15
Crankshaft, Main Bearings and Flywheel/Remove Front Oil Seal
REMOVE CRANKSHAFT FRONT OIL SEAL
(WITH TIMING GEAR COVER INSTALLED ON
ENGINE)
IMPORTANT: Whenever front oil seal is replaced, the
wear sleeve must also be replaced.
-UN-26OCT92
NOTE: If timing gear cover is going to be removed from
engine, remove front seal after timing gear cover
is removed.
RG6471
1. Check oil seal and wear sleeve for wear, damage, or
leakage.
2. Center punch seal casing at 12 O’clock position.
RG,CTM42,G15,38-19-03MAY93
-UN-26OCT92
3. Drill 1/8 in. hole in casing.
RG6472
15
16
RG,CTM42,G15,39-19-29OCT92
4. Using JDG719 Seal Puller along with JDE38-2 Shank,
JDE38-3 Hammer, and metal screw; remove seal.
RG6473
-UN-26OCT92
5. Remove keyway from keyslot of crankshaft.
RG,CTM42,G15,40-19-29OCT92
CTM42 (24MAR95)
15-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=145
Crankshaft, Main Bearings and Flywheel/Install Front Wear Sleeve
REMOVE CRANKSHAFT FRONT WEAR
SLEEVE (WITH TIMING GEAR COVER
INSTALLED OR REMOVED)
-UN-26OCT92
1. Position JDG786 Front Wear Sleeve Puller on
crankshaft nose.
RG6474
2. Center puller on wear sleeve and thread onto sleeve
approximately two full turns.
3. Tighten forcing screw until wear sleeve is removed
from crankshaft flange.
-UN-26OCT92
NOTE: To remove wear sleeve from tool, place tool in
vise and cut two slots adjacent from each other
in wear sleeve using hack saw or parting wheel.
Put file or similar flat object in slots and turn
wear sleeve out of tool.
RG6475
4. Clean crankshaft flange using Brake Kleen or Ignition
Cleaner and Drier.
RG,CTM42,G15,41-19-03MAY93
15
17
INSTALL CRANKSHAFT FRONT WEAR
SLEEVE
-UN-26OCT92
NOTE: Wear sleeve can also be installed with timing
gear cover removed, but seal must be installed
with timing gear cover installed.
RG6476
1. Coat ID of new wear sleeve with LOCTITE 609
Retaining Compound.
2. Using JDG467 Driver from JDE3 Installer along with
washer and 5/8-11 UNC x 3 in. cap screw that secures
damper pulley assembly to crankshaft. Tighten cap screw
until driver bottoms.
RG6477
-UN-26OCT92
3. Remove installation tools and clean any sealant from
OD of wear sleeve or ID of seal bore.
RG,CTM42,G15,42-19-11JUN93
CTM42 (24MAR95)
15-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=146
Crankshaft, Main Bearings and Flywheel/Install Front Oil Seal
INSTALL CRANKSHAFT FRONT OIL SEAL
(WITH TIMING GEAR COVER INSTALLED ON
ENGINE)
-UN-26OCT92
IMPORTANT: Whenever front oil seal is replaced, the
wear sleeve MUST be replaced also.
RG6479
1. Place JDG720-2 Seal Protector (A) on nose of
crankshaft. Lubricate ID of front oil seal lips with clean
engine oil. Slide seal with spring side of seal facing
engine onto seal protector. Be careful not to roll oil seal
lips.
2. Place JDG720-3 Seal Installer onto seal protector
against seal. Do not use spacer ring provided with tool
set.
-UN-26OCT92
3. With nut and washer installed onto JDG720-1 Forcing
Screw, thread forcing screw into nose of crankshaft until
it bottoms.
RG6480
4. Tighten nut against crossplate of installer until installer
bottoms onto front face of timing gear cover.
5. Remove installation tools. Verify seal is installed
square in bore and that seal lips are not rolled on wear
sleeve.
15
18
Oil seal should be 8.4 mm (0.33 in.) below front lip of
seal bore.
RG,CTM42,G15,43-19-03MAY93
CTM42 (24MAR95)
15-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=147
Crankshaft, Main Bearings and Flywheel/Replace Timing Gear Cover (6076HRW33, 34, and 35 Engines)
REPLACE TIMING GEAR COVER (6076HRW33, 34, AND 35 ENGINES) —ENGINE
INSTALLED IN VEHICLE
6076HRW33, 34, and 35 Engines used in 8100,
8200, and 8300 Tractors are equipped with front
frame/oil sump, refer to TM1575 (8100, 8200, 8300,
and 8400 Tractors—Repair) for access to front
frame/oil sump-to-engine block cap screws.
9. Remove front oil seal from timing gear cover and
discard seal.
To Remove Timing Gear Cover:
To Install Timing Gear Cover:
1. Remove viscous fan drive, drive housing, and
coupler. (Refer to TM1575.)
1. Thoroughly clean all timing gear cover gasket
surfaces and front oil seal bore.
2. Remove crankshaft vibration damper as detailed
earlier in this group.
NOTE: Front wear sleeve can be installed with timing
gear cover removed or installed.
3. Disconnect water piping and remove water pump
cover with water bypass tube. Remove and discard
gaskets.
2. Install a new front wear sleeve on crankshaft
flange (See INSTALL FRONT WEAR SLEEVE, later
in this group).
4. Back out all front frame/oil sump-to-engine block
cap screws 9.5 mm (0.38 in.)
3. Install timing gear cover (See INSTALL TIMING
GEAR COVER, later in this group).
5. Disconnect engine speed sensor connector from
sensor.
4. Install Front oil seal (See INSTALL CRANKSHAFT
FRONT OIL SEAL WITH TIMING GEAR COVER
INSTALLED ON ENGINE, later in this group).
10. Remove front wear sleeve from crankshaft flange
and discard sleeve.
6. Remove injection pump drive gear cover.
7. Slowly lift engine block assembly approximately 6.4
mm (0.25 in.) using safety approved lifting equipment.
15
19
5. Install vibration damper (See INSTALL VIBRATION
DAMPER, later in this group).
6. Tighten front frame/oil sump cap screws as
detailed in Group 20, Lubrication System of this
manual (See TIGHTEN CAP SCREWS ON FRONT
FRAME/OIL SUMP) or TM1575.
IMPORTANT: The timing gear cover must not be
“dragged” horizontally while in
contact with front frame/oil sump
gasket. Doing so may damage
gasket sealing bead.
7. Complete final assembly as outlined in TM1575.
8. Remove remaining cap screws and carefully
remove timing gear cover. Remove and discard timing
gear cover gasket.
RG,CTM42,G15,49-19-21MAR95
CTM42 (24MAR95)
15-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=148
Crankshaft, Main Bearings and Flywheel/Inspect, Measure and Repair Flywheel
REMOVE TIMING GEAR COVER
-UN-12AUG91
1. Remove magnetic pick-up (A, if equipped) and
injection pump drive gear cover (B). Discard gasket.
2. Remove timing gear cover (C). Discard gasket.
RG5828
3. Remove oil seal from cover and discard.
RG,CTM42,G15,44-19-29OCT92
INSPECT AND MEASURE FLYWHEEL
1. Inspect the clutch contact face for scoring,
overheating, or cracks. Replace flywheel if defective.
2. Examine flywheel ring gear for worn or broken teeth.
Replace ring gear if defective, as described later in this
group.
15
20
IMPORTANT: Maintain constant end pressure on
crankshaft to hold shaft against thrust
bearing when measuring flywheel or
housing face.
3. Measure flywheel housing face run-out, flywheel face
flatness, and pilot bearing bore concentricity, as outlined
later in this group. Resurface flywheel face or replace as
required.
S55,2015,N
CTM42 (24MAR95)
15-20
-19-08MAR94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=149
Crankshaft, Main Bearings and Flywheel/Check Flywheel Face Flatness
CHECK FLYWHEEL HOUSING FACE
RUNOUT
-UN-14DEC88
1. Mount dial indicator on flywheel. Set pointer to contact
PTO mounting surface on flywheel housing at right
angles. Pointer should not contact holes in flywheel
housing.
R22212
IMPORTANT: Maintain constant end pressure on
crankshaft to hold shaft against thrust
bearing when measuring flywheel
housing face runout.
2. Rotate flywheel by turning crankshaft. Read total dial
indicator movement.
FLYWHEEL HOUSING FACE RUNOUT SPECIFICATION
Maximum Variation . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
S55,2015,L
-19-29OCT92
15
21
CHECK FLYWHEEL FACE FLATNESS
-UN-14DEC88
1. Mount dial indicator base on flywheel housing.
Position pointer to contact driving ring mounting surface.
Do not allow pointer to contact driving ring mounting
holes.
R22213
IMPORTANT: Maintain constant end pressure on
crankshaft to hold shaft against thrust
bearing when measuring flywheel face
runout.
2. Rotate flywheel by turning crankshaft. Read total dial
indicator movement. Resurface flywheel face or replace
as required.
FLYWHEEL FACE FLATNESS SPECIFICATION
Maximum Variation . . . . . . . . . . . . . . . . . . . . . 0.23 mm (0.009 in.)
Maximum Variation per 25 mm
(1.0 in.) of Travel . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.)
S11,5005,AM
CTM42 (24MAR95)
15-21
-19-02FEB94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=150
Crankshaft, Main Bearings and Flywheel/Remove Flywheel
CHECK PILOT BEARING BORE
CONCENTRICITY
-UN-14DEC88
1. Mount dial indicator on flywheel housing face and
position pointer to contact ID of pilot bearing bore in
flywheel.
R22214
2. Rotate flywheel by turning crankshaft. Read total dial
indicator movement.
BEARING BORE CONCENTRICITY SPECIFICATION
Maximum Variation . . . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 in.)
S55,2015,M
-19-08MAR94
REMOVE FLYWHEEL
-UN-14DEC88
N
CAUTION: Flywheel is heavy. Plan a proper
lifting procedure to avoid personal injury.
RG3836
15
22
NOTE: SAE 1 and SAE 2 flywheel housings MUST BE
removed before flywheel can be removed from
engine. See REMOVE SAE 1 AND SAE 2
FLYWHEEL HOUSING, later in this group.
1. Remove two flywheel attaching cap screws (A), and
install two pilot studs in their place.
2. Remove remaining cap screws, remove drive hub (if
equipped), and carefully pull flywheel from crankshaft.
4. Check condition of dowel pin in crankshaft rear flange.
Dowel pin must not be cracked or chipped. Measure
protrusion of dowel pin from face of flange. If dowel pin
is damaged, or protrusion is not within specifications,
replace dowel pin.
NOTE: When replacing dowel pin, crankshaft must be
removed to prevent damage to crankshaft thrust
bearings.
CRANKSHAFT DOWEL PIN SPECIFICATIONS
Protrusion From Crankshaft
Rear Flange . . . . . . . . . . . . . . . .
13.5—14.5 mm (0.53—0.57 in)
RG,CTM42,G15,52-19-16AUG94
CTM42 (24MAR95)
15-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=151
Crankshaft, Main Bearings and Flywheel/Remove SAE 3 Flywheel Housing
REMOVE SAE 1 AND SAE 2 FLYWHEEL
HOUSING
N
CAUTION: Flywheel housing is heavy. Plan a
proper lifting procedure to avoid personal
injury.
1. Remove attaching cap screws.
2. Remove flywheel housing.
3. Inspect mounting holes in flywheel housing for thread
damage.
S11,2015,GK
-19-29OCT92
REMOVE SAE 3 FLYWHEEL HOUSING
NOTE: The flywheel MUST be removed before removing
the SAE 3 flywheel housing. See REMOVE
FLYWHEEL earlier in this group.
N
15
23
CAUTION: Flywheel housing (A) is heavy. Plan
a proper lifting procedure to avoid personal
injury.
-UN-14DEC88
1. Remove flywheel housing attaching cap screws.
2. Remove flywheel housing.
RG5005
3. Inspect mounting holes in flywheel housing for thread
damage.
S11,2015,GO
CTM42 (24MAR95)
15-23
-19-29OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=152
Crankshaft, Main Bearings and Flywheel/Replace Flywheel Ring Gear
REPLACE FLYWHEEL RING GEAR
CAUTION: Oil fumes or oil can ignite above
193˚C (380˚F). Use a thermometer and do not
exceed 182˚C (360˚F). Do not allow a flame or
heating element to be in direct contact with the
oil. Heat the oil in a well ventilated area. Plan a
safe handling procedure to avoid burns.
-UN-14OCT88
N
T90596
1. If ring gear is damaged, place the flywheel on a solid
flat surface.
2. Remove ring gear with a brass drift and hammer.
-UN-14OCT88
IMPORTANT: If flame heat is used, be sure gear is
heated uniformly around circumference.
DO NOT OVERHEAT. Overheating may
destroy original heat treatment of gear.
SEE CAUTION.
RG3838
3. Heat new ring gear to 148˚C (300˚F) using either
heated oil, oven heat, or flame heat.
4. Install ring gear against shoulder of flywheel so
chamfered side (A) is on engine side of flywheel.
15
24
S11,2015,FX
CTM42 (24MAR95)
15-24
-19-16SEP92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=153
Crankshaft, Main Bearings and Flywheel/Replace Rear Oil Seal Housing (6076HRW33, 34, and 35 Engines)
REPLACE REAR OIL SEAL HOUSING (6076HRW33, 34, AND 35 ENGINES)—ENGINE
INSTALLED IN VEHICLE
6076HRW33, 34, and 35 Engines used in 8100,
8200, and 8300 tractors are equipped with front
frame/oil sump, refer to TM1575 (8100, 8200, 8300,
and 8400 Tractors—Repair) for access to front
frame/oil sump-to-engine block cap screws.
7. Remove rear oil seal housing (A).
IMPORTANT: Remove rear oil seal housing (A) for
replacement purposes only, it is not
necessary to remove seal housing
for rear seal and wear sleeve
replacement.
To Install Rear Oil Seal Housing:
8. Remove rear wear sleeve from crankshaft flange
with JDG790 Wear Sleeve Puller Kit as detailed
earlier in this group. Clean flange with emery cloth.
1. Install rear oil seal housing and check runout. (See
INSTALL CRANKSHAFT REAR OIL SEAL HOUSING
and CHECK OIL SEAL HOUSING RUNOUT, later in
this group.)
To Remove Rear Oil Seal Housing:
NOTE: Refer to TM1575 for access to rear crankshaft
seal housing area.
1. Remove flywheel cover.
2. Remove transmission input shaft coupler bolts and
pry coupler rearward.
2. Carefully lower engine onto locating dowels of front
frame/oil sump.
3. Tighten front frame/oil sump cap screws as
detailed in Group 20, Lubrication System of this
manual (See TIGHTEN CAP SCREWS ON FRONT
FRAME/OIL SUMP) or TM1575.
4. Install a new rear oil seal and wear sleeve
assembly. (See INSTALL CRANKSHAFT REAR OIL
SEAL AND WEAR SLEEVE, WITHOUT ENGINE
DISASSEMBLY, earlier in this group.)
NOTE: Use a set screw to separate damper from
flywheel, if necesssary.
15
25
3. Remove torsional damper from flywheel.
4. Remove flywheel from right side of tractor.
5. Install flywheel. (See INSTALL FLYWHEEL, later in
this group.)
5. Back out all front frame/oil sump-to-engine block
cap screws 9.5 mm (0.38 in.)
6. Install torsional damper onto flywheel. (See
TM1575.)
6. Slowly lift engine block assembly approximately 6.4
mm (0.25 in.) using safety approved lifting equipment.
7. Pull transmission input shaft coupler forward, install
cap screws and tighten to specified torque. (See
TM1575.)
IMPORTANT: The rear oil seal housing must not
be “dragged” horizontally while in
contact with front frame/oil sump
gasket. Doing so may damage
gasket sealing bead.
8. Install flywheel cover. (See TM1575.)
9. Start engine and chack for leaks.
RG,CTM42,G15,48-19-21MAR95
CTM42 (24MAR95)
15-25
6076 Diesel Engines—S.N. (500000—
)
160101
PN=154
Crankshaft, Main Bearings and Flywheel/Remove Rear Oil Seal Housing and Wear Sleeve
-UN-14DEC88
REMOVE REAR OIL SEAL HOUSING AND
WEAR SLEEVE (WITH ENGINE
DISASSEMBLED)
RG3839
These instructions are for use when the oil seal housing
and oil pan will be removed. Refer to REMOVE
CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE
(WITH OIL SEAL HOUSING INSTALLED), earlier in this
group, for instructions without the oil seal housing and oil
pan being removed.
1. Remove rear oil seal housing (A).
IMPORTANT: If rear oil seal is replaced, also replace
rear wear sleeve. The wear sleeve does
not have to be removed to remove
crankshaft.
2. Rear oil seal (B) will come off with housing. Use a
small punch and hammer to remove oil seal. Discard
seal.
RG,CTM42,G15,14-19-16AUG94
15
26
CTM42 (24MAR95)
15-26
6076 Diesel Engines—S.N. (500000—
)
160101
PN=155
Crankshaft, Main Bearings and Flywheel/Remove Crankshaft Main Bearings
IMPORTANT: The preferred method of removing the
wear sleeve is with JDG790 Rear Wear
Sleeve Puller. When removing wear
sleeve with a chisel, DO NOT gouge
crankshaft flange. Nicks or burrs
should be removed with a medium-grit
stone. Polishing cloth (180-grit or finer)
may also be used when a stone is not
available.
Rear wear sleeve can be removed using one of the
following procedures: These procedures may also be
followed when crankshaft has been removed from
engine.
• Use JDG790 Wear Sleeve Puller to remove wear
sleeve from crankshaft flange, as described earlier in this
group.
• Use the ball side of a ballpeen hammer and tap wear
sleeve across its width in a straight line (to deform and
stretch sleeve).
• Score but do not cut the wear sleeve in several places
around OD with a blunt chisel.
Remove wear sleeve from crankshaft flange. Clean
flange with a light file and emery cloth.
15
27
RG,CTM42,G15,54-19-02APR93
REMOVE CRANKSHAFT MAIN BEARINGS
RG5832
-UN-12AUG91
IMPORTANT: Before removing main bearing caps (A),
check for proper torque on all main
bearings. Also, check each bearing cap
to make sure they are numbered for
reassembly on the same numbered
main bearing bosses. Keep matched
bearing inserts with their respective
main bearing cap for comparison with
crankshaft journal (surface) from which
removed.
NOTE: When removing main bearings and caps, leave
No. 1 and 7 main bearing caps installed until all
of the connecting rod caps have been removed.
RG,CTM42,G15,16-19-29OCT92
CTM42 (24MAR95)
15-27
6076 Diesel Engines—S.N. (500000—
)
160101
PN=156
Crankshaft, Main Bearings and Flywheel/Check Main Bearing Clearance
1. Loosen main bearing cap screws and washers.
2. Remove main bearing caps by extending cap screws
(A) and forcing heads of screws together. Wiggle bearing
cap (B) back and forth while applying an upward force
with cap screws until free from main bearing cap
support.
RG5833
-UN-12AUG91
3. Use PLASTIGAGE to measure oil clearance on each
main bearing as they are removed. See CHECK MAIN
BEARING OIL CLEARANCE later in this group.
RG,CTM42,G15,17-19-14SEP94
CHECK MAIN BEARING CLEARANCE
The use of PLASTIGAGE will determine wear but will not
determine condition of the bearing or journal surfaces.
-UN-09NOV88
1. Put a strip of PLASTIGAGE in the center of the main
bearing cap (with insert) about three-fourths of the width
of the bearing.
2. Use oil (SAE30) on PLASTIGAGE to prevent
smearing.
T42576NY
15
28
3. Install cap and tighten to 203 N·m (150 lb-ft).
4. Remove cap and compare width of PLASTIGAGE with
scale provided on wrapper to determine oil clearance.
MAIN BEARING CLEARANCE SPECIFICATIONS
Main Bearing-to-Journal Clearance . . . . . . . . . . . . 0.030—0.107 mm
(0.0012—0.0042 in.)
S11,0403,Z
CTM42 (24MAR95)
15-28
-19-08AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=157
Crankshaft, Main Bearings and Flywheel/Remove Crankshaft
REMOVE CRANKSHAFT
-UN-12AUG91
1. Rotate crankshaft using JDE81-1 Flywheel Turning
Tool until connecting rod caps can be removed easily.
You will be able to remove two rod caps at each
position.
N
RG5806
2. Remove all connecting rod caps (A) with bearings (B),
then remove No. 1 and 7 main bearing caps and
bearings. See REMOVE PISTONS AND CONNECTING
RODS in Group 10.
CAUTION: Crankshaft is very heavy. Plan a
proper handling procedure to avoid injury.
-UN-12AUG91
NOTE: Install a screw on each end of crankshaft to aid
in lifting crankshaft.
3. Attach a lifting strap to crankshaft. Using proper lifting
equipment, carefully raise crankshaft out of cylinder
block.
RG5834
4. Clean crankshaft, especially oil passages, using
solvent and compressed air.
5. Put crankshaft on clean V-blocks.
If wear sleeve has not been removed from crankshaft,
the following procedures may be used. However,
removing wear sleeve using JDG790 Wear Sleeve Puller
Kit while crankshaft is installed in engine is the preferred
method.
15
29
• Use JDG790 Wear Sleeve Puller to remove wear
sleeve from crankshaft, as described earlier in this
group. Position crankshaft rod journals in V-blocks so
that crankshaft does not rotate while removing wear
sleeve.
• Use the ball side of a ball peen hammer and tap wear
sleeve across its width in a straight line (to deform and
stretch sleeve).
• Score (A), but do not cut, the wear sleeve in several
places around OD with a blunt chisel.
RG,CTM42,G15,18-19-16AUG94
CTM42 (24MAR95)
15-29
6076 Diesel Engines—S.N. (500000—
)
160101
PN=158
Crankshaft, Main Bearings and Flywheel/Inspect Crankshaft
INSPECT CRANKSHAFT
NOTE: If the crankshaft damper damage was
discovered during teardown, it is
recommended that the crankshaft be
magna-fluxed. This will verify whether or not it
has microscopic cracks or fissures. (See
INSPECT VIBRATION DAMPER, earlier in
this group.) The vibration damper should be
replaced whenever the crankshaft is replaced.
1. Thoroughly clean crankshaft. Clear restrictions from
all oil passages.
2. Inspect crankshaft for signs of load stress, cracks,
or scratches on journals. Also check each journal for
evidence of excessive overheating or discoloration. If
either condition exists, replace crankshaft since heat
treatment has probably been destroyed.
4. Inspect the keyway for evidence of cracks or wear.
Replace crankshaft as necessary.
5. Carefully inspect the rear hub of the crankshaft in
the area of the wear sleeve contact surface for
evidence of a rough or grooved condition. Any
imperfections in this area will result in oil leakage.
Slight ridges may be cleaned up with emery cloth and
crocus cloth.
6. Check each journal for evidence of excessive
overheating or discoloration. If either condition exists,
replace crankshaft since heat treatment has probably
been destroyed.
3. Inspect (front) crankshaft gear and (rear) oil pump
drive gear for cracks, chipped teeth, or excess wear.
Replace gear(s) as required. (See REPLACE FRONT
CRANKSHAFT GEAR and REPLACE CRANKSHAFT
OIL PUMP DRIVE GEAR, later in this group.)
15
30
RG,CTM42,G15,93-19-16AUG94
CTM42 (24MAR95)
15-30
6076 Diesel Engines—S.N. (500000—
)
160101
PN=159
Crankshaft, Main Bearings and Flywheel/Inspect Crankshaft
7. Carefully check the crankshaft for cracks in the area
of rod journal oil holes (A) and at journal fillets (B).
Replace crankshaft if any cracks are found.
-UN-15DEC88
IMPORTANT: Small cracks may not be visible to the
eye. Use a method such as the
Fluorescent Magnetic Particle method.
This method magnetizes the crank,
employs magnetic particles which are
fluorescent and glow under “black
light”. The crankshaft must be
de-magnetized after the test.
RG5093
8. Check condition of dowel pin in crankshaft rear flange.
Dowel pin must not be cracked or chipped. Measure
protrusion of dowel pin from face of flange. If dowel pin
is damaged, or protrusion is not within specifications,
replace dowel pin. If dowel pin is damaged, also inspect
flywheel for damage.
NOTE: If replacing dowel pin, crankshaft must be
removed to prevent damage to crankshaft thrust
bearings.
CRANKSHAFT DOWEL PIN SPECIFICATIONS
Dowel Pin Protrusion From
Rear Flange . . . . . . . . . . . . . . . . 13.5—14.5 mm (0.53—0.57 in.)
15
31
RG,CTM42,G15,94-19-16AUG94
CTM42 (24MAR95)
15-31
6076 Diesel Engines—S.N. (500000—
)
160101
PN=160
Crankshaft, Main Bearings and Flywheel/Measure Assembled ID of Bearings And OD Of Crankshaft Journals
MEASURE ASSEMBLED ID OF BEARINGS
AND OD OF CRANKSHAFT JOURNALS
1. With crankshaft removed from engine, install main
bearing inserts and caps (be sure inserts are installed
correctly).
-UN-12AUG91
2. Tighten main bearing cap screws to 203 N·m (150
lb-ft).
3. Measure I.D. of all bearings with an inside
micrometer.
RG5835
MAIN BEARING ID SPECIFICATIONS
With Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 85.705—85.755 mm
(3.3742—3.3762 in.)
Without Bearing . . . . . . . . . . . . . . . . . . . . . . . 92.125—92.151 mm
(3.627—3.628 in.)
NOTE: Inspect and measure assembled ID of connecting
rod bearings. Compare measurements with
connecting rod journal OD on crankshaft. (See
Group 10.)
RG,CTM42,G15,34-19-16AUG94
4. Measure OD of all respective crankshaft journals at
several points around journal.
CRANKSHAFT SPECIFICATIONS
OD of Main Bearing Journal . . . . . . . . . . . . . . . . . . 85.649—85.674
(3.3720—3.3730 in.)
-UN-14DEC88
NOTE: If engine has previously had a major overhaul
and undersized bearing inserts were used, above
listed ID and OD dimensions may not be the
same as those recorded. However, oil clearance
should be within specifications. Oil clearance is
0.030—0.107 mm (0.0012—0.0042 in.).
Use crankshaft journal OD measurements to determine if
journal is out-of-round or tapered.
RG1808
15
32
CRANKSHAFT WEAR SPECIFICATIONS
Journal Taper Per 25.4 mm (1.0 in.) of
Journal Length . . . . . . . . . . . . . . . . . . . . . 0.0025 mm (0.0001 in.)
Journal Out-of-Roundness . . . . . . . . . . . . . . 0.025 mm (0.0010 in.)
S11,0403,AD
CTM42 (24MAR95)
15-32
-19-17AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=161
Crankshaft, Main Bearings and Flywheel/Main Bearing Cap Line Bore Specifications
MAIN BEARING CAP LINE BORE SPECIFICATION
MAIN BEARING CAP BORE SPECIFICATIONS
1. With crankshaft removed from cylinder block, install
main bearing caps without bearing inserts.
2. Tighten main bearing cap screws to 203 N·m (150
lb-ft).
3. Measure ID of all bearing caps, at several
locations, with an inside micrometer.
ID Without Bearings (Standard) . . . . . . . . . . 92.125—92.151 mm
(3.627—3.628 in.)
Maximum Bore Diameter Variation . . . . . . . . . . . . . . . 0.013 mm
(0.0005 in.)
Maximum Bore Diameter Taper . . . . . . . . . . . . . . . . . 0.013 mm
(0.0005 in.)
If any main bearing cap assembled ID is not within
specification, blank (generic) bearing caps are
available and must be line bored to specification.
Replace individual bearing caps as needed.
Maximum Straightness Variation
(Any Bore-to-Adjacent Bore) . . . . . . . . . . . . . . . . . . . 0.038 mm
(0.0015 in.)
IMPORTANT: Main bearing cap line boring should
be done ONLY by experienced
personnel on equipment capable of
maintaining bore specifications.
Maximum Straightness Variation
(5 Center Bores-to-End Bores) . . . . . . . . . . . . . . . . . . 0.08 mm
(0.003 in.)
Centerline of Bore-to-Top Deck . . . . . . . . . . 352.35—352.50 mm
(13.872—13.878 in.)
S11,2515,BY
-19-21MAR95
15
33
CTM42 (24MAR95)
15-33
6076 Diesel Engines—S.N. (500000—
)
160101
PN=162
Crankshaft, Main Bearings and Flywheel/Crankshaft Grinding Guidelines
CRANKSHAFT GRINDING GUIDELINES
IMPORTANT: Crankshaft grinding should be done
ONLY by experienced personnel on
equipment capable of maintaining
crankshaft size and finish
specifications.
In addition to the standard size main and connecting
rod bearings, 0.05, 0.25, 0.51 and 0.76 mm (0.002,
0.010, 0.020 and 0.030 in.) undersize bearings are
available. If journals are tapered, out-of-round, scored
or damaged, grind the crankshaft and install the
proper undersize bearings.
NOTE: The 0.05 mm (0.002 in.) undersize bearings
are used normally to compensate for slight
un-even wear on crankshafts. Regrinding is
usually unnecessary when this size bearing is
used.
15
34
IMPORTANT: If undersize bearings are used,
check bearing clearance after
bearing caps have been tightened to
specified torque. If undersize
bearings are too tight and clearance
is not within specifications, the
journal and bearing will be wiped
clean of all oil. This would result in
premature wear of parts.
If the crankshaft is to be reground, use the following
recommended procedure:
1. Compare the crankshaft journal measurements
taken during inspection and determine the size which
the journals are to be reground.
2. If one or more main or connecting rod journals
require grinding, then grind all of the main journals or
all of the connecting rod journals to the same
required size.
3. All journal fillets radii must be free of any sharp
grind marks or scratches. The fillet must blend
smoothly into the journal and crank cheek. Check the
radius with a fillet gage.
IMPORTANT: Care must be taken to avoid
localized heating which often
produces grinding cracks.
S11,2015,DM
CTM42 (24MAR95)
15-34
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=163
Crankshaft, Main Bearings and Flywheel/Crankshaft Grinding Guidelines
CRANKSHAFT GRINDING GUIDELINES—CONTINUED
4. Cool the crankshaft while grinding by using coolant
generously. DO NOT crowd the grinding wheel into
the work.
IMPORTANT: Grind crankshaft with journals
turning counterclockwise, as viewed
from the front end of crankshaft.
Lap or polish journals in opposite
direction of grinding.
5. Polish or lap the ground surfaces to the specified
finish to prevent excessive wear of the journals. (See
CRANKSHAFT GRINDING SPECIFICATIONS, later in
this group.)
NOTE: Production crankshafts are induction hardened
and shotpeened at the factory. Field
shotpeening is not recommended due to the
equipment required and part geometry.
NOTE: When thrust surfaces are reground and an
oversize washer is used, crankshaft end play
specification must be maintained to within
0.038—0.380 mm (0.0015—0.0150 in.) (See
CHECK CRANKSHAFT END PLAY, earlier in
this group.)
7. Stone the edge of all oil holes in the journal
surfaces smooth to provide a radius of approximately
1.50 mm (0.060 in.).
8. When finished grinding, inspect the crankshaft for
cracks with the Florescent Magnetic Particle method,
or similar method.
9. De-magnetize the crankshaft.
10. Thoroughly clean the crankshaft and oil passages
with solvent. Dry with compressed air.
6. If the thrust surfaces of the crankshaft are worn or
grooved excessively, regrind and polish. Maintain the
specified radius between each thrust surface and the
bearing journal. An oversize thrust washer set
containing one standard washer and two 0.18 mm
(0.007 in.) oversize washers is available. (See
THRUST BEARING NEW PART SPECIFICATIONS,
later in this group.)
15
35
S11,2015,HD
CTM42 (24MAR95)
15-35
-19-08MAR94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=164
Crankshaft, Main Bearings and Flywheel/Thrust Bearing New Part Specifications
THRUST BEARING NEW PART
SPECIFICATIONS
IMPORTANT: Install thrust bearing in cylinder block
and tighten to specification before
regrinding or polishing thrust surfaces
to assure that all surface on bearing
and on block web are correctly aligned.
THRUST BEARING NEW PART SPECIFICATION
Thrust Washer Clearance Base
Circle Diameter . . . . . . . . . . . 123.70—125.30 mm (4.87—4.93 in.)
Thrust Surface Thickness . . . . . . . . . . . . . . . . . .
37.44—37.54 mm
(1.474—1.478 in.)
Relief Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚
39.16—39.66 mm
(1.542—1.561 in.)
-UN-14DEC88
Bearing Overall Width . . . . . . . . . . . . . . . . . . . .
Maximum Thrust Surface Runout . . . . . . . . . . 0.025 mm (0.0010 in.)
RG5269
A—Thrust Washer Clearance Base Circle Diameter
B—Thrust Surface Thickness
C—Relief Angle
D—Bearing Overall Width
15
36
S55,2015,P
CTM42 (24MAR95)
15-36
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=165
Crankshaft, Main Bearings and Flywheel/Crankshaft Grinding Specifications
CRANKSHAFT GRINDING SPECIFICATIONS
ITEM
Engine Stroke . . . . . . . . . . . . . . .
Main and Rod Journal Surface Finish
Thrust Journal Surface Finish . . . . .
Rod Journal Fillet Radius . . . . . . . .
Main Journal Fillet Radius . . . . . . .
Thrust Journal Fillet Radius . . . . . .
Thrust Journal Width . . . . . . . . . . .
Bearing Size
SPECIFICATION
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Crankshaft Main Journal OD
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..............
121 mm (4.75 in.)
............
Lap 0.20 Um (8 AA)
............
Lap 0.40 Um (16AA)
...
3.94—4.44 mm (0.155—0.175 in.)
...
3.94—4.44 mm (0.155—0.175 in.)
...
3.56—4.06 mm (0.140—0.160 in.)
44.387—44.487 mm (1.7475—1.7515 in.)
Crankshaft Rod Journal OD
Standard . . . . . . . . . . . . . . . . . . . . 85.649—85.674 mm . . . . . . . . . . . . . . . . . 76.149—76.175 mm
(3.3720—3.3730 in.)
(2.9980—2.9990 in.)
0.05 mm (0.002 in.) . . . . . . . . . . . . 85.598—85.623 mm . . . . . . . . . . . . . . . . . 76.098—76.124 mm
Undersize
(3.3700—3.3710 in.)
(2.9960—2.9970 in.)
0.25 mm (0.010 in.) . . . . . . . . . . . . 85.394—85.420 mm . . . . . . . . . . . . . . . . . 75.895—75.920 mm
Undersize
(3.3620—3.3630 in.)
(2.9880—2.9890 in.)
0.51 mm (0.020 in.) . . . . . . . . . . . . 85.140—85.166 mm . . . . . . . . . . . . . . . . . 75.641—75.667 mm
Undersize
(3.3520—3.3530 in.)
(2.9780—2.9790 in.)
0.76 mm (0.030 in.) . . . . . . . . . . . . 84.887—84.912 mm . . . . . . . . . . . . . . . . . 75.387—75.413 mm
Undersize
(3.3420—3.3430 in.)
(2.9680—2.9690 in.)
S11,2015,HG
CTM42 (24MAR95)
15-37
15
37
-19-17AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=166
Crankshaft, Main Bearings and Flywheel/Replace Crankshaft Oil Pump Drive Gear
REPLACE (CRANKSHAFT) OIL PUMP DRIVE
GEAR
IMPORTANT: Protect all machined surfaces of
crankshaft from grinding debris and
weld spatter when removing old gear
and installing new gear. DO NOT use a
cutting torch to remove failed gear.
1. Using a rotary grinding wheel or parting disc, grind
weld beads (A) until flush with crankshaft flange.
2. Remove gear (B) by alternately striking gear at each
weld location using a brass drift and soft lead mallet.
3. After removal of gear, clean up OD of crankshaft
flange and remove any burrs or remaining weld bead to
eliminate interference when installing new gear.
15
38
-UN-14DEC88
CAUTION: Oil fumes or oil can ignite above
193˚C (380˚F). Use a thermometer and do not
exceed 182˚C (360˚F). Do not allow a flame or
heating element to be in direct contact with the
oil. Heat the oil in a well-ventilated area. Plan a
safe handling procedure to avoid burns.
RG5018
N
4. Heat new gear to 148˚C (300˚F) using either heated
oil or oven heat.
IMPORTANT: DO NOT OVERHEAT GEAR. SEE
CAUTION. Overheating may also
destroy original heat treatment of gear.
5. Drive gear onto crankshaft flange until flush against
shoulder.
NOTE: When driving oil pump drive gear onto crankshaft
flange. The beveled edge of gear teeth should
face the flywheel end of crankshaft.
6. Weld two 25.4 mm (1 in.) beads according to
illustration using 1/8 in. diameter 7018 welding rod. Grind
away excess weld to eliminate the possibility of
interference with cylinder block.
S11,2515,BG
CTM42 (24MAR95)
15-38
-19-08AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=167
Crankshaft, Main Bearings and Flywheel/Replace Crankshaft Gear
REPLACE CRANKSHAFT GEAR
NOTE: Remove crankshaft gear for replacement only;
it is not necessary to remove gear for
crankshaft removal.
7. Heat crankshaft gear (if removed) to 148˚C
(300˚F), using either heated oil or oven heat.
IMPORTANT: If flame heat is used, be sure gear
is heated uniformly around
circumference. DO NOT OVERHEAT.
SEE CAUTION. Overheating may
also destroy original heat treatment
of gear.
1. Install JDG787 Thread Protector in nose of
crankshaft.
2. Protect crankshaft wear sleeve surface with
masking tape.
8. Install Woodruff key in crankshaft.
3. Remove crankshaft gear using D01251AA* Puller
or an equivalent puller.
9. Place gear on crankshaft flange. Be sure key on
crankshaft is properly aligned with keyway in gear.
4. Discard gear after removal.
IMPORTANT: When installing gear, do not gouge
or nick crankshaft flange.
5. Remove Woodruff key from crankshaft keyway.
6. Remove masking tape.
10. Use JDH7 Driver to firmly seat gear against
crankshaft flange.
IMPORTANT: Crankshaft gear must be installed
on crankshaft before crankshaft is
installed in engine, otherwise
damage to thrust bearings could
occur.
N
11. Once gear cools, reseat gear using JDH7 Driver.
CAUTION: Oil fumes or oil can ignite above
193˚C (380˚F). Use a thermometer and do
not exceed 182˚C (360˚F). Do not allow a
heating element to be in direct contact with
the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid
burns.
*Part of D01047AA 17-1/2 and 30-Ton Puller Set.
CTM42 (24MAR95)
15
39
RG,CTM61,G15,27-19-30APR93
15-39
6076 Diesel Engines—S.N. (500000—
)
160101
PN=168
Crankshaft, Main Bearings and Flywheel/Remove and Clean Piston Cooling Orifices
INSPECT THRUST BEARINGS
1. Check thrust surfaces of the thrust bearing and the
thrust bearing journal on crankshaft and replace as
necessary.
-UN-15DEC88
Thrust bearings are available in each of the previously
mentioned insert undersizes. An oversize thrust washer
set containing one regular size washer and two 0.18 mm
(0.007 in.) oversize washers is also available.
R24545
NOTE: Thrust bearings must be installed with slots
facing crankshaft flange. Two halves (A) and (C)
go on cap side, not block.
A—Lower Rear Thrust Washer
B—Upper Rear Thrust Washer
C—Lower Front Thrust Washer
D—Main Bearing Block Thrust Bearing
E—Main Bearing Cap Thrust Bearing
F—Large Tang
G—Small Tang
S11,0403,AF
-19-08MAR94
15
40 REMOVE AND CLEAN PISTON COOLING
ORIFICES
1. Remove all six piston cooling orifices (A) and inspect
each cooling orifice to make sure it is not plugged or
damaged.
2. Use a soft wire and compressed air to clean orifice.
Replace, if condition is questionable.
-UN-12AUG91
IMPORTANT: A piston cooling orifice failure could
cause damage to pistons, piston pins,
rod pin bushings, and liners. If a piston
cooling orifice is left out, low or no oil
pressure will result.
RG5811
3. Install orifices and tighten to 11 N·m (8 lb-ft) (96
lb-in.).
RG,CTM42,G15,20-19-29OCT92
CTM42 (24MAR95)
15-40
6076 Diesel Engines—S.N. (500000—
)
160101
PN=169
Crankshaft, Main Bearings and Flywheel/Install Main Bearings and Crankshaft
INSTALL MAIN BEARINGS AND
CRANKSHAFT
IMPORTANT: If new main or thrust bearing inserts or
thrust washers are installed, they must
be installed as a matched set.
-UN-15DEC88
During assembly, apply a liberal coating of clean engine
oil to:
—All main bearing webs in block
R24545
—Both sides of main bearing inserts, thrust bearing
inserts, and thrust washers
—Entire OD of crankshaft main bearing journal
No. 5 Main Thrust Bearing Assembly
1. Install six main bearing inserts in block except No. 5
thrust bearing insert. Be sure locating tabs on inserts are
properly positioned with slot in block web.
IMPORTANT: Thrust washers (A,C) go on both sides
of bearing cap and thrust washer (B)
on rear side of block web only with the
slots facing the crankshaft.
-UN-13AUG91
2. Install No. 5 main thrust bearing insert (D) in block.
Install upper thrust washer on bearing insert at rear of
block web. Be sure tangs on washer are properly
positioned on thrust bearing insert.
RG5892
3. Check to make sure that oil holes in main bearing
web are properly aligned with oil holes in bearing inserts.
A—Lower Rear Thrust Washer
B—Upper Rear Thrust Washer
C—Lower Front Thrust Washer
D—Main Bearing Block Thrust Bearing
E—Main Bearing Cap Thrust Bearing
F—Large Tang
G—Small Tang
RG,CTM42,G15,21-19-14SEP94
CTM42 (24MAR95)
15-41
6076 Diesel Engines—S.N. (500000—
)
160101
PN=170
15
41
Crankshaft, Main Bearings and Flywheel/Install Main Bearings and Crankshaft
RG5834
RG3741
-UN-12AUG91
-UN-14DEC88
INSTALL CRANKSHAFT
N
CAUTION: Crankshaft is heavy. Plan a
proper lifting procedure to avoid injuries.
5. Tighten No.’s 1, 2, 3, 4, 6 and 7 main bearing cap
screws to 68 N·m (50 lb-ft). Hand-tighten No. 5 main
thrust bearing cap screws.
1. Carefully position crankshaft onto main bearing
inserts using a hoist and lift sling.
6. Gently pry crankshaft rearward and then forward to
align thrust washers on No. 5 main thrust bearing.
2. Dip entire main bearing cap screws in clean
engine oil and position them in the main bearing
caps. Apply a liberal amount of oil to bearing inserts
in caps.
15
42
NOTE: DO NOT PRY crankshaft on No. 5 main
thrust bearing.
3. Install each bearing cap (B), bearings (C), and cap
screws with washer (A) with the recesses and tabs
aligned in matching order. Make sure bearing tabs
also match up before tightening cap screws.
7. Tighten No. 5 main thrust bearing cap screws to
68 N·m (50 lb-ft).
8. Tighten all main bearing cap screws (including No.
5) to 203 N·m (150 lb-ft).
NOTE: Make sure main bearing caps are installed on
the bearing bosses from which they were
removed. The numbers stamped on the caps
should be on the same side as the numbers
on the block. If there is an arrow on cap,
arrow must be on the camshaft side of the
block pointing towards the front of the engine.
If bearing caps have been rebored, make sure
bearing caps have numbers stamped on them.
9. Turn crankshaft by hand. If it does not turn easily,
disassemble parts and determine the cause.
IMPORTANT: Do not use pneumatic wrench to
install main bearing cap screws, as
damage may occur to threads.
12. Install oil pump and check drive
gear-to-crankshaft clearance. See INSTALL ENGINE
OIL PUMP in Group 20.
10. Install connecting rod bearings and connecting
rods caps. See INSTALL PISTONS AND
CONNECTING RODS in Group 10.
11. Check crankshaft for 0.038—0.380 mm
(0.0015—0.0150 in.) end play.
4. Before tightening cap screws on main bearing
caps, align upper and lower thrust flanges on main
thrust bearings. Using a soft-face hammer, tap
crankshaft to the rear and then to the front to line up
thrust bearing flanges.
RG,CTM42,G15,22-19-03MAY93
CTM42 (24MAR95)
15-42
6076 Diesel Engines—S.N. (500000—
)
160101
PN=171
Crankshaft, Main Bearings and Flywheel/Install Crankshaft Rear Oil Seal Housing
INSTALL CRANKSHAFT REAR OIL SEAL
HOUSING
-UN-14DEC88
These instructions are for when oil seal housing and oil
pan have been removed from cylinder block.
RG4637
1. Make sure the OD of crankshaft flange (A) and ID of
seal housing (B) are free from nicks or burrs. Restore
damage surfaces with a fine file or emery cloth. Clean
with compressed air.
2. Install oil seal housing (C) on cylinder block using a
new gasket. Install all six cap screws with washers, and
tighten finger tight.
RG,CTM42,G15,24-19-29OCT92
15
43
CTM42 (24MAR95)
15-43
6076 Diesel Engines—S.N. (500000—
)
160101
PN=172
Crankshaft, Main Bearings and Flywheel/Install Crankshaft Rear Oil Seal Housing
IMPORTANT: Installation tools must be clean to
assure proper positioning on
crankshaft flange and to hold runout
within specification so oil seal does not
fail prematurely.
NOTE: For oil seal housings stamped R78124, use
JDG748 Driver*. For oil seal housings stamped
R115050, use JDG796 Alignment Tool.
-UN-14DEC88
3. Slip the proper tool (A) over crankshaft flange and into
seal housing bore to center oil seal housing.
RG4638
The driver is designed to center the oil seal housing in
relation to crankshaft flange. However, the use of a
magnetic base dial indicator is still recommended to
measure the seal housing runout. Runout should not
exceed 0.15 mm (0.006 in.).
-UN-13OCT92
4. Position bottom of oil seal housing flush (B) with
cylinder block-to-oil pan mating surface. Tighten seal
housing cap screws to 27 N·m (20 lb-ft), using sequence
shown in bottom illustration, beginning with cap screw
No. 1.
5. Remove driver from end of crankshaft flange.
6. Check oil seal housing runout with a magnetic base
dial indicator. See CHECK OIL SEAL HOUSING
RUNOUT, later in this group.
RG6427
15
44
7. Trim off excess gasket material extending below
bottom of oil seal housing.
*From JDG476(85) Oil Seal and Wear Sleeve Installer Set.
CTM42 (24MAR95)
RG,CTM42,G15,25-19-16AUG94
15-44
6076 Diesel Engines—S.N. (500000—
)
160101
PN=173
Crankshaft, Main Bearings and Flywheel/Check Oil Seal Housing Runout
CHECK OIL SEAL HOUSING RUNOUT
IMPORTANT: On service “short block” assemblies,
rear oil seal housing runout is preset at
the factory. Do not remove housing
from block.
1. Position magnetic base dial indicator (A) on end of
crankshaft flange as shown. Preset dial indicator tip on
ID of oil seal housing bore (B).
-UN-05AUG91
2. Zero dial indicator and rotate crankshaft one full
revolution, observe full indicator movement. The
maximum oil seal housing bore runout is 0.15 mm (0.006
in.).
RG5751
If runout exceeds specification, loosen cap screws and
adjust housing to obtain an acceptable runout while
keeping bottom of seal housing flush with oil pan mating
surface.
3. Recheck oil seal housing bore runout. If runout still
exceeds specification, oil seal housing bore is possibly
distorted and should be replaced. See INSTALL
CRANKSHAFT REAR OIL SEAL HOUSING, earlier in
this group.
15
45
S11,2515,AK
CTM42 (24MAR95)
15-45
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=174
Crankshaft, Main Bearings and Flywheel/Crankshaft Rear Oil Seal And Wear Sleeve Handling Precautions
CRANKSHAFT REAR OIL SEAL AND WEAR
SLEEVE HANDLING PRECAUTIONS
Use the following precautions for handling seal and wear
sleeve:
—Seal (A) and wear sleeve (B) are assembled. DO NOT
SEPARATE. If parts become separated, discard and
replace with a new assembly. Attempts to reassemble
will cause the wear sleeve to damage the seal allowing
engine oil to leak past seal.
—Always install seal and wear sleeve assembly
immediately after removal from plastic bag to avoid
possible dirt contamination.
-UN-07JUL89
—No lubrication of any kind is to contact seal when
installing. Use of a lubricant may result in premature seal
failure.
15
46
RG5575
—Install oil seal/wear sleeve assembly with the open
side of seal and wear sleeve ID chamfer toward the
engine. If seal is reversed, engine oil may be lost
because grooves in oil seal lip would be incorrect with
respect to direction of crankshaft rotation.
—Oil seal/wear sleeve assembly MUST be installed with
the JDG476(85) Crankshaft Rear Oil Seal Installation
Tool Set. Tool set consists of JDG477(85) Pilot and
JDG478 Driver.
S11,2015,GP
CTM42 (24MAR95)
15-46
-19-08MAR94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=175
Crankshaft, Main Bearings and Flywheel/Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly
INSTALL CRANKSHAFT REAR OIL SEAL
AND WEAR SLEEVE ASSEMBLY
-UN-14DEC88
1. Apply a light coating of LOCTITE 609 Retaining
Compound, or equivalent, completely around the leading
edge of crankshaft flange. Wipe away any sealant that
may have gotten on seal housing bore.
RG4639
IMPORTANT: DO NOT allow sealant to get on any
part of wear sleeve OD or on oil seal.
2. Install JDG477(85) Pilot (A) on end of crankshaft
using the Allen head cap screws (B) supplied with tool
set. Tighten cap screws securely.
IMPORTANT: Handle seal and wear sleeve assembly
carefully. If assembly becomes
separated, discard these parts and
install a new assembly.
3. Carefully start oil seal/wear sleeve assembly (C) over
JDG477(85) Pilot and crankshaft flange with open side of
seal toward engine.
IMPORTANT: When installing the JDG478 Driver on
JDG477(85) Pilot and crankshaft flange
to position oil seal/wear sleeve
assembly, locate crossbar of installer at
right angle (90˚) to Allen head cap
screws. This allows the crossbar to
bottom on pilot, not head of cap
screws, assuring correct installation.
15
47
RG,CTM42,G15,26-19-29OCT92
4. Position JDG478 Driver (A) so that hole in the cross
plate goes over threaded stud of pilot. Install washer and
nut on stud.
-UN-14DEC88
5. Tighten nut to draw JDG478 Driver in until crossbar
bottoms on JDG477(85) Pilot. When the tool bottoms,
seal and wear ring assembly (B) will be correctly
positioned.
RG4640
6. Remove JDG476(85) Tool Set from engine.
RG,CTM42,G15,27-19-11JUN93
CTM42 (24MAR95)
15-47
6076 Diesel Engines—S.N. (500000—
)
160101
PN=176
Crankshaft, Main Bearings and Flywheel/Install Front Wear Sleeve
INSTALL TIMING GEAR COVER
-UN-12AUG91
IMPORTANT: Tightening the timing gear cover cap
screws in numerical sequence controls
the total runout of the front crankshaft
oil seal.
RG5828
1. Install a new gasket on the engine block. Lightly
grease the gasket to hold it in place. Install timing gear
cover (C). Tighten cap screws in sequence one through
nine (as shown) to 27 N·m (20 lb-ft).
2. Trim timing gear cover gasket flush with oil pan
gasket rail.
3. Lightly grease and install a new injection pump drive
gear cover gasket on timing gear cover. Install cover (B).
Tighten cap screws to 27 N·m (20 lb-ft).
RG5783
-UN-13OCT92
4. Using a new O-ring, install magnetic pickup (A, if
equipped) in timing gear cover and tighten to 14 N·m (10
lb-ft).
15
48
RG,CTM42,G15,30-19-24MAR95
INSTALL FRONT WEAR SLEEVE
-UN-13AUG91
NOTE: Front wear sleeve can be installed with timing
gear cover removed or installed.
1. Coat I.D. of new wear sleeve (if removed) with
LOCTITE 609 Retaining Compound or equivalent.
RG5879
2. Use the JDE3 Driver (B), large washer, and cap
screw threaded in nose of crankshaft to press on wear
sleeve (A).
RG,CTM42,G15,29-19-29OCT92
CTM42 (24MAR95)
15-48
6076 Diesel Engines—S.N. (500000—
)
160101
PN=177
Crankshaft, Main Bearings and Flywheel/Install Damper Pulley Assembly
INSTALL CRANKSHAFT FRONT OIL SEAL
(WITH TIMING GEAR COVER INSTALLED ON
ENGINE)
-UN-26OCT92
IMPORTANT: Whenever front oil seal is replaced, the
wear sleeve MUST be replaced also.
RG6479
1. Place JDG720-2 Seal Protector (A) on nose of
crankshaft. Lubricate ID of front oil seal lips with clean
engine oil. Slide seal with spring side of seal facing
engine onto seal protector. Be careful not to roll oil seal
lips.
2. Place JDG720-3 Seal Installer onto seal protector
against seal. Do not use spacer ring provided with tool
set.
-UN-26OCT92
3. With nut and washer installed onto JDG720-1 Forcing
Screw, thread forcing screw into nose of crankshaft until
it bottoms.
RG6480
4. Tighten nut against crossplate of installer until installer
bottoms onto front face of timing gear cover.
5. Remove installation tools. Verify seal is installed
square in bore and that seal lips are not rolled on wear
sleeve.
15
49
Oil seal should be 8.4 mm (0.33 in.) below front lip of
seal bore.
RG,CTM42,G15,43-19-03MAY93
INSTALL DAMPER PULLEY ASSEMBLY
-UN-14DEC88
1. If vibration damper (A) was removed from damper
pulley (B), install washer (C) and tighten cap screws to
41 N·m (30 lb-ft).
RG3928
NOTE: Vibration damper and pulley orientation may vary
depending on specific engine application. Be sure
damper and pulley are assembled in the same
orientation as when removed.
S11,2015,DT
CTM42 (24MAR95)
15-49
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=178
Crankshaft, Main Bearings and Flywheel/Install SAE 3 Flywheel Housing
2. Make sure crankshaft Woodruff key is in place, with
tab facing forward. Position damper pulley assembly (B)
onto crankshaft.
3. Use hardened washer (part of damper assembly) and
insert a cap screw that is 25 mm (1 in.) longer than
original cap screw (A). Tighten cap screw until it just
bottoms out.
-UN-13AUG91
4. Remove cap screw and insert original cap screw with
same hardened washer.
5. Tighten cap screw to 230 N·m (170 lb-ft).
RG5882
6. Install water bypass pipe.
RG,CTM42,G15,31-19-16AUG94
INSTALL SAE 3 FLYWHEEL HOUSING
On SAE 1 and SAE 2 flywheel housings, the flywheel
housing is installed AFTER the flywheel.
N
CAUTION: Flywheel housing (A) is heavy. Plan
a proper lifting procedure to avoid personal
injury.
-UN-14DEC88
1. On engines requiring a gasket between block and
flywheel housing, inspect cylinder block and flywheel
housing gasket surfaces to see that they are clean.
Scrape off all old gasket material. Install a new gasket
without sealant between block and flywheel housing.
2. Install flywheel housing on cylinder block.
RG5005
15
50
NOTE: Use new cap screws when installing flywheel
housing.
3. Dip threads of cap screw in engine oil before
installing. Install and tighten cap screws to 407 N·m (300
lb-ft).
S11,2015,GL
CTM42 (24MAR95)
15-50
-19-29OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=179
Crankshaft, Main Bearings and Flywheel/Install SAE 1 and SAE 2 Flywheel Housing
INSTALL FLYWHEEL
N
-UN-14DEC88
Two guide studs may be used to aid in flywheel
installation.
CAUTION: Flywheel is heavy. Plan a proper
handling procedure to avoid personal injuries.
RG4383
NOTE: ALWAYS use new cap screws when installing
flywheel. Flywheel must be clean and free of oil
before installing.
1. Coat threads of flywheel attaching cap screws with
LOCTITE 242 or its equivalent.
2. Position flywheel over dowel pin (A) and install drive
hub (if equipped). Start four cap screws. Remove guide
studs and install remaining cap screws.
3. Install remaining flywheel attaching cap screws.
4. Tighten flywheel attaching cap screws to 115 N·m (85
lb-ft).
S11,2020,L
-19-29OCT92
15
51
INSTALL SAE 1 AND SAE 2 FLYWHEEL
HOUSING
On SAE 3 flywheel housings, the housing MUST be
installed BEFORE installing flywheel.
N
CAUTION: Flywheel housing is heavy. Plan a
proper lifting procedures to avoid personal
injury.
1. Scrape off all old gasket material. Install a new gasket
without sealant between block and flywheel housing, if
equipped.
2. Install flywheel housing on cylinder block.
NOTE: ALWAYS use new cap screws when installing
flywheel housing.
3. Dip threads of cap screw in engine oil before
installing. Install and tighten cap screws to 407 N·m (300
lb-ft).
S11,2015,GT
CTM42 (24MAR95)
15-51
-19-29OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=180
Crankshaft, Main Bearings and Flywheel/Complete Final Assembly
COMPLETE FINAL ASSEMBLY
1. Install fan assembly.
2. Install oil pan and fill with clean engine oil.
3. Fill cooling system with proper coolant after engine
installation and perform engine break-in. (See PERFORM
ENGINE BREAK-IN in Group 05.)
S55,2015,Y
-19-29OCT92
15
52
CTM42 (24MAR95)
15-52
6076 Diesel Engines—S.N. (500000—
)
160101
PN=181
Group 16
Camshaft and Timing Gear Train
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
-19-05JUN91
RG,JDG820
-19-14FEB95
RG,JDE814,86
-19-14FEB95
-UN-10AUG94
Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820
RG7056
Used to rotate engine to check damper radial runout and
time engine. JDE81-1 may be used also if JDG820 is
not available.
RG5068
-UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train, adjusting
valve clearance, and installing fuel injection pump. Use
with JDG820 and JDE81-1 Flywheel Turning Tools.
RG5073
-UN-23AUG88
Magnetic Follower Holder Kit . . . . . . . . . . D15001NU
Hold cam followers when removing or installing camshaft.
16
1
S53,D15001,NU -19-24APR92
-UN-15DEC88
Slide Hammer . . . . . . . . . . . . . . . . . . . . D01299AA
RG78104H1
Used with JDG405 Camshaft Bushing Service Set and
JDG606 Camshaft Bushing Adapter Set to service
camshaft bushings.
S53,D01299,AAA -19-09SEP91
CTM42 (24MAR95)
16-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=182
Camshaft and Timing Gear Train/Special or Essential Tools
Hub Puller Kit
. . . . . . . . . . . . . . . . . . . . . . JDG721
RG5763
-UN-06AUG91
Used with JDG787 Thread Protector to remove vibration
damper pulley assembly on some engine applications.
RG,JDG721
-19-03MAY93
S53,JDG405,A
-19-28APR92
Camshaft Bushing Service Set . . . . . . . . . . . JDG405
-UN-27JAN92
Used with JDG606 Camshaft Bushing Adapter Set and
D01299AA Slide Hammer to service camshaft bushings.
RG4228
NOTE: JDE6 Service Set may be used along with
JDG602 Adapter Set if JDG405 is not available.
Used with JDG602 Camshaft Bushing Adapter Set to
service camshaft bushings.
R26149N
NOTE: JDG405 Service Set may be used along with
JDG606 Adapter Set if JDE6 is not available.
S53,JDE6A
-19-09SEP91
S53,JDG602
-19-09SEP91
Camshaft Bushing Adapter Set . . . . . . . . . . . JDG602
-UN-23AUG88
Used with JDE6 Camshaft Bushing Service Set to
service camshaft bushings. JDG602 consists of JDG603
Driver and JDG604 Receiver Cup.
RG5336
16
2
-UN-23AUG88
Camshaft Bushing Service Set . . . . . . . . . . . . . JDE6
CTM42 (24MAR95)
16-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=183
Camshaft and Timing Gear Train/Other Material
Camshaft Bushing Adapter Set . . . . . . . . . . . JDG606
RG5337
-UN-28AUG91
Used with JDG405 Camshaft Bushing Service Set and
D01299AA Slide Hammer to service camshaft bushings.
JDG606 consists of JDG607 Driver and JDG608 Pilot.
S53,JDG606
-19-09SEP91
SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog
(MTC). Some tools may be available from a local supplier.
Name
Use
D01207AA Puller Kit
Used to remove vibration damper.
D01045AA Bushing, Bearing, and Seal Driver Master Set
Used to install front oil seal in timing gear
cover.
RG,CTM42,G16,4 -19-10SEP91
OTHER MATERIAL
Name
Use
High Temperature Grease
(TY6333 OR TY6347)
Lubricate camshaft lobes and thrust washers before
camshaft installation.
FEL-PRO® C-670 Molybdenum Disulfide Paste
Lubricate camshaft nose to provide lubrication to
aid in camshaft gear installation.
PERMATEX AVIATION (Form-A-Gasket No.3 )
(TY6299)
Lubricate camshaft bore steel cap plug.
16
3
RG,CTM42,G16,1 -19-29OCT92
CTM42 (24MAR95)
16-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=184
Camshaft and Timing Gear Train/Camshaft and Timing Gear Train Specifications
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS
ITEM
SPECIFICATION
WEAR LIMIT
Camshaft End Play . . . . . . . . . . . . . . . . . . . . 0.0130—0.5000 mm
(0.0005—0.0200 in.)
16
4
0.65 mm (0.026 in.)
Camshaft Thrust Washer Thickness . . . . . . . . . 2.24—2.34 mm
(0.088—0.092 in.)
——
Camshaft Journal OD
. . . . . . . . . . . . . . . . . . 66.987—67.013 mm
(2.6373—2.6383 in.)
——
Camshaft Bushing ID . . . . . . . . . . . . . . . . . . . 67.076—67.102 mm
(2.6408—2.6418 in.)
——
Camshaft Bushing-to-Journal Clearance . . . . . . 0.063—0.115 mm
(0.0025—0.0045 in.)
Camshaft Gear-to-Injection
Pump Drive Gear Backlash . . . . . . . . . . . . . 0.051 mm
(0.0020 in.) minimum
Camshaft Bushing Bore in Block
(without bushings) . . . . . . . . . . . . . . . . . . . 69.987—70.013 mm
(2.7554—2.7564 in.)
——
Maximum Runout of Camshaft Bore . . . . . . . . . 0.038 mm (0.0015 in.)
——
Maximum Runout of Camshaft
Gear Thrust Surfaces . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
——
Camshaft Drive Gear-to-Crankshaft
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . 0.076 mm (0.0030 in.) minimum
——
——
——
Camshaft Lobe Lift:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.69—7.07 mm (0.303—0.307 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25—8.35 mm (0.325—0.329 in.)
Cam Follower OD . . . . . . . . . . . . . . . . . . . . . 17.33—17.35 mm
(0.682—0.683 in.)
Cam Follower Bore Diameter in Block
7.19 mm (0.283 in.)
7.75 mm (0.305 in.)
——
. . . . . . . 17.384—17.440 mm
(0.6845—0.6865 in.)
——
Valve Lift at 0.00 mm (in.) Clearance:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.53—13.71 mm (0.533—0.540 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 14.52—14.70 mm (0.572—0.579 in.)
12.65 mm (0.498 in.)
13.64 mm (0.537 in.)
Crankshaft Front Oil Seal Bore Runout . . . . . . . 0.254 mm (0.010 in.) maximum
——
Crankshaft Front Oil Seal Installed Depth
(below front face of cover) . . . . . . . . . . . . . . 8.4 mm (0.33 in.)
——
RG,CTM42,G16,2 -19-16AUG94
CTM42 (24MAR95)
16-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=185
Camshaft and Timing Gear Train/Camshaft and Timing Gear Train Specifications
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS—CONTINUED
TORQUES
Rocker Arm Shaft Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N·m (55 lb-ft)
Rocker Arm Cover-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N·m (6 lb-ft) (72 lb-in.)
Timing Gear Cover-to-Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
Injection Pump Gear Cover
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
Magnetic Pickup-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 N·m (10 lb-ft)
RG,CTM42,G16,3 -19-24MAR95
16
5
CTM42 (24MAR95)
16-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=186
Camshaft and Timing Gear Train/Check Valve Lift
CHECK VALVE LIFT
NOTE: Measuring valve lift can give an indication of
wear on camshaft lobes and cam followers or
bent push rods.
IMPORTANT: For a more accurate measurement, it is
recommended that valve lift be
measured at 0.00 mm (in.) valve
clearance.
-UN-09AUG91
1. Remove turbocharger oil inlet line clamp and rocker
arm cover. Loosen locknut on rocker arm. Set valve
clearance at 0.00 mm (in.). Tighten locknut.
2. Put dial indicator tip on valve rotator. Be sure that
valve is fully closed.
RG5789
3. Check pre-set on dial indicator. Set dial indicator
pointer at zero.
4. Manually turn engine in running direction, using the
engine rotation tools previously mentioned for checking
valve clearance.
5. Observe dial indicator reading as valve is moved to
fully open position.
VALVE LIFT SPECIFICATION AT 0.00 MM (IN.) CLEARANCE
16
6
Intake . . . . . . . . . . . . . . . . . . 13.53—13.71 mm (0.533—0.540 in.)
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.)
Exhaust . . . . . . . . . . . . . . . . . 14.52—14.70 mm (0.572—0.579 in.)
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . 13.65 mm (0.537 in.)
6. Follow same procedure for all remaining valves and
adjust valve clearance to specification. (See CHECK
AND ADJUST VALVE CLEARANCE in Group 05.)
RG,CTM42,G16,5 -19-16AUG94
CTM42 (24MAR95)
16-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=187
Camshaft and Timing Gear Train/Remove Damper Pulley and Timing Gear Cover
CHECK CAMSHAFT END PLAY
-UN-06AUG91
NOTE: Camshaft end play must be measured before
removing timing gear cover, as thrust washer in
back side of timing gear cover limits camshaft
end play.
RG5769
1. Remove injection pump drive gear cover (shown
removed).
2. Install magnetic base dial indicator on front face of
cylinder block.
3. Position dial indicator tip on front face of camshaft
gear, as shown. Set dial indicator to zero.
4. Move camshaft gear back and forth and observe end
play reading. Compare reading with specification given
below.
CAMSHAFT END PLAY SPECIFICATIONS
Camshaft End Play (NEW) . . . . . . . . . . . . . . . . . 0.013—0.500 mm
(0.0005—0.0200 in.)
Maximum Allowable End Play . . . . . . . . . . . . . . . . . . . . . . 0.65 mm
(0.0260 in.)
If end play is excessive, remove timing gear cover and
camshaft and measure thickness of thrust washers.
16
7
RG,CTM42,G16,12-19-29OCT92
REMOVE DAMPER PULLEY AND TIMING
GEAR COVER
-UN-06AUG91
1. Drain oil (if not previously done), and remove oil pan.
Remove oil pump if crankshaft is to be removed.
2. Remove cap screw and washer on damper pulley.
RG5765
IMPORTANT: DO NOT use a jaw-type puller to
remove vibration damper. Damage
could result to the damper. Never apply
thrust on outer ring of damper. Do not
drop damper or strike with a hammer.
3. Remove pulley and damper from crankshaft using
D01207AA Puller Set.
RG,CTM42,G16,8 -19-29OCT92
CTM42 (24MAR95)
16-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=188
Camshaft and Timing Gear Train/Measure Camshaft Drive Gear-to-Crankshaft Gear Backlash
4. Remove magnetic pick-up (A, if equipped) and
injection pump drive gear cover (B).
-UN-06AUG91
5. Check camshaft end play. (See CHECK CAMSHAFT
ENDPLAY earlier in this group.)
RG5766
IMPORTANT: Whenever timing gear cover is
removed, ALWAYS install a new front
oil seal.
6. Remove timing gear cover (C).
7. Remove front oil seal from timing gear cover. Install a
new seal after timing gear cover is installed. See
INSTALL FRONT OIL SEAL (WITH TIMING GEAR
COVER INSTALLED ON ENGINE) in Group 15.
8. Remove front crankshaft wear sleeve.
RG,CTM42,G16,9 -19-16AUG94
MEASURE CAMSHAFT DRIVE
GEAR-TO-CRANKSHAFT GEAR BACKLASH
Measure backlash between camshaft drive gear and
crankshaft gear in three (3) different positions around the
camshaft gear. Use a magnetic base dial indicator with
indicator plunger resting on camshaft gear tooth.
CAMSHAFT DRIVE GEAR-TO-CRANKSHAFT GEAR BACKLASH
SPECIFICATION
Camshaft Gear Backlash . . . . . . . . . . . . . 0.076 mm (0.003 in.) min.
-UN-06AUG91
Replace gears if backlash is not within specification.
RG5770
16
8
RG,CTM42,G16,13-19-29OCT92
CTM42 (24MAR95)
16-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=189
Camshaft and Timing Gear Train/Remove Camshaft
REMOVE CAMSHAFT
-UN-06AUG91
NOTE: It is not necessary to remove cylinder head from
engine for camshaft removal. If push rods are
bent or show excessive scuffing, it may be
necessary to remove cylinder head for inspection
of block, head, cam lobes and cam followers.
RG5764
1. Drain engine oil and coolant, if not previously done.
2. Disconnect turbocharger oil inlet line at turbocharger
or oil conditioning housing.
3. Set engine at No. 1 cylinder’s “TDC-Compression”
stroke with JDE81-4 Timing Pin. (See Group 05, Cylinder
Head and Valves.)
4. Remove rocker arm cover, rocker arm assembly and
push rods. Remove cylinder head, if desired. (See Group
05, Cylinder Head and Valves.)
RG,CTM42,G16,32-19-29OCT92
5. When removing camshaft with engine on rollover
stand, roll engine to a vertical position (horizontal shown)
and hold cam followers away from camshaft lobes with
D15001NU Magnetic Holding Set.
RG5778
-UN-06AUG91
16
9
RG,CTM42,G16,33-19-29OCT92
CTM42 (24MAR95)
16-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=190
Camshaft and Timing Gear Train/Remove Camshaft
6. Examine camshaft gear (A) and injection pump drive
gear (B) for worn or damaged gear teeth. Gears should
have a minimum backlash of 0.051 mm (0.0020 in.).
RG5771
-UN-06AUG91
NOTE: Timing marks on crankshaft and camshaft gear
should be aligned and No. 1 cylinder locked at
“TDC Compression” stroke when removing
camshaft.
RG,CTM42,G16,15-19-29OCT92
7. Carefully remove camshaft (B) from cylinder block so
that camshaft lobes do not drag in bores.
NOTE: Rotate camshaft carefully to aid in removing.
8. Remove thrust washer (A) from behind cam gears.
9. Remove cam followers.
RG5772
-UN-06AUG91
16
10
RG,CTM42,G16,16-19-29OCT92
CTM42 (24MAR95)
16-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=191
Camshaft and Timing Gear Train/Measure Thrust Washer Thickness
REMOVE CAMSHAFT GEARS
NOTE: Camshaft gears are pressed onto the camshaft.
Removal of gears from camshaft will require
approximately a 10-ton press.
-UN-06AUG91
IMPORTANT: Prevent camshaft from striking floor
when pushing camshaft nose out of
gear. Camshaft may be damaged if it is
allowed to fall to the floor.
1. Support outer camshaft gear (A) in a press.
2. Remove outer gear from camshaft.
RG5773
3. Support inner camshaft gear (B) in a press.
4. Remove inner gear from camshaft.
RG5774
-UN-06AUG91
5. Clean camshaft and gears in solvent. Dry with
compressed air.
16
11
RG,CTM42,G16,17-19-29OCT92
MEASURE THRUST WASHER THICKNESS
-UN-06AUG91
1. After removal of camshaft, check the two thrust
washers individually for proper thickness.
THRUST WASHER THICKNESS SPECIFICATIONS
Thrust Washer Thickness . . . . . . . . . . . . . . . . . . . . 2.24—2.34 mm
(0.088—0.092 in.)
RG5775
2. Replace washers if worn or damaged.
RG,CTM42,G16,18-19-29OCT92
CTM42 (24MAR95)
16-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=192
Camshaft and Timing Gear Train/Visually Inspect Camshaft
INSPECT AND MEASURE CAMSHAFT
FOLLOWERS
-UN-23FEB89
1. Inspect camshaft followers for uneven wear or
damage. Also inspect corresponding camshaft lobe for
wear or damage. Replace as necessary.
RG2745
2. Measure follower OD and follower bore ID in cylinder
block.
CAMSHAFT FOLLOWER AND BORE SPECIFICATIONS
Camshaft Follower OD . . . . . . . . . . . . . . . . . . . .
17.33—17.35 mm
(0.682—0.683 in.)
Camshaft Follower Bore
ID in Block . . . . . . . . . . . . . . . . . . . . . . . . . 17.384—17.440 mm
(0.6845—0.6865 in.)
Replace cam followers that are not within specification.
Replace cylinder block if any one cam follower bore is
not within specification.
RG,CTM42,G16,19-19-15SEP94
VISUALLY INSPECT CAMSHAFT
1. Clean camshaft in solvent. Dry with compressed air.
-UN-06AUG91
2. Visually inspect camshaft lobes (A) and journals (B)
for wear or damage. Replace as necessary. New
camshaft followers can be used with old camshaft (if
camshaft is serviceable). DO NOT reuse old cam
followers with a new camshaft.
RG3500
16
12
NOTE: Very light score marks may be found, but are
acceptable if valve lift is within specification.
Pitting or galling dictates replacement. (See
CHECK VALVE LIFT earlier in this group.)
RG,CTM42,G16,20-19-29OCT92
CTM42 (24MAR95)
16-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=193
Camshaft and Timing Gear Train/Measure Camshaft Lobe Lift
MEASURE CAMSHAFT JOURNAL OD AND
BUSHING ID
-UN-07NOV88
1. Measure each camshaft journal OD. If camshaft
journal OD is not within specification, install a new
camshaft.
T81260
2. Measure each camshaft bushing ID when installed in
cylinder block.
Compare measurements with specs given below.
Replace camshaft and bushings as needed.
CAMSHAFT JOURNAL AND BUSHING SPECIFICATIONS
Camshaft Journal Diameter (NEW)
. . . . . . . . . . 66.987—67.013 mm
(2.6373—2.6383 in.)
Camshaft Bushing ID (NEW) . . . . . . . . . . . . . . . 67.076—67.102 mm
(2.6408—2.6418 in.)
RG,CTM42,G16,21-19-15SEP94
MEASURE CAMSHAFT LOBE LIFT
1. Measure each camshaft lobe at its highest point and
at its narrowest point. Subtract narrowest dimension from
highest dimension to find camshaft lobe lift.
-UN-01NOV88
16
13
If camshaft lobe lift is not within the wear specification
on any one lobe, install a new camshaft.
T81262
CAM LOBE LIFT NEW PART SPECIFICATION
Intake Lobe Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 7.69—7.79 mm
(0.303—0.307 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 mm (0.283 in.)
Exhaust Lobe Lift . . . . . . . . . . . . . . . . . . . . . . . . . 8.25—8.35 mm
(0.325—0.329 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . 7.75 mm (0.305 in.)
RG,CTM42,G16,22-19-16AUG94
CTM42 (24MAR95)
16-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=194
Camshaft and Timing Gear Train/Install Camshaft Gears
INSTALL CAMSHAFT GEARS
1. Support camshaft under first bearing journal in a
hydraulic press.
-UN-06AUG91
2. Install Woodruff key (A). Lubricate camshaft nose with
FEL-PRO® C-670 Molybdenum Disulfide Paste.
RG5776
3. Set inner gear (B) on camshaft with thrust washer
surface to the inside (toward the camshaft). Align
Woodruff key and keyway
4. Install gear onto nose of camshaft. Push inner gear
on until tight against the camshaft bearing journal.
5. Set outer gear on camshaft with timing mark upward
(away from the camshaft). Align Woodruff key and
keyway (C) of outer gear (D).
6. Push outer gear onto camshaft nose until tight against
inner gear.
RG5777
-UN-17SEP91
A—Woodruff Key
B—Inner Gear
C—Keyway
D—Outer Gear
16
14
RG,CTM42,G16,23-19-29OCT92
7. Support each end of the camshaft on centers. Use a
dial indicator with plunger resting on the thrust surface of
the camshaft gears.
8. Check the runout of the inner and outer gear thrust
surfaces.
CAMSHAFT GEAR THRUST SURFACE RUNOUT SPECIFICATIONS
Camshaft Gear Thrust Surface Runout . . . . . . . . . . . . . . . . 0.10 mm
(0.004 in.)
RG,CTM42,G16,24-19-23SEP91
CTM42 (24MAR95)
16-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=195
Camshaft and Timing Gear Train/Service Camshaft Bushings using JDG602 Adapter Set
SERVICE CAMSHAFT BUSHINGS USING
JDG602 ADAPTER SET
1. Inspect camshaft journals and bushings for wear or
damage. Measure cam journals and bushings to
determine if proper oil clearance exists. Replace
camshaft and/or bushings as necessary.
CAMSHAFT JOURNAL AND BUSHING NEW PART SPECIFICATION
-UN-06DEC88
Camshaft Bushing Bore in Block . . . . . . . . . . . . 69.987—70.013 mm
(2.7554—2.7564 in.)
RG5272
Journal OD . . . . . . . . . . . . . . . . . . . . . . . . . . 66.987—67.013 mm
(2.6373—2.6383 in.)
Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.076—67.102 mm
(2.6408—2.6418 in.)
Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063—0.115 mm
(0.0025—0.0045 in.)
-UN-30AUG91
NOTE: The front two bushings can be reached from the
front of the engine. The flywheel and rear
camshaft bore plug (G) must be removed to
reach the other two bushings.
3. Tighten nut on end of bushing screw until bushing is
pulled out of camshaft bushing bore. Inspect and
measure camshaft bushing bore in block (B). Follow
same procedure for remaining bushings to be replaced.
RG5949
2. Remove camshaft bushings (F) using JDG603
Bushing Driver (E) and JDG604 Receiver Cup (D) along
with the components shown from JDE6 Camshaft
Bushing Replacement Set (A and C).
16
15
A—Bushing Screw (JDE6-1)
B—Cylinder Block Web
C—Lock Bushing (No. 25916)
D—Receiver Cup (JDG604)
E—Bushing Driver (JDG603)
F—Camshaft Bushing
G—Camshaft Bore Plug
RG,CTM42,G16,30-19-15SEP94
CTM42 (24MAR95)
16-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=196
Camshaft and Timing Gear Train/Service Camshaft Bushings using JDG602 Adapter Set
IMPORTANT: Oil holes in bushings and cylinder
block must be aligned after installation
or oil starvation will occur. The
elongated hole in bushing must be
toward the top. After installation, use a
small mirror with extension to be sure
oil holes are properly aligned.
-UN-06DEC88
4. Slide a new camshaft bushing (F) onto JDG603
Bushing Driver (E). Assemble driver and JDG604
Receiver Cup (D) along with components shown from
JDE6 Camshaft Bushing Replacement Set (A and C).
6. Check bushing-to-cylinder block oil hole alignment
using a small mirror with extension.
RG5273
5. Be sure bushing is started square in bore and oil
holes are aligned with holes in block. Tighten nut to pull
bushing in until it is properly positioned in bore.
A—Bushing Screw (JDE6-1)
B—Cylinder Block Web
C—Lock Bushing (No. 25916)
D—Receiver Cup (JDG604)
E—Bushing Driver (JDG603)
F—Camshaft Bushing
S55,2016,N
-19-23SEP91
16
16
CTM42 (24MAR95)
16-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=197
Camshaft and Timing Gear Train/Service Camshaft Bushings using JDG606 Adapter Set
SERVICE CAMSHAFT BUSHINGS USING
JDG606 ADAPTER SET
1. Inspect camshaft journals and bushings for wear or
damage. Measure cam journals and bushings to
determine if proper oil clearance exists. Replace
camshaft and/or bushings as necessary.
CAMSHAFT JOURNAL AND BUSHING NEW PART SPECIFICATIONS
-UN-06DEC88
Camshaft Bushing Bore in Block . . . . . . . . . . . . 69.987—70.013 mm
(2.7554—2.7564 in.)
RG5332
Journal OD . . . . . . . . . . . . . . . . . . . . . . . . . . 66.987—67.013 mm
(2.6373—2.6383 in.)
Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.076—67.102 mm
(2.6408—2.6418 in.)
Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063—0.115 mm
(0.0025—0.0045 in.)
-UN-30AUG91
NOTE: The front two bushings can be reached from the
front of the engine. The flywheel and rear
camshaft bore plug (G) must be removed to
reach the other two bushings.
2. Remove camshaft bushing (B) using JDG607 Bushing
Driver (A), JDG408 Slide Hammer Adapter (D) (from
JDG405 Camshaft Bushing Service Set), JDG608
Bushing Pilot (E), and D01299AA Slide Hammer (F).
NOTE: End bushing at front and rear of cylinder block
may be removed with just JDG607 Bushing
Driver and D01299AA Slide Hammer.
RG5949
Lubricate O-ring on JDG608 Bushing Pilot with
clean engine oil before installing in cylinder block
web (C).
16
17
A—Bushing Driver (JDG607)
B—Camshaft Bushing
C—Cylinder Block Web
D—Slide Hammer Adapter (JDG408)
E—Bushing Pilot (JDG608)
F—Slide Hammer (D01299AA)
G—Camshaft Bore Plug
3. Inspect and measure each camshaft bushing bore in
block as bushings are removed.
RG,CTM42,G16,31-19-15SEP94
CTM42 (24MAR95)
16-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=198
Camshaft and Timing Gear Train/Install Camshaft
IMPORTANT: Oil holes in bushings and cylinder
block must be aligned after installation.
The elongated hole in bushing must be
toward top. After installation, use a
small mirror with extension to be sure
oil holes are properly aligned.
-UN-06DEC88
4. Slide a new camshaft bushing (B) onto JDG607
Bushing Driver (A). With JDG608 Bushing Pilot installed
in outside cylinder block web (C), assemble D01299AA
Slide Hammer (E) and JDG408 Slide Hammer Adapter
(D) with bushing driver as shown.
6. Check bushing-to-cylinder block alignment using a
small mirror with extension.
7. Apply PERMATEX AVIATION (Form-A-Gasket No. 3)
to new camshaft bore steel cap plug and install plug in
bore. Plug edge must be seated below edge of bore.
RG5333
5. Be sure bushing is started square in bore and oil
holes are aligned with holes in block. Pull bushing into
bore with slide hammer until properly positioned.
A—Bushing Driver (JDG607)
B—Camshaft Bushing
C—Cylinder Block Web
D—Slide Hammer Adapter (JDG408)
E—Slide Hammer (D01299AA)
S55,2016,P
-19-29OCT92
INSTALL CAMSHAFT
IMPORTANT: Set engine at TDC of No. 1 piston’s
compression stroke before installing
camshaft so timing marks on camshaft
and crankshaft gears will be aligned.
-UN-06AUG91
1. If camshaft followers were removed with engine on a
rollover stand, reinstall followers but do not obstruct
camshaft bore. Roll engine to an angle where followers
fall away from camshaft bores.
NOTE: If D15001NU Magnetic Holding Tool Set is used,
hold camshaft followers away from camshaft bore
until camshaft is installed.
RG5780
16
18
2. Lubricate thrust washer (A) with TY6333 or TY6347
High Temperature Grease and install on camshaft behind
inner gear.
3. Lubricate camshaft lobes with TY6333 or TY6347
High Temperature Grease and bearing journals with
clean engine oil.
RG,CTM42,G16,25-19-29OCT92
CTM42 (24MAR95)
16-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=199
Camshaft and Timing Gear Train/Install Camshaft
RG5781
-UN-06AUG91
4. Carefully install camshaft (A) in cylinder block so that
camshaft lobes do not drag in bores. Rotate camshaft
during installation to avoid obstruction in any bore.
RG,CTM42,G16,26-19-10SEP91
RG5779
-UN-06AUG91
5. With No. 1 piston on “TDC” compression, align timing
marks on camshaft and crankshaft gears. Check injection
pump timing.
RG,CTM42,G16,27-19-10SEP91
CTM42 (24MAR95)
16-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=200
16
19
Camshaft and Timing Gear Train/Install Thrust Washer and Timing Gear Cover
INSTALL THRUST WASHER AND TIMING
GEAR COVER
-UN-06AUG91
1. Lubricate thrust washer (A) with TY6333 or TY6347
High Temperature Grease and install in timing gear
cover.
RG5782
2. Install a new gasket on the engine block. Apply a light
film of grease to the gasket to hold it in place.
NOTE: Tightening the timing gear cover cap screws in
proper sequence controls the total runout for the
front crankshaft oil seal.
3. Install timing gear cover. Tighten cap screws in
sequence one through nine (as shown) to 27 N·m (20
lb-ft).
4. Trim timing gear cover gasket flush with oil pan
gasket rail.
RG5783
-UN-13OCT92
5. Check camshaft endplay. (See CHECK CAMSHAFT
END PLAY earlier in this group.)
16
20
RG,CTM42,G16,28-19-29OCT92
CTM42 (24MAR95)
16-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=201
Camshaft and Timing Gear Train/Install Front Oil Seal
INSTALL CRANKSHAFT FRONT OIL SEAL
(WITH TIMING GEAR COVER INSTALLED ON
ENGINE)
-UN-26OCT92
IMPORTANT: Whenever front oil seal is replaced, the
wear sleeve MUST be replaced also.
RG6479
1. Place JDG720-2 Seal Protector (A) on nose of
crankshaft. Lubricate ID of front oil seal lips with clean
engine oil. Slide seal with spring side of seal facing
engine onto seal protector. Be careful not to roll oil seal
lips.
2. Place JDG720-3 Seal Installer onto seal protector
against seal. Do not use spacer ring provided with tool
set.
-UN-26OCT92
3. With nut and washer installed onto JDG720-1 Forcing
Screw, thread forcing screw into nose of crankshaft until
it bottoms.
RG6480
4. Tighten nut against crossplate of installer until installer
bottoms onto front face of timing gear cover.
5. Remove installation tools. Verify seal is installed
square in bore and that seal lips are not rolled on wear
sleeve.
Oil seal should be 8.4 mm (0.33 in.) below front lip of
seal bore.
16
21
RG,CTM42,G15,43-19-03MAY93
CTM42 (24MAR95)
16-21
6076 Diesel Engines—S.N. (500000—
)
160101
PN=202
Camshaft and Timing Gear Train/Complete Final Assembly
COMPLETE FINAL ASSEMBLY
1. Install the magnetic pickup assembly in timing gear
cover (if equipped). Tighten to 14 N·m (10 lb-ft).
2. Install injection pump drive gear cover and gasket.
Tighten the six cap screws to 27 N·m (20 lb-ft).
3. Install vibration damper and pulley assembly. (See
Group 15, Crankshaft, Main Bearings and Flywheel.)
4. Install cylinder head, valve train, and rocker arm
assembly. (See Group 05, Cylinder Head and Valves.)
5. Install oil pan and new gasket. (See Group 20,
Lubrication System.) Fill engine with clean engine oil.
6. Perform engine break-in as required. (See PERFORM
ENGINE BREAK-IN, Group 05.)
RG,CTM42,G16,29-19-24MAR95
16
22
CTM42 (24MAR95)
16-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=203
Group 20
Lubrication System
OTHER MATERIAL
Name
Use
PERMATEX AVIATION (Form-A-Gasket No. 3)
(TY6299)
To seal gasket surfaces on oil pan.
LOCTITE 242 Thread Lock and Sealer
(TY9370 or T43512)
Oil filter adapter threads
LOCTITE 592 Pipe Sealant with TEFLON
(TY9374/TY9375)
To seal oil pan elbow drain fitting.
High Temperature Grease
(TY6343 or TY6347)
To lubricate oil pump components.
RG,CTM42,G20,1 -19-16AUG94
LUBRICATION SYSTEM SPECIFICATIONS
ITEM
Oil Filter Bypass Valve Operating Pressure
SPECIFICATION
. . . . . . 210 kPa (2.1 bar) (30 psi)
Oil Pressure Regulating Valve Spring:
Compressed Length . . . . . . . . . . . . . . . . . . . . 43.0 mm @ 66—74 N (1.69 in. @ 15—17 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . 85.0 mm (3.35 in.)
Oil Filter Bypass Valve Spring:
Compressed Length . . . . . . . . . . . . . . . . . . . . 30.0 mm @ 64—78 N (1.18 in. @ 14—18 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm (1.73 in.)
20
1
Oil Cooler Bypass Valve Spring:
Compressed Length . . . . . . . . . . . . . . . . . . . . 30.0 mm @ 64—78 N (1.18 in. @ 14—18 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm (1.73 in.)
Oil Pump:
Crankshaft Gear-to-Oil Pump Drive Gear
Minimum Backlash . . . . . . . . . . . . . .
Pump Gear Backlash . . . . . . . . . . . . . .
Oil Pump Drive Gear-to-Crankshaft Throw
Minimum Clearance . . . . . . . . . . . . .
Maximum Drive Shaft End Play . . . . . . .
Maximum Drive Shaft Side Movement . .
. . . . . . 0.08 mm (0.003 in.)
. . . . . . 0.33—2.00 mm (0.013—0.079 in.)
. . . . . . 0.38 mm (0.015 in.)
. . . . . . 0.15 mm (0.006 in.)
. . . . . . 0.17 mm (0.0065 in.)
RG,CTM42,G20,2 -19-07JUN93
CTM42 (24MAR95)
20-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=204
Lubrication System/Drain Engine Oil and Remove Oil Pan
LUBRICATION SYSTEM SPECIFICATIONS—CONTINUED
TORQUES
Oil Conditioning Housing-to-Cylinder Block: *
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 N·m (15 lb-ft)
37 N·m (27 lb-ft)
Oil Pump:
Drive Gear-to-Pump Drive Shaft Nut
Pump Cover-to-Housing . . . . . . . .
Intake Tube-to-Cover . . . . . . . . . .
Pump Housing-to-Cylinder Block . . .
54
41
41
47
Oil Pan: **
3/8 in. Cap Screws
1/2 in. Cap Screws
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N·m
N·m
N·m
N·m
(40
(30
(30
(35
lb-ft)
lb-ft)
lb-ft)
lb-ft)
................................................
68 N·m (50 lb-ft)
..............................................
156 N·m (115 lb-ft)
Oil Pan Drain Plug:
Aluminum Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cast Iron Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 N·m (75 lb-ft)
47 N·m (35 Lb-ft)
* Refer to INSTALL OIL FILTER AND OIL CONDITIONING HOUSING,
later in this group, for proper cap screw tightening sequence.
** Initially tighten all cap screws to 54 N·m (40 lb-ft), starting at right
rear corner of oil pan (facing toward flywheel end) and proceed
counterclockwise. Finish tightening cap screws to torques specified
above, using the same sequence and tighten all 3/8 in. cap screws
first.
RG,CTM42,G20,32-19-16AUG94
20
2 DRAIN ENGINE OIL AND REMOVE OIL PAN
1. Drain engine coolant.
2. Disconnect turbocharger oil inlet line at turbocharger
or oil conditioning housing. (See DISCONNECT
TURBOCHARGER OIL INLET LINE, in Group 03.)
3. Drain engine oil.
4. Remove oil level sight gauge (if equipped).
5. Remove oil pan and discard gasket.
S11,0404,C
CTM42 (24MAR95)
20-2
-19-04JUN93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=205
Lubrication System/Oil Filter and Oil Conditioning Housing Assembly
RG5896
-UN-16AUG91
OIL FILTER AND OIL CONDITIONING HOUSING ASSEMBLY
A—Gasket
B—Oil Cooler
C—Gasket
D—Fitting
E—Plug
F—O-Ring
G—Spring
H—Oil Cooler Bypass Valve
I—Oil Conditioning Housing
J—Cap Screw (10 Used)
K—Adapter
L—Oil Filter
M—Plug
N—O-Ring
O—Spring
P—Oil FIlter Bypass Valve
Q—Oil Pressure Regulating
Valve
R—Spring
S—O-Ring
T—Plug
RG,CTM42,G20,5 -19-09OCT92
CTM42 (24MAR95)
20-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=206
20
3
Lubrication System/Inspect and Replace Oil Filter Adapter
REMOVE OIL FILTER AND OIL
CONDITIONING HOUSING
1. Disconnect turbocharger oil inlet line (B) from oil
conditioning housing (A).
2. Turn oil filter (C) counterclockwise and remove filter
from housing.
RG5897
-UN-16AUG91
3. Remove cap screws securing oil conditioning housing
to cylinder block and remove housing.
RG,CTM42,G20,6 -19-09OCT92
INSPECT AND REPLACE OIL FILTER
ADAPTER
1. Inspect threads on oil filter adapter (B) for damage.
Remove adapter from housing (A) if necessary.
-UN-07JUL94
2. Coat adapter-to-oil conditioner housing threads with
LOCTITE 242 Thread Lock and Sealer before installing
adapter in housing.
RG7214
20
4
RG,CTM42,G20,41-19-16AUG94
CTM42 (24MAR95)
20-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=207
Lubrication System/Remove, Inspect, and Install Valves from Oil Conditioning Housing
REMOVE, INSPECT, AND INSTALL OIL PRESSURE REGULATING VALVE, OIL FILTER
BYPASS VALVE, AND OIL COOLER BYPASS VALVE
NEW OIL FILTER BYPASS VALVE SPRING SPECIFICATION
See OIL FILTER AND OIL CONDITIONING
HOUSING ASSEMBLY, earlier in this group, for
illustration of valves.
Working Load at 64—78 N . . . . . . . . . . . . . . . . . . . . . 30.0 mm
(14—18 lb force)
(1.18 in.)
• Oil Pressure Regulating Valve
Spring Free Length . . . . . . . . . . . . . . . . . . . 44.0 mm (1.73 in.)
1. Remove plug (T), O-ring (S), spring (R), oil
pressure regulating valve (Q) from housing (I).
Discard O-ring.
4. Dip all parts in clean engine oil, insert valve and
spring in housing.
5. Install new O-ring on plug. Install plug and tighten
securely.
2. Inspect valve and valve bore for damage. Replace
if necessary.
NOTE: Filter bypass valve operating pressure is 210
kPa (2.10 bar) (30 psi).
3. Check spring for proper compression.
NEW PRESSURE REGULATING VALVE SPRING SPECIFICATION
Working Load at 66—74 N . . . . . . . . . . . . . . . . . . . . . 43.0 mm
(15—17 lb force)
(1.69 in.)
Spring Free Length . . . . . . . . . . . . . . . . . . . 85.0 mm (3.35 in.)
4. Dip all parts in clean engine oil, insert valve and
spring in housing.
• Oil Cooler Bypass Valve
1. Remove plug (E), O-ring (F), spring (G), and oil
cooler bypass valve (H) from oil conditioning housing
(I). Discard O-ring.
2. Check housing for clogged passages and all other
parts for scale build-up.
5. Install plug using a new O-ring and tighten
securely.
3. Clean all parts with a stiff bristle brush and
solvent, if necessary. Dry with compressed air.
• Oil Filter Bypass Valve
4. Inspect bypass valve for damage. Replace if
necessary.
1. Remove plug (M) with O-ring (N), spring (O), and
oil filter bypass valve (P) from oil conditioning housing
(I). Discard O-ring.
5. Check bypass valve spring for proper
specifications. Replace if not within specifications.
NEW OIL COOLER BYPASS VALVE SPRING SPECIFICATION
2. Inspect valve and housing bore for scoring or
damage. Replace if necessary.
3. Check spring for proper compression. Replace if
necessary.
20
5
Working Load at 64—78 N . . . . . . . . . . . . . . . . . 30.0 mm
(14-18 lb force)
(1.18 in.)
Spring Free Length . . . . . . . . . . . . . . . . . . . 44.0 mm (1.73 in.)
RG,CTM42,G20,29-19-12APR93
CTM42 (24MAR95)
20-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=208
Lubrication System/Install Oil Filter and Oil Conditioning Housing
RG5904
-UN-20AUG91
INSTALL OIL FILTER AND OIL CONDITIONING HOUSING
A—Oil Conditioning Housing
B—Gasket
C—Oil Cooler
D—Gasket
1. Remove all gasket material from cylinder block and
oil conditioning housing (A).
E—Tab
2. Install gasket (D), engine oil cooler (C), gasket (B),
and oil conditioning housing onto cylinder block using
5/16 x 3 in. studs. Tab (E) on gasket with silicone
bead should be downward and to the right.
RG,CTM42,G20,9 -19-09OCT92
3. Tighten cap screws to 20 N·m (15 lb-ft) following
sequence shown in diagram.
4. Retighten cap screws to 37 N·m (27 lb-ft) following
same sequence.
-UN-16AUG91
NOTE: It may be helpful to put an ink mark on each cap
screw after tightening each time to assure all cap
screws have been tightened.
RG5905
20
6
RG,CTM42,G20,10-19-09OCT92
CTM42 (24MAR95)
20-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=209
Lubrication System/Remove Engine Oil Cooler
REMOVE ENGINE OIL COOLER
6076 Engines are equipped with a 6-plate engine oil
cooler.
1. Remove cover (A).
RG5907
-UN-16AUG91
2. Remove oil cooler.
RG5908
-UN-16AUG91
6-plate oil cooler
RG,CTM42,G20,25-19-09OCT92
CTM42 (24MAR95)
20-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=210
20
7
Lubrication System/Clean, Inspect, and Install Engine Oil Cooler
RG5904
-UN-20AUG91
CLEAN, INSPECT, AND INSTALL ENGINE OIL COOLER
A—Oil Conditioning Housing
B—Gasket
1. Once oil cooler is removed, scrape off all old
gasket material from cooler and block.
2. Clean all parts with clean solvent and a brass wire
brush. Dry with compressed air.
3. Inspect all parts for serviceability. Replace parts as
necessary.
C—Oil Cooler
D—Gasket
NOTE: If mixing of oil and coolant is suspected,
pressure test oil cooler in liquid and
compressed air. Use 140—170 kPa (1.4—1.7
bar) (20—25 psi) air pressure for testing.
Replace oil cooler as necessary.
4. Using new gaskets install oil cooler/oil conditioning
housing. See INSTALL OIL FILTER AND OIL
CONDITIONING HOUSING, earlier in this group.
RG,CTM42,G20,12-19-09OCT92
20
8
CTM42 (24MAR95)
20-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=211
Lubrication System/Remove Engine Oil Pump
CHECK CRANKSHAFT GEAR-TO-OIL PUMP
DRIVE GEAR BACKLASH
Before removing oil pump, determine if there is adequate
backlash between oil pump and crankshaft drive gears.
1. Mount dial indicator (A) and measure backlash
between pump drive gear (B) and crankshaft gear (C).
RG5914
-UN-16AUG91
IMPORTANT: Backlash must be at least 0.08 mm
(0.003 in.). If backlash is less than 0.08
mm (0.003 in.), replace the oil pump
drive gear.
RG,CTM42,G20,16-19-09OCT92
REMOVE ENGINE OIL PUMP
1. Remove four oil pump housing cap screws (A).
2. Remove oil pump assembly with drive gear (B)
attached.
RG5915
-UN-16AUG91
20
9
RG,CTM42,G20,17-19-09OCT92
CTM42 (24MAR95)
20-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=212
Lubrication System/Inspect and Clean Oil Pump
INSPECT AND CLEAN OIL PUMP
1. Visually inspect oil pump for wear or damage.
IMPORTANT: DO NOT disassemble engine oil pump
for flushing, inspection, or performing
wear checks. Individual components of
oil pump are not available through
sevice parts, Replace pump as a
complete assembly.
2. Flush pump assembly internally with clean solvent to
remove oil. Spin pump gears to help remove solvent.
3. Place oil pump on a work bench with pump-to-cylinder
block mounting surface facing upward (same as when
mounted on engine).
NOTE: Leave pump drive gear installed when making
checks.
IMPORTANT: To help insure accurate wear
measurements, be sure the oil pump is
clean and faces the same way as when
mounted on the cylinder block.
RG,CTM42,G20,18-19-15SEP94
20
10
CTM42 (24MAR95)
20-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=213
Lubrication System/Check Drive Shaft Side Movement
CHECK DRIVE SHAFT END PLAY
1. Mount dial indicator with indicator plunger resting
against end of pump drive shaft.
2. Move shaft toward and away from indicator.
If end play exceeds 0.15 mm (0.006 in.), there is
excessive wear on pump cover and/or wear on end of
pump drive gear.
RG5916
-UN-16AUG91
Replace oil pump if end play exceeds 0.15 mm (0.006
in.).
RG,CTM42,G20,19-19-09OCT92
CHECK DRIVE SHAFT SIDE MOVEMENT
1. Mount dial indicator with indicator plunger resting on
one of the hex nut flats.
2. Move shaft from side-to-side.
20
11
-UN-16AUG91
If shaft side movement exceeds 0.17 mm (0.0065 in.),
there is excessive wear on drive shaft bushing and/or
drive shaft.
RG5917
Replace oil pump if shaft side movement exceeds 0.17
mm (0.0065 in.).
RG,CTM42,G20,20-19-09OCT92
CTM42 (24MAR95)
20-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=214
Lubrication System/Inspect Oil Pump Drive Gear
CHECK PUMPING GEAR BACKLASH
1. Mount dial indicator with indicator plunger resting
against side of gear tooth.
2. Hold idler gear stationary. Slowly rotate drive gear
back and forth until contact with idler gear is felt.
-UN-16AUG91
If backlash is not within 0.33—2.00 mm (0.013—0.079
in.) specification, there is excessive pumping gear wear
and/or idler shaft and gear bushing wear. If there is less
than 0.33 mm (0.013 in.) backlash, re-clean gears and
check backlash again.
RG5918
3. Replace oil pump if pumping gear backlash exceeds
2.00 mm (0.079 in.).
RG,CTM42,G20,21-19-16AUG94
INSPECT OIL PUMP DRIVE GEAR
NOTE: Oil pump does not need to be removed from
engine, when inspecting drive gear.
-UN-13OCT92
1. Inspect drive gear teeth for chips, cracks, or wear.
Replace as necessary.
RG6435
20
12
RG,CTM42,G20,31-19-09OCT92
CTM42 (24MAR95)
20-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=215
Lubrication System/Install Engine Oil Pump
INSTALL ENGINE OIL PUMP
1. Lubricate bottom surface of oil pump housing gear
pocket bores, idler shaft, gear teeth on drive shaft, and
oil pump cover ends of both gears with TY6333 or
TY6347 High Temperature Grease.
2. Tighten oil pump drive gear-to-drive shaft nut (A) to
54 N·m (40 lb-ft). Install oil pump cover (B)-to-oil pump
housing (C).
-UN-16AUG91
3. Using a new gasket, install oil pump intake (F)-to-oil
pump cover and tighten cap screws to 41 N·m (30 lb-ft).
RG5922
NOTE: Oil pump gears must turn freely after installation
of oil pump cover and intake.
4. Install oil pump assembly over hollow dowel pin in
cylinder block. Tighten oil pump housing-to-cylinder block
cap screws to 47 N·m (35 lb-ft).
A—Shaft Nut
B—Oil Pump Cover
C—Oil Pump Housing
D—Oil Pump Drive Gear
E—Crankshaft Gear
F—Oil Pump Intake
NOTE: Make sure oil pump drive gear (D) meshes
properly with crankshaft gear (E).
RG,CTM42,G20,23-19-16AUG94
IMPORTANT: Push crankshaft rearward (toward
flywheel end). Check clearance between
oil pump drive gear face and throw of
crankshaft. There should be a
clearance of at least 0.38 mm (0.0015
in.). If clearance is below specification,
check thrust bearings for proper
placement. Gently pry crankshaft
forward and check (after oil pump is
installed) the oil pump drive gear (A),
and crankshaft gear (B) to see that they
are properly meshed.
RG5923
-UN-20AUG91
20
13
RG,CTM42,G20,24-19-22AUG91
CTM42 (24MAR95)
20-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=216
Lubrication System/Install Oil Pan
INSTALL OIL PAN
-UN-29NOV88
Before installing oil pan, remove old gasket and sealant
material from pan and cylinder block mating surfaces.
Guide studs may be used if desired.
RG5010
1. Apply a thin layer of PERMATEX AVIATION
(Form-A-Gasket No. 3) across entire front and rear
gasket rail of block. Install gasket (A) onto cylinder block
and apply a layer of sealant to gasket across front and
rear gasket face. On engines equipped with multi-piece
gaskets, also apply sealant to mating joints. Install oil
pan.
2. Insert all 3/8 in. and 1/2 in. cap screws in their
appropriate locations.
3. Use a straightedge against oil pan and cylinder block
(flywheel end) to be sure oil pan is flush with block
flange.
4. Proceeding counterclockwise (bold arrows) from
flywheel end (B), tighten all cap screws to 47 N·m (35
lb-ft).
5. Repeat sequence by tightening all 3/8 in. cap screws
to 68 N·m (50 lb-ft).
6. Complete sequence by tightening counterclockwise all
1/2 in. cap screws to 156 N·m (115 lb-ft). Check torque
on all 3/8 in. cap screws after final torque of 1/2 in. cap
screws. Trim gasket flush with rear of pan flange.
-UN-29NOV88
Some engine oil pans may be equipped with an elbow
fitting (E) and drain hose (F).
RG5267
20
14
7. Bottom oil pan drain plug (D) uses either an aluminum
washer or rubber O-ring (C) for sealing. Apply a light
coat of engine oil to new rubber O-rings for bottom drain
plug. Install aluminum washer on drain plug so raised
center contacts head of plug.
8. Install drain plug and tighten to specifications listed
below. Fill engine crankcase with correct engine oil.
OIL PAN DRAIN PLUG TORQUE SPECIFICATIONS
Aluminum Oil Pans . . . . . . . . . . . . . . . . . . . . . . 102 N·m (75 lb-ft)
Cast Iron Oil Pans . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
NOTE: On engine equipped with elbow fittings and drain
hose, the threads and sealing surfaces must be
free of any oil film to insure an effective seal.
Apply a light coat of LOCTITE 592 to fittings
except for the leading one to three threads.
Tighten fittings securely.
A—Oil Pan Gasket
B—Location For First Cap Screw
C—O-Ring or Aluminum Washer
D—Drain Plug
E—Elbow Fitting
F—Drain Hose
S55,2020,O
CTM42 (24MAR95)
20-14
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=217
Lubrication System/Tighten cap screws on front frame/oil sump
RG7223
-UN-21JUN94
TIGHTEN CAP SCREWS ON FRONT FRAME/OIL SUMP
A—0.375 x 7.625 in. (2 used)
B—0.500 x 4.000 in. (4 used)
C—0.500 x 6.000 in. (8 used)
D—0.375 x 2.500 in. (2 used)
1. Be sure dowel pins are in place.
E—0.500 x 2.500 in. (6 used)
F—0.375 x 1.875 in. (2 used)
20
15
4. Install all 3/8 in. and 1/2 in. cap screws in their
appropriate locations.
IMPORTANT: DO NOT apply gasket sealant to
gasket, front frame/oil sump,
trimmed edges of timing gear cover
gasket, oil seal housing gasket, or
cylinder block mating surfaces.
Before installing engine, be sure
mating surfaces of engine and front
frame/oil sump are clean.
2. Install front frame/oil sump-to-cylinder block gasket.
5. Tighten all 1/2 in. cap screws to 133 N·m (98 lb-ft).
Tighten all 3/8 in. cap screws to 58 N·m (43 lb-ft).
6. Re-tighten all 3/8 in. cap screws to 58 N·m (43
lb-ft). Re-tighten all 1/2 in. cap screws to 133 N·m
(98 lb-ft).
7. Apply clean engine oil to new O-ring for bottom
drain plug and install drain plug.
3. Carefully lower engine onto front frame/oil sump.
RG,CTM42,G20,33-19-17MAR95
CTM42 (24MAR95)
20-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=218
Lubrication System/Tighten cap screws on front frame/oil sump
20
16
CTM42 (24MAR95)
20-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=219
Group 25
Cooling System
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
-19-05JUN91
Push Puller . . . . . . . . . . . . . . . . . . . . . . D01206AA
RG5097
-UN-23AUG88
Used to remove water pump impeller from water pump
and to remove fan pulley from shaft pressed into water
manifold. Also used with D01217AA to remove water
pump drive gear from water pump.
RG,CTM42,G25,33-19-10SEP91
Bearing Puller* . . . . . . . . . . . . . . . . . . . . D01217AA
RG4981
-UN-06APR89
Used with D01206AA to remove water pump drive gear
from water pump.
* Part of D01212AA Step Plate Adapter Set
RG,CTM42,G25,34-19-10SEP91
Belt Tension Gauge . . . . . . . . . . . . . . . . . . JDG529
Used to check and adjust fan belt tension.
RG5082
-UN-23AUG88
25
1
S53,JDG529
RG5588
-19-06APR94
-UN-13SEP89
Belt Tension Gauge . . . . . . . . . . . . . . . . . . JDST28
Used with a straightedge to check fan belt tension.
RG,CTM61,G25,26-19-17MAR92
CTM42 (24MAR95)
25-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=220
Cooling System/Other Material
Bearing Driver . . . . . . . . . . . . . . . . . . . . . . JDG727
RG5963
-UN-03SEP91
Used to remove and install water pump bearing
assembly in water pump housing. Installs new bearing to
the correct depth.
RG,CTM42,G25,35-19-10SEP91
OTHER MATERIAL
Name
Use
LOCTITE 518 (TY6304) Flexible Sealant
Water pump, thermostat cover and water
manifold gaskets.
LOCTITE 242 (TY9370) Thread Lock and Sealer
Water outlet manifold-to-cylinder head cap screws.
LOCTITE 592 (TY9375) Pipe Sealant with TEFLON
Water pump and block drain valves.
High Temperature Grease
(TY6333 or TY6347)
Pack bearings in fan drive.
RG,CTM42,G25,7 -19-16AUG94
25
2
CTM42 (24MAR95)
25-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=221
Cooling System/Cooling System Specifications
COOLING SYSTEM SPECIFICATIONS
ITEM
SPECIFICATION
Water Pump:
Impeller Bore ID . . . . . . . . . . . . . . . . . . . . . . . .
Shaft OD Impeller End . . . . . . . . . . . . . . . . . . . .
Bearing Bore in Water Pump Housing (NEW) . . . . .
Maximum Allowable Pump Bearing Bore . . . . . . . .
Bearing OD . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Gear Bore ID . . . . . . . . . . . . . . . . . . . . . .
Shaft OD Drive Gear End . . . . . . . . . . . . . . . . . .
Water Pump Seal Installed Height . . . . . . . . . . . .
Impeller Installed Depth Below Gasket Surface . . . .
Bearing Installed Depth Below Pump Housing Nose
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15.849—15.875
15.905—15.917
38.041—38.067
............
38.087—38.100
. . 18.90—18.92
18.948—18.960
. . 10.16—10.42
. . . . 2.75—3.50
. . . . 6.75—7.00
mm (0.624—0.625 in.)
mm (0.626—0.627 in.)
mm (1.498—1.499 in.)
38.067 mm (1.499 in)
mm (1.499—1.500 in.)
mm (0.744—0.745 in.)
mm (0.746—0.747 in.)
mm (0.400—0.410 in.)
mm (0.108—0.138 in.)
mm (0.266—0.276 in.)
Thermostat Opening Temperature:
82˚C (180˚F) Thermostat(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80—84˚C (175—182˚F)
89˚C (192˚F) Thermostat(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87—91˚C (188—195˚F)
Heavy Duty Adjustable Fan Drive*:
Bearing Bore ID in Housing . . . .
Shaft OD for Bearings . . . . . . . .
Bearing OD . . . . . . . . . . . . . . .
Bearing ID . . . . . . . . . . . . . . . .
Maximum Shaft End Play . . . . . .
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71.999—72.025 mm
35.001—35.017 mm
71.987—72.013 mm
34.987—35.013 mm
..............
(2.8346—2.8356
(1.3780—1.3786
(2.8341—2.8351
(1.3774—1.3785
0.50 mm (0.020
Standard Duty Adjustable Fan Drive*:
Bearing Bore ID in Housing . . . . . . . . . . . . . . . .
Bearing OD (Housing End) . . . . . . . . . . . . . . . . .
Shaft OD (Pulley End) . . . . . . . . . . . . . . . . . . . .
Fan Pulley Bore ID . . . . . . . . . . . . . . . . . . . . . .
Bearing/Shaft Installed Dim. From Pulley Front Face
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47.576—47.612 mm
47.612—47.625 mm
25.387—25.400 mm
25.336—25.362 mm
. . . . Flush to 1.30
(1.8731—1.8745 in.)
(1.8745—1.8750 in.)
(0.9995—1.0000 in.)
(0.9975—0.9985 in.)
mm (0.05 in.) Below
Water Manifold Mounted, Fixed Fan Drive*:
Shaft Installed Dimension From Manifold
Mounting Face-to-End of Shaft . . . . . . .
Fan Pulley Bore ID . . . . . . . . . . . . . . .
Bearing OD (Pulley End) . . . . . . . . . . .
Shaft OD (Manifold End) . . . . . . . . . . .
Manifold Bore ID . . . . . . . . . . . . . . . . .
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. . . 33.31—33.57 mm (1.311—1.322
47.576—47.612 mm (1.8731—1.8745
47.612—47.625 mm (1.8745—1.8750
25.387—25.400 mm (0.9995—1.0000
25.336—25.362 mm (0.9975—0.9985
in.)
in.)
in.)
in.)
in.)
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47.612—47.625
25.387—25.400
47.576—47.612
25.336—25.362
in.)
in.)
in.)
in.)
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Injection Pump Drive Gear Cover Mounted, Fan Pulley:
Bearing OD (Pulley End) . . . . . . . . . . . . . . . . . . . . .
Bearing OD (Drive Gear Cover End) . . . . . . . . . . . . . .
Fan Pulley Bore ID . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Gear Cover ID . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Installed Dimension
Injection Pump Drive Gear Cover Mounting Face-to-End
(1.8745—1.8750
(0.9995—1.0000
(1.8731—1.8745
(0.9975—0.9985
25
3
of Shaft . . . . . . . . 3.43—3.69 mm (0.135—0.145 in.)
* Specifications apply only to fan drives supplied by John Deere
Factory. Refer to manufacturers specifications for other fan drives.
CTM42 (24MAR95)
mm
mm
mm
mm
in.)
in.)
in.)
in.)
in.)
RG,CTM42,G25,1 -19-17MAR95
25-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=222
Cooling System/Cooling System Specifications
COOLING SYSTEM SPECIFICATIONS—CONTINUED
ITEM
Standard V-Belt Tension Using JDG529 Gauge:
Single Belt System:
New Belts . . . . . . . . . . . . . . . . . . . . . . . .
Belts in Service (minimum 10-minutes use) .
Dual Belt System*:
New Belts . . . . . . . . . . . . . . . . . . . . . . . .
Belts in Service (minimum 10-minutes use) .
SPECIFICATION
. . . . . . . . . . . . . . . . . . . . . . . . . . 578—622 N (130—140 lb)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 378—423 N (85—95 lb)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 422—463 N (95—104 lb)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 378—423 N (85—95 lb)
Poly V-Belt Tension Using JT05975 Gauge:
New Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890—1068 N (200—240 lb)
Belt in Service (minimum 10-minutes use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800—979 N (180—220 lb)
Fan Belt Tension Using JDST28 Tension Gauge and Straight Edge:
(force applied halfway between pulleys)
Standard V-Belts (new and used) . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (3/4 in.) with 89 N (20 lb) force
Poly V-Belts (new and used) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2 in.) with 130 N (30 lb) force
* On engines with dual belts, check tension on front belt only. Measure
tension on long part of belt.
RG,CTM42,G25,41-19-29OCT92
25
4
CTM42 (24MAR95)
25-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=223
Cooling System/Service Equipment and Tools
COOLING SYSTEM SPECIFICATIONS—CONTINUED
TORQUES
Water Pump-to-Cylinder Block Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
Water Manifold-to-Cylinder Head—Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N·m (45 lb-ft)
—Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 lb-ft)
Thermostat Cover-to-Water Manifold—Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
—Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 lb-ft)
Water Pump Cover-to-Water Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m (22 lb-ft)
Water Pump Drain Valve-to-Water Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
Water Inlet Manifold Elbow-to-Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m (22 lb-ft)
Fan-to-Fan Hub or Pulley* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N·m (30 lb-ft)
Fan Drive Assembly-to-Support Plate (Heavy Duty Adjustable Fan Drive) . . . . . . . . . . . . . . . 80 N·m (60 lb-ft)
Fan Spacer and Pulley-to-Hub
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
Fan Pulley Mounted Injection Pump Drive Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
* Applies only to fans provided by the John Deere factory. See
equipment manufacturers recommendations for torque specifications on
OEM supplied fans.
RG,CTM42,G25,2 -19-17MAR95
SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from your SERVICE-GARD™
Catalog. Some tools may be available from a
local supplier.
25
5
Name
Use
D01045AA Bushing, Bearing and Seal Driver Set
Remove and install seals.
D01217AA Bearing Pulling Attachment
Support gear during removal.
D01206AA Gear and Pulley Puller
Remove gear from water pump shaft.
RG,CTM42,G25,38-19-06APR94
CTM42 (24MAR95)
25-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=224
Cooling System/Replace Bearings in Standard Duty, Adjustable Fan Drive Assembly
RG7305
-UN-13MAR95
REPLACE BEARINGS IN STANDARD DUTY, ADJUSTABLE FAN DRIVE ASSEMBLY
A—Fan Hub/Pulley
B—Bearing Housing
D—Support Plate
• To Disassemble Fan Drive:
STANDARD DUTY, ADJUSTABLE FAN DRIVE SPECIFICATIONS
1. Remove V-belt and remove support plate (D) with
fan drive assembly.
Housing ID . . . . . . . . . 47.576—47.612 mm (1.8731—1.8745 in.)
2. Remove fan drive assembly from support plate.
3. Support back side of fan hub/pulley (A), and press
bearing/shaft (C) out of hub bore.
25
6
C—Bearing/Shaft
4. Support back side of bearing housing (B) and
press bearing/shaft out of housing. Discard bearing.
5. Thoroughly clean and inspect fan hub/pulley and
bearing housing for cracks or any other damage.
Measure parts and compare with specifications given
later.
Bearing OD . . . . . . . . 47.612—47.625 mm (1.8745—1.8750 in.)
Shaft OD . . . . . . . . . . 25.387—25.400 mm (0.9954—1.0000 in.)
Pulley ID . . . . . . . . . . 25.336—25.362 mm (0.9975—0.9985 in.)
Shaft Installed Dimension From Pulley
Front Face . . . . . . . . . . . . Flush to 1.30 mm (0.05 in.) Below
Replace parts that are cracked or not within
specification.
RG,CTM42,G25,44-19-21MAR95
CTM42 (24MAR95)
25-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=225
RG7305
-UN-13MAR95
Cooling System/Replace Bearings in Standard Duty, Adjustable Fan Drive Assembly
A—Fan Hub/Pulley
B—Bearing Housing
To Assemble Fan Drive:
1. Support front nose of bearing housing (B) with ID
open so bearing/shaft (B) can pass through opening
when installed.
2. Press on outer shell of bearing and install bearing
into housing until bearing bottoms. Shaft end of
bearing will protrude from hoousing.
C—Bearing/Shaft
D—Support Plate
5. Install fan drive housing assembly onto support
plate (D). Tighten four cap screws with washers to 80
N·m (60 lb-ft).
6. Install support plate onto engine. Tighten 5/16-in.
cap screws to 27 N·m (20 lb-ft) and 3/8-in. cap
screws to 47 N·m (35 lb-ft).
7. Install V-belts and position onto belt tensioner.
3. Support inner portion of bearing and press fan
hub/pulley (A) omto shaft until shaft is flush to 1.30
mm (0.05 in.) below front face of pulley.
25
7
4. Spin pulley by hand to assure assembly turns
freely and bearing was not damaged during
assembly.
RG,CTM42,G25,45-19-21MAR95
CTM42 (24MAR95)
25-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=226
Cooling System/Replace Bearings in Heavy Duty, Adjustable Fan Drive Assembly
RG5760
-UN-06AUG91
REPLACE BEARINGS IN HEAVY DUTY, ADJUSTABLE FAN DRIVE ASSEMBLY
A—Fan Hub/Pulley
B—Grease Seal
C—Snap Ring
D—Ball Bearing (2 used)
E—Shaft
• To Disassemble Fan Drive:
1. Remove V-belts and remove fan. Remove fan
drive assembly from engine.
F—Bearing Housing
G—Pipe Plug
H—Support Spacer
J—Support Plate
6. Thoroughly clean and inspect shaft and bearing
housing (F) for cracks or any other damage. Measure
parts and compare with specifications given below.
HEAVY DUTY, ADJUSTABLE FAN DRIVE SPECIFICATIONS
25
8
2. Clamp fan hub/pulley (A) in a soft-jawed vise.
Support fan hub (so it does not fall to floor), and
remove cap screw securing hub to shaft (E). Remove
fan hub.
3. Remove pipe plug (G), grease seal (B), and snap
ring (C). Discard seal and snap ring.
4. Remove shaft with bearings (D) by lightly tapping
with a rubber mallet or brass hammer.
Housing ID . . . . . . . . . 71.999—72.025 mm (2.8346—2.8356 in.)
Shaft OD . . . . . . . . . . 35.001—35.017 mm (1.3780—1.3786 in.)
Bearing ID . . . . . . . . . 34.987—35.013 mm (1.3774—1.3785 in.)
Bearing OD . . . . . . . . 71.987—72.013 mm (2.8341—2.8351 in.)
Replace parts that are cracked or not within
specification.
5. Remove bearings from shaft using a press and
discard bearings.
RG,CTM42,G25,9 -19-24MAR95
CTM42 (24MAR95)
25-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=227
RG5760
-UN-06AUG91
Cooling System/Replace Bearings in Heavy Duty, Adjustable Fan Drive Assembly
A—Fan Hub/Pulley
B—Grease Seal
C—Snap Ring
D—Ball Bearing (2 used)
E—Shaft
F—Bearing Housing
G—Pipe Plug
H—Support Spacer
J—Support Plate
7. Apply a thin coat of clean engine oil to OD of seal
casing (B) and to seal lips. Install seal in housing
bore until metal casing is flush-to-0.50 mm (0.020 in.)
below housing face.
• To Assemble Fan Drive:
1. Pack inner and outer bearings (D) with TY6333 or
TY6347 High Temperature Grease. Apply clean
engine oil to bearing ID and shaft OD.
2. Support end of shaft (E) and install bearings
against shoulder. Apply force to bearing inner race
only.
8. Apply clean engine oil to ID of fan hub/pulley (A).
Support end of shaft through pipe plug hole in
bearing housing and push hub onto other end of
shaft until it bottoms against shoulder.
3. Support bearing housing (F) on a firm flat surface
with bearing bore in the upward position.
9. Install washer and cap screw. Tighten cap screw
to 80 N·m (60 lb-ft).
4. Install bearing and shaft assembly into housing.
Small end of shaft should extend through housing.
10. Apply LOCTITE 592 Pipe Sealant to threads of
pipe plug (G). Install and tighten plug in bearing
housing.
25
9
5. Determine proper snap ring (C) thickness needed
to obtain 0.10 mm (0.004 in.) end play.
11. Install fan drive assembly onto support plate (J).
6. Install snap ring in housing groove. Visually inspect
snap ring installation for proper seating in housing
groove.
12. Install support plate assembly onto engine and
tighten 5/16-in mounting cap screws to 27 N·m (20
lb-ft) and all 3/8-in. cap screws to 47 N·m (35 lb-ft).
RG,CTM42,G25,3 -19-17MAR95
CTM42 (24MAR95)
25-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=228
Cooling System/Water Manifold Mounted Fixed Fan Drive Assembly
RG6437
-UN-13OCT92
REPLACE BEARINGS IN WATER MANIFOLD MOUNTED, FIXED FAN DRIVE ASSEMBLY
A—Water Manifold
B—Fan Pulley
C—Bearing
D—Bearing Shaft Installed
Dimension
E—Hub*
WATER MANIFOLD MOUNTED, FIXED FAN DRIVE
SPECIFICATIONS
• To Disassemble Fan Drive:
1. Remove three water manifold-to-cylinder head cap
screws. Remove water manifold (A) and fan pulley
(B) assembly from cylinder head and lift to dislodge
water bypass pipe from manifold.
2. Support front face of water manifold and use a
press to push bearing (C) and pulley out of manifold.
3. Support front face of fan pulley and push bearing
out of pulley, and fan spacer (if equipped). Discard
bearing.
25
10
Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . 25.387—25.400 mm
(0.9995—1.0000 in.)
Bearing OD . . . . . . . . . . . . . . . . . . . . . . . 47.612—47.625 mm
(1.8745—1.8750 in.)
Pulley ID, Bearing End . . . . . . . . . . . . . . . . 47.576—47.612 mm
(1.8731—1.8745 in.)
Pulley ID, Fan Spacer End** . . . . . . . . . . . . 49.485—49.518 mm
(1.9482—1.9495 in.)
Fan Spacer OD** . . . . . . . . . . . . . . . . . . . 49.457—49.483 mm
(1.9471—1.9481 in.)
4. Thoroughly inspect water manifold and pulley for
cracks or damage. Measure parts and compare
readings with specifications given below. Replace
parts as necessary.
Manifold ID . . . . . . . . . . . . . . . . . . . . . . . . 25.336—25.362 mm
(0.9975—0.9985 in.)
Shaft Installed Dimension from Manifold
Mounting Face-to-End of Shaft . . . . . . . . . .
IMPORTANT: Support fan pulley on a flat, firm
surface and press on bearing outer
race to prevent damage to the
bearing.
33.31—33.47 mm
(1.311—1.318 in.)
5. Install new bearing into pulley until outer race
bottoms in bore of pulley. End of shaft will extend
through bearing stop.
*In some applications, bearing is pressed into hub (E). The fan spacer
and pulley are then bolted to hub. In some applications, the fan spacer
is press-fit into the pulley. Dimension (D) is the same for all
applications.
**Units with press-fit fan spacer only.
CTM42 (24MAR95)
RG,CTM42,G25,10-19-14FEB95
25-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=229
RG6437
-UN-13OCT92
Cooling System/Water Manifold Mounted Fixed Fan Drive Assembly
A—Water Manifold
B—Fan Pulley
C—Bearing
D—Bearing Shaft Installed
Dimension
E—Hub*
• To Assemble Fan Drive:
IMPORTANT:Support water manifold on machined
surface and press on inner shaft to
prevent damage to bearing.
1. On units with a press-fit fan spacer, press spacer
into pulley flush to 0.5 mm (0.020 in.) below front
face of pulley.
(1.311—1.318 in.) (D) from manifold mounting
surface. Hold water manifold firmly and turn fan
pulley by hand to assure bearings rotate freely.
3. Install a new gasket and O-rings. Insert water
bypass pipe in manifold and install assembly onto
locating pin in front face of cylinder head. Tighten cap
screws to 60 N·m 45 (lb-ft).
4. Install fan and V-belts. Refer to appropriate
operator’s manual for proper belt tensioning.
2. Press bearing shaft (C) into water manifold (A).
End of shaft should be 33.31—33.47 mm
*In some applications, bearing is pressed into hub (E). The fan spacer
and pulley are then bolted to hub. In some applications, the fan spacer
is press-fitinto the pulley. Dimension (D) is the same for all applications.
CTM42 (24MAR95)
25-11
25
11
RG,CTM42,G25,48-19-22MAR95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=230
Cooling System/Replace Bearing in Injection Pump Drive Gear Mounted Fan Drive
RG6441
-UN-13OCT92
REPLACE BEARING IN INJECTION PUMP DRIVE GEAR COVER MOUNTED, FAN DRIVE
A—Bearing
B—Fan Pulley
C—Injection Pump Drive
Gear Cover
D—Bearing Shaft Installed
Dimension
• To Disassemble Fan Drive:
• To Assemble Fan Drive:
1. Remove injection pump drive gear cover (C) and
fan pulley assembly from timing gear cover.
IMPORTANT: Support fan pulley on a flat, firm
surface and press on bearing outer
race to prevent damage to the
bearing.
2. Support front face of injection pump gear cover
and press bearing (A) and pulley (B) out of cover.
1. Install new bearing into pulley against stop.
3. Support front face of fan pulley and push bearing
out of pulley. Discard bearing.
25
12
IMPORTANT: Support injection pump drive gear
cover on machined mounted surface
and press on inner shaft to prevent
damage to bearing.
4. Thoroughly inspect cover and pulley for cracks or
damage. Measure parts and compare readings with
specifications given below. Replace parts as
necessary.
INJECTION PUMP DRIVE GEAR COVER MOUNTED
FIXED FAN PULLEY SPECIFICATIONS
Bearing OD (Pulley End) . . . . . . . . . . . . . . 47.612—47.625 mm
(1.8745—1.8750 in.)
Bearing OD (Cover End)
. . . . . . . . . . . . . . 25.387—25.400 mm
(0.9995—1.0000 in.)
Fan Pulley Bore ID . . . . . . . . . . . . . . . . . . 47.576—47.612 mm
(1.8731—1.8745 in.)
Drive Gear Cover ID . . . . . . . . . . . . . . . . . 25.336—25.362 mm
(0.9975—0.9985 in.)
2. Press bearing into cover. End of shaft should be
3.43—3.69 mm (0.135—0.145 in.) from cover
mounting surface (D).
3. Hold cover firmly and turn fan pulley by hand to
assure bearings rotate freely.
4. Using new gasket, install cover onto timing gear
cover. Tighten cap screws to 27 N·m (20 lb-ft).
5. Install fan and V-belts. Refer to the appropriate
operator’s manual for proper belt tensioning.
RG,CTM42,G25,40-19-14FEB95
CTM42 (24MAR95)
25-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=231
Cooling System/Inspect and Check Belt Tensioner Spring Tension
INSPECT AND CHECK BELT TENSIONER
SPRING TENSION
-UN-17JUN92
NOTE: The pulleys and the spring tensioner are not
serviceable. If spring tension is not within
specification, replace tensioner assembly.
RW21151
1. Release tension on belt using a long-handle 1/2 in.
drive tool (A). Remove belt from the alternator pulley.
2. Release the tension on the tension arm and remove
drive tool.
3. Put a mark (B) on swing arm of tensioner as shown.
-UN-17JUN92
RW21153
6. Note the torque wrench measurement and compare
with specification below. Replace tensioner assembly as
required.
RW21152
5. Rotate the arm using a torque wrench (positioned as
shown) until mark (B) and (C) are aligned.
-UN-17JUN92
4. Measure 21 mm (13/16 in.) from (B) and put a mark
(C) on the mounting bracket.
SPRING TENSION
Specification . . . . . . . . . . . . . . . . . . . . . . 24—28 N·m (17—21 lb-ft)
A—1/2 in. Drive Tool
B—Tension Arm Mark
C—Mounting Bracket Mark
RG,CTM42,G25,46-19-17MAR95
25
13
CTM42 (24MAR95)
25-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=232
Cooling System/Remove Water Pump
REPLACE BELT TENSIONER ASSEMBLY
2. Remove cap screw (A) and remove the tensioner
assembly.
NOTE: Locator pin in tensioner base fits in hole in
injection pump drive gear cover to assure proper
positioning.
RW21154
-UN-17JUN92
1. Release tension on pulley (B) and remove belt,
(shown removed).
3. Install tensioner and tighten cap screw to 50 N·m (37
lb-ft).
4. Check spring tension on newly installed tensioner.
(See INSPECT AND CHECK BELT TENSIONER
SPRING TENSION earlier in this group.)
5. Install belt and position onto tensioner.
RG,CTM42,G25,47-19-17MAR95
REMOVE WATER PUMP
IMPORTANT: Both water pump drain valve and block
drain valve must be opened to
completely drain both sides of the
engine.
RG5836
25
14
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Wait until engine is cool enough to
touch with bare hands before draining coolant.
Slowly loosen radiator cap to first stop to
relieve pressure.
-UN-28AUG91
N
1. Open both water pump drain valve (A) and block drain
valve (B) and drain coolant from engine.
RG,CTM42,G25,11-19-14FEB95
CTM42 (24MAR95)
25-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=233
Cooling System/Disassemble Water Pump
2. Remove fitting (A) and water bypass tube.
-UN-13AUG91
3. Remove water inlet manifold elbow cap screws (B)
and water pump mounting cap screws (C).
RG5837
NOTE: Oil dipstick may have to be removed to provide
clearance for water pump removal. Rotate water
pump inlet downward and lift inlet manifold elbow
up between block and dipstick tube while sliding
water pump to the rear. Some applications may
be different.
4. Slide water pump nose out of cylinder block flange
bore. Remove O-ring.
RG,CTM42,G25,12-19-29OCT92
DISASSEMBLE ENGINE WATER PUMP
RG5847
-UN-13AUG91
25
15
A—Cover
B—Housing
C—Gasket
D—O-Ring
E—Impeller
F—Seal (Water Pump)
G—Bearing
H—Seal (Oil)
I—Drive Gear
J—Drain Valve
K—Weep Hole Filters (2
used)
RG,CTM42,G25,13-19-23FEB93
CTM42 (24MAR95)
25-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=234
Cooling System/Disassemble Water Pump
1. Remove four cap screws and remove cover (A) from
housing (B).
RG5851
-UN-13AUG91
2. Remove and discard gasket. Scrape all gasket
material from cover and housing face.
RG,CTM42,G25,14-19-12SEP91
RG5840
-UN-13AUG91
3. Remove the water pump gear (I) by supporting the
back side of the gear with D01217AA Bearing Puller and
using D01206AA Puller to pull the gear off of the bearing
shaft.
RG,CTM42,G25,16-19-12SEP91
4. Roll oil seal lip (H) using a punch and hammer. Using
needle nose pliers, remove and discard oil seal.
RG5841
25
16
-UN-13AUG91
5. Using a press, remove bearing (G), water pump seal
(F), and impeller (not shown). Support pump housing (B)
on gasket surface so that impeller will clear the supports
and press on the outer race of the bearing from the gear
end with JDG727 Bearing Driver. Discard bearing, seal,
and impeller.
NOTE: It is not recommended that bearing and impeller
be reused once they have been removed from
the water pump. A new bearing, water pump
seal, and impeller are provided in water pump
overhaul kit.
RG,CTM42,G25,17-19-29OCT92
CTM42 (24MAR95)
25-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=235
Cooling System/Disassemble Water Pump
RG5842
-UN-13AUG91
6. Remove and discard foam weep hole filters (K).
RG,CTM42,G25,36-19-12SEP91
25
17
CTM42 (24MAR95)
25-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=236
Cooling System/Inspect Water Pump Parts
INSPECT WATER PUMP PARTS
1. Measure water pump housing bore ID (A) and drive
gear ID (B). Replace parts if worn, damaged, cracked, or
not within specifications.
WATER PUMP SPECIFICATIONS
Impeller Bore ID . . . . . . . . . . . . . . . . . . . . . . . 15.849—15.875 mm
(0.624—0.625 in.)
-UN-13AUG91
Shaft OD Impeller End . . . . . . . . . . . . . . . . . . . 15.905—15.917 mm
(0.626—0.627 in.)
Bearing Bore in Water Pump
Housing (NEW) . . . . . . . . . . . . . . . . . . . . . . . 38.041—38.067 mm
(1.498—1.499 in.)
Maximum Allowable Pump
Bearing Bore . . . . . . . . . . . . . . . . . . . . . . 38.067 mm (1.499 in.)
Drive Gear Bore ID . . . . . . . . . . . . . . . . . . . . . .
RG5843
Bearing OD . . . . . . . . . . . . . . . . . . . . . . . . . . 38.087—38.100 mm
(1.499—1.500 in.)
18.90—18.92 mm
(0.744—0.745 in.)
Shaft OD Drive Gear End . . . . . . . . . . . . . . . . . 18.948—18.960 mm
(0.746—0.747 in.)
Water Pump Seal Installed Height . . . . . . . . . . . .
10.16—10.42 mm
(0.400—0.410 in.)
Impeller Installed Depth
Below Gasket Surface . . . . . . . . . . . . . . . . . . . . . 2.75—3.50 mm
(0.108—0.138 in.)
Bearing Installed Depth
Below Pump Housing Nose . . . . . . . . . . . . . . . . . . 6.75—7.00 mm
(0.266—0.276 in.)
2. Clean gear and housing with clean solvent and dry
with compressed air.
25
18
3. Inspect water pump housing for debris, cracks, or
damage. Be sure the “weep holes” in the housing are
cleaned and foam filters (C) are removed from weep
holes while pump is disassembled.
NOTE: Make sure all gasket material is removed from
pump.
RG,CTM42,G25,18-19-29OCT92
CTM42 (24MAR95)
25-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=237
Cooling System/Assemble Water Pump
ASSEMBLE ENGINE WATER PUMP
IMPORTANT: When installing water pump bearing
into housing, press only on outer
bearing race. Do NOT press on bearing
shaft as this will damage the bearing.
-UN-13AUG91
1. Support pump housing on gasket surface. Using
JDG727 Bearing Driver, press a new bearing into drive
gear end of pump housing until outer race is 6.75—7.00
mm (0.266—0.276 in.) below nose of housing. Press
only on outer race. Bearing driver will bottom against
nose of housing, leaving bearing at correct depth.
RG5845
-UN-13AUG91
RG5844
2. Apply a light film of clean engine oil to the drive gear
end of shaft and to the oil seal lip. Install the new oil
seal with spring loaded lip facing outward toward gear
end of bearing shaft. Seal should be installed flush with
housing nose.
RG,CTM42,G25,19-19-23FEB93
25
19
CTM42 (24MAR95)
25-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=238
Cooling System/Assemble Water Pump
-UN-13AUG91
IMPORTANT: When installing drive gear, support
impeller end of shaft so pressing load
is transmitted through the shaft.
Bearing damage will result if load is
transmitted through the outer bearing
race.
RG5846
3. Support water pump on impeller end of bearing shaft.
Press drive gear onto shaft until gear is flush with end of
shaft.
IMPORTANT: When installing water pump seal,
support drive gear end of shaft so
pressing load is transmitted through
the shaft.
RG5848
-UN-13AUG91
4. Support water pump on gear end of bearing shaft and
use R113749 Seal Driver (A) (supplied with water pump
overhaul kit) and JDG727 Water Pump Bearing Driver to
install a new water pump seal. Seal height (B) should be
10.16—10.42 mm (0.400—0.410 in.) when properly
installed. R113749 Seal Driver will install seal to proper
height.
RG,CTM42,G25,37-19-04FEB93
-UN-15OCT92
5. Support water pump on gear end of bearing shaft and
press new impeller (A) onto shaft until impeller face is
2.97—3.23 mm (0.117—0.127 in.) below gasket surface
(B). Use straightedge and dial caliper from bottom of
straightedge to impeller to measure depth specification.
Pump impeller must rotate freely. Disassemble and
correct problem if interference is felt.
RG5849
25
20
IMPORTANT: When installing impeller, support drive
gear end of shaft so pressing load is
transmitted through the shaft. Bearing
damage will result if load is transmitted
through the outer bearing race.
RG,CTM42,G25,20-19-29OCT92
CTM42 (24MAR95)
25-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=239
Cooling System/Install Water Pump
-UN-13AUG91
6. Apply a coat of LOCTITE 518 Flexible Sealant to the
gasket surfaces (A and B). Install a new gasket and
pump cover. Tighten the four cover cap screws to 30
N·m (22 lb-ft).
7. If drain valve is removed, apply LOCTITE 592 Pipe
Sealant to threads and tighten drain valve to 27 N·m (20
lb-ft).
RG5851
8. Install new weep hole filters and a new O-ring on the
pump housing pilot.
RG,CTM42,G25,21-19-16AUG94
INSTALL ENGINE WATER PUMP
-UN-13AUG91
1. Apply a light coat of engine oil to water pump housing
O-ring (A). Install pump into pilot bore in block making
sure that pump drive gear properly meshes with
camshaft gear.
RG5850
2. Install two water pump mounting cap screws and
tighten to 27 N·m (20 lb-ft).
3. Install a new gasket (B) between water inlet manifold
elbow and cylinder block. Install two 5/16 in. inlet
manifold elbow cap screws and tighten to 27 N·m (20
lb-ft).
RG,CTM42,G25,22-19-16AUG94
4. Install new O-ring (A) into bore of water outlet
manifold. Lubricate O-ring with engine oil and install
bypass pipe into water outlet manifold.
25
21
-UN-13AUG91
5. Install new O-ring (B) in water bypass fitting. Lubricate
O-ring with engine oil and install fitting onto pump end of
bypass pipe.
RG5853
6. Apply LOCTITE 592 Pipe Sealant with TEFLON to
fitting threads and screw fitting into water pump housing.
Tighten securely.
7. Install clamp (C) with “J” of clamp toward rear of
engine on inside-upper injection pump drive gear cover
cap screw.
RG,CTM42,G25,23-19-16AUG94
CTM42 (24MAR95)
25-21
6076 Diesel Engines—S.N. (500000—
)
160101
PN=240
Cooling System/Remove and Test Thermostats
REMOVE AND TEST THERMOSTATS
-UN-14DEC88
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Do not drain coolant until coolant
temperature is below operating temperature.
Always loosen cooling system filler cap,
radiator cap, or drain cock slowly to relieve
pressure.
RG5279
N
1. Visually inspect the area around the water manifold
for leaks. Partially drain coolant from the cooling system.
2. Remove thermostat cover (A).
RG,CTM42,G25,24-19-29OCT92
3. Remove thermostats (A). Discard gasket (B).
-UN-09DEC88
4. Inspect thermostats for debris or damage, and test
each thermostat using an approved thermostat testing
procedure. See INSPECT THERMOSTAT AND TEST
THERMOSTAT OPENING TEMPERATURE in Group 105
for thermostat testing procedure. Thermostats should
start to open within the range specified.
82˚C (180˚F) Thermostat(s)
89˚C (192˚F) Thermostat(s)
RG5280
THERMOSTAT OPENING TEMPERATURE SPECIFICATIONS
. . . . . . . . . . . . . 80—84˚C (175—182˚F)
. . . . . . . . . . . . . 87—91˚C (188—195˚F)
If either thermostat fails to open within this range,
replace both thermostats.
25
22
RG,CTM42,G25,43-19-29OCT92
CTM42 (24MAR95)
25-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=241
Cooling System/Remove Water Manifold
INSTALL THERMOSTATS
-UN-09DEC88
1. Apply LOCTITE 518 Flexible Sealant to water
manifold-to-thermostat cover mating surface.
NOTE: Install thermostats in slot in housing first, then
install gasket after thermostat is properly seated
in housing.
RG5280
2. Install thermostats (A) and a new gasket (B).
3. Install cover and tighten cap screws to 47 N·m (35
lb-ft)—Cast Iron housing, 20 N·m (15 lb-ft)—Aluminum
housing.
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head, bleed plug or petcock
at top front of cylinder head, or plug in
thermostat housing to allow air to
escape when filling system. Retighten
fitting or plug when all the air has been
expelled.
RG,CTM42,G25,25-19-14FEB95
REMOVE WATER MANIFOLD
1. Remove air bleed line from cylinder
head-to-thermostat housing (if equipped) and aftercooler
hose from water manifold-to-aftercooler (if equipped).
-UN-13AUG91
25
23
2. Remove three water manifold-to-cylinder head cap
screws (A) and remove water manifold assembly.
RG5854
NOTE: Pull water manifold straight ahead (toward front
of engine) approximately 6.35 mm (0.25 in.) to
disengage from locator (spring) pin (B), then lift
straight up to disengage from bypass pipe (C).
3. Remove bypass pipe. Remove and discard O-rings
from bore of water manifold and from water pump fitting.
RG,CTM42,G25,26-19-29OCT92
CTM42 (24MAR95)
25-23
6076 Diesel Engines—S.N. (500000—
)
160101
PN=242
Cooling System/Remove Coolant Heater
INSTALL WATER MANIFOLD
-UN-13AUG91
1. Install a new O-ring into water manifold and water
pump fitting bores. Lubricate O-rings with grease to ease
bypass pipe installation. Install bypass pipe (A) into bore
of water manifold (B), be careful not to cut O-ring.
RG5855
2. Using LOCTITE 518 Flexible Sealant and a new
gasket, install water manifold assembly. Be sure water
manifold is properly positioned on spring pin (in front
face of cylinder head) and that bypass pipe is fully
seated in water manifold and water pump fitting bores.
3. Apply LOCTITE 242 Thread Sealer to water
manifold-to-cylinder head cap screw threads 360 degrees
(except for the leading one to three threads). Tighten
water manifold cap screws to 61 N·m (45 lb-ft)—Cast
Iron housing, 20 N·m (15 lb-ft)—Aluminum housing..
4. Install bypass pipe “J” clamp to inside-upper injection
pump gear cover cap screw and tighten to 27 N·m (20
lb-ft).
5. If equipped, install aftercooler hose to water manifold,
and bleed line from cylinder head-to-thermostat housing.
RG,CTM42,G25,28-19-14FEB95
REMOVE COOLANT HEATER—IF EQUIPPED
1. Unplug heater (A) from electrical power source.
-UN-30AUG91
2. Drain cooling system.
3. Remove electrical cord, loosen nut, and pull heater
element out of block.
RG5948
25
24
RG,CTM42,G25,29-19-29OCT92
CTM42 (24MAR95)
25-24
6076 Diesel Engines—S.N. (500000—
)
160101
PN=243
Cooling System/Install Coolant Heater
INSTALL COOLANT HEATER—IF EQUIPPED
CAUTION: To avoid shock or hazardous
operation, always use a three-wire heavy-duty
electrical cord equipped with three-wire
connectors. If a two-to-three contact adapter is
used at the wall receptacle, always connect
green wire to a good ground. Keep electrical
connectors clean to prevent arcing.
-UN-23AUG88
N
TS210
Only plug coolant heater into electrical power
if heating element is immersed in coolant.
Sheath could burst and result in personal
injury.
-UN-14DEC88
NOTE: The heater element (A) cannot be repaired. If
defective, replace with a new one.
1. Lubricate O-ring (B) with clean engine oil and install
onto groove of flange nut (D). Install gasket (C) onto
heater element and install element into flange nut.
3. Install assembly into threaded heater hole in block.
While holding heater element in the upward, vertical
position, tighten flange nut to 68 N·m (50 lb-ft) making
sure O-ring seals against block.
IMPORTANT: HEATER element must remain in
upright vertical position after
installation. Heater element may be
damaged if it touches internal walls of
block.
RG5275
2. Install nut (E) onto threads of heater element finger
tight only.
A—Heating Element
B—O-Ring
C—Gasket
D—Flange Nut Adapter
E—Nut
F—Cap
G—Wiring Lead
4. Hold assembly so that flats on threaded end of heater
element are vertical. Tighten nut to 34 N·m (25 lb-ft).
25
25
5. Install wiring lead (G) or dust cap (F) when wiring
lead is not being used.
RG,CTM42,G25,30-19-05MAY93
CTM42 (24MAR95)
25-25
6076 Diesel Engines—S.N. (500000—
)
160101
PN=244
Cooling System/Fan Belt Tension Specifications
COMPLETE FINAL ASSEMBLY
NOTE: Consult your engine operator’s manual or see
Group 02 of this CTM for coolant
recommendations in your area.
1. Fill cooling system to proper level with the proper
coolant.
2. Start engine and run for several minutes to check for
leaks in the cooling system.
3. After fan belts cool, check belt tension as detailed in
your operator’s manual.
RG,CTM42,G25,31-19-15SEP94
FAN BELT TENSION SPECIFICATIONS
• JDG529 Gauge Method (Standard V-belts)
JT05975 Gauge Method (Poly V-belts):
FAN BELT TENSION SPECIFICATIONS
(Using JDG529 or JT05975 Tension Gauge Method)
New Belt
Belt in Service*
Standard V-Belts:
Single Belt System
578—623 N
378—423 N
(130—140 lb)
(85—95 lb)
2-Belt System
(Tension Front Belt
Only)
Poly V-Belts:
Single Belt System
25
26
423—463 N
(95—104 lb)
378—423 N
(85—95 lb)
890—1068 N
(200—240 lb)
801—979 N
(180—220 lb)
• JDST28 Belt Tension Gauge/Straightedge Method:
—On new and used standard V-belts, an 89 N (20 lb)
force halfway between the pulleys should deflect the belt
19 mm (3/4 in.).
—On new and used poly V-belts, a 130 N (30 lb) force
halfway between the pulleys should deflect the belt 13
mm (1/2 in.).
*Belts are considered used after 10 minutes of operation.
CTM42 (24MAR95)
RG,CTM42,G25,39-19-01SEP94
25-26
6076 Diesel Engines—S.N. (500000—
)
160101
PN=245
Group 30
Air Intake And Exhaust System
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
S53,JDG626
-19-09SEP91
RG,JDG683
-19-09SEP91
RG5367
Use with JDE80 and standard 9/16 12-point, 3/8 in. drive
socket to remove and install rear cap screw on
turbocharger drain tube.
-19-05JUN91
-UN-14DEC88
Special Socket Adapter . . . . . . . . . . . . . . . . JDG626
DX,TOOLS
Sealing Ring Compression Tool
. . . . . . . . . . JDG683
RG5571
-UN-04JUL89
Used to compress aftercooler sealing ring for
cover-to-intake manifold alignment during assembly.
Starter Wrench . . . . . . . . . . . . . . . . . . . . . . . JDE80
-UN-09FEB90
Use with JDG626 and standard 9/16 12-point, 3/8 in.
drive socket to remove and install rear cap screw on
turbocharger drain tube.
R26547
30
1
RG,CTM42,G30,32-19-10SEP91
CTM42 (24MAR95)
30-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=246
Air Intake And Exhaust System/Air Intake and Exhaust System Specifications
OTHER MATERIAL
Name
Use
PT569 NEVER-SEEZ Compound
Exhaust manifold cap screws, turbocharger-to-exhaust
manifold cap screws, and aftercooler cover-to-intake
manifold cap screws.
LOCTITE 592 (TY9374/TY9375)
Pipe Sealant with TEFLON
Turbocharger oil supply and drain lines.
RG,CTM42,G30,1 -19-29OCT92
AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS
ITEM
SPECIFICATION
Total Indicator Reading Limits (AiResearch):
Radial Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08—0.15 mm (0.003—0.006 in.)
Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03—0.10 mm (0.001—0.004 in.)
Total Indicator Reading Limits (Schwitzer):
Radial Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13—0.18 mm (0.005—0.007 in.)
Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05—0.13 mm (0.002—0.005 in.)
Exhaust Adapter End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.59 mm (0.0625 in.)
RG,CTM42,G30,2 -19-29OCT92
30
2
CTM42 (24MAR95)
30-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=247
Air Intake And Exhaust System/Air Intake and Exhaust System Specifications
AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS—CONTINUED
TORQUES
Compressor Housing-to-Backplate (AiResearch) . . . . . . . . . . . . . . . . . . . . . 15.3—18.7 N·m (135—165 lb-in.)
Turbine Housing-to-Center Housing (AiResearch) . . . . . . . . . . . . . . . . . . . . 15.8—19.2 N·m (140—170 lb-in.)
Compressor Housing-to-Backplate (Schwitzer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—8 N·m (60—70 lb-in.)
Turbine Housing-to-Center Housing (Schwitzer) . . . . . . . . . . . . . . . . . . . . . . . . 15—16 N·m (135—145 lb-in.)
Turbocharger-to-Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 lb-ft)
Turbocharger Oil Inlet Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26—34 N·m (19—25 lb-ft)
Turbocharger Coupling Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N·m (100 lb-in.)
Exhaust Manifold-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
Intake Manifold-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
Exhaust Elbow-to-Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 lb-ft)
Exhaust Adapter V-Band Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 lb-ft)
Intake Manifold-to-Aftercooler Cover (6076A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N·m (25 lb-ft)
Aftercooler Inlet and Outlet Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N·m (35 lb-in.)
Intake Manifold-to-Intake Hose Clamps . . . . . . . . . . . . . . . . . . . . . 9—13 N·m (12—17 lb-ft) (146—203 lb-in.)
RG,CTM42,G30,56-19-14FEB95
30
3
CTM42 (24MAR95)
30-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=248
Air Intake And Exhaust System/Extending Turbocharger Life
EXTENDING TURBOCHARGER LIFE
Turbochargers are designed to last the life of the engine,
but, because they operate at such high speeds (100,000
rpm or more); a moment’s carelessness can cause them
to fail in seconds.
The major causes of turbocharger failures are
attributed to:
•
•
•
•
•
•
•
Lack of lube oil (quick starts and hot shutdowns)
Oil contamination
Ingestion of foreign objects
Restricted oil drainage
Low oil level
Operation on excessive side slopes
Abnormally high exhaust temperatures
S55,3005,E
• Lack of Lube Oil
Oil not only lubricates the turbocharger’s spinning
shaft and bearings, it also carries away heat. When
oil flow stops or is reduced, heat is immediately
transferred from the hot turbine wheel to the
bearings, which are also heating up because of the
increased friction due to the lack of oil. This
combination causes the turbocharger shaft
temperature to increase rapidly.
30
4
If oil flow does not increase and the process
continues, bearings will fail. Once the bearings fail
(which can happen in just seconds) seals, shaft,
turbine and compressor wheels can also be
damaged.
The principle causes of turbocharger bearing
lubrication problems are low oil pressure, a bent,
plugged or undersized oil lube supply line, plugged or
restricted oil galleries in the turbocharger, or improper
machine start-up and shutdown procedure.
Oil levels and pressure should always be closely
monitored and all worn hoses and lines should be
replaced. The turbocharger oil supply line should be
checked frequently to make sure it is not kinked or
bent and it should always be replaced with a line of
equal size, length and strength.
The easiest way to damage a turbocharger is through
improper start-up and shutdown procedures. Always
idle the engine for at least 30 seconds (no load) after
start-up and before shutdown. Warming the engine up
before applying a load allows oil pressure to build up
and lines to fill with oil.
Idling the engine before shutdown allows the engine
and turbocharger to cool. “Hot” shutdowns can cause
the turbocharger to fail because after high-speed
operation the turbocharger will continue to rotate long
after the engine has been shut off and oil pressure
has dropped to zero. This will cause heat to build up
and possible bearing damage. It can also cause
carbon and varnish deposits to form.
S55,3005,F
CTM42 (24MAR95)
-19-06APR94
30-4
-19-04JUN93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=249
Air Intake And Exhaust System/Extending Turbocharger Life
• Oil Contamination
Four good ways of avoiding oil contamination are:
A second cause of turbocharger failures is
contaminated oil. It can be caused by a worn or
damaged oil filter or not changing the lube oil at
recommended intervals. Expecting the oil filter to
remove dirt, sand, metal chips, etc. from the oil
before they reach the engine or turbocharger can be
a costly mistake because contaminated oil may
completely bypass the engine oil filter if the oil filter
or oil cooler is clogged, if the filter element is
improperly installed, or if the oil is thick during cold
weather.
— Always inspect the engine thoroughly during
major overhaul. Look especially for any sludge or
debris left in lube oil galleries.
— Change lube oil at recommended intervals.
Analysis of oil samples at filter change periods can
help identify potentially harmful contaminants in the
oil.
— Clean the area around the oil fill cap before
adding oil.
— Use a clean container when adding oil.
S11,3005,MK
• Ingestion of Foreign Objects
The third cause of turbocharger damage is the
ingestion of foreign objects. Foreign objects or
particles can be ingested and cause damage to the
turbocharger on both compressor and turbine sides.
This is easy to avoid.
-19-04JUN93
The result is erosion of compressor blades that can
cause the delicately balanced wheel to wobble.
IMPORTANT: Whenever an internal engine failure
(valve, valve seat, piston) occurs, a
thorough inspection of the
turbocharger MUST BE performed
before returning engine to service.
On the compressor side, foreign objects usually take
the form of dust, sand, or shreds of air cleaner
element that enter through improperly installed air
cleaner elements. Leaky air inlet piping (loose clamps
or torn rubber joints) or torn pleats in dry-type air
cleaner elements also create problems.
S11,3005,ML
• Restricted Oil Drainage
A fourth cause of turbocharger damage is restricted
lube oil drainage. The lubricating oil carries away
heat generated by friction of the bearings and from
the hot exhaust gases. If drainage back to the sump
is impeded, the bearings will overheat with damage
that will ultimately lead to failure.
-19-04JUN93
30
5
There are two primary reasons for restricted drainage.
A blocked drain tube, due to either damage or a
buildup of sludged oil or high crankcase pressure
which can be due to restricted crankcase breather or
excessive engine blowby.
Periodically check both the turbocharger oil drain tube
and engine breather tube for damage or restriction.
Correction of these conditions leads to longer
turbocharger life.
RG,CTM8,G30,R1 -19-04JUN93
CTM42 (24MAR95)
30-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=250
Air Intake And Exhaust System/Remove Turbocharger
• Abnormally High Exhaust Temperatures
Causes of restricted air flow can include damaged
inlet piping, clogged air filters, excessive exhaust
restriction, or operation at extreme altitudes.
Overpowering generally is due to improper fuel
delivery or injection timing. If overtemperature
operation has been identified, an inspection of the air
inlet and exhaust systems should be performed. Also,
check the fuel delivery and timing.
A fifth cause of turbocharger damage is abnormally
high exhaust temperatures. Elevated exhaust
temperatures cause coking of oil which can lead to
bearing failure. Extreme over-temperature operation
can case wheel burst.
There are two basic causes of over-temperature. The
first is restricted air flow and the second is
overpowering the engine. In either case the engine
has more fuel than available air for proper
combustion, this overfueled condition leads to
elevated exhaust temperatures.
RG,CTM8,G30,R2 -19-19AUG92
REMOVE TURBOCHARGER
N
CAUTION: After operating engine, allow
exhaust system to cool before removal.
Thoroughly clean exterior of turbocharger and
surrounding area to prevent entry of dirt into the air
intake system during removal.
IMPORTANT: When cleaning turbocharger, do not
spray directly into compressor cover
or turbine housing. If turbocharger
inspection is required, do not clean
exterior prior to removal. Doing so
may wash away evidence of a
potential failure mode. (See
TURBOCHARGER SEVEN STEP
INSPECTION, later in this group.)
NOTE: Your 6076 Engine is equipped with either
AiResearch/Garrett, Holset, or Schwitzer
turbochargers. Removal and installation
procedures are the same for all turbochargers,
but repair of AiResearch/Garrett and Schwitzer
differ. Refer to the proper repair section when
repairing turbocharger. Repair parts are not
available for Holset turbochargers; if defective,
install a replacement.
30
6
RG,CTM42,G30,11-19-29OCT92
CTM42 (24MAR95)
30-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=251
Air Intake And Exhaust System/Remove Turbocharger
NOTE: 6076A shown, 6076T and H similar.
1. Remove exhaust elbow (A). Remove clamp and
exhaust adapter (B).
2. Disconnect oil inlet line (C). Loosen oil return tube cap
screws using JDG626 Special Socket Adapter with
JDE80 and standard 9/16 12-point, 3/8 in. drive socket
and remove oil return tube (D). Discard gasket.
-UN-20DEC88
3. Remove four turbocharger mounting cap screws with
washers and lift turbocharger from exhaust manifold.
Disengage turbocharger from intake manifold coupling
(E). Discard turbocharger-to-coupling O-ring.
RG5283
4. Cap or plug all openings (exhaust and intake manifold
related) and place turbocharger on a clean flat table for
inspection.
5. Perform turbocharger seven-step inspection, as
described later, if failure mode has not been determined.
A—Exhaust Elbow
B—Exhaust Adapter
C—Oil Inlet Line
D—Oil Return Tube
E—Intake Manifold Coupling
RG,CTM42,G30,12-19-29OCT92
30
7
CTM42 (24MAR95)
30-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=252
Air Intake And Exhaust System/Turbocharger Failure Analysis
TURBOCHARGER FAILURE ANALYSIS
The following is a guide for diagnosing the cause of
turbocharger failures after removal from the engine.
COMPRESSOR HOUSING INLET DEFECTS
Problem
Possible Cause
Suggested Remedy
Foreign Object Damage
Objects left in intake
system.
Disassemble and inspect intake system for
foreign objects (this group).
Inspect engine for internal damage.
Leaking and/or defective
intake system.
Inspect air intake system connections including
air filter; repair as required (this group).
Inspect air intake related engine components.
Compressor Wheel Rub
Bearing failure.
Determine if engine and/or operator contributed
to lack of lubrication, contaminated
lubrication, excessive temperature, or
debris generating engine failure in progress.
Correct as required.
Manufacturing defects.
Correct as required.
COMPRESSOR HOUSING OUTLET DEFECTS
Oil and/or Dirt in Housing
Restricted air intake system.
Inspect and clean air cleaner.
Prolonged periods of low RPM
engine idling.
Check with operator to confirm conditions.
(See Operators manual.)
Defective oil seal ring.
Repair as required. (This group.)
Restricted oil drain line.
Inspect and clear oil drain line as required.
TURBINE HOUSING INLET DEFECTS
Oil in Housing
30
8
Center Wall Deteriorated
Internal engine failure.
Inspect and repair engine as required.
Oil leaking from compressor
housing seal.
Verify that oil is in compressor housing and
refer to “Compressor Housing Outlet Defects”
as listed earlier in this chart.
Excessive operating
temperature.
Check for restricted air intake.
Check engine for overfueling.
Check injection pump timing.
RG,CTM8,G30,R3 -19-11SEP92
CTM42 (24MAR95)
30-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=253
Air Intake And Exhaust System/Turbocharger Failure Analysis
TURBINE HOUSING OUTLET DEFECTS
Problem
Possible Cause
Suggested Remedy
Turbine Wheel Rub
Bearing failure.
Determine if engine and/or operator contributed
to lack of lubrication, contaminated
lubrication, excessive temperature, or debris
generating engine failure in progress. Correct
as required.
Manufacturing defect.
Correct as required (this group).
Internal engine failure.
Inspect and repair engine as required.
Objects left in intake system.
Disassemble and inspect air intake system,
(this group).
Leaking air intake system.
Correct as required, (this group).
Internal engine failure.
Verified by oil in turbine housing. Correct
as required.
Turbine seal failure.
Inspect for excessive heat from overfueling
and/or restricted air intake.
Prolonged periods of low RPM
engine idling.
Verify with operator to run engine under load
or a higher RPM. (Operator’s Manual.)
joints.
Restricted oil drain line.
Inspect and clear oil drain line as required.
Foreign Object Damage
Oil and/or Excessive Carbon
EXTERNAL CENTER HOUSING AND JOINT DEFECTS
Leaks from Casting
Leaks from Joints
Defective casting.
Replace turbocharger, (this group).
Defective gasket.
Verify that leaks are not occurring at
gasket joints.
Loose attaching screws.
Tighten to specifications in CTM, (this group).
Defective gasket.
Inspect and repair as required.
INTERNAL CENTER HOUSING DEFECTS
Excessive Carbon Build up
in Housing or on Shaft
CTM42 (24MAR95)
30
9
Hot engine shut-down.
Review proper operation with operator
as shown in Operator’s manual.
Excessive operating
temperature.
Restricted air intake;
Overfueling or
Mistimed engine
Restricted oil drain line.
Inspect and clean oil drain lines as required.
Operating engine at high
speeds and loads immediately
after start-up.
Idle engine for a few minutes to allow oil to
reach bearings before applying heavy loads.
30-9
S11,3005,JG
-19-28SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=254
Air Intake And Exhaust System/Turbocharger Seven-Step Inspection
TURBOCHARGER SEVEN-STEP INSPECTION
The following inspection procedure is recommended
for systematic failure analysis of a suspected failed
turbocharger. This procedure will help to identify when
a turbocharger has failed, and why it has failed so
the primary cause of the failure can be corrected.
Proper diagnosis of a non-failed turbocharger is
important for two reasons. First, identification of a
non-failed turbocharger will lead to further
investigation and repair of the cause of a
performance complaint.
Second, proper diagnosis eliminates the unnecessary
expense incurred when a non-failed turbocharger is
replaced.
The seven recommended inspection steps, which are
explained in detail on following pages, are:
—Compressor Housing Inlet and Compressor Wheel.
—Compressor Housing Outlet.
—Turbine Housing Inlet.
—Turbine Housing Outlet and Turbine Wheel.
—External Center Housing and Joints.
—Internal Center Housing.
—Turbocharger Bench Test.
NOTE: To enhance the turbocharger inspection, an
inspection sheet (Form No. DF-2280 available
from Distribution Service Center) can be used
that lists the inspection steps in the proper
order and shows potential failure modes for
each step. Check off each step as you
complete the inspection and record any details
or problems obtained during inspection. Retain
this with the work order for future reference.
S11,3005,IF
-19-16AUG94
S11,3005,IG
-19-07AUG92
Compressor Housing Inlet and Compressor Wheel
NOTE: Foreign object damage may be extensive or
minor. In either case, the source of the foreign
object must be found and corrected to eliminate
further damages.
RG4523
30
10
-UN-20DEC88
1. Check compressor inlet and compressor wheel (A) for
foreign object damage.
2. Mark findings on your checklist and continue the
inspection.
CTM42 (24MAR95)
30-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=255
Air Intake And Exhaust System/Turbocharger Seven-Step Inspection
NOTE: You will need a good light source for this check.
RG4524
-UN-20DEC88
3. Check compressor inlet for wheel rub on the housing
(arrow). Look very closely for any score marks on the
housing itself and check the tips of the compressor
wheel blades for damage.
S11,3005,IH
-19-07AUG92
S11,3005,II
-19-07AUG92
S11,3005,IJ
-19-11SEP92
Compressor Housing Outlet
-UN-20DEC88
1. Check compressor housing outlet (A). The outlet
should be clean and free of dirt or oil.
RG4525
2. Mark it on your checklist if dirt or oil is found and
continue the inspection.
Turbine Housing Inlet
-UN-20DEC88
1. Check the turbine housing inlet ports (arrow) for oil in
housing, excessive carbon deposit or erosion of center
walls.
RG4526
NOTE: If the inlet is wet with oil, or has excessive
carbon deposits, an engine problem is likely.
Center wall erosion (cracking or missing pieces),
indicate excessive exhaust temperature.
30
11
Turbine Housing Outlet and Turbine Wheel
RG4527
-UN-20DEC88
1. Use a flashlight to look up inside the turbine housing
outlet (A) and check blades (B) for foreign object
damage.
S11,3005,IK
CTM42 (24MAR95)
30-11
-19-11SEP92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=256
Air Intake And Exhaust System/Turbocharger Seven-Step Inspection
RG4528
-UN-20DEC88
2. Inspect the wheel blades and housing for evidence of
wheel rub (arrow). Wheel rub can bend the tips of the
blades with the housing showing wear or damage.
S11,3005,IL
-19-11SEP92
S11,3005,IM
-19-07AUG92
S11,3005,IN
-19-07AUG92
S11,3005,IO
-19-07AUG92
External Center Housing and Joints
-UN-20DEC88
1. Visually check the outside of the center housing, all
connections to the compressor, and turbine housing for
oil.
RG4529
NOTE: If oil is present, make sure it is not coming from
a leak at the oil supply or return line.
Internal Center Housing
RG4530
-UN-20DEC88
1. Using a flashlight, look through the oil return hole (A),
to check the condition of the shaft and/or bearings.
There should not be excess carbon deposits on the shaft
or in the housing.
-UN-20DEC88
2. Excessive “blueing” or “coking” of oil along the
complete length of the shaft (A) indicates a possible lack
of lubrication caused by an engine failure, or improper
operation, such as hot shutdowns.
RG4531
30
12
CTM42 (24MAR95)
30-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=257
Air Intake And Exhaust System/Turbocharger Seven-Step Inspection
Turbocharger Bench Test
1. Mount the turbocharger in a vise.
RG4532
-UN-20DEC88
2. Rotate the shaft, using both hands, to check rotation
and clearance. The shaft should turn freely, however,
there may be a slight amount of drag.
S11,3005,IP
-19-29APR93
S11,3005,IQ
-19-07AUG92
S11,3005,IR
-19-07AUG92
-UN-20DEC88
3. Next, pull up on the compressor end of the shaft and
press down on the turbine end while rotating shaft.
Neither the compressor wheel nor the turbine wheel
should contact the housing at any point.
RG4533
NOTE: There will be some “play” because the bearings
inside the center housing are free floating.
RG4534
-UN-20DEC88
4. Next, check shaft endplay by moving the shaft back
and forth while rotating. There will be some endplay but
not to the extent that the wheels contact the housings.
30
13
CTM42 (24MAR95)
30-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=258
Air Intake And Exhaust System/Turbocharger Seven-Step Inspection
NOTE: These diagnostic procedures will allow you to
determine the condition of the turbocharger. If
the turbocharger has failed, analysis of your
inspection notes should direct you to the
specific areas of the engine to correct the
problems causing the turbocharger failure
(See TURBOCHARGER FAILURE ANALYSIS,
outlined earlier in this group). It is not unusual
to find that a turbocharger has not failed. If
your turbocharger passes all the inspections,
the problem lies somewhere else.
IMPORTANT: Before you finalize your conclusion
that the turbocharger has not failed,
it is strongly recommended that the
following procedures of checking
radial bearing clearance and axial
bearing endplay with a dial indicator
be performed. These procedures are
not required if a failure mode has
already been identified.
S11,3005,IS
-19-14OCT94
30
14
CTM42 (24MAR95)
30-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=259
Air Intake And Exhaust System/Perform Radial Bearing Clearance Test
PERFORM RADIAL BEARING CLEARANCE
TEST
This test will give an indication of the condition of radial
bearings within the center housing and rotating
assembly.
1. Fasten a magnetic base (plunger-type) dial indicator to
the turbocharger mounting base. Assemble an extension
adapter and indicator extension rod onto dial indicator.
-UN-20DEC88
2. Position indicator tip (through center housing oil
return) on center of shaft. Preload indicator tip and zero
dial on indicator.
R20006
3. Grasp rotating shaft at both ends and move the shaft
toward the indicator then away from the indicator
(arrows). Use care to move the shaft in the same
direction as the dial indicator tip travels and apply equal
pressure at both ends of the shaft.
4. Observe and record the total dial indicator movement.
TURBOCHARGER SHAFT RADIAL MOVEMENT SPECIFICATION
Garrett/AiResearch . . . . . . . . . . . 0.08—0.15 mm (0.003—0.006 in.)
Schwitzer . . . . . . . . . . . . . . . . . . 0.13—0.18 mm (0.005—0.007 in.)
If total indiactor reading is not within specification,
replace center housing and rotating assembly. (See
REPLACE CENTER HOUSING AND ROTATING
ASSEMBLY, later in this group.)
RG,CTM42,G30,29-19-29OCT92
30
15
CTM42 (24MAR95)
30-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=260
Air Intake And Exhaust System/Repair Turbocharger
PERFORM AXIAL BEARING END PLAY TEST
This test will give an indication of the condition of the
thrust bearing within the center housing and rotating
assembly.
-UN-20DEC88
1. Mount magnetic base dial indicator (arrow) so
indicator tip rests on flat surface on turbine end of shaft.
Preload indicator tip and zero dial on indicator.
2. Move shaft axially back and forth by hand.
R24653N
3. Observe and record total dial indicator movement.
TURBOCHARGER SHAFT AXIAL END PLAY SPECIFICATION
Garrett/AiResearch . . . . . . . . . . . 0.03—0.10 mm (0.001—0.004 in.)
Schwitzer . . . . . . . . . . . . . . . . . . 0.05—0.13 mm (0.002—0.005 in.)
If bearing end play is not within specifications, replace
center housing and rotating assembly, as outlined later in
this group.
RG,CTM42,G30,28-19-29OCT92
REPAIR TURBOCHARGER
AiResearch/Garrett and Schwitzer turbochargers used on
the engines covered in this manual are available through
service parts as a complete remanufactured assembly or
as a new center housing and rotating assembly only.
When a new center housing and rotating assembly are
being installed, thoroughly inspect and reuse turbine and
compressor housings from existing turbocharger. New
mounting hardware MUST be used.
30
16
IMPORTANT: Repairing a turbocharger center
housing and rotating assembly requires
specialized tooling and highly trained
personnel and thus it is not
recommended that the turbocharger be
disassembled completely.
CTM8,GR30,7
CTM42 (24MAR95)
30-16
-19-13JAN95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=261
Air Intake And Exhaust System/Disassemble Turbocharger
RG5857
-UN-13AUG91
DISASSEMBLE TURBOCHARGER
A—Compressor Housing
B—Clamp Plates
C—Center Housing Assembly
D—Clamp Plates
E—Turbine Housing
Cap or plug all openings (including exhaust and
intake ports) and clean exterior of turbocharger with a
pressure spray of cleaning solvent. Dry turbocharger
with compressed air.
2. If equipped, straighten ears on lock plates.
IMPORTANT: When cleaning turbocharger do not
spray directly into compressor cover
or turbine housing. Spinning rotor
with high pressure spray may cause
bearing damage.
4. Remove compressor housing. Gently tap
compressor housing with a soft hammer, if necessary,
to remove. Be careful not to damage compressor
housing or compressor wheel.
3. Remove compressor housing cap screws, lock
plates (if equipped), and clamps (B).
Put turbocharger on a clean flat surface.
5. Remove turbine housing cap screws, lock plates (if
equipped), and clamps (D).
1. Scribe a location mark on the turbine housing (E),
center housing (C), and compressor housing (A) to
assist proper indexing of housings when turbocharger
is assembled.
6. Remove turbine housing. Gently tap turbine
housing with a soft hammer, if necessary, to remove.
Be careful not to damage turbine housing or turbine
wheel.
30
17
NOTE: Some turbochargers may not have lock plates
on compressor or turbine housing cap screws.
RG,CTM42,G30,30-19-16AUG94
CTM42 (24MAR95)
30-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=262
Air Intake And Exhaust System/Clean and Inspect Turbine and Compressor Housings
CLEAN AND INSPECT TURBINE AND
COMPRESSOR HOUSINGS
1. Thoroughly clean compressor housing (A) and turbine
housing (C) using a commercially approved solvent only.
Caustic solutions may damage housings. Dry housings
with compressed air after cleaning. After a part is
cleaned, place it on a clean flat surface and inspect as
outlined below.
• Inspect turbine housing for:
-UN-05AUG91
—Wheel rub damage within the contour area that cannot
be polished out with 60-grit silicon carbide abrasive cloth.
—Nicks, dents or warpage that could prevent proper
sealing between the turbine housing and center housing.
RG5747
—Corroded or stripped threaded mounting holes.
• Inspect compressor housing for:
—Wheel rub damage within the contour area that cannot
be polished out with 80-grit silicon carbide abrasive cloth.
—Nicks, dents, or warpage that could prevent proper
sealing between the compressor housing and center
housing.
A—Compressor Housing
B—Compressor Clamp
C—Turbine Housing
D—Turbine Clamp
—Corroded or stripped threaded mounting holes.
NOTE: Use new mounting cap screws when
turbocharger is reassembled.
2. Clean all threads in housings with a tap.
3. Replace either housing if any of the above defects are
found.
30
18
RG,CTM42,G30,31-19-15SEP94
CTM42 (24MAR95)
30-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=263
Air Intake And Exhaust System/Replace Center Housing Assembly and Assemble Turbocharger
REPLACE CENTER HOUSING ASSEMBLY
AND ASSEMBLE TURBOCHARGER
NOTE: Center housing and rotating assembly is serviced
as a complete assembly; individual internal parts
are not available.
-UN-13AUG91
1. Carefully transfer the scribed marks from the original
center housing (C) to the replacement assembly, if
necessary. Use the same procedure for the turbine
housing (E) and compressor housing (A), if they are also
being replaced.
RG5857
2. Lay turbine housing on it’s side and install center
housing assembly (C) into turbine housing (E). Align
scribed reference marks (scribed during disassembly) on
turbine housing and center housing.
3. Apply a coat of PT569 NEVER-SEEZ Compound to
cap screws. Install clamps (D), lock plates (if equipped),
and cap screws. Tighten cap screws to specification.
Bend lock plates up against head of cap screws.
TURBOCHARGER CAP SCREW TORQUE SPECIFICATIONS
Garrett/AiResearch
Turbine Housing-to-Center Housing . . . . . . . . . . . . 15.8—19.2 N·m
(140—170 lb-in.)
Compressor Housing-to-Backplate . . . . . . . . . . . . . 15.3—18.7 N·m
(135—165 lb-in.)
Schwitzer
Turbine Housing-to-Center Housing . . . . . . . . . . . . . . . . 7—8 N·m
(60—70 lb-in.)
Compressor Housing-to-Backplate . . . . . . . . . . . . . . . . . 7—8 N·m
(60—70 lb—in.)
A—Compressor Housing
B—Clamp Plates
C—Center Housing Assembly
D—Clamp Plates
E—Turbine Housing
4. Position compressor housing (A) onto center housing
assembly (C). Align scribed reference marks (scribed
during disassembly) on compressor housing and center
housing.
5. Apply a coat of PT569 NEVER-SEEZ Compound to
cap screws. Install clamps (B), lock plates (if equipped),
and cap screws. Tighten cap screws to specification.
30
19
IMPORTANT: DO NOT spin the rotor assembly with
compressed air. Damage to bearings
can occur when using compressed air.
6. After assembly, spin rotating assembly by hand to
check for binding and wheel rub. If either condition
exists, disassemble turbocharger and determine the
cause.
7. Prelube turbocharger bearings with clean engine oil
before putting turbocharger into service.
RG,CTM42,G30,33-19-29OCT92
CTM42 (24MAR95)
30-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=264
Air Intake And Exhaust System/Install Turbocharger
PRELUBE TURBOCHARGER
IMPORTANT: DO NOT spin the rotor assembly with
compressed air. Damage to bearings
can occur when using compressed air.
Fill oil return (drain) port with clean engine oil and spin
rotating assembly by hand to properly lubricate bearings.
RG5858
-UN-13AUG91
If turbocharger is to be stored for an extended period of
time, lubricate internally and install protective covers on
all openings.
RG,CTM42,G30,34-19-29OCT92
INSTALL TURBOCHARGER
30
20
RG5859
If not previously done, prime turbocharger lubrication
system prior to mounting turbocharger on engine. Fill
center housing with new engine oil through oil drain hole
(as shown). Turn rotating assembly by hand to lubricate
bearings.
-UN-13AUG91
IMPORTANT: If turbocharger failed because of
foreign material entering the air intake
system, be sure to examine the system
and clean as required to prevent a
repeat failure.
6076A shown, 6076T similar
1. Apply a coat of grease to O-rings (A) and install on
compressor housing outlet (C) and coupling (B).
2. Put a new gasket on turbocharger-to-exhaust manifold
mounting surface (not shown).
RG,CTM42,G30,35-19-29OCT92
CTM42 (24MAR95)
30-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=265
Air Intake And Exhaust System/Install Turbocharger
NOTE: Coat coupling O-rings with liquid soap or grease
as an aid during assembly.
Install turbocharger oil drain tube on engine
before mounting turbocharger.
Guide studs may be used to position exhaust
gasket during turbocharger installation.
-UN-20DEC88
3. Mount turbocharger on engine, making sure coupling
(E) is properly seated over compressor housing and in
intake manifold.
RG5283
4. Apply PT569 NEVER-SEEZ Compound to all
turbocharger mounting cap screws. Install cap screws
and tighten to 24 N·m (18 lb-ft). On 6076T engines,
tighten hose clamps on intake manifold and coupling
hose to 9—13 N·m (12—17 lb-ft) (146—203 lb-in.).
NOTE: Remove all caps or plugs from turbocharger
openings.
5. Using a new gasket, install oil drain tube (D). Tighten
cap screws securely using JDG626 Special Socket
Adapter with JDE80 and standard 9/16, 12-point, 3/8 in.
drive socket. Connect oil inlet line (C) and tighten to
26—34 N·m 19—25 lb-ft).
A—Exhaust Elbow
B—Exhaust Adapter
C—Oil Inlet Line
D—Oil Drain Tube
E—Coupling
6. Install exhaust adapter (B) to turbine housing outlet
with V-band clamp. Tighten clamp to 20 N·m (15 lb-ft).
7. Install exhaust elbow (A). Apply PT569 NEVER-SEEZ
Compound to mounting cap screws and tighten to 24
N·m (18 lb-ft).
8. Install air intake hose and tighten hose clamps
securely.
IMPORTANT: BEFORE STARTING an engine with a
new or repaired turbocharger, crank the
engine over (but do not start) for
several seconds to allow engine oil to
reach turbocharger bearings. DO NOT
crank engine longer than 30 seconds at
a time to avoid damage to starting
motor.
30
21
9. Start and run engine at low idle while checking oil
inlet and air piping connections for leaks.
RG,CTM42,G30,39-19-24MAR95
CTM42 (24MAR95)
30-21
6076 Diesel Engines—S.N. (500000—
)
160101
PN=266
Air Intake And Exhaust System/Remove, Inspect, and Install Intake Manifold
REMOVE, INSPECT, AND INSTALL INTAKE
MANIFOLD (6076T AND 6076H ENGINES)
-UN-13AUG91
IMPORTANT: All intake manifold connections at the
turbocharger and engine cylinder head
must be tight to prevent loss of power
resulting from lower manifold pressure.
RG5860
Intake manifold hose and cap screw connections should
be inspected periodically for tightness.
Whenever a tune-up has been performed on the engine,
or whenever it is suspected that the horsepower output
might be low, the intake manifold pressure (turbocharger
boost should be checked. (See Group 110.)
NOTE: On 6076 HRW 33, 34, and 35 Engines, the
exhaust manifold must be removed before
removing intake manifold.
1. On 6076T engines, loosen hose clamps (A) on lower
air intake hose.
2. On 6076H engines, remove connections from
compressor outlet and intake manifold.
3. Disconnect aneroid line, if equipped.
4. Disconnect ether starting aid pipe from manifold, if
equipped.
5. Remove six manifold mounting cap screws and intake
manifold.
6. Inspect the intake manifold for serviceability. Replace
if it is cracked or otherwise damaged.
7. Inspect the machined mating surfaces of cylinder head
and intake manifold. Clean, as required, by using a
scraper and/or wire brush, and compressed air.
30
22
8. To install intake manifold, reverse removal procedures
and use new gaskets.
9. Make sure air intake hose is in good condition.
Tighten hose clamps to 9—13 N·m (12—17 lb-ft)
(146—203 lb-in.).
10. Tighten intake manifold attaching cap screws to 47
N·m (35 lb-ft).
RG,CTM42,G30,40-19-14FEB95
CTM42 (24MAR95)
30-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=267
Air Intake And Exhaust System/Remove Vertically-Mounted Aftercooler and Intake Manifold
REMOVE VERTICALLY-MOUNTED
AFTERCOOLER AND INTAKE MANIFOLD
(6076A ENGINES)
N
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Wait until engine coolant is cool
enough to touch with bare hands before
draining. Slowly loosen radiator cap to first
stop to relieve pressure.
-UN-13AUG91
NOTE: On some applications, aftercooler may be
mounted horizontally on engine. Specifications
are the same regardless of how aftercooler is
mounted.
RG5861
1. Open water pump and block drain valves to
completely drain engine coolant.
2. Thoroughly clean exterior of turbocharger (B), intake
manifold and adjacent areas to prevent entry of dirt into
the engine when parts are removed.
3. Remove turbocharger as described earlier in this
group.
4. Loosen clamps (A) on inlet and outlet hoses. Remove
coolant hoses from aftercooler.
A—Clamps
B—Turbocharger
C—Aneroid-to-Intake Manifold Connector
D—Ether Starting Aid Pipe
E—Air Intake Cover Cap Screws
5. Remove aneroid-to-intake manifold connector (C) and
ether starting aid pipe (D), if equipped.
6. Remove air intake cover cap screws (E).
RG,CTM42,G30,44-19-29OCT92
30
23
CTM42 (24MAR95)
30-23
6076 Diesel Engines—S.N. (500000—
)
160101
PN=268
Air Intake And Exhaust System/Remove Vertically-Mounted Aftercooler and Intake Manifold
7. Carefully lift air intake cover (A) from intake manifold
(C).
-UN-13AUG91
8. Remove aftercooler (B).
9. Remove and discard gaskets (D).
RG5862
10. Inspect aftercooler end seal (E) and replace as
needed.
A—Air Intake Cover
B—Aftercooler
C—Intake Manifold
D—Gaskets
E—Aftercooler End Seal
RG,CTM42,G30,45-19-23SEP91
11. Remove the six intake manifold-to-cylinder head cap
screws (A) and remove intake manifold. Remove and
discard all manifold gaskets.
RG5863
-UN-13AUG91
12. Inspect and repair aftercooler. See INSPECT AND
REPAIR AFTERCOOLER (6076A ENGINES), later in this
group.
RG,CTM42,G30,46-19-29OCT92
30
24
CTM42 (24MAR95)
30-24
6076 Diesel Engines—S.N. (500000—
)
160101
PN=269
Air Intake And Exhaust System/Remove and Disassemble Horizontally-Mounted Aftercooler Assembly
REMOVE AND DISASSEMBLE
HORIZONTALLY-MOUNTED AFTERCOOLER
ASSEMBLY (6076A ENGINES)
-UN-26OCT92
NOTE: On some applications, aftercooler may be
mounted vertically on engine. Specifications are
the same regardless of how aftercooler is
mounted.
1. Completely drain engine coolant from aftercooler.
RG6486
2. Disconnect turbocharger oil inlet (A) and return (B)
lines.
3. Remove four turbocharger-to-exhaust manifold cap
screws.
4. Remove coolant inlet and outlet hoses (C) from
aftercooler.
-UN-26OCT92
5. Remove top three intake manifold cap screws. Install
guide studs at the three locations. Remove remaining
cap screws.
RG6487
6. Remove intake manifold and aftercooler as an
assembly.
7. Remove and discard intake manifold gaskets.
8. Remove turbocharger from aftercooler cover.
RG,CTM42,G30,55-19-29OCT92
9. Install JDG683 Sealing Ring Compression Tool (A)
onto aftercooler coolant tubes with cross bar across slot.
10. Remove intake manifold cover (B).
11. Remove JDG683 tool.
30
25
-UN-26OCT92
12. Remove aftercooler core from intake manifold.
13. Inspect aftercooler end seal and replace as needed.
RG6488
14. Inspect and repair aftercooler. See INSPECT AND
REPAIR AFTERCOOLER (6076A ENGINES), as
described earlier in this group.
RG,CTM42,G30,59-19-29OCT92
CTM42 (24MAR95)
30-25
6076 Diesel Engines—S.N. (500000—
)
160101
PN=270
Air Intake And Exhaust System/Inspect and Repair Intake Manifold and Cover
INSPECT AND REPAIR AFTERCOOLER
(6076A ENGINES)
1. Inspect aftercooler for overall condition. The fins
should be reasonably straight, and cross straps should
be free of cracks.
-UN-04JUL89
2. Inspect aftercooler inlet and outlet hoses. Replace
either hose if cracked or damaged.
3. Test the aftercooler for leaks by plugging one of the
tubes (A).
RG5572
4. Apply compressed air to the other tube while unit is
submerged under water. Use 140—170 kPa (1.4—1.7
bar) (20—25 psi) air pressure for testing.
IMPORTANT: Coolant leakage from the aftercooler
may cause severe engine damage.
A minor leak that is accessible may be repaired.
However, if the condition of the core is questionable,
replace the aftercooler.
RG,CTM42,G30,47-19-29OCT92
INSPECT AND REPAIR INTAKE MANIFOLD
AND AIR INTAKE COVER (6076A ENGINES)
1. Inspect air intake cover (A) for cracks or damage.
Replace as necessary.
-UN-05AUG91
2. Check intake manifold (B) for damage. Inspect
machined mounting surfaces for burrs or other defects
which might prevent gaskets from sealing properly.
Repair as required.
30
26
RG5750
3. Thoroughly steam clean interior of intake manifold and
covers.
IMPORTANT: Do not use a hot tank to clean
aluminum parts as damage and severe
deterioration can occur.
4. Scrape all gasket material from cylinder head and
intake manifold mounting surfaces.
RG,CTM42,G30,48-19-29OCT92
CTM42 (24MAR95)
30-26
6076 Diesel Engines—S.N. (500000—
)
160101
PN=271
Air Intake And Exhaust System/Install Intake Manifold and Vertically-Mounted Aftercooler
RG5749
-UN-05AUG91
INSTALL INTAKE MANIFOLD AND VERTICALLY-MOUNTED AFTERCOOLER (6076A
ENGINES)
A—Air Intake Cover
B—Intake Coupling
C—Aftercooler
D—End Seal
E—Intake Manifold
F—Gasket (2 used)
6076A Engine—Two-Pass Aftercooler
Apply PT569 NEVER-SEEZ Compound to all
aftercooler cover-to-intake manifold cap screws before
assembly.
RG,CTM42,G30,49-19-29OCT92
30
27
-UN-13AUG91
IMPORTANT: Debris left in intake manifold can cause
engine damage. Make sure that the
inside of manifold is clean before
assembly.
1. Install the intake manifold on cylinder head using new
gaskets.
RG5863
2. Tighten the six cap screws (A) to 47 N·m (35 lb-ft).
RG,CTM42,G30,50-19-23SEP91
CTM42 (24MAR95)
30-27
6076 Diesel Engines—S.N. (500000—
)
160101
PN=272
Air Intake And Exhaust System/Install Intake Manifold and Vertically-Mounted Aftercooler
3. Install a new gasket (A) on top of intake manifold.
-UN-13AUG91
4. Install aftercooler end seal (B) on inlet and outlet
tubes.
RG5864
5. Install aftercooler on top of intake manifold. Put a new
gasket on top of aftercooler. Carefully align cap screw
holes in aftercooler, intake manifold, and gaskets.
RG,CTM42,G30,51-19-29OCT92
6. Install air intake cover (A) over aftercooler so inlet and
outlet tubes are protruding through hole in cover.
IMPORTANT: Improperly seated or crimped end seal
can result in loss of power and
possible engine damage. Make sure
end seal is properly seated.
7. Install JDG683 Sealing Ring Compression Tool (B)
onto aftercooler coolant tubes (C) with crossbar across
slot as shown.
8. Tighten tool until air intake cover cap screw holes are
aligned with holes in gaskets, aftercooler, and intake
manifold.
RG5570
-UN-09JAN90
IMPORTANT: All intake manifold and aftercooler
connections at the turbocharger and
engine cylinder head must be tight to
prevent loss of power resulting from
lower manifold pressure, and possible
engine damage.
9. Apply PT569 NEVER-SEEZ to all intake
manifold-to-aftercooler cover cap screws. Install cap
screws and tighten to 34 N·m (25 lb-ft). Remove seal
compression tool.
30
28
RG,CTM42,G30,52-19-14FEB95
CTM42 (24MAR95)
30-28
6076 Diesel Engines—S.N. (500000—
)
160101
PN=273
Air Intake And Exhaust System/Assemble and Install Horizontally-Mounted Aftercooler Assembly
RG6489
-UN-26OCT92
ASSEMBLE AND INSTALL HORIZONTALLY-MOUNTED AFTERCOOLER ASSEMBLY
(6076A ENGINES)
A—Gasket (3 Used)
B—Intake Manifold
C—Washer (6 Used)
D—Cap Screw (6 Used)
E—Gasket (2 Used)
F—Aftercooler Core
G—O-Ring
H—Intake Coupler
I—O-Ring
J—Aftercooler Cover
K—Pipe Plug
L—End Seal
M—Clamps (4 Used)
N—Hose
O—Hose
P—Nipple (2 Used)
Q—Cap Screw (12 Used)
R—Washer (12 Used)
3. Install JDG683 Sealing Ring Compression Tool
onto aftercooler coolant tubes with cross bar across
slot.
IMPORTANT: Improperly seated or crimped
aftercooler end seal can result in
loss of power and possible engine
damage. Make sure end seal is
properly seated.
4. Tighten tool until intake manifold cover cap screw
holes are aligned with holes in gaskets, aftercooler,
and intake manifold. Use guide studs as needed to
hold alignment.
1. Install aftercooler end seal on coolant tubes.
IMPORTANT: Debris left in intake manifold can
cause engine damage. Make sure
that inside of manifold is clean
before assembly.
5. Apply PT569 NEVER-SEEZ Compound to all
aftercooler cover-to-intake cap screws. Tighten cap
screws to 34 N·m (25 lb-ft). Remove seal
compression tool.
2. Position aftercooler core into intake manifold using
new gaskets.
30
29
6. Apply multi-purpose grease to turbocharger
compressor O-ring and install turbocharger onto
aftercooler cover.
RG,CTM42,G30,57-19-16AUG94
CTM42 (24MAR95)
30-29
6076 Diesel Engines—S.N. (500000—
)
160101
PN=274
Air Intake And Exhaust System/Assemble and Install Horizontally-Mounted Aftercooler Assembly
7. Install three guide studs (A) in locations shown.
-UN-26OCT92
IMPORTANT: All intake manifold connections must
be tight to prevent loss of power
resulting from lower manifold pressure,
and possible engine damage.
RG6490
8. Using new gaskets, install aftercooler assembly to
cylinder head. Tighten cap screws to 47 N·m (35 lb-ft).
9. Connect coolant inlet and outlet hoses to aftercooler
and tighten clamps.
10. Connect turbocharger oil inlet and return lines.
RG,CTM42,G30,58-19-29OCT92
30
30
CTM42 (24MAR95)
30-30
6076 Diesel Engines—S.N. (500000—
)
160101
PN=275
Air Intake And Exhaust System/Remove, Inspect, and Install Exhaust Manifold
REMOVE, INSPECT, AND INSTALL
EXHAUST MANIFOLD
-UN-13AUG91
NOTE: On 6076 HRW 33, 34, and 35 Engines, exhaust
manifold can be removed without removing intake
manifold.
RG5865
1. Remove turbocharger, air intake and manifold
assembly as described earlier in this group.
2. Remove turbocharger oil return pipe (D).
3. Remove cap screws and lift off front exhaust manifold
(A) and rear exhaust manifold (B).
-UN-03AUG92
4. Remove and discard front-to-rear exhaust manifold
sealing ring (C).
5. Remove all residue and gasket material from gasket
surfaces.
7. Inspect each exhaust manifold for cracks or damage.
Inspect machined mounting surfaces for burrs or other
defects which might prevent gaskets from sealing
properly. Replace parts as necessary.
8. To install exhaust manifold, reverse removal procedure
and use new gaskets.
RG6338
6. Thoroughly clean passages in exhaust manifolds and
exhaust elbow.
A—Front Exhaust Manifold
B—Rear Exhaust Manifold
C—Sealing Ring
D—Turbocharger Oil Return Pipe
9. Coat exhaust manifold cap screws with PT569
NEVER-SEEZ Compound and tighten to 47 N·m (35
lb-ft) in sequence as shown.
30
31
RG,CTM42,G30,53-19-14FEB95
CTM42 (24MAR95)
30-31
6076 Diesel Engines—S.N. (500000—
)
160101
PN=276
Air Intake And Exhaust System/Remove, Inspect, and Install Exhaust Manifold
30
32
CTM42 (24MAR95)
30-32
6076 Diesel Engines—S.N. (500000—
)
160101
PN=277
Group 35
Fuel System
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
RG5099
-19-05JUN91
-UN-23AUG88
Nozzle Thread Cleaning Brush . . . . . . . . . D17030BR
Used to clean nozzle threads in cylinder head.
S53,D17030,BR -19-16FEB87
-UN-10AUG94
Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820
RG7056
Used to rotate engine to check damper radial runout and
time engine. JDE81-1 may be used also if JDG820 is
not available.
RG5068
RG,JDG820
-19-14FEB95
RG,JDE814,86
-19-14FEB95
-UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train, adjusting
valve clearance, and installing fuel injection pump. Use
with JDG820 and JDE81-1 Flywheel Turning Tools.
RG5290
Serrated Wrench
-UN-15OCT92
. . . . . . . . . . . . . . . . . . . . . JDE90
Use to hold injection pump fuel outlet fittings on Bosch
“P” pump from turning when loosening and tightening
fuel pipe connections.
S54,JDE90
-19-29OCT92
Nozzle Socket . . . . . . . . . . . . . . . . . . . . . . . JDE92
Used to remove and install 21 mm injection nozzles.
R28362N
-UN-20DEC88
35
1
S11,3010,OU
CTM42 (24MAR95)
35-1
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=278
Fuel System/Special or Essential Tools
RG5100
-UN-23AUG88
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDF5
Used to restore nozzle threads in cylinder head.
S53,JDF5
-19-08MAR94
Nozzle Cleaning Kit . . . . . . . . . . . . . JDF13 (JDE105)
RG4953
-UN-14DEC88
Used to clean injection nozzles.
S11,3010,OW
-19-09SEP91
S55,3010,BA
-19-25JUL91
S53,JDF22,1
-19-02DEC87
S53,JDF33
-19-02DEC87
S53,JDG609
-19-02DEC87
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDF15
RG2017
-UN-30NOV88
Used to install spindle seals in fuel supply pumps.
RG5288
Crowsfoot Wrench
-UN-23AUG88
. . . . . . . . . . . . . . . . . . . . JDF22
Use to loosen and tighten fuel pipes at injection nozzles
and at injection pump.
RG5287
-UN-23AUG88
Special Socket . . . . . . . . . . . . . . . . . . . . . . . JDF33
35
2
Used to loosen and tighten fast idle stop screw on
Nippondenso injection pumps when adjusting engine
speeds.
RG5289
-UN-23AUG88
Nozzle Seat Reamer . . . . . . . . . . . . . . . . . . JDG609
Used to clean carbon from nozzle seats in cylinder head.
CTM42 (24MAR95)
35-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=279
Fuel System/Special or Essential Tools
RG7212
-UN-23JUL94
Injection Pump Timing Pin . . . . . . . . . . . . . . JDG886
Used to set in-line fuel injection pump timing prior to
removal of pump.
RG,JDG886
-19-10AUG94
Injection Pump Drive Gear Puller . . . . . . . . . JDG670A
RG6032
-UN-13JAN92
Remove drive gear from tapered shaft on Stanadyne
DB4 fuel injection pumps.
RG,JDG670A,400 -19-02OCT92
A—Fuel Injection Nozzle Tester
. . . D01109AA (Y900)
B—Fuel Line Assembly . . . . . . . . . . . . . . . Y900-2A*
-UN-14DEC88
C—Adapter Nut . . . . . . . . . . . . . . . . . . . . Y900-21**
D—Straight Adapters . . . . . . . . Y900-7* and Y900-15*
RG4954
Used to test operational performance and opening
pressure of nozzles.
*Included in D01110AA (Y910A) Adapter Set.
**May be used instead of Y900-7 and Y900-15.
S11,3010,OX
-19-09SEP91
35
3
CTM42 (24MAR95)
35-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=280
Fuel System/Diesel Fuel System Specifications
OTHER MATERIAL
Name
Use
AR54749 Soap Lubricant
Injection pump mounting flange O-ring.
PT569 NEVER-SEEZ Compound
Gland nut threads and fuel injection nozzle barrel.
LOCTITE 242 (TY9370/T43512) Thread Lock
and Sealer
Injection pump timing hole plug.
LOCTITE 592 (TY9374/TY9375) Pipe Sealant
with TEFLON
Fuel filter drain plug and bleed plug.
RG,CTM42,G35,76-19-15SEP94
DIESEL FUEL SYSTEM SPECIFICATIONS
ITEM
SPECIFICATION
Engine Operating Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Applicable Machine TM
Injection Pump Timing to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDC
Hydraulic Aneroid Activator Operating Pressure (If Equipped) . . . . . . . . . . . . . . . . 100 kPa (1.0 bar) (14.5 psi)
Overflow Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . 130—180 kPa (1.3—1.8 bar) (19—26 psi)
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
New Nozzle Opening Pressure (for tip sizes)
7 x 0.22 mm, 7 x 0.23 mm, 7 x 0.255 mm . . . . . . . . . 29 000—30 200 kPa (290—302 bar) (4200—4370 psi)
Used Nozzle Minimum Opening Pressure (for tip sizes)
7 x 0.22 mm, 7 x 0.23 mm, 7 x 0.255 mm . . . . . . . . . . . . . . . . . . . . . . . . 26 200 kPa (262 bar) (3800 psi)
Injection Pump Static Timing:
In-Line Pumps (Robert Bosch/Nippondenso) . . . . . . . . . . . . Lock No. 1 cylinder at TDC compression stroke.
Align mark on injection pump drive hub with pointer mark.
Install pump, recheck alignment of marks.
35
4
Rotary Pumps (Stanadyne) . . . . . . . . . . . . . . . . . . . . . . . Lock No. 1 cylinder at TDC compression stroke.
Align marks on injection pump mounting flange
with factory (dynamic) timing mark on cylinder block.
RG,CTM42,G35,1 -19-16AUG94
CTM42 (24MAR95)
35-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=281
Fuel System/Diesel Fuel System Specifications
DIESEL FUEL SYSTEM
SPECIFICATIONS—CONTINUED
TORQUES
Injection Pump-to-Cylinder Block Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
Injection Pump Drive Gear-to-Pump Hub Cap Screws:
A-Series Injection Pumps* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
P-Series Injection Pumps* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N·m (45 lb-ft)
Injection Pump Drive Gear-to-Tapered Shaft Hex Nut:
Stanadyne DB4 Injection Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 N·m (105 lb-ft)
Injection Line Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
Nozzle Gland Nut-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N·m (65 lb-ft)
Nozzle Retaining Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60—79 N·m (44—68 lb-ft)
Supply Pump Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—7 N·m (4—5 lb-ft)(45—60 lb-in.)
Leak-off Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N·m (13 lb-ft)(150 lb-in.) Max.
Fuel Filter Base-to-Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34—54 N·m (25—40 lb-ft)
Fuel Pipe Connections at Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N·m (13 lb-ft)(150 lb-in.) Max.
Injection Pump Drive Gear Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)
Fuel Shutoff Solenoid Bracket-to-Oil Filter Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . 23 N·m (17 lb-ft)
Fuel Shutoff Solenoid-to-Bracket Hex Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N·m (5 lb-ft)(60 lb-in.)
*Refer to IDENTIFICATION OF IN-LINE INJECTION PUMPS later in
this group.
RG,CTM42,G35,98-19-17MAR95
35
5
CTM42 (24MAR95)
35-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=282
Fuel System/Replace Rectangular Fuel Filter Element
RELIEVE FUEL SYSTEM PRESSURE
-UN-23AUG88
CAUTION: Escaping diesel fuel under pressure
can have sufficient force to penetrate the skin,
causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before
applying pressure to the system, be sure ALL
connections are tight and lines, pipes and
hoses are not damaged. Keep hands and body
away from pinholes and and nozzles which
eject fluid under pressure. Use a piece of
cardboard or wood, rather than hands, to
search for suspected leaks.
X9811
N
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline,
Illinois, or other knowledgeable medical
source.
Any time the fuel system has been opened up for
service (lines disconnected or filters removed), it will be
necessary to bleed air from the system. (See BLEED
FUEL SYSTEM in Group 115.)
RG,CTM8,G35,6 -19-29SEP94
REPLACE RECTANGULAR FUEL FILTER
ELEMENT
NOTE: Refer to your operator’s manual for proper
servicing and replacement (hourly) intervals.
1. Close fuel shut-off valve at bottom of fuel tank (not
illustrated).
-UN-19AUG91
2. Loosen bleed plug (C) and remove drain plug (B).
Drain fuel from filter.
3. With fuel filter firmly against base, lift up on top
retaining spring and pull down on bottom retaining
spring. Pull fuel filter off guide pins (A) of fuel filter base
and discard.
RG5866
35
6
RG,CTM42,G35,2 -19-03OCT92
CTM42 (24MAR95)
35-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=283
Fuel System/Replace Fuel Check Valve
4. Install fuel filter onto guide pins on fuel filter base.
Hold filter firmly against base.
5. Secure bottom retaining spring first, then secure top
retaining spring.
6. Install drain plug, shown installed. Tighten bleed plug
and drain plug securely. Do not overtighten.
RG5867
-UN-19AUG91
7. Open fuel shut-off valve and bleed fuel system. (See
BLEED THE FUEL SYSTEM, in Group 115.)
RG,CTM42,G35,3 -19-03OCT92
REPLACE FUEL CHECK VALVE
IMPORTANT: Remove fuel check valve only for
replacement purposes, since O-ring
seals tightly in bore, removal usually
damages check valve assembly.
-UN-19AUG91
1. Drain and remove fuel filter (A) as described earlier in
this group.
2. Remove fuel filter inlet line (B), (shown removed).
RG5868
3. Inspect and clean fuel filter base as described later in
this group.
4. Remove check valve adapter housing (C) from fuel
filter base, and discard.
5. Install new check valve assembly and tighten
securely.
6. Install fuel inlet line and tighten connection 17 N·m
(13 lb-ft)(150 in-lb) maximum. DO NOT overtighten.
35
7
7. Install fuel filter and bleed fuel system. (See BLEED
THE FUEL SYSTEM, in Group 115.)
RG,CTM42,G35,4 -19-17MAR95
CTM42 (24MAR95)
35-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=284
Fuel System/Remove Round Fuel Filter Element
REPLACE ROUND FUEL FILTER ELEMENT
1. Thoroughly clean exterior of filter element (C) and
base (A). Also clean around filter mounting area on
block.
2. Rotate retaining ring (D) counterclockwise (left) 1/4
turn. Lifting ring as it is rotated helps to get it past
retaining detent. Ring should now drop down and release
filter from base.
-UN-15OCT92
NOTE: Notice indexing keys (F) on filter element. These
keys insure proper alignment of filter element to
filter base.
4. Install retaining ring to filter base, making certain dust
seal (B) is in place on filter base. Tighten retaining ring
until it locks into detent position.
5. Loosen bleed screw (E) and bleed fuel system. (See
BLEED THE FUEL SYSTEM, in Group 115.)
RG6445
3. Index filter element until longer, vertical keys are
oriented away from engine. Insert filter element into base
securely. It may be necessary to rotate filter slightly to
left or right for correct alignment.
A—Filter Element Base
B—Dust Seal
C—Filter Element
D—Retaining Ring
E—Bleed Screw
F—Indexing Keys
RG,CTM42,G35,91-19-28OCT92
35
8
CTM42 (24MAR95)
35-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=285
Fuel System/Identification of fuel supply and fuel injection pumps
-UN-23APR94
IDENTIFICATION OF MECHANICAL FUEL
SUPPLY PUMPS
RG2170
NOTE: 6076TRW31 engines are epuipped with
Stanadyne DB4 rotary-style injection pump which
uses an electric fuel supply pump, all other 6076
engines are equipped with an in-line injection
pump (Bosch or Nippondenso) and mechanical
supply pump.
Mechanical fuel supply pumps mount onto the side of
the in-line injection pump. A tappet on the supply pump
is activated by the injection pump rotating cam during
engine revolution. The tappet on the supply pump may
be either a roller-type tappet (Nippondenso) or a flat
plunger-type tappet (Bosch). The type of tappet can be
determined visually, when the fuel supply pump is
removed, or by the “size of injection pump” indicator in
the pump model number.
FUEL SUPPLY PUMP IDENTIFICATION NUMBER
FP/KE22AD290
FP . . . . . . . .
/K . . . . . . .
E ......
22 . . . . .
A ....
D ...
290
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. . . . . . . . . Fuel Supply Pump
. . Single-Acting Plunger Pump
Pump Driven by Eccentric Cam
. . . Diameter of Plunger in mm
. . Size of Injection Pump Used
. . . . . . . . . . . . Pump Version
Manufacturer’s Design Number
RG,CTM42,G35,92-19-17MAR95
35
9
CTM42 (24MAR95)
35-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=286
Fuel System/Remove Mechanical Fuel Supply Pump
REMOVE MECHANICAL FUEL SUPPLY
PUMP
-UN-19AUG91
NOTE: To diagnose mechanical fuel supply pump
malfunctions or test for leaks, refer to Group 115.
RG5893
Thoroughly clean exterior of supply pump. Also clean
around supply pump mounting area on injection pump
housing.
1. Disconnect fuel inlet line (A), shown disconnected,
and outlet line (B). Cap all line openings so
contaminants do not enter fuel system.
2. Remove three mounting nuts (C).
3. Pull fuel supply pump straight out from injection pump
housing. Cover supply pump mounting bore so debris
cannot enter injection pump.
RG,CTM42,G35,8 -19-03OCT92
35
10
CTM42 (24MAR95)
35-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=287
Fuel System/Test Mechanical Fuel Supply Pump for Leaks
TEST MECHANICAL FUEL SUPPLY PUMP
FOR LEAKS
Fuel delivery pressure should be checked before
removing supply pump from injection pump. (See
CHECK MECHANICAL FUEL SUPPLY PUMP
OPERATION, in Group 115.)
1. Connect compressed air line (A) to a pressure gauge
(B) and to supply pump inlet fitting. Air line should have
a regulating valve to control pressure.
-UN-19AUG91
2. Cap or plug supply pump outlet fitting (C).
3. Submerge supply pump in a container of clean diesel
fuel. Regulate air pressure to 200 kPa (2.0 bar) (29 psi).
RG5894
4. Move roller tappet (Nippondenso pumps) or spindle
(Bosch pumps) in and out by hand. No air bubbles
should appear around roller tappet or spindle bore.
NOTE: If bubbles appear, it is an indication that either
the O-ring seal is defective or spindle or tappet is
worn (or possibly both).
IMPORTANT: Serious injection pump or engine
damage could occur, if enough diesel
fuel leaks past spindle and seal. Fuel
leakage past spindle dilutes engine oil.
RG,CTM42,G35,9 -19-28OCT92
35
11
CTM42 (24MAR95)
35-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=288
Fuel System/Disassemble Mechanical Fuel Supply Pump (Nippondenso)
RG5901
-UN-19AUG91
DISASSEMBLE MECHANICAL (ROLLER TAPPET) FUEL SUPPLY PUMP—NIPPONDENSO
1—Hand Primer
2—Washer (4 used)
3—Spring (2 used)
4—Valve
5—O-Ring (2 used)
6—Elbow Fitting (2 used)
7—Plug
8—Washer
9—Spring
10—O-Ring/Spindle Seal
11—Roller Tappet Assembly
12—Snap Ring
13—Plug
14—Pump Housing
15—Pressure Spindle
16—Plunger
17—Banjo fitting
1. Remove elbow fitting (6) by loosening locknut and
unscrewing elbow fitting from pump housing. Remove
and discard O-ring (5).
RG,CTM42,G35,10-19-14FEB95
2. Remove hand primer (A), banjo fitting (B), and plug
(C) from housing. Discard copper washer.
-UN-28AUG91
3. Remove plug (D) from housing. Discard copper
washers.
A—Hand Primer
B—Banjo Fitting
C—Plug
D—Plug
RG5945
35
12
RG,CTM42,G35,61-19-02NOV92
CTM42 (24MAR95)
35-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=289
Fuel System/Disassemble Mechanical Fuel Supply Pump (Nippondenso)
RG2323
-UN-30NOV88
4. Remove valves (A) and springs (B).
RG,CTM42,G35,62-19-10SEP91
5. Remove plug (A), spring (B) and plunger (C) from
pump housing. Discard copper washer.
-UN-20DEC88
6. Remove snap ring (D) from outer circumference of
pump housing neck.
RG2318
NOTE: Snap ring has a tang on one end which extends
vertically down through a hole in pump housing
to retain roller tappet assembly.
A—Plug
B—Spring
C—Plunger
D—Snap Ring
S55,3010,Y
-19-03OCT92
RG4028
-UN-30NOV88
7. Remove roller tappet (A) and spindle (B) from pump
housing. Remove and discard O-ring on spindle.
S55,3010,Z
CTM42 (24MAR95)
35-13
35
13
-19-03OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=290
Fuel System/Inspect and Repair Mechanical Fuel Supply Pump (Nippondenso)
-UN-30NOV88
NOTE: Spindle/seal O-ring (B) is pressed into pump
housing. This seal keeps diesel fuel from leaking
past spindle (A) and entering injection pump
crankcase.
RG4029
8. Remove spindle seal from housing using needle nose
pliers. Discard seal.
S55,3010,AA
-19-03OCT92
INSPECT AND REPAIR MECHANICAL
(ROLLER TAPPET) FUEL SUPPLY PUMP
COMPONENTS—NIPPONDENSO
-UN-19AUG91
1. Inspect supply pump housing for cracks and wear. Be
sure valve seating areas are not pitted. Replace housing
as necessary.
RG5902
2. Check roller tappet and plunger bore for wear and
scoring. Remove any deposits in housing with a suitable
solvent. Rinse housing in clean diesel fuel.
3. Check condition of threads for inlet and outlet fittings.
Pump elbow fittings have 1/2-20 threads.
RG,CTM42,G35,11-19-14FEB95
-UN-30NOV88
4. Inspect roller (A) OD for excessive wear. Be sure
roller turns freely on pin (B) and in tappet (C).
RG2321
5. Inspect sliding blocks (D). Edges should be square
and unpitted. Blocks should slide in and out of tappet
easily.
6. Inspect tappet for wear and scoring. Remove any
deposits with a suitable solvent.
35
14
Be sure land on tappet that contacts pressure spindle is
flat and undamaged.
A—Roller
B—Pin
C—Tappet
D—Sliding Block (2 used)
S11,3010,QN
CTM42 (24MAR95)
35-14
-19-24NOV86
6076 Diesel Engines—S.N. (500000—
)
160101
PN=291
Fuel System/Assemble Mechanical Fuel Supply Pump (Nippondenso)
-UN-30NOV88
7. Inspect pressure spindle (A) and plunger (B) for pits
and burrs. Replace parts as necessary.
RG2322
8. Inspect spring (C) for cracks and distortion. Replace
parts as necessary.
S11,32010,QO
-19-24NOV86
S11,3010,QP
-19-24NOV86
-UN-30NOV88
9. Inspect valves (A), especially valve face, for cracks,
pits and wear. Replace as necessary.
RG2323
10. Spring (B) should not be bent or broken.
ASSEMBLE MECHANICAL (ROLLER
TAPPET) FUEL SUPPLY
PUMP—NIPPONDENSO
-UN-30NOV88
IMPORTANT: Always use new copper gaskets. Dip
parts in clean diesel fuel before
assembly. Hands should be wet with
diesel fuel when assembling internal
components of fuel supply pump.
RG2013
1. Install new spindle seal (C) into pump housing (B)
using JDF15 Driver (A). Be sure seal is started straight
in housing bore and drive until driver contacts housing.
2. To assemble supply pump, reverse disassembly
procedure using new O-rings.
35
15
Perform leak test described in Group 115.
RG,CTM42,G35,12-19-14FEB95
CTM42 (24MAR95)
35-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=292
Fuel System/Disassemble Mechanical Fuel Supply Pump (Robert Bosch)
DISASSEMBLE MECHANICAL (FLAT
PLUNGER) FUEL SUPPLY PUMP—ROBERT
BOSCH
1. Remove inlet elbow fitting (A) and outlet elbow fitting
(B) by loosening locknut and unscrewing fittings from
pump housing. Remove and discard O-rings.
2. Remove hand primer (C) from housing. Remove and
discard copper washer (D).
RG5909
-UN-19AUG91
A—Inlet Elbow Fitting
B—Outlet Elbow Fitting
C—Hand Primer Pump
D—Copper Washer
RG,CTM42,G35,63-19-14FEB95
3. Remove fuel pump outlet valve fitting (A) from pump
housing (C). Remove and discard O-ring (B).
-UN-28AUG91
4. Remove spindle (I) and spindle guide plug (H) by
unscrewing guide plug from pump housing. Remove and
discard O-rings (J and G).
35
16
RG5912
5. Remove plunger (F), spring wear plates (D), and
spring (E).
A—Outlet Valve Fitting
B—O-Ring
C—Supply Pump Housing
D—Spring Wear Plates
E—Spring
F—Plunger Assembly
G—O-Ring
H—Spindle Guide Plug
I—Spindle
J—O-Ring
RG,CTM42,G35,64-19-28OCT92
CTM42 (24MAR95)
35-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=293
Fuel System/Inspect and Repair Mechanical Fuel Supply Pump (Robert Bosch)
6. Push inlet valve (B) and seal (C) out of plunger (A) by
poking rounded end of a small pin through closed end of
plunger.
-UN-28AUG91
NOTE: The outlet valve is located in outlet valve fitting
(D) and is not removable from fitting.
RG5913
A—Plunger
B—Inlet Valve Seal
C—Inlet Valve
D—Outlet Valve and Fitting
RG,CTM42,G35,65-19-03OCT92
INSPECT AND REPAIR MECHANICAL (FLAT
PLUNGER) FUEL SUPPLY PUMP—ROBERT
BOSCH
-UN-28AUG91
1. Inspect supply pump housing (C) for cracks and wear.
Be sure plunger bore is not worn or scored. Check
condition of threads for inlet and outlet fittings, hand
primer pump, and spindle guide plug (H).
3. Inspect plunger (F) for burrs and pits. Remove any
deposits with a suitable solvent.
4. Inspect spring (E) and wear plates (D) for cracks,
distortion, and wear.
5. Inspect inlet valve and seal (not shown) for wear,
cracks, and broken or missing spring.
RG5912
2. Inspect spindle (I) for wear, scoring on OD, and burrs.
Check lands that contact plunger and fuel pump cam
lobe to be sure they are flat and undamaged. Remove
any deposits with a suitable solvent.
A—Outlet Valve Fitting
B—O-Ring
C—Supply Pump Housing
D—Spring Wear Plates
E—Spring
F—Plunger Assembly
G—O-Ring
H—Spindle Guide Plug
I—Spindle
J—O-Ring
6. Inspect outlet valve and fitting (A) for wear, cracks,
broken or missing spring, or damaged threads.
If any of the above parts are damaged, worn, or
defective, replace as necessary.
35
17
RG,CTM42,G35,66-19-14FEB95
CTM42 (24MAR95)
35-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=294
Fuel System/Install Mechanical Fuel Supply Pump
1. Assemble seal (B) into plunger (C) so flat side of seal
is against closed end of plunger. Install inlet valve (A)
into plunger so spring side of valve protrudes through
center of seal and faces toward closed end of plunger.
RG5946
IMPORTANT: Always use new copper gaskets and
O-rings. Dip parts in clean diesel fuel
before assembly. Hands should be wet
with diesel fuel when assembling
internal components of fuel supply
pump.
-UN-28AUG91
ASSEMBLE MECHANICAL (FLAT PLUNGER)
FUEL SUPPLY PUMP—ROBERT BOSCH
2. To assemble supply pump, reverse disassembly
procedure using new O-rings and copper washer.
Perform leak test described in Group 115.
RG,CTM42,G35,67-19-14FEB95
INSTALL MECHANICAL FUEL SUPPLY
PUMP
-UN-19AUG91
IMPORTANT: Before installing supply pump, test
pump to make sure fuel will not leak
around spindle and spindle seal. (See
TEST MECHANICAL FUEL SUPPLY
PUMP FOR LEAKS, in Group 115.)
RG5906
1. On Nippondenso (roller tappet) pumps, put a new
O-ring in counterbore of injection pump housing next to
fuel supply pump mounting face.
On Robert Bosch pumps, install a new gasket on supply
pump mounting face (A).
Bosch pump shown
35
18
2. Position pump over mounting studs. Tighten mounting
stud nuts 5—7 N·m (4—5 lb-ft) (45—60 lb-in.).
3. Install fuel inlet and outlet lines when engine is
installed in vehicle. Tighten all connections securely.
4. Bleed fuel system. (See BLEED THE FUEL SYSTEM,
in Group 115.)
RG,CTM42,G35,14-19-14FEB95
CTM42 (24MAR95)
35-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=295
Fuel System/Remove and Install Electric Fuel Supply Pump
REMOVE AND INSTALL ELECTRIC FUEL
SUPPLY PUMP—6076TRW31 ENGINES
NOTE: Refer to Group 115 for operation and test of
electric fuel supply pump.
1. Thoroughly clean exterior of supply pump and
mounting area on block.
-UN-26OCT92
2. Disconnect fuel inlet line (A) and outlet line (B). Cap
all line openings.
3. Disconnect wiring harness (C) at connector.
4. Remove mounting bracket (D).
RG6460
5. Remove pump from mounting bracket.
6. To install pump, reverse disassembly procedure.
Tighten mounting bracket cap screws to 8.5 N·m (6 lb-ft)
(75 lb-in.).
7. Check for leaks during engine operation.
A—Fuel Inlet Line
B—Fuel Outlet Line
C—Wiring Harness
D—Mounting Bracket
RG,CTM42,G35,81-19-17MAR95
35
19
CTM42 (24MAR95)
35-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=296
Fuel System/Clean or Replace Electric Fuel Supply Pump Filter Screen
CLEAN OR REPLACE ELECTRIC FUEL
SUPPLY PUMP FILTER
SCREEN—6076TRW31 ENGINES
Electric supply pump filter screen element (B) should be
cleaned frequently under normal engine operating
conditions. If output flow or pressure is below
specifications, it may be result of a partially obstructed
filter screen. Refer to operator’s manual for
recommended hourly maintenance interval.
1. Remove cap screws from cover plate (D). Remove
cover and gasket (C) from pump (A).
2. With clean hands, remove filter screen from pump.
-UN-13OCT92
IMPORTANT: Do not clean or touch screen or inside
of pump with cotton cloth. The smallest
piece of lint may cause fuel system
contamination.
RG6452
3. Using compressed air, clean by blowing air through
filter from inside to outside. If screen is damaged, either
by holes or sealing surfaces, it must be replaced.
4. Install screen with flange end of screen against filter
plate gasket.
5. Install cover plate.
A—Electric Fuel Supply Pump
B—Filter Screen Element
C—Gasket
D—Cover Plate
RG,CTM42,G35,82-19-17MAR95
35
20
CTM42 (24MAR95)
35-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=297
Fuel System/Remove Hydraulic Aneroid Activator
REPAIR ANEROID—IF EQUIPPED
For aneroid repair and adjustment, have an authorized
diesel repair station perform the work.
The aneroid controls fuel delivery when intake manifold
pressure is about 100 kPa (1.00 bar) (15 psi) or less.
Therefore, all final adjustments are to be made on the
test stand with aneroid mounted on injection pump.
IMPORTANT: Correct aneroid adjustments are
essential for satisfactory engine
performance. Whenever aneroid has
been disassembled or adjustments
have been altered, injection pump
(including aneroid) must be calibrated
on test stand before releasing pump for
service.
S11,3010,PG
-19-14FEB95
REMOVE HYDRAULIC ANEROID
ACTIVATOR—IF EQUIPPED
-UN-20DEC88
NOTE: The hydraulic aneroid activator is located on back
side of governor housing next to cylinder block.
1. Remove injection pump as described later in this
group.
3. Remove spring (D), restricter wire (E) and capillary
valve (F) from activator housing (G). Remove activator
housing.
NOTE: Do not bend restricter wire or other activator
parts.
RG3546
2. Remove special screw (A), copper washers (B) and
banjo connector (C). Discard copper washers.
A—Special Screw
B—Copper Washer (2 used)
C—Banjo Connector
D—Spring
E—Restricter Wire
F—Capillary Valve
G—Activator Housing
35
21
RG,CTM42,G35,70-19-14FEB95
CTM42 (24MAR95)
35-21
6076 Diesel Engines—S.N. (500000—
)
160101
PN=298
Fuel System/Service Injection Pump Overflow Valve
DISASSEMBLE AND CLEAN HYDRAULIC
ANEROID ACTIVATOR PARTS—IF
EQUIPPED
1. Remove gasket (G), piston (F) and piston spring (E).
-UN-20DEC88
2. Wash all parts in clean solvent and dry with
compressed air. Blow out all openings to make sure they
are open.
RG3547
3. Check piston (F) and activator housing (H) for general
condition. Piston must move freely in its bore.
4. Inspect piston spring (E) and capillary valve spring (L).
Replace if weak or broken.
5. Inspect condition of restricter wire (K). Wire must not
be bent or broken and must fit loosely in capillary valve
(J).
6. Check condition of return spring (B), washer (C) and
retaining ring (D) on starting fuel control shaft (A).
Replace spring if weak or broken. Be sure retaining ring
is secure on shaft.
A—Starting Fuel Control
Shaft
B—Return Spring
C—Washer
D—Retaining Ring
E—Piston Spring
F—Piston
G—Gasket
H—Activator Housing
I—Mounting Screw (2
used)
J—Capillary Valve
K—Restricter Wire
L—Capillary Valve
Spring
M—Washers
N—Special Screw
RG,CTM42,G35,71-19-14FEB95
ASSEMBLE AND INSTALL HYDRAULIC
ANEROID ACTIVATOR—IF EQUIPPED
NOTE: Refer to previous illustration.
1. To assemble and install activator, reverse disassembly
procedure using new gaskets.
RG,CTM42,G35,83-19-14FEB95
SERVICE INJECTION PUMP OVERFLOW
VALVE
-UN-19AUG91
NOTE: Overflow valve can be serviced with injection
pump installed.
1. Remove leak-off line (A) and remove elbow (B).
2. Remove valve assembly (C) from pump.
RG5872
35
22
RG,CTM42,G35,16-19-28OCT92
CTM42 (24MAR95)
35-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=299
Fuel System/Service Injection Pump Overflow Valve
3. Remove reducer (A) and copper washer (B) from
valve body (C). Discard copper washer.
-UN-20DEC88
4. Unscrew spring seat (D); then remove spring (E) and
valve (F).
5. Inspect for foreign material imbedded in seat of nylon
valve.
RG3549
6. Check spring to see that it is not weak or broken.
7. Wash all parts in solvent and air dry.
NOTE: There is no adjustment on valve to regulate
housing pressure. If suspected that valve is
malfunctioning replace valve to restore proper
operation.
8. Reverse order of removal for reassembly of overflow
valve. Install new copper washers.
A—Reducer
B—Washer
C—Valve Body
D—Spring Seat
E—Spring
F—Valve
G—Washer
RG,CTM42,G35,72-19-03OCT92
35
23
CTM42 (24MAR95)
35-23
6076 Diesel Engines—S.N. (500000—
)
160101
PN=300
Fuel System/Remove and Install Fuel Shutoff Solenoid
RG5968
-UN-11SEP91
REMOVE AND INSTALL FUEL SHUTOFF SOLENOID
A—Wiring Connector
B—Fuel Shutoff Solenoid
C—Solenoid Shaft
D—Cotter Pin
E—Washer
F—Fuel Shutoff Lever
1. Disconnect electrical wiring connector (A) in
solenoid lead.
2. Remove cotter pin (D), washer (E), and pull
solenoid shaft (C) out of fuel shutoff lever (F).
3. Remove fuel shutoff solenoid (B) from solenoid
mounting bracket (J) by removing hex nuts (H), lock
washers, and machine screws (G).
4. If solenoid mounting bracket is to be removed,
remove cap screws (I) and lock washers that fasten
the bracket to oil filter housing.
G—Lock Washer and Screws
H—Hex Nuts
I—Cap Screws
J—Solenoid Mounting
Bracket
IMPORTANT: Fuel shutoff solenoid linkage should
move freely back and forth. On “A”
pumps if linkage is binding, check
pump for proper alignment. (See
INSTALL IN-LINE “A” AND “P” FUEL
INJECTION PUMPS, later in this
group.)
NOTE: Electric fuel shutoff solenoids are factory
adjusted to a specified length and should not
require additional adjustment. See machine
technical manual for fuel shutoff solenoid
diagnostics.
5. To install fuel shutoff solenoid, reverse removal
procedure. Tighten cap screws (I) to 23 N·m (17 lb-ft)
and hex nuts (H) to 7 N·m (5 lb-ft).
35
24
RG,CTM42,G35,77-19-16AUG94
CTM42 (24MAR95)
35-24
6076 Diesel Engines—S.N. (500000—
)
160101
PN=301
Fuel System/Identification of In-Line Injection Pumps
IDENTIFICATION OF IN-LINE FUEL
INJECTION PUMPS
-UN-25APR94
The in-line fuel injection pumps used on 6076 engines
are either A-Series or P-Series pumps. The type of
pump is easily determined by the “Size of Pump”
indicator in the model number on the pump identification
plate.
RG2432
FUEL INJECTION PUMP IDENTIFICATION NUMBERS
A—922 14019
000 00000 . . . . . . . . . . . . . . . . . . . . . . . Pump Serial Number
Fuel Pump Identification Plate
B—PESP6P110A720RS1009
PESP . . . . . . .
6 ......
P .....
110 . .
A ..
000
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. . . Injection Pump With Housing Flange
. . . . . . . . . . . . . . Number of Plungers
. . . . . . . . . . . . . . . . . . Size of Pump
Plunger Diameter in mm (110 is 11 mm)
. . . . Letter Designating Design Change
. Three Numbers Denoting an Assembly
. . . . . . . . . . . . . . Right-Hand Rotation
(Viewed From Drive End)
S . . . . . . . . . . . . . . . . . . . . Production Pump
0000 . . . . . . . . . Pump Identification Number
C—0 402 076 030
0 000 000 000 . . . . . . . . . . . . . . . . . . . . . Bosch Part Number
RG,CTM42,G35,99-19-14FEB95
35
25
CTM42 (24MAR95)
35-25
6076 Diesel Engines—S.N. (500000—
)
160101
PN=302
Fuel System/Remove In-Line Fuel Injection Pump
REMOVE IN-LINE FUEL INJECTION PUMP
-UN-19AUG91
IMPORTANT: Never steam clean or pour cold water
on an injection pump while pump is
running, or while it is still warm. To do
so may cause seizure of pump parts.
RG5873
1. Clean injection lines and area around the injection
pump with cleaning solvent or a steam cleaner.
NOTE: Follow same removal procedure for injection
pumps equipped with mechanical governor and
electronic governor. Differences will be noted.
2. Remove timing hole plug (A, shown removed).
3. Rotate engine flywheel (in normal running direction)
until No. 1 piston is at “TDC” of its compression stroke.
At this point, JDE81-4 Timing Pin should enter hole in
flywheel.
4. Timing marks on injection pump drive hub (B) and
timing pointer (C) should be in alignment.
RG,CTM42,G35,73-19-28OCT92
35
26
CTM42 (24MAR95)
35-26
6076 Diesel Engines—S.N. (500000—
)
160101
PN=303
Fuel System/Remove In-Line Fuel Injection Pump
NOTE: Remove alternator at this time if not previously
removed.
-UN-07FEB95
5. Remove injection pump drive gear cover (shown
removed), remove and discard all gasket material.
NOTE: In some situations JDG886 Injection Pump
Timing Pin cannot be installed.
RG7283
6. Install JDG886 Injection Pump Timing Pin through
injection pump drive gear into injection pump hub until it
bottoms. In some instances it may be necessary to
rotate the pump drive hub slightly to get the pin installed.
7. Remove injection pump drive gear cap screws.
-UN-19AUG91
8. Disconnect injection pump lube line (B) from cylinder
block fitting. Remove oil filter (C).
RG5875
9. On standard governor pumps, remove fuel shutoff
solenoid (not shown) from oil filter housing. (See
REMOVE AND INSTALL FUEL SHUTOFF SOLENOID,
earlier in this group.)
10. Remove fuel inlet line (D). Remove fuel leak-off line
(E).
11. Disconnect fuel supply pump lines (F). Photo shows
only one line.
12. Disconnect aneroid line (G), if equipped.
A—JDG886 Injection Pump Timing Pin
B—Injection Pump Lube Line
C—Oil Filter
D—Fuel Inlet Line
E—Leak-Off Line
F—Fuel Supply Pump Lines
G—Aneroid Line
RG,CTM42,G35,18-19-14FEB95
NOTE: For injection pumps equipped with electronic
governors (A), disconnect wiring harness at
governor and shut-off solenoid (B). Protect
connectors on wiring harness while pump is
disconnected so debris does not enter connector
ends.
RG5876
-UN-19AUG91
35
27
RG,CTM42,G35,19-19-10SEP91
CTM42 (24MAR95)
35-27
6076 Diesel Engines—S.N. (500000—
)
160101
PN=304
Fuel System/Remove In-Line Fuel Injection Pump
13. Remove fuel injection line nuts (A).
-UN-19AUG91
On Robert Bosch “P” injection pumps use JDE90
Serrated Wrench (B) with either JDF22 Crowsfoot
Wrench (C) or a standard 3/4 in. Line Wrench (D).
RG5877
On Nippondenso “P” injection pumps, use a 22 mm
Open End Wrench with either the 3/4 in. line wrench or
Crowsfoot Wrench mentioned above.
-UN-19AUG91
IMPORTANT: JDE-90 Serrated Wrench (Robert
Bosch) and 22 mm Open End Wrench
(Nippondenso) must be used to keep
delivery valve fittings stationary while
loosening line nuts. If a delivery valve
and barrel housing rotates while
loosening or tightening a fuel line nut,
injection pump delivery will be altered.
The pump will have to be recalibrated
on a test stand.
RG5878
14. Remove four mounting stud nuts which secure
injection pump to cylinder block.
15. Carefully remove injection pump and place it on a
clean flat surface.
A—Fuel Injection Line Nuts
B—JDE-90 Serrated Wrench
C—JDF-22 Crowsfoot Wrench
D—3/4 in. Line Wrench
RG,CTM42,G35,20-19-14FEB95
35
28
CTM42 (24MAR95)
35-28
6076 Diesel Engines—S.N. (500000—
)
160101
PN=305
Fuel System/Install In-Line Fuel Injection Pump
INSTALL IN-LINE FUEL INJECTION PUMP
-UN-09AUG91
1. If engine was rotated after injection pump was
removed, rotate flywheel until timing pin enters flywheel
at No. 1 cylinder’s “TDC” compression stroke.
RG5791
NOTE: When No. 1 cylinder is at “TDC” compression
stroke, intake and exhaust valves for No. 1
cylinder will be closed and both rocker arms will
be loose.
2. On standard governor pumps, install fuel shutoff
solenoid. (See REMOVE AND INSTALL FUEL SHUTOFF
SOLENOID, earlier in this group.)
RG,CTM42,G35,47-19-28OCT92
35
29
CTM42 (24MAR95)
35-29
6076 Diesel Engines—S.N. (500000—
)
160101
PN=306
Fuel System/Install In-Line Fuel Injection Pump
3. Rotate injection pump drive hub until marks on drive
hub (B) and pointer (A) are aligned.
-UN-07SEP94
NOTE: It may be necessary to rotate pump hub slightly
to allow JDG886 Timing Pin (E) to enter bearing
plate.
RG7741
4. Thread JDG886 Timing Pin into drive hub as shown,
and tighten until it bottoms against bearing plate (D).
5. Install a new O-ring (C) on bearing plate. Lightly
lubricate O-ring with AR54749 Soap Lubricant to aid in
pump installation and prevent O-ring damage.
IMPORTANT: “A” Series injection pumps must be
installed straight (upright) on the
engine to assure correct alignment of
fuel shutoff solenoid linkage.
Misaligned linkage will bind and not
allow shutoff solenoid to operate
properly, if pump is incorrectly
installed. Pump is correctly aligned if
linkage can be moved freely back and
forth.
A—Pointer
B—Drive Hub
C—O-Ring
D—Bearing Plate
E—JDG886 Timing Pin
6. Install injection pump using moderate forward pressure
and slight rocking motion to work O-ring into mounting
bore. Injection pump flange should seat solidly against
cylinder block.
7. Install mounting stud nuts and tighten to 47 N·m (35
lb-ft).
RG,CTM42,G35,74-19-14FEB95
35
30
CTM42 (24MAR95)
35-30
6076 Diesel Engines—S.N. (500000—
)
160101
PN=307
Fuel System/Install In-Line Fuel Injection Pump
-UN-07FEB95
8. Place injection pump drive gear in timing gear housing
(if previously removed) with chamfered side of gear
toward injection pump. Chamfer is at outer edge of bore
for easier installation of gear to pump drive hub.
RG7283
9. Carefully install drive gear on pump drive hub, position
gear so mounting cap screws are approximately centered
in mounting slots. This will allow for minor adjustment of
pump timing, should the need arise.
10. Install drive gear-to-pump hub cap screws (C) and
tighten to:
—47 N·m (35 lb-ft) on “A” pumps
—61 N·m (45 lb-ft) on “P” pumps
11. Remove JDG886 Timing Pin (A) from injection pump
hub. Install timing hole plug using LOCTITE 242
(TY9370) Thread Lock and Sealant, tighten plug
securely.
12. Install injection pump drive gear cover using a new
gasket, tighten cap screws to 27 N·m (20 lb-ft).
RG,CTM42,G35,21-19-14FEB95
NOTE: Remove protective caps and plugs that were
installed on fuel system components during
injection pump removal.
-UN-19AUG91
13. Connect fuel delivery lines using JDE90 Serrated
Wrench (B) and JDF22 Crowsfoot Wrench (C). Tighten
line nuts (A) to 27 N·m (20 lb-ft).
RG5877
IMPORTANT: DO NOT move delivery valve fittings
while tightening line nuts. If delivery
valve and barrel housing rotates while
tightening a fuel line nut, injection
pump fuel delivery will be altered. The
injection pump will have to be
recalibrated on a test stand by an
authorized diesel repair station.
35
31
RG,CTM42,G35,23-19-03OCT92
CTM42 (24MAR95)
35-31
6076 Diesel Engines—S.N. (500000—
)
160101
PN=308
Fuel System/Install In-Line Fuel Injection Pump
RG5876
-UN-19AUG91
14. On injection pumps equipped with electronic
governors (A), connect wiring harness at governor and
shut-off solenoid (B). Tighten connections securely.
RG,CTM42,G35,24-19-02OCT92
15. Connect aneroid line (G), if equipped.
16. Connect fuel supply pump lines (F).
-UN-19AUG91
17. Connect fuel inlet line (D) and leak-off line (E).
18. Install oil filter (C).
RG5875
19. Connect injection pump oil line (B) to cylinder block
fitting.
20. Tighten all connections securely.
B—Injection Pump Oil Line
C—Oil Filter
D—Fuel Inlet Line
E—Fuel Leak-Off Line
F—Supply Pump Lines
G—Aneroid Line
RG,CTM42,G35,25-19-24MAR95
-UN-20DEC88
IMPORTANT: Oil fill locations may vary by injection
pump applications. Familiarize yourself
with the location on your engine before
adding oil to pump.
21. Remove oil fill plug (arrow) and add enough clean
engine oil until oil comes out fill hole. Engine should be
level when checking oil level.
22. Bleed fuel system. (See BLEED THE FUEL
SYSTEM, in Group 115.)
RG2636
35
32
23. Connect throttle levers and adjust engine speeds as
required. (See ADJUST ENGINE SPEEDS, in Group
115.)
RG,CTM42,G35,80-19-03OCT92
CTM42 (24MAR95)
35-32
6076 Diesel Engines—S.N. (500000—
)
160101
PN=309
Fuel System/Remove Rotary Fuel Injection Pump—Stanadyne DB4
REMOVE ROTARY FUEL INJECTION
PUMP—STANADYNE DB4
-UN-22OCT92
IMPORTANT: Never steam clean or pour cold water
on an injection pump while pump is
running, or while it is still warm. To do
so may cause seizure of pump parts.
1. Clean injection lines and area around injection pump
with cleaning solvent or a steam cleaner to keep debris
out of fuel system.
RG6456
2. Remove injection pump timing gear cover (shown
removed).
3. Rotate engine flywheel (in normal running direction)
until No. 1 piston is at “TDC” of its compression stroke,
and JDE81-4 Timing Pin enters hole in flywheel. “V”
marks on injection pump drive gear (A) and drive gear
access opening (B) MUST align.
If marks do not align, remove timing pin and rotate
engine one full revolution until timing pin enters hole in
flywheel again. “V” timing marks should now align.
RG,CTM42,G35,84-19-28OCT92
4. Disconnect shut-off cable and speed control rod.
5. Disconnect fuel leak-off line (A).
6. Disconnect fuel supply line (B).
RG6461
-UN-26OCT92
7. Disconnect fuel delivery (pressure) lines (C), using a
suitable 17 mm deep-well crowsfoot socket.
RG,CTM42,G35,85-19-28OCT92
CTM42 (24MAR95)
35-33
6076 Diesel Engines—S.N. (500000—
)
160101
PN=310
35
33
Fuel System/Install Rotary Fuel Injection Pump—Stanadyne DB4
8. Remove hex nut (A) and washer securing pump drive
gear to pump shaft. Be careful not to drop nut or washer
inside engine.
-UN-26OCT92
9. Attach JDG670A Injection Pump Drive Gear Puller (B)
to injection pump gear and shaft.
RG6462
10. Loosen three pump mounting nuts several turns to
permit separation of pump shaft and drive gear.
IMPORTANT: Pump may fall to floor if mounting nuts
are removed from threaded studs prior
to shaft/gear separation.
11. Tighten large hex head cap screw clockwise until
pump shaft is loosened from tapered bore of drive gear.
12. Remove three mounting hex nuts and withdraw
pump from mounting studs.
RG6463
-UN-26OCT92
13. Remove JDG670A Gear Puller from drive gear. Plug
or cap all openings on pump.
RG,CTM42,G35,86-19-28OCT92
INSTALL ROTARY FUEL INJECTION
PUMP—STANADYNE DB4
NOTE: When No. 1 cylinder is at “TDC” compression
stroke, intake and exhaust valves for No. 1
cylinder will be closed and both rocker arms will
be loose. Insure that gear backlash is taken out
of system by smoothly rotating flywheel until
timing pin engages.
RG5791
35
34
-UN-09AUG91
1. If engine was rotated after injection pump was
removed, rotate flywheel until timing pin enters flywheel
at No. 1 cylinder’s “TDC” compression stroke.
RG,CTM42,G35,87-19-28OCT92
CTM42 (24MAR95)
35-34
6076 Diesel Engines—S.N. (500000—
)
160101
PN=311
Fuel System/Install Rotary Fuel Injection Pump—Stanadyne DB4
2. Position injection pump drive gear in timing gear cover
so “V” mark (A) on gear aligns with “V” mark (B) on
drive gear access opening.
RG6464
-UN-26OCT92
3. Lubricate injection pump mounting flange O-ring with
AR54749 Soap Lubricant before installing pump on
engine.
RG,CTM42,G35,88-19-16AUG94
Make sure index pin is installed in pump shaft. Replace
pump drive shaft and/or pin as necessary.
IMPORTANT: DO NOT drop shaft nut or washer into
timing gear area while installing
injection pump.
-UN-26OCT92
4. Install injection pump onto cylinder block mounting
studs until pump flange is square to cylinder block.
Retain shaft in gear with nut and washer. Install stud
nuts with washers and finger tighten.
• Injection Pump Timing:
RG6463
NOTE: DO NOT use window on side of injection pump
to time DB4 pumps; there are no internal timing
marks.
5. Index injection pump so timing marks (A) on pump
flange and cylinder block face align.
6. Tighten injection pump mounting nuts to 47 N·m (35
lb-ft).
RG6465
-UN-26OCT92
7. Tighten injection pump drive gear-to-shaft nut to 142
N·m (105 lb-ft).
RG,CTM42,G35,89-19-16AUG94
CTM42 (24MAR95)
35-35
6076 Diesel Engines—S.N. (500000—
)
160101
PN=312
35
35
Fuel System/Install Rotary Fuel Injection Pump—Stanadyne DB4
8. Connect injection pump pressure lines (D). Beginning
with outlet (A) and continue around pump head in
counterclockwise direction, attaching lines in engine firing
order.
-UN-26OCT92
9. Tighten pressure lines at pump to 27 N·m (20 lb-ft),
using a suitable 17 mm wrench.
RG6466
IMPORTANT: When tightening fuel pressure lines at
fuel injection pump, be sure not to turn
fuel injection pump fittings. Turning
fittings may cause internal pump
damage.
10. Connect fuel supply line (B), leak-off line (C), shut-off
cable and speed control rod.
11. Bleed air from fuel system as outlined in Group 115.
12. Remove timing pin from cylinder block. Tighten
injection lines to injection nozzles to 27 N·m (20 lb-ft).
Hold injection nozzle holders during tightening.
A—Outlet Connection to No. 1 Cylinder
B—Fuel Supply Line
C—Fuel Leak-off Line
D—Fuel Pressure Lines
RG,CTM42,G35,90-19-14FEB95
35
36
CTM42 (24MAR95)
35-36
6076 Diesel Engines—S.N. (500000—
)
160101
PN=313
Fuel System/Remove Fuel Injection Nozzles
REMOVE FUEL INJECTION NOZZLES
General Nozzle Service Precautions:
-UN-19AUG91
1. Thoroughly clean area around injection pump and
nozzles, including all line connections, using compressed
air.
RG5877
2. Cap or plug all fuel lines as they are disconnected to
prevent dirt and debris from entering fuel system. Debris
in fuel system can plug injectors and cause engine
damage.
• On In-Line Injection Pumps:
4. Remove fuel injection line nuts (A).
RG5878
IMPORTANT: On “P” injection pumps, JDE90
Serrated Wrench (Robert Bosch) (B)
and 22 mm Open End Wrench
(Nippondenso) must be used to keep
delivery valve fittings stationary while
loosening line nuts. If a delivery valve
and barrel housing rotates while
loosening or tightening a fuel line nut,
injection pump delivery will be altered.
Pump must be recalibrated on a test
stand.
-UN-19AUG91
3. Disconnect injection lines from injection pump using
JDF22 Crowsfoot Wrench.
A—Fuel Injection Line Nuts
B—JDE90 Serrated Wrench
C—JDF22 Crowsfoot Wrench
D—3/4 in. Line Wrench
On Robert Bosch “P” injection pumps use JDE90
Serrated Wrench with either JDF22 Crowsfoot Wrench
(C) or a standard 3/4 in. Line Wrench (D).
On Nippondenso “P” injection pumps, use a 22 mm
Open End Wrench with either JDF22 Crowsfoot Wrench
or equivalent crowsfoot wrench mentioned above.
On “A” injection pumps, use either JDF22 Crowsfoot
Wrench or an equivalent crowsfoot wrench.
35
37
RG,CTM42,G35,96-19-28OCT92
CTM42 (24MAR95)
35-37
6076 Diesel Engines—S.N. (500000—
)
160101
PN=314
Fuel System/Remove Fuel Injection Nozzles
• On Rotary Pumps:
5. Disconnect shut-off cable and speed control rod.
6. Disconnect fuel leak-off line (A) and fuel supply line
(B).
-UN-26OCT92
7. Using a suitable 17 mm deep-well crowsfoot socket,
disconnect fuel delivery (pressure) lines (C).
RG6461
A—Fuel Leak-off Lines
B—Fuel Supply Line
C—Fuel Pressure Lines
RG,CTM42,G35,97-19-28OCT92
• On In-Line and Rotary Pumps:
8. Disconnect turbocharger oil line (A) at turbocharger.
-UN-06DEC88
9. Remove fuel delivery lines from injection nozzles. Lift
injection line assembly from engine.
RG5323
10. Disconnect fuel leak-off line from injection nozzle
leak-off connectors. Remove complete leak-off assembly.
RG,CTM42,G35,49-19-28OCT92
11. Remove packing (C) and line nuts (B) from each
leak-off connector. Discard packing.
-UN-05AUG91
12. Remove leak-off connector (A) with O-ring from each
injection nozzle.
RG5756
35
38
RG,CTM42,G35,27-19-02OCT92
CTM42 (24MAR95)
35-38
6076 Diesel Engines—S.N. (500000—
)
160101
PN=315
Fuel System/Remove Fuel Injection Nozzles
NOTE: The socket portion of JDE92 Nozzle Wrench (A)
may be used to remove nozzles from cylinder
head.
-UN-05AUG91
13. If JDE92 Nozzle Wrench is not used, use a 24 mm
(15/16 in.) deep socket on nozzle gland nut to remove
nozzles. Gland nut will act as a jack screw to raise
nozzle out of cylinder head bore. Remove hardened
steel washer from injection nozzle bore if it does not
come out with nozzle.
RG5757
14. To prevent debris from entering combustion chamber
after nozzles are removed, insert a 12.7 mm (1/2 in.)
hardwood dowel in nozzle bore.
RG,CTM42,G35,28-19-03OCT92
35
39
CTM42 (24MAR95)
35-39
6076 Diesel Engines—S.N. (500000—
)
160101
PN=316
Fuel System/Diagnose Injection Nozzle Malfunction
DIAGNOSE INJECTION NOZZLE MALFUNCTION
Problem
Possible Cause
Suggested Remedy
Failed Carbon Stop Seal Washer
Nozzle replaced without using
new seal or washer.
Install new seal or washer.
Carbon stop seal groove not
cleaned when new seal was
installed.
Clean groove. Install new seal.
Improper adjustment.
Adjust opening pressure.
Broken spring.
Replace spring.
Plugged orifices.
Clean.
Chipped orifices.
Replace nozzle.
Bottomed lift screw.
Adjust lift screw.
Plugged orifices.
Clean.
Chipped orifices.
Replace nozzle.
Cracked nozzle tip.
Replace nozzle.
Plugged orifice.
Clean.
Chipped orifice.
Replace nozzle.
Cracked nozzle tip.
Replace nozzle.
Valve not free.
See “Inconsistent Chatter”.
Spring components misaligned.
Adjust opening pressure.
Varnish on valve.
Clean guide area.
Deposits in seat area.
Clean seat.
Bent valve.
Replace nozzle.
Distorted body.
Replace nozzle.
Incorrect Opening Pressure
Nozzle Will Not Open
Poor Spray Pattern
Poor Atomization
Inconsistent Chatter
35
40
S11,3010,NS
CTM42 (24MAR95)
35-40
-19-08APR94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=317
Fuel System/Diagnose Injection Nozzle Malfunction
DIAGNOSE INJECTION NOZZLE MALFUNCTION—CONTINUED
Problem
Possible Cause
Suggested Remedy
No Chatter
Spring components misaligned.
Adjust opening pressure.
Varnish on valve.
Clean guide area.
Deposits in seat area.
Clean seat.
Bent valve.
Replace nozzle.
Valve seat eroded or pitted.
Lap valve to seat. Replace
nozzle as necessary.
Tip seat pitted.
Lap tip to seat. Replace
nozzle as necessary.
Seat interference angle worn.
Replace nozzle.
Distorted body.
Replace nozzle.
Deposits in seat area
Clean seat.
Valve seat eroded or pitted.
Lap valve to seat. Replace
nozzle as necessary.
Tip seat pitted.
Lap tip to seat. Replace
nozzle as necessary.
Valve not free.
See “Inconsistent Chatter”.
See “No Chatter”.
Distorted body.
Replace nozzle.
Cracked tip.
Replace nozzle.
High Leak-Off
Wear or Scratched at Guide
Lap valve to guide. Replace
nozzle.
Low Leak-Off
Varnish on valve.
Clean guide area.
Insufficient clearance.
Clean nozzle. Lap valve to guide.
Replace nozzle as necessary.
Seat Leakage
S11,3010,NT
CTM42 (24MAR95)
35-41
35
41
-19-13MAY93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=318
Fuel System/Test Fuel Injection Nozzles
TEST FUEL INJECTION NOZZLES
-UN-23AUG88
Before disassembling, test injection nozzles with clean
filtered fuel to determine its condition.
N
X9811
Test for:
—Opening Pressure
—Leakage
—Chatter
—Spray Pattern
CAUTION: Nozzle tip should always be directed
away from operator. Fuel from spray orifices
can penetrate skin and clothing, causing
serious personal injury. Enclosing nozzle in a
transparent cover, or glass beaker is
recommended.
Before applying pressure to nozzle tester, be
sure all connections are tight and fittings are
not damaged. Fuel escaping from a very small
hole can be almost invisible. Use a piece of
cardboard or wood; rather than your hands, to
search for suspected leaks.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or
gangrene may result.
S11,0408,AL
-19-08APR94
35
42
CTM42 (24MAR95)
35-42
6076 Diesel Engines—S.N. (500000—
)
160101
PN=319
Fuel System/Perform Opening Pressure Test
PERFORM OPENING PRESSURE TEST
1. Connect injection nozzle to D01109AA Nozzle Tester
(Y900) (A), using No. Y900-2A Fuel Line (B) and Y900-7
and Y900-15 Straight Adapters (C). Y900-21 90˚ Adapter
may also be used. Place a glass beaker (D) around
nozzle.
2. Pump handle several times to flush out nozzle fittings.
Tighten fittings.
-UN-19AUG91
3. Expel air from nozzle by operating pump handle
several strokes. Then raise pressure until valve opens.
4. Recheck by completely releasing pressure, then
gradually building pressure until valve opens.
RG5883
IMPORTANT: Nozzle tester should be checked
periodically for accuracy.
A—Nozzle Tester
B—Fuel Line
C—Adapter
D—Beaker
RG,CTM42,G35,30-19-03OCT92
35
43
CTM42 (24MAR95)
35-43
6076 Diesel Engines—S.N. (500000—
)
160101
PN=320
Fuel System/Injection Nozzle Specifications
New Nozzle Opening Pressures
(by nozzle tip size)**
7 x 0.22 mm, 7 x 0.23 mm,
7 x 0.255 mm . . . . . . . . . . . . . 29 000—30 200 kPa (290—302 bar)
(4200—4370 psi)
RG3410
A new nozzle or a used nozzle with a new spring (A),
should open at approximately the following pressures. A
used nozzle that has been rebuilt with a new spring
and/or valve should be reset to same pressures as a
new nozzle. New nozzle opening pressures are:
-UN-20DEC88
INJECTION NOZZLE SPECIFICATIONS
On nozzles which have been in service, spring (A) and
spring seat (B) will have taken a normal set. In this
case, opening pressure is satisfactory if it meets or
exceeds used nozzle minimum opening pressure given
below, but does not exceed new opening pressure given
above. Used nozzle minimum opening pressures are:
Used Nozzle Minimum Opening Pressures
(by nozzle tip size)**
7 x 0.22 mm, 7 x 0.23 mm,
7 x 0.255 mm . . . . . . . . . . . . . . . 26 200 kPa (262 bar) (3800 psi)
Shims (C) of different thickness are available for
changing opening pressure adjustment. Each 0.05 mm
(0.002 in.) of shim thickness changes opening pressure
approximately 700 kPa (7 bar) (100 psi).
IMPORTANT: ALWAYS use John Deere nozzle
adjusting shims which are specially
hardened. Other shims will not be
satisfactory.
If nozzle opening pressures are not correct, disassemble
injection nozzles (as described in this group) and change
shims until nozzles open at proper new nozzle pressure
given above. The difference in nozzle opening pressures
between cylinders in an engine should not exceed 350
kPa (3.5 bar) (50 psi).
35
44
**See ASSEMBLE FUEL INJECTION NOZZLE later in this group for
nozzle tip size identification.
CTM42 (24MAR95)
35-44
RG,CTM42,G35,31-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=321
Fuel System/Perform Nozzle Leakage Test
RG5951
-UN-30AUG91
PERFORM NOZZLE LEAKAGE TEST
A—Gland Nut O-Ring
B—Gland Nut
C—Nozzle Holder
D—Shim
E—Nozzle Valve Spring
F—Spring Seat
G—Intermediate Plate
H—Nozzle Valve
I—Nozzle
J—Nozzle Retaining Nut
Nippondenso Nozzle (Bosch Similar)
1. Wipe nozzle dry.
2. Bring pressure up slowly to 1970 kPa (20 bar)
(285 psi) below the opening pressure. Watch for an
accumulation of fuel from spray orifice, indicating a
bad seat.
3. Check for leakage around nozzle retaining nut (J)
thread connection with nozzle holder (C).
Leakage indicates a bad seat either between nozzle
and intermediate plate (G) or between nozzle holder
and intermediate plate.
If nozzle drips within 10 seconds, replace nozzle
valve (H) and nozzle (I).
RG,CTM42,G35,32-19-03OCT92
35
45
CTM42 (24MAR95)
35-45
6076 Diesel Engines—S.N. (500000—
)
160101
PN=322
Fuel System/Perform Chatter and Spray Pattern Test
RG2248
-UN-20APR89
IMPORTANT: Do not lap the machined surfaces (A)
of the intermediate plate in an attempt
to stop fuel leakage at these locations.
Dowels (spring pins) (B) in plate have
to be removed before surfaces can be
lapped. Removing dowels is not
recommended as removal is likely to
damage them, and replacement dowels
are not available as service parts.
If leakage is observed, tighten nozzle retaining nut to a
maximum of 79 N·m (58 lb-ft). Replace injection nozzle if
leakage continues.
S11,0408,AP
-19-08APR94
PERFORM CHATTER AND SPRAY PATTERN
TEST
1. Injection nozzle should chatter very softly, and only
when hand lever movement is very rapid (four to six
downward movements per second). Failure to chatter
may be caused by a binding or bent nozzle valve.
2. Until chattering range is reached, the test oil emerges
as non-atomized streams. When lever movement is
accelerated, sprays should be very broad and finely
atomized.
A partially clogged or eroded orifice will usually cause
spray to deviate from the correct angle. Spray will also
be steady rather than finely atomized.
3. Disassemble nozzle for cleaning or reconditioning if it
fails to chatter or spray properly.
35
46
RG,CTM42,G35,33-19-03OCT92
CTM42 (24MAR95)
35-46
6076 Diesel Engines—S.N. (500000—
)
160101
PN=323
Fuel System/Disassemble Fuel Injection Nozzle
DISASSEMBLE FUEL INJECTION NOZZLE
General Nozzle Repair Notes:
NOTE: Disassembly of nozzles is not recommended
unless servicing is indicated by nozzle operation
and testing.
• Since dirt and water are the worst contaminants in fuel
injection system, working area, tools and cleaning
materials must be kept spotlessly clean. Whenever
possible, work in an isolated, dust-free area.
• Cover workbench with clean paper before disassembly
of injection nozzles.
• As parts are disassembled, place them in a pan of
clean diesel fuel and leave there until needed. Do not
permit parts to strike each other.
• Use a separate pan of clean diesel fuel for washing
parts before assembly.
S11,0408,AR
-19-08APR94
NOTE: Bosch KDEL and Nippondenso KDAL injection
nozzles are metric units. Only metric tools should
be used.
-UN-19AUG91
1. Use a 11 mm box or open-end wrench and unscrew
leak-off connector (A) (if not removed previously) out of
nozzle holder (B).
RG5884
2. Clamp flats of nozzle holder in a soft jawed vise.
Remove nozzle retaining nut (C) from nozzle holder
using a 12-point 19mm wrench.
3. Slip gland nut (D) off nozzle holder.
NOTE: Bosch nozzles have a snap ring and O-ring at
top of gland nut that must be removed before
gland nut can be removed. After removing gland
nut, lower snap ring can be removed.
A—Leak-Off Connector
B—Nozzle Holder
C—Nozzle Retaining Nut
D—Gland Nut
35
47
RG,CTM42,G35,50-19-03OCT92
CTM42 (24MAR95)
35-47
6076 Diesel Engines—S.N. (500000—
)
160101
PN=324
RG5951
-UN-30AUG91
Fuel System/Disassemble Fuel Injection Nozzle
A—Gland Nut O-Ring
B—Gland Nut
C—Nozzle Holder
D—Shim
E—Nozzle Valve Spring
F—Spring Seat
G—Intermediate Plate
H—Nozzle Valve
N
4. Remove nozzle assembly (H and I).
5. Pull off intermediate plate (G).
6. Remove spring seat (F), spring (E), and shims (D).
7. Remove gland nut O-ring (A).
I—Nozzle
J—Nozzle Retaining Nut
CAUTION: Use nozzle cleaning fluids in
accordance with manufacturer’s
instructions.
Do not permit lapped surfaces of valve and nozzle to
come in contact with any hard substance. DO NOT
touch valve unless your hands are wet with fuel.
8. Withdraw nozzle valve (H) from nozzle (I). If valve
is stuck, it may be necessary to soak nozzle
assembly in Bendix cleaner, acetone, or other
commercial cleaners sold especially for freeing stuck
valves.
RG,CTM42,G35,51-19-03OCT92
35
48
CTM42 (24MAR95)
35-48
6076 Diesel Engines—S.N. (500000—
)
160101
PN=325
Fuel System/Clean and Inspect Fuel Injection Nozzle Assembly
CLEAN AND INSPECT FUEL INJECTION
NOZZLE ASSEMBLY
-UN-20DEC88
IMPORTANT: Never use a steel brush to clean
nozzles. Steel brush may damage
injection nozzles.
RG3411
1. Remove anti-corrosive coating from new or
reconditioned nozzles by washing them thoroughly with
diesel fuel.
2. Remove carbon from used nozzles and clean by
washing them in diesel fuel. If parts are coated with
hardened carbon or lacquer, it may be necessary to use
a brass wire brush.
3. After removing carbon or lacquer from nozzle exterior,
inspect lapped surface for nicks or scratches. Replace if
not in good condition.
4. Inspect piston part of nozzle valve (A) to see that it is
not scratched or scored. If any of these conditions are
present, replace nozzle assembly.
5. Inspect nozzle valve seat, nozzle, and intermediate
plate. Contact area of parts (B) must not be scored or
pitted. Use inspection magnifier in JDF13 (JDE105)
Nozzle Cleaning Kit to aid inspection.
NOTE: A bad nozzle valve seat will cause fuel to drip
from nozzle. This condition will usually be noted
when making the “Leakage Test”.
S11,0408,AU
-19-08APR94
35
49
CTM42 (24MAR95)
35-49
6076 Diesel Engines—S.N. (500000—
)
160101
PN=326
Fuel System/Clean Spray Orifices
PERFORM NOZZLE SLIDE TEST
NOTE: DO NOT touch lapped surface (D) unless hands
are wet with diesel fuel.
1. Dip nozzle valve (A) in clean diesel fuel.
2. Insert valve in nozzle (B).
-UN-30AUG91
3. Hold nozzle vertical and pull valve out about one-third
of its engaged length.
RG5953
4. Release valve. Valve should slide down (C) to its seat
by its own weight. Always replace a nozzle assembly if
valve does not fall freely to its seat.
A—Nozzle Valve
B—Nozzle
C—Free-Fall Distance
D—Lapped Surface
RG,CTM42,G35,53-19-03OCT92
CLEAN SPRAY ORIFICES
-UN-30AUG91
1. Begin with cleaning wire (D) 0.07—0.10 mm
(0.003—0.004 in.) from JDF13 (JDE105) Nozzle Cleaning
Kit.
NOTE: Stoning wire to provide a flat surface on one side
will help in reaming carbon from clogged hole.
RG5954
2. Clamp cleaning wire in pin vise (A). Wire should not
protrude from vise more than 0.8 mm (1/32 in.).
3. Insert wire into orifice (C) and rotate.
4. For final cleaning, use cleaning wire 0.03 mm (0.001
in.) smaller than orifice size. Follow previous steps until
orifices are clean of any carbon deposits.
A—Pin Vise
B—Nozzle
C—Orifice
D—Cleaning Wire
RG,CTM42,G35,54-19-05APR93
35
50
CTM42 (24MAR95)
35-50
6076 Diesel Engines—S.N. (500000—
)
160101
PN=327
Fuel System/Inspect Nozzle Holder
RG5959
-UN-30AUG91
INSPECT NOZZLE HOLDER
A—Lapped Surface
B—Nozzle Holder
C—M19 x 0.75
D—M6 x 1
1. Inspect lapped surface (A) on bottom end of
nozzle holder (B) for nicks or scratches. Replace
holder if not in good condition.
E—M14 x 1.5
4. Remove carbon deposits on both inner and outer
surfaces of nozzle retaining nut.
2. Inspect threads M19 x 0.75 (C), M6 x 1 (D), and
M14 x 1.5 (E) on nozzle holder for general condition.
Threads that are nicked slightly may be “dressed-up.”
Replace holder if threads cannot be restored to a
serviceable condition.
5. Inspect retaining nut for cracks caused by
overtightening or a damaged lower seating surface. A
seat may be restored by rubbing the surface with
emery cloth. Any nozzle nut which cannot be
reconditioned, must be replaced.
3. Check fuel passages in nozzle holder to make
sure they are open. Clean with compressed air.
RG,CTM42,G35,55-19-03OCT92
35
51
CTM42 (24MAR95)
35-51
6076 Diesel Engines—S.N. (500000—
)
160101
PN=328
Fuel System/Inspect Nozzle Holder
RG2248
-UN-20APR89
RG2249
-UN-20APR89
6. Examine lapped surfaces on intermediate plate (A) for
nicks, scratches, or worn areas which would permit fuel
to leak past.
7. Replace intermediate plate if lapped surfaces are worn
or damaged.
IMPORTANT: Do not lap machined surfaces of
intermediate plate. Dowel pins (B) in
plate have to be removed before
surfaces can be lapped. Removing
dowels is not recommended as removal
is likely to damage them. Replacement
dowels are not available as service
parts.
8. Inspect spring seat for splitting, cracking, or excessive
wear.
Replace seat if any of these conditions are evident.
RG,CTM42,G35,75-19-03OCT92
35
52
CTM42 (24MAR95)
35-52
6076 Diesel Engines—S.N. (500000—
)
160101
PN=329
Fuel System/Inspect Gland Nut
9. Examine spring and shims for pitting or excessive
wear.
Replace as necessary.
-UN-30AUG91
NOTE: The edge-type filter is pressed into nozzle holder
and is not removable for service.
RG5962
-UN-30AUG91
RG5955
10. Clean filter by applying compressed air to nozzle
holder fuel passage (A) at nozzle end.
RG,CTM42,G35,56-19-03OCT92
INSPECT GLAND NUT
-UN-30AUG91
1. Inspect nozzle holder gland nut for general condition,
be sure that it is not cracked or split.
2. Inspect M28 x 1.5 threads (A) for general condition.
Threads which are slightly nicked or damaged may be
“dressed up.”
RG5956
Replace gland nut if unable to restore to a serviceable
condition.
RG,CTM42,G35,57-19-05APR93
CTM42 (24MAR95)
35-53
6076 Diesel Engines—S.N. (500000—
)
160101
PN=330
35
53
Fuel System/Assemble Fuel Injection Nozzle
3. Check passage in leak-off connector to see that it is
open.
-UN-19AUG91
4. Blow through connector passage with compressed air.
RG5886
5. Inspect the M6 x 1 threads (A) for general condition.
Replace connector if threads are damaged and cannot
be restored to a serviceable condition.
RG,CTM42,G35,34-19-03OCT92
ASSEMBLE FUEL INJECTION NOZZLE
-UN-30AUG91
IMPORTANT: Be sure to install correct nozzle
assembly on nozzle holder. Do not
intermix different size nozzle
assemblies.
RG5958
To help determine correct nozzle assembly for each
application, note markings on lower part of nozzle.
The illustration shows a nozzle marked 7 x 0.255. The
number “7” (A) indicates the number of orifices and
“0.255” (B) indicates the size of each orifice in
millimeters.
IMPORTANT: Immerse parts in clean fuel before
assembly. DO NOT dry parts with
towels or compressed air. Dust
particles might collect and stay on
pressure faces of nozzle valve and
nozzle holder.
RG,CTM42,G35,35-19-03OCT92
35
54
CTM42 (24MAR95)
35-54
6076 Diesel Engines—S.N. (500000—
)
160101
PN=331
Fuel System/Assemble Fuel Injection Nozzle
1. Install a new O-ring (A) on nozzle holder.
-UN-30AUG91
2. Apply PT569 NEVER-SEEZ compound liberally to
inside bore of gland nut to prevent gland nut from
seizing on holder body. Slide gland nut over nozzle
holder until it bottoms against shoulder (B).
RG5960
NOTE: Bosch nozzles have a snap ring toward bottom
end that gland nut bottoms against, and an
O-ring and snap ring at top end of gland nut to
keep it captive. Gland nut is installed from top of
nozzle holder on Bosch nozzles.
Nippondenso Shown (Bosch Similar)
RG,CTM42,G35,58-19-03OCT92
3. Place shims (A), spring (B), and spring seat (C) in
nozzle holder (D) while still wet with diesel fuel.
-UN-30AUG91
NOTE: Make sure intermediate plate (E) is free of any
foreign material before reassembling.
RG5957
A—Shims
B—Spring
C—Spring Seat
D—Nozzle Holder
E—Intermediate Plate
RG,CTM42,G35,59-19-12SEP91
4. Position intermediate plate (A) on nozzle holder (B).
Dowel pins (C) in plate will permit installation only one
way.
-UN-30AUG91
5. Insert nozzle valve (D) into nozzle (E) while holding
parts below diesel fuel level in pan.
RG5961
A—Intermediate Plate
B—Nozzle Holder
C—Dowel Pins
D—Nozzle valve
E—Nozzle
RG,CTM42,G35,36-19-03OCT92
CTM42 (24MAR95)
35-55
6076 Diesel Engines—S.N. (500000—
)
160101
PN=332
35
55
RG5951
-UN-30AUG91
Fuel System/Assemble Fuel Injection Nozzle
A—Gland Nut O-Ring
B—Gland Nut
C—Nozzle Holder
D—Shim
E—Nozzle Valve Spring
F—Spring Seat
G—Intermediate Plate
H—Nozzle Valve
I—Nozzle
J—Nozzle Retaining Nut
Nippondenso Nozzle (Bosch Similar)
6. Install nozzle assembly on nozzle holder (C) and
secure with nozzle retaining nut (J).
7. Clamp nozzle holder in a soft-jawed vise. Tighten
nozzle retaining nut (12) to 60—79 N·m (44—58
lb-ft).
NOTE: Leak-off connector and O-ring should be
installed on nozzle holder even though they
will have to be removed to install injection
nozzle in cylinder head. This will prevent
misplacement of connector and O-ring before
installation on engine.
8. Install leak-off connector on nozzle holder (C),
using a new O-ring.
RG,CTM42,G35,60-19-03OCT92
35
56
CTM42 (24MAR95)
35-56
6076 Diesel Engines—S.N. (500000—
)
160101
PN=333
Fuel System/Adjust Injection Nozzles
ADJUST FUEL INJECTION NOZZLES
CAUTION: Nozzle tip should always be directed
away from operator. Fuel from spray orifices
can penetrate clothing and skin causing
serious personal injury. Enclosing nozzle in a
glass beaker is recommended.
-UN-23AUG88
N
X9811
Before applying pressure to nozzle tester, be
sure all connections are tight, and fittings are
not damaged. Fluid escaping from a very small
hole can be almost invisible. Use a piece of
cardboard or wood, rather than hands, to
search for suspected leaks.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or
gangrene may result.
1. Connect nozzle to nozzle tester, as directed earlier in
this group.
2. Refer to PERFORM OPENING PRESSURE TEST,
earlier in this group, to test opening pressure of nozzle.
Adjust as needed.
3. Refer to PERFORM NOZZLE LEAKAGE TEST, earlier
in this group, to test for leakage.
4. Refer to PERFORM CHATTER AND SPRAY
PATTERN TEST, earlier in this group, to test nozzle
overall operation.
S11,3010,OE
-19-30SEP94
35
57
CTM42 (24MAR95)
35-57
6076 Diesel Engines—S.N. (500000—
)
160101
PN=334
Fuel System/Inspect and Clean Cylinder Head Nozzle Bore
INSPECT AND CLEAN CYLINDER HEAD
NOZZLE BORE
-UN-14DEC88
1. Inspect condition of threads for gland nut. Threads are
metric (M28 x 1.5).
2. Inspect condition of nozzle seating surface in cylinder
head.
RG5251
Cylinder head threads and nozzle seating surface must
be free of debris and carbon deposits.
IMPORTANT: If injection nozzle gland nut threads are
not clean, a false torque wrench
reading may be obtained when injection
nozzle is installed. This may prevent
injection nozzle from seating properly
in cylinder head.
3. Clean threads which have light foreign deposits using
an electric drill and D17030BR Thread Cleaning Brush.
Work brush up and down several times to clean threads.
S55,3010,AU
-19-03OCT92
4. Clean threads with heavy foreign deposits or clean up
damaged threads by using JDF5 Tap (M28 x 1.5 mm).
Be sure to start tap straight to avoid possible
cross-threading. A light coat of grease on tap will help
collect foreign deposits on tap and prevent them from
falling into nozzle bore.
-UN-20DEC88
5. After cleaning threads, insert a 13 mm (1/2 in.)
tapered hardwood dowel to plug nozzle tip bore.
R28263N
6. Blow out debris from nozzle cavity with compressed
air; then remove wood dowel.
35
58
RG,CTM42,G35,37-19-03OCT92
CTM42 (24MAR95)
35-58
6076 Diesel Engines—S.N. (500000—
)
160101
PN=335
Fuel System/Install Fuel Injection Nozzles
INSPECT AND CLEAN NOZZLE SEATING
SURFACE
1. Inspect nozzle seating surface for carbon deposits.
2. If seat is not clean, use the JDG609 Nozzle Seat
Reamer to remove carbon. Stop using tool when seat
comes clean.
-UN-20DEC88
3. Insert a 13 mm (1/2 in.) tapered hardwood dowel to
plug the nozzle tip bore.
R26860N
4. Blow out debris from nozzle cavity with compressed
air; then remove wood dowel.
RG,CTM42,G35,38-19-02OCT92
INSTALL FUEL INJECTION NOZZLES
-UN-19AUG91
1. Apply PT569 NEVER-SEEZ compound to gland nut
threads and nozzle barrel (arrows). Be sure that
NEVER-SEEZ compound was also applied to inside bore
of gland nut during assembly.
RG5888
NOTE: Applying NEVER-SEEZ compound at these
locations will help prevent possible seizure of
gland nut to holder body.
2. Install a new R84472 Special Steel Washer (A) on tip
end of assembled injection nozzle.
IMPORTANT: Do not intermix injection nozzles of
different suppliers or different tip sizes
within a single engine.
RG,CTM42,G35,39-19-03OCT92
3. Insert injection nozzle into cylinder head. Turn gland
nut by hand to make sure it is threaded straight in
cylinder head.
35
59
-UN-19AUG91
4. Use outer socket of JDE92 Nozzle Socket and turn
gland nut down to remove most of the looseness.
RG5889
5. Rotate nozzle holder so hole for leak-off connector
threads (A) are facing straight out from cylinder head.
RG,CTM42,G35,41-19-15SEP94
CTM42 (24MAR95)
35-59
6076 Diesel Engines—S.N. (500000—
)
160101
PN=336
Fuel System/Install Fuel Injection Nozzles
6. Position inner socket (D) over nozzle holder and
engage with flats at top of nozzle holder.
7. Place outer socket (C) portion of JDE92 Nozzle
Socket on gland nut with socket “window” (B) facing
outward.
-UN-05AUG91
8. Insert handle (A) through window into inner socket.
Ball detent in handle will keep it secured to inner socket.
NOTE: Handle simulates position of leak-off connector,
which must be square with engine to permit
proper installation of leak-off lines.
RG5758
A—Handle
B—Window
C—Outer Socket
D—Inner Socket
RG,CTM42,G35,42-19-15SEP94
9. Tighten injection nozzle gland nut to 88 N·m (65 lb-ft).
Keep handle (A) pointing straight out while tightening.
-UN-05AUG91
Socket window (B) is cut deep enough to obtain a new
“bite” without removing inner socket.
RG5759
10. Be sure O-ring is positioned against injection nozzle
gland nut.
RG,CTM42,G35,43-19-03OCT92
-UN-19AUG91
11. Install leak-off connectors (A) with O-rings on
injection nozzles. Tighten securely.
RG5890
35
60
RG,CTM42,G35,44-19-10SEP91
CTM42 (24MAR95)
35-60
6076 Diesel Engines—S.N. (500000—
)
160101
PN=337
Fuel System/Install Fuel Injection Nozzles
12. Loosen all leak-off line fittings (A), remove pipes (B),
and inspect packings (C). Discard packings that are worn
or cut.
-UN-14DEC88
NOTE: Mark each leak-off pipe before disassembly to
assure assembly in correct location.
RG5091
13. Check all pipes and fittings for wear or damage and
replace as necessary.
14. Reinstall new packings (if needed), and pipes into
tee-fittings. Tighten all connections securely.
15. Install nuts (D) and packings onto leak-off
connectors. Install complete assembly over appropriate
leak-off line connectors.
-UN-19AUG91
16. Tighten all leak-off line connections securely at each
injection nozzle.
RG5880
17. Connect leak-off line at injection pump (E) and
tighten securely.
A—Fittings
B—Pipes
C—Packings
D—Nuts
E—Pump Leak-off Line
RG,CTM42,G35,45-19-28OCT92
35
61
CTM42 (24MAR95)
35-61
6076 Diesel Engines—S.N. (500000—
)
160101
PN=338
Fuel System/Install Fuel Injection Nozzles
RG5877
-UN-19AUG91
IMPORTANT: Use JDE90 Serrated Wrench (B) on
Robert Bosch “P” injection pumps, or a
22 mm open end wrench on
Nippondenso “P” and all “A” pumps, to
keep delivery valve fittings stationary
while tightening fuel line nuts. If a
delivery valve and barrel housing
rotates while tightening a fuel line nut,
injection pump fuel delivery will be
altered, and pump will have to be
recalibrated on a test stand.
-UN-19AUG91
18. Remove protective caps and plugs, that were
installed during disassembly, from injection lines, nozzles
and delivery valves. Install and connect injection line
assembly at each respective injection nozzle and delivery
valve.
19. Tighten fuel injection line nozzle nuts (A) to 27 N·m
(20 lb-ft).
21. Bleed the fuel system. (See BLEED THE FUEL
SYSTEM, in Group 115.)
RG5878
20. Tighten line nuts at delivery valves to 27 N·m (20
lb-ft) using JDF22 Crowsfoot Wrench (C) or a 3/4 in.
Line Wrench (D) along with JDE90 Serrated Wrench (B)
(Robert Bosch “P” Pumps) or a 22 mm open end wrench
(all other pumps).
A—Fuel Injection Line Nuts
B—JDE90 Serrated Wrench
C—JDF22 Crowsfoot Wrench
D—3/4 in. Line Wrench
RG,CTM42,G35,46-19-03OCT92
35
62
CTM42 (24MAR95)
35-62
6076 Diesel Engines—S.N. (500000—
)
160101
PN=339
Group 100
Engine Tune-Up and Break-In
EFFECTS OF ALTITUDE AND
TEMPERATURE ON ENGINE
PERFORMANCE
Altitude, fuel temperature, air temperature, and humidity
may affect engine performance. As a general rule,
atmospheric changes will usually cause a decrease in
engine power by the percentages shown in chart below.
ATMOSPHERIC CHANGE
% POWER DECREASE
Fuel Temperature Rise of 1˚C (1.8˚ F)
above 40˚C (104˚F) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.29
Air Temperature Rise of 5.5˚ C (10˚ F)
above 25˚C (77˚F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50
Naturally Aspirated Engines:
Altitude Rise of 300 m (1000 ft)
above 183 m (600 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.00**
Turbocharged Engines:
Altitude Rise of 300 m (1000 ft)
above 183 m (600 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50*
Relative Humidity Rise of 10%
above 0% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.07
If engine required less fuel for acceptable performance at
higher elevation, contact your local authorized fuel
injection pump repair station for service.
*Engine may have to be defueled when a substantial percentage of
operating time occurs at 2250 m (7500 ft) or higher.
**Engine may have to be defueled when a substantial percentage of
operating time occurs at 1500 m (5000 ft) or higher.
RG,CTM42,G100,6-19-30SEP94
100
1
CTM42 (24MAR95)
100-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=340
Engine Tune-Up and Break-In/Preliminary Engine Testing
PRELIMINARY ENGINE TESTING
Before tuning-up an engine, determine if a tune-up
will restore operating efficiency. If in doubt, the
following preliminary tests will help determine if the
engine can be tuned-up. Choose from the following
procedures only those necessary to restore the unit.
2. With engine stopped, inspect engine coolant for oil
film. With engine running, inspect coolant for air
bubbles. Either condition would indicate problems
which require engine repairs rather than just a
tune-up.
1. After engine has stopped for several hours, loosen
crankcase drain plug and watch for any water to seep
out. A few drops could be due to condensation, but
any more than this would indicate problems which
require engine repairs rather than just a tune-up.
3. Perform a dynamometer test and record power
output. See DYNAMOMETER TEST later in this
group. Repeat dynamometer test after tune-up.
Compare power output before and after tune-up.
4. Perform compression test (See Group 105).
S11,22010,BW
-19-08APR94
100
2
CTM42 (24MAR95)
100-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=341
Engine Tune-Up and Break-In/General Tune-Up Recommendations
GENERAL TUNE-UP RECOMMENDATIONS
The following services are recommended each time a tune-up is performed. Disregard those services that do
not apply to any particular application.
Operation
Detailed Reference
Check overall engine for fuel, lubricant, and coolant leaks.
Repair leaks as necessary.
Change engine oil and filters.
Operator’s Manual
Lubricate PTO clutch internal levers and linkage.
Operator’s Manual
Replace fuel filter and water separator, if equipped.
Group 35/Operator’s Manual
Clean crankcase ventilation assembly.
This Group/Operator’s Manual
Replace air cleaner elements and check air intake system.
This Group/Operator’s Manual
Check exhaust system.
This Group
Check and service engine cooling system.
This Group/Operator’s Manual
Check and adjust fan and alternator belts.
Replace if necessary.
Operator’s Manual
Check electrical system.
This Group
Check crankshaft vibration damper.
Group 15/Operator’s Manual
Inspect turbocharger and check turbocharger boost pressure.
Group 110
Check fuel injection system: Check engine-to-injection pump
timing, clean injection nozzles, and adjust nozzle opening
pressure.
Group 35 and 115
Check engine oil pressure. Adjust if necessary.
Group 105
Check engine valve clearance. Adjust if necessary.
Group 05/Operator’s Manual
Check engine speeds. Adjust if necessary.
Group 115
Check engine performance on dynamometer.
Group 105
100
3
RG,CTM6,G100,2 -19-08APR94
CTM42 (24MAR95)
100-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=342
Engine Tune-Up and Break-In/Dynamometer Test
DYNAMOMETER TEST
NOTE: High elevations may affect engine performance.
See EFFECT OF ALTITUDE AND
TEMPERATURE ON ENGINE PERFORMANCE,
earlier in this group.
1. Connect engine to dynamometer using manufacturer’s
instructions.
2. Operate engine at one-half load until coolant and
crankcase oil temperatures are up to normal.
3. Run engine at fast idle.
4. Gradually increase load on engine until speed is
reduced to rated speed rpm.
NOTE: Refer to the appropriate machine technical
manual for average power ratings of specific
applications, allow ±5% for minimum and
maximum power.
5. Read horsepower on dynamometer and record
reading.
6. Compare readings taken with power rating level for
your engine application.
RG,CTM86,G100,2-19-16SEP94
100
4
CTM42 (24MAR95)
100-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=343
Engine Tune-Up and Break-In/Engine Break-In Guidelines
ENGINE BREAK-IN GUIDELINES
Engine break-in should be performed when the following
repair have been made:
• Main bearings, rod bearings, crankshaft, or any
combination of these parts have been replaced.
• Pistons, rings, or liners have been replaced.
• Rear crankshaft oil seal and wear sleeve have been
replaced. (Primary objective is to see if oil seal still
leaks).
• Cylinder head has been removed. Check and reset
valve clearance.
• Injection pump has been removed or critical
adjustments have been made while it is on the engine.
(Primary objective is to check power).
RG,CTM61,G105,2-19-29SEP94
100
5
CTM42 (24MAR95)
100-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=344
Engine Tune-Up and Break-In/Perform Engine Break-In
PERFORM ENGINE BREAK-IN
ENGINE BREAK-IN AFTER MAJOR OVERHAUL
Use a dynamometer to perform the following break-in
procedure. If necessary, engine break-in can be
performed without a dynamometer if under controlled
operating conditions.
IMPORTANT: DO NOT use TORQ-GARD SUPREME
PLUS-50™ engine oil during break-in
period of a new engine or engine
that has had a major overhaul.
TORQ-GARD SUPREME PLUS-50 oil
will not allow a new or overhauled
engine to properly wear during this
break-in period.
During break-in, periodically check
engine oil pressure and coolant
temperature. Also check for signs of
fuel, oil, or coolant leaks.
Fill engine crankcase with John Deere Break-In oil to
proper level for use during the break-in operation.
This oil is specifically formulated to enhanced break-in
of John Deere diesel engines. Add John Deere
Break-In oil as needed to maintain the specified oil
level during break-in period.
Time
5 Minutes
5 Minutes
5 Minutes
10 Minutes
10 Minutes
10 Minutes
Load
Engine Speed
No Load
No Load
1/4 Load
1/2 Load
1/2—3/4 Load
3/4—Full Load
850 rpm
1500—2000 rpm
1900—2100 rpm
1900—2100 rpm
1900—2100 rpm
Rated Speed
Check and readjust valve clearance as necessary.
Cylinder head retorque is not required. (See Group
05, Cylinder Head and Valves.)
Sufficiently load engine during the first 100 hours of
operation, but, avoid over-loads, excessive idling, and
extended no-load operation.
A second 100-hour service interval with John Deere
Engine Break-In Oil may be required if the engine is
operated under light loads during the first 100-hour
break-in period.
After 100 hours maximum, drain break-in oil and
change oil filter. Fill crankcase with John Deere
TORQ-GARD SUPREME PLUS-50™ or other
heavy-duty diesel engine oil within the same service
classification as recommended in this manual. See
DIESEL ENGINE OIL in Group 02, Fuels, Lubricants,
and Coolant.
RG,CTM86,G100,5-19-26OCT94
100
6
CTM42 (24MAR95)
100-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=345
Engine Tune-Up and Break-In/Check Air Intake System
CHECK CRANKCASE VENTILATION SYSTEM
1. Inspect crankcase ventilation system for restrictions.
Lack of ventilation causes sludge to form in engine
crankcase. This can lead to clogging of oil passages,
filters, and screens; resulting in serious engine damage.
RG5930
-UN-20AUG91
2. Clean crankcase vent tube (A) with solvent and
compressed air if restricted. Install and tighten hose
clamps securely.
RG,CTM42,G100,1-19-29OCT92
CHECK AIR INTAKE SYSTEM
-UN-20DEC88
1. Replace air cleaner primary filter element. Replace
secondary element if primary element has holes in it.
2. Check condition of air intake hose(s). Replace hoses
that are cracked, split, or otherwise in poor condition.
RG4689
3. Check hose clamps (A) for tightness. Replace clamps
that cannot be properly tightened. This will help prevent
dust from entering the air intake system which could
cause serious engine damage.
S11,22010,CU
-19-08APR94
100
7
CTM42 (24MAR95)
100-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=346
Engine Tune-Up and Break-In/Check and Service Cooling System
CHECK EXHAUST SYSTEM
1. Inspect exhaust system for leaks or restrictions. Check
manifold for cracks. Repair or replace as necessary.
2. Check that turbocharger-to-exhaust elbow adapter
clamps are securely tightened and do not leak.
3. Check exhaust stack for evidence of oil leakage past
valve stem seals.
Oil in exhaust stack may be caused by excessive valve
stem-to-guide clearance or excessive light load engine
idling.
S55,22010,C
-19-08APR94
CHECK AND SERVICE COOLING SYSTEM
-UN-05SEP91
1. Remove trash that has accumulated on or near
radiator.
2. Visually inspect entire cooling system and all
components for leaks or damage. Repair or replace as
necessary.
RG5964
3. Remove the foam filters from weep holes (A) located
in the bottom of water pump housing. Inspect the weep
holes for any restrictions.
4. Insert a heavy gauge wire deep into weep holes to
make sure holes are open.
5. Install new foam filters flush with pump housing in
each weep hole, if pump assembly passes inspection.
RG,CTM42,G100,2-19-29OCT92
100
8
CTM42 (24MAR95)
100-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=347
Engine Tune-Up and Break-In/Check and Service Cooling System
CAUTION: Do not drain coolant until the
coolant temperature is below operating
temperature. Always loosen water pump drain
valve (A) and block drain valve (B) slowly to
relieve any excess pressure.
-UN-23AUG88
N
TS281
IMPORTANT: Both water pump drain valve and block
drain valve must be opened to
completely drain both sides of the
engine.
6. Remove and check thermostats. See REMOVE AND
TEST THERMOSTATS in Group 25.
7. Drain and flush cooling system. See FLUSHING AND
SERVICING COOLING SYSTEM in Group 02.
RG5836
-UN-28AUG91
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head, bleed plug or petcock
at top front of cylinder head, or plug in
thermostat housing to allow air to
excape when filling system. Retighten
fitting or plug when all the air has been
expelled.
8. Fill cooling system with coolant. Follow
recommendations in Group 02.
9. Run engine until it reaches operating temperature.
Check entire cooling system for leaks.
10. After engine cools, check coolant level.
NOTE: Coolant level should be approximately 19 mm
(3/4 in.) below bottom of radiator filler neck.
11. Check system for holding pressure. See PRESSURE
TEST COOLING SYSTEM AND RADIATOR CAP in
Group 105.
RG,CTM42,G100,3-19-29OCT92
100
9
CTM42 (24MAR95)
100-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=348
Engine Tune-Up and Break-In/Check Electrical System
CHECK ELECTRICAL SYSTEM
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
-UN-23AUG88
N
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
1. Clean batteries, and cables with a damp cloth. If
corrosion is present, remove it and wash the terminals
with a solution of ammonia or baking soda in water.
Then flush area with clean water.
2. Coat battery terminals and connectors with petroleum
jelly mixed with baking soda to retard corrosion.
3. Test batteries. If batteries are not near full charge, try
to find out why.
4. On low-maintenance batteries, check level of
electrolyte in each cell of each battery. Level should be
to bottom of filler neck. If water is needed, use clean,
mineral-free water.
If water must be added to batteries more often than
every 250 hours, alternator may be overcharging.
NOTE: Water cannot be added to maintenance-free
batteries.
5. If batteries appear to be either undercharged or
overcharged, check alternator and charging circuit.
6. Check tension of fan belts. See operator’s manual.
7. Check operation of starting motor and gauges.
S11,22010,CZ
-19-16SEP94
100
10
CTM42 (24MAR95)
100-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=349
Group 105
Engine System Operation and Test
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
-19-05JUN91
RG,JT01674
-19-17SEP91
RG,JDG782
-19-02APR93
S11,22005,R
-19-16AUG94
Compression Test Kit . . . . . . . . JT01674 (D14546BA)
A—Gauge and Hose Assembly
JT01682 (D14547BA)
-UN-09AUG91
B—Nozzle Adapter . . . . . . . . JT01675A (D14557BA)
C—Adapter Nut . . . . . . . . . . . . . . . . . . . . JT01677
-UN-29JAN93
RG5784
Used to test each cylinder’s compression pressure.
Oil Galley Plug Tool . . . . . . . . . . . . . . . . . . JDG782
RG6612
Used to remove and install oil galley plug.
Nozzle Socket . . . . . . . . . . . . . . . . . . . . . . . JDE92
R28362N
-UN-20DEC88
Used to remove and install fuel injection nozzles.
RG5162
-UN-23AUG88
Universal Pressure Test Kit . . . . JT05470 (D15027NU)
Used for testing engine oil pressure.
105
1
S55,22005,B
CTM42 (24MAR95)
105-1
-19-17SEP91
6076 Diesel Engines—S.N. (500000—
)
160101
PN=350
Engine System Operation and Test/Special or Essential Tools
-UN-10AUG94
Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820
RG7056
Used to rotate engine to check damper radial runout and
time engine. JDE81-1 may be used also if JDG820 is
not available.
RG5068
RG,JDG820
-19-14FEB95
S53,JDE814A
-19-08AUG94
S55,22005,C
-19-17SEP91
-UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train.
Cooling System Pressure Pump . . . . . . . .
D05104ST
R26406N
-UN-29NOV88
Used to pressure test radiator cap and cooling system.
105
2
CTM42 (24MAR95)
105-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=351
Engine System Operation and Test/Engine Test Specifications
ENGINE TEST SPECIFICATIONS
ITEM
SPECIFICATION
Compression Pressure:
(at 275—325 RPM cranking speed) . . . . . . . . . . . . 2380—2790 kPa (23.8—27.9 bar) (345—405 psi)
Maximum Variation between cylinders . . . . . . . . . . 340 kPa (3.4 bar) (50 psi)
Oil Pressure at 115˚C (240˚F):
Minimum No Load at 850 rpm (Slow Idle) . . . . . . . 138 kPa (1.4 bar) (20 psi)
Maximum Full Load at 1800—2200 rpm
Rated Speed) . . . . . . . . . . . . . . . . . . . . . . . . 400 kPa (4.0 bar) (58 psi)
Cooling System Leakage Test Pressure
. . . . . . . . . 50 kPa (0.5 bar) (7 psi)
RG,CTM42,G105,1-19-16AUG94
105
3
CTM42 (24MAR95)
105-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=352
Engine System Operation and Test/Engine—Sectional View
RG5805
-UN-12AUG91
ENGINE—SECTIONAL VIEW
A—Rocker Arm Shaft
B—Cylinder Head
C—Push Rod
D—Cam Follower
E—Camshaft
F—Cylinder Block
G—Crankshaft
H—Crankshaft Counterweight
I—Oil Pan
J—Connecting Rod
K—Liner Packing Rings
L—Cylinder Liner
M—Piston
N—Piston Pin
O—Piston Rings
P—Valve
Q—Fuel Injection Nozzle
R—Valve spring
S—Rocker Arm
T—Oil Pump
105
4
RG,CTM42,G1,6 -19-20AUG91
CTM42 (24MAR95)
105-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=353
Engine System Operation and Test/General Engine Description
GENERAL ENGINE DESCRIPTION
All 6076 Engines are vertical stroke, in-line,
valve-in-head, 6-cylinder diesel engines. The cylinder
firing order is 1-5-3-6-2-4.
On 6076 Engines, direct fuel injection is provided by
an in-line injection pump and 21 mm injection nozzles
mounted in cylinder head. The pump is driven by an
intermediate gear in the timing gear train meshing
with the camshaft gear.
The pump has an engine-driven camshaft which
rotates at one-half engine speed. Roller cam
followers, riding on the camshaft lobes, operate the
plungers to supply high-pressure fuel through the
delivery valves to the injection nozzles. A
governor-operated control rack is connected to the
control sleeves and plungers to regulate the quantity
of fuel delivered to the engine.
The crankshaft is a one-piece, heat treated,
dynamically balanced steel forging which rotates in
replaceable two-piece main bearings. The rear thrust
bearing has a flange on each side to reduce
crankshaft deflection and to limit end play during high
load operation.
Cylinder liners are of a wet sleeve, flanged, and
centrifugally cast design. O-rings are used to seal the
connection between cylinder block and liners. Liners
are induction hardened and are individually
replaceable.
Pistons are constructed of high-grade cast aluminum
alloy and are cam ground. A double Ni-Resist ring
carrier is cast integrally in the piston to greatly
improve the life of the two ring grooves. A deep
combustion chamber design provides maximum
combustion efficiency. Pistons have a three ring
combination. The top two rings are compression rings
and the lower ring is an oil control ring.
All engines are turbocharged. Operated by exhaust
gases, the turbocharger compresses intake air from
air cleaner and routes it to each cylinder’s
combustion chamber.
An air-to-air aftercooler cools the turbocharger
compressor discharge air by routing it through a heat
exchanger (usually mounted in front of radiator)
before it enters the intake manifold. The heat
exchanger uses no liquid coolant, but relies on air
flow to cool the charge air.
The camshaft and followers are made of chilled iron.
The cam lobes are individually flame hardened to
provide excellent wear characteristics. Spherically
ground followers riding on tapered cam lobes help
insure positive follower rotation.
Intake and exhaust valves are operated by cam
followers, push rods, and rocker arm assembly.
Cylinder heads have replaceable inserts and valves,
and have positive rotators for both intake and exhaust
valves.
The highly polished, hardened piston pins are
fully-floating and held in position by means of snap
rings. Spray jets (piston cooling orifices) in cylinder
block direct pressure oil to lubricate piston pins and
cool pistons.
Connecting rods are of forged steel and have
replaceable bushing and bearing inserts. They are
weight controlled (by machining) on both ends to
minimize engine vibration.
The engine is supplied with lubricating oil by a spur
gear pump driven off the rear of the crankshaft. Oil is
conditioned in a housing located on the right side of
the engine. Oil temperature is limited by an oil cooler
and filtered by a full flow oil filter. Individual cooler
and filter bypass valves protect the system and
ensure engine lubrication during times of high
restriction; such as cold starts. Oil pressure is
controlled by a pressure regulating valve located
before the gallery.
105
5
RG,CTM42,G1,5 -19-29OCT92
CTM42 (24MAR95)
105-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=354
Engine System Operation and Test/How the Lubrication System Works
HOW THE LUBRICATION SYSTEM WORKS
NOTE: Refer to illustration on following page. A
separate illustration of the oil conditioning
housing assembly is found later in this group.
The engine lubrication system consists of a
gear-driven (crankshaft), positive displacement pump
(O), oil cooler (A), oil filter (C), cooler bypass valve
(B), filter bypass valve (D), and oil pressure
regulating valve (E).
Oil is drawn up from the oil pan through the oil pump.
After it leaves the oil pump, oil flows to the oil cooler
through a machined passage in the cylinder block.
The oil conditioning housing (V) contains the oil
cooler bypass valve, oil filter bypass valve, oil
pressure regulating valve, and the engine oil filter. Oil
then proceeds through the oil cooler where it
exchanges heat with the coolant.
If high restriction is sensed, such as during a cold
start, oil bypasses the oil cooler through the cooler
bypass valve and goes directly to the oil filter. If
excessively high restriction is sensed at the filter, oil
is diverted directly to the regulating valve. After
flowing past the regulating valve; pressurized, cooled
clean oil is supplied to the main oil gallery. Oil is then
distributed, under pressure, to each main bearing (F)
and piston cooling orifice (I). Oil from the piston
cooling orifices lubricates the piston pin and bushing
(J) through a hole in the top of the connecting rod.
The regulating valve permits excess oil to be diverted
back to the oil pan.
From the main oil gallery, cooled clean oil is pressure
fed to the main and rod bearings (G), piston cooling
orifices, and camshaft bushings (H). Oil from the front
camshaft bushing is fed through a drilled hole in the
camshaft nose and lubricates the camshaft thrust
washer and splash lubes the front gears. The
injection pump is pressure lubed off of the main
gallery.
Oil from the rear camshaft bushing is fed through a
drilling in the cylinder block and cylinder head and up
to the rocker arm shaft. Oil from the shaft is
distributed to the rocker arms. Oil from the rocker
arms lubricates the other valve train components and
camshaft followers.
Clean oil from the oil filter goes to the turbocharger
oil inlet line (K) and is returned through the
turbocharger oil return tube (L). Oil completes the
circuit by returning to the oil pan.
CTM42,G105,20 -19-29OCT92
105
6
CTM42 (24MAR95)
105-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=355
Engine System Operation and Test/How the Lubrication System Works
RGC6421
-UN-
HOW THE LUBRICATION SYSTEM WORKS—CONTINUED
A—Engine Oil Cooler
B—Oil Cooler Bypass Valve
C—Oil Filter
D—Filter Bypass Valve
E—Oil Pressure Regulating
Valve
F—Main Bearings
G—Connecting Rod Bearings
H—Camshaft Bushings
I—Piston Cooling Orifices
J—Piston Pin and Bushing
K—Turbocharger Oil Inlet
Line
L—Turbocharger Oil Return
Tube*
M—High Pressure Engine Oil
N—Low Pressure Engine Oil
O—Engine Oil Pump
P—From Oil Cooler*
*Not shown on this artwork, refer to artwork later in this group.
Q—To Oil Cooler*
R—From Oil Pump*
S—To Main Oil Gallery*
T—To Oil Pan*
U—To Turbocharger*
V—Oil Conditioning Housing*
CTM42,G105,21 -19-29OCT92
105
7
CTM42 (24MAR95)
105-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=356
Engine System Operation and Test/How the Lubrication System Works
HOW THE LUBRICATION SYSTEM WORKS—CONTINUED
A—Engine Oil Cooler*
B—Oil Cooler Bypass Valve
C—Oil Filter
D—Filter Bypass Valve
E—Oil Pressure Regulating
Valve
F—Main Bearings*
G—Connecting Rod
Bearings*
H—Camshaft Bushings*
I—Piston Cooling Orifices*
J—Piston Pin and Bushing*
K—Turbocharger Oil Inlet
Line*
L—Turbocharger Oil Return
Tube*
M—High Pressure Engine Oil
N—Low Pressure Engine Oil
O—Engine Oil Pump*
P—From Oil Cooler
*Not shown on artwork on following page. Refer to artwork earlier in
this group.
Q—To Oil Cooler
R—From Oil Pump
S—To Main Oil Gallery
T—To Oil Pan
U—To Turbocharger
V—Oil Conditioning Housing
CTM42,G105,22 -19-29OCT92
105
8
CTM42 (24MAR95)
105-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=357
Engine System Operation and Test/How the Lubrication System Works
RGC6422
-UN-
HOW THE LUBRICATION SYSTEM WORKS—CONTINUED
Oil Conditioning Assembly
CTM42,G105,23 -19-30APR93
105
9
CTM42 (24MAR95)
105-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=358
Engine System Operation and Test/How the Cooling System Works
HOW THE COOLING SYSTEM WORKS
Refer to illustration on the following page.
The coolant flows toward the front end of the cylinder
head where it passes through the outlet cavity and
into the water outlet manifold (G) and thermostat
housing.
The pressurized cooling system consists of a
conventional radiator (A), water pump (C),
thermostats (H), and water outlet manifold (G).
The pump draws low temperature coolant from the
bottom of the radiator and discharges it through the
water inlet manifold elbow (D), into the main coolant
gallery (E) on the right-hand side of the engine.
Coolant from the main coolant gallery flows into the
lower end of the engine oil cooler cavity (F),
circulates around the oil cooler plates to cool the
engine oil, and then flows out the upper end of the oil
cooler cavity and into the cylinder block coolant
jacket.
Coolant enters the coolant jacket near the rear of the
engine, and flows around the cylinder liners
progressing upward toward the cylinder head and
forward from No. 6 cylinder toward No. 1 cylinder. As
the coolant circulates around the cylinder liners, it
carries excess heat away from the liners.
The coolant then flows through the block deck
passages and cylinder head gasket into the cylinder
head. Coolant passages in the block deck, cylinder
head gasket, and cylinder head are sized to provide
even coolant flow in all parts of the cylinder head.
Upon entering the cylinder head, the coolant
circulates through cavities around intake and exhaust
ports, injector bores, valve guides and valve seats to
keep all parts of the head at acceptable temperature
levels.
If the coolant temperature in the thermostat housing
is below the thermostat opening temperature,
thermostats will remain closed (as during warm-up
periods), causing coolant to be directed back through
the bypass pipe (B) and into the water pump inlet to
be recirculated through the engine. This provides a
faster and more uniform warm-up.
If the coolant temperature in the thermostat housing
is above the thermostat opening temperature,
thermostats will be open (engine is at normal
operating temperature) and coolant will flow through
the thermostats into the thermostat cover and on to
the radiator top tank to be cooled.
On 6076A engines, coolant is taken from the upper
left cylinder block and routed into the aftercooler (I)
where it circulates through the aftercooler core and
back out to the thermostat housing. Coolant
circulating through the aftercooler absorbs heat from
the pressurized intake air and carries the heat back
to the engine cooling system to be dissipated through
the radiator.
Two locations are provided for draining the coolant
out of the engine. The block drain valve (J) is located
in the center of the left-hand side of the cylinder
block, and is used to drain the left side of the engine.
The water pump drain valve (K) is located on the
bottom rear of the water pump, and is used to drain
the right side of the engine (water pump, oil cooler,
main coolant gallery).
CTM42,G105,24 -19-29OCT92
105
10
CTM42 (24MAR95)
105-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=359
Engine System Operation and Test/How the Cooling System Works
HOW THE COOLING SYSTEM WORKS—CONTINUED
A—Radiator
B—Coolant Bypass Pipe
C—Water Pump
D—Water Inlet Manifold
Elbow
E—Main Coolant Gallery
F—Engine Oil Cooler
G—Water Outlet Manifold
H—Thermostats (2 used)
I—Aftercooler (’A’ Engines)
J—Block Drain Valve
K—Water Pump Drain Valve
L—Low Temperature Engine
Coolant
M—High Temperature Engine
Coolant
105
11
CTM42,G105,25 -19-29OCT92
CTM42 (24MAR95)
105-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=360
Engine System Operation and Test/Head Gasket Joint Construction and Operation
RG6430
-UN-17SEP92
RG6447
-UN-13OCT92
HEAD GASKET JOINT CONSTRUCTION AND OPERATION
A—Cylinder Head
B—Cylinder Head Cap
Screws
C—Dowel Pins
D—Cylinder Liners
E—Cylinder Block
F—Gasket Body
G—Fire Ring Combustion
Seal
H—Stainless Steel Flange
The head gasket joint consists of:
105
12
•
•
•
•
•
Cylinder
Cylinder
Cylinder
Cylinder
Cylinder
head gasket
head (A)
block (E)
liners (C)
head cap screws (B)
CTM42,G105,15 -19-08APR94
CTM42 (24MAR95)
105-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=361
Engine System Operation and Test/Head Gasket Joint Construction and Operation
Refer to illustration on previous page.
The head gasket must form an air-tight seal between
cylinder liners and cylinder head that can withstand
the temperatures and pressures of the combustion
process. The gasket must also form a liquid-tight seal
between the cylinder head and cylinder block to
retain coolant and oil in their respective passages.
The gasket is constructed of thin, formed sheets of
steel-inserted, non-asbestos material (F). The surface
of gasket is treated to improve liquid sealing and
anti-stick characteristics. A fire ring combustion seal
(G) is located at each cylinder bore and is held in
place by a U-shaped stainless steel flange (H).
The cylinder head and block must be flat to provide
an even clamping pressure over the entire surface of
gasket, and must have the proper surface finish to
keep gasket material from moving in the joint. Dowels
(D) are used to properly locate head gasket on block.
The cylinder liners must protrude evenly from top of
cylinder block the specified amount to provide
adequate clamping force on fire ring of each cylinder.
The cap screws must be proper length, made of
proper material, and be tightened to proper torque in
order to provide an adequate clamp load between
other joint components.
Each of the above components contributes to the
integrity of the head gasket joint. If any of these
components do not conform to specifications, gasket
joint may fail resulting in combustion leaks, coolant
leaks, or oil leaks.
Operating conditions such as coolant, oil, and
combustion temperatures, and combustion pressures
can reduce the ability of the head gasket joint to
function properly. Failure of head gasket and mating
parts may occur when coolant and oil temperatures
become excessive, or when abnormally high
combustion temperatures and pressures persist.
CTM42,G105,26 -19-29OCT92
105
13
CTM42 (24MAR95)
105-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=362
Engine System Operation and Test/Diagnosing Head Gasket Joint Failures
DIAGNOSING HEAD GASKET JOINT
FAILURES
Head gasket failures generally fall into three categories:
• Combustion seal leakage.
• Coolant seal leakage.
• Oil seal leakage.
Combustion seal leakage failures occur when combustion
gases escape between cylinder head and head gasket
combustion flange, or between combustion flange and
cylinder liner. Leaking combustion gases may vent to an
adjacent cylinder, to a coolant or oil passage, or
externally.
-UN-13OCT92
Coolant or oil seal leakage failures occur when oil or
coolant escapes between cylinder head and gasket body,
or between cylinder block and gasket body. The oil or
coolant may leak to an adjacent coolant or oil passage,
or externally. Since oil and coolant passages are
primarily on right hand (camshaft) side of engine, fluid
leaks are most likely to occur in that area.
1. Before starting or disassembling engine, conduct a
visual inspection of machine, and note any of the
following:
• Oil or coolant in head gasket seam, or on adjacent
surfaces. Especially right rear corner of gasket joint.
• Displacement of gasket from normal position.
• Discoloration or soot from combustion gas leakage.
• Leaking radiator, overflow tank, or hoses.
• Leaking coolant from water pump weep hole.
• Damaged or incorrect radiator, fan, or shroud.
• Obstructed air flow or coolant flow.
• Worn or slipping belts.
• Damaged or incorrect pressure cap.
• Presence of oil in coolant.
• Low coolant levels.
• Improper coolant.
• Unusually high or low oil levels.
• Oil degradation, dilution, or contamination.
• Correctly specified injection pump.
• Indications of fuel or timing adjustments.
• Unburned fuel or coolant in exhaust system.
RG6449
Follow these diagnostic procedures when a head gasket
joint failure occurs, or is suspected.
A—Combustion Sealing Areas
B—Oil Sealing Areas (Push Rod)
C—Coolant Sealing Areas
D—Cylinder Head Cap Screws
105
14
CTM42,G105,16 -19-08APR94
CTM42 (24MAR95)
105-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=363
Engine System Operation and Test/Diagnosing Head Gasket Joint Failures
2. Obtain coolant and oil samples for further analysis.
3. Start and warm up engine if it can be safely
operated. Examine all potential leakage areas again
as outlined previously. Using appropriate test and
measurement equipment, check for the following:
• White smoke, excessive raw fuel, or moisture in
exhaust system.
• Rough, irregular exhaust sound, or misfiring.
• Air bubbles, gas entrainment in radiator or
overflow tank.
• Loss of coolant from overflow.
• Excessive cooling system pressure.
• Coolant overheating.
• Low coolant flow.
• Loss of cab heating (air lock).
4. Shut engine down. Recheck crankcase, radiator,
and overflow tank for any significant differences in
fluid levels, viscosity, or appearance.
5. Compare your observations from above steps with
the following diagnostic charts. If diagnostic
evaluations and observations provide conclusive
evidence of combustion gas, coolant, or oil leakage
from head gasket joint, the cylinder head must be
removed for inspection and repair of gasket joint
components.
RG,CTM8,G105,11-19-29OCT92
Combustion Seal Leakage
Symptoms:
Possible Causes:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Exhaust from head gasket crevice
Air bubbles in radiator/overflow tank
Coolant discharge from overflow tube
Engine overheating
Power loss
Engine runs rough
White exhaust smoke
Loss of cab heat
Gasket section dislodged, missing (blown)
Coolant in cylinder
Coolant in crankcase oil
Low coolant level
Insufficient liner standout
Excessive liner standout differential between cylinders
Low head bolt clamping loads
Rough/damaged liner flange surface
Cracked/deformed gasket combustion flange
Out-of-flat/damaged/rough cylinder head surface
Missing/mislocated gasket fire ring
Block cracked in liner support area
Excessive fuel delivery
Advanced injection pump timing
Hydraulic or mechanical disturbance of combustion seal
NOTE: Cracked cylinder head or liners may also allow combustion
gas leakage into coolant.
RG,CTM8,G105,12-19-16SEP92
105
15
CTM42 (24MAR95)
105-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=364
Engine System Operation and Test/Diagnosing Head Gasket Joint Failures
Coolant Seal Leakage
Symptoms:
Possible Causes:
•
•
•
•
•
•
•
•
•
•
•
•
•
Coolant discharge from head gasket crevice
Coolant in crankcase oil
Low coolant level
High oil level
Coolant discharge from crankcase vent
Excessive liner standout
Excessive liner standout differential between cylinders
Low head bolt clamping loads
Out-of-flat/damaged/rough block surface
Out-of-flat/damaged/rough cylinder head surface
Oil or coolant overheating
Cracks/creases in gasket body surfaces
Damage/voids in elastomer beading
NOTE: Cracked cylinder head, liners, liner packings, defective
oil cooler or aftercooler may also allow coolant leakage
into crankcase.
RG,CTM8,G105,13-19-13MAY93
Oil Seal Leakage
Symptoms:
Possible Causes:
•
•
•
•
•
•
•
•
•
•
•
•
•
Oil discharge from head gasket crevice
Oil in coolant
Low crankcase oil level
Reduced oil to rocker arms (noisy)
Excessive liner standout
Excessive liner standout differential between cylinders
Low head bolt clamping loads
Out-of-flat/damaged/rough block surface
Out-of-flat/damaged/rough cylinder head surface
Oil or coolant overheating
Cracks/creases in gasket body surfaces
Damage/voids in elastomer beading
Damaged/missing O-ring seal at oil port to rocker arms
NOTE: Defective oil cooler may also allow oil leakage into coolant.
RG,CTM8,G105,14-19-16SEP92
105
16
CTM42 (24MAR95)
105-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=365
Engine System Operation and Test/Head Gasket Inspection and Repair Sequence **M:CTM42,G105,18 -19-
RG6448
-UN-13OCT92
HEAD GASKET INSPECTION AND REPAIR SEQUENCE
A—Combustion Seals
(Flanges)
B—Gasket Body
C—Rocker Arm Oil Port
D—Elastomer Beading Strips
The following inspection procedures are
recommended whenever a head gasket joint failure
occurs, or when joint disassembly takes place.
E—Front of Engine
5. Observe surfaces of removed head gasket.
Examine combustion seals (A) for the following:
• Flange severed/expanded/cracked/deformed.
• Adjacent body area burned/eroded.
• Fire ring severed/displaced/missing.
• Flange sealing pattern eccentric/contains voids.
• Discoloration of flange and adjacent body areas.
• Flange surfaces rough/abraided/channelled.
1. Review historical data relating to machine
operation, maintenance and repair, along with
diagnostic observations. Note all areas requiring
further inspection and analysis.
2. Remove rocker arm cover and check for presence
of coolant in the oil.
3. Record head cap screw torques prior to removal.
Upon removal, check cap screw length differences.
4. Remove cylinder head using appropriate lifting
devices to prevent handling damage to head gasket.
See REMOVE CYLINDER HEAD in Group 05.
Examine gasket body (B) for the following:
• Combustion gas erosion paths or soot deposits
originating at combustion seals.
• Extreme discoloration/hardening/embrittlement in
localized areas.
• O-ring seal missing/damaged in port area (C).
• Elastomer missing/damaged in port areas (D).
• Oil or coolant paths from port areas.
• Localized areas of low compression.
6. Before cleaning components, inspect head, block,
and liners for evidence of combustion gas and fluid
leakage. Inspect cylinders and valve ports for unusual
deposits.
105
17
CTM42,G105,17 -19-08APR94
CTM42 (24MAR95)
105-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=366
Engine System Operation and Test/Diagnosing Engine Malfunctions
DIAGNOSING ENGINE MALFUNCTIONS
• Will Not Crank:
• Engine Misfiring:
Electrical System Malfunction
Weak battery
Corroded or loose battery connections
Defective main switch or start safety switch
Starter solenoid defective
Starter defective
Service Problem
Water in fuel
Mixture of gasoline and diesel fuel
Fuel System Malfunction - See Group 115
Air in fuel system
Defective fuel injection nozzles
Defective fuel injection pump
Fuel injection nozzles improperly installed
Leaking fuel injection nozzle seals
Worn or defective fuel supply pump
Fuel injection pump incorrectly timed
Basic Engine Problem
Engine overheated
Lobes of camshaft worn
Weak valve springs
Pre-ignition
Engine compression too low
Improper valve clearance
Burnt, damaged or stuck valves
• Hard to Start or Will Not Start:
Electrical System Malfunction
Loose or corroded battery connections
Weak battery
Excessive resistance in starter circuit
Fuel System Malfunction - See Group 115
Empty fuel tank
Improper fuel
Fuel shut off at tank
Water, dirt or air in fuel system
Plugged fuel filter
Fuel shut-off cable not pushed in
Dirty or faulty fuel injection nozzles
Defective fuel injection pump
Defective fuel supply pump
Fuel injection pump incorrectly timed
Service Problem
Too high viscosity crankcase oil
• Engine Runs Irregularly or Stalls Frequently:
105
18
Basic Engine Problem
Coolant temperature too low
Improper valve clearance
Cylinder head gasket leaking
Worn or broken compression rings
Valves sticking or burned
Exhaust system restricted
Engine compression too low
Engine overheating
Worn camshaft lobes
Fuel System Malfunction - See Group 115
Defective fuel injection pump
Low fuel supply
Air in fuel
Vent on fuel tank cap obstructed
Fuel injection nozzles defective or leaking
Fuel filter or fuel lines restricted
Defective fuel supply pump
Fuel injection pump incorrectly timed
Service Problem
Improper fuel
• Lack of Engine Power:
Service Problem
Air cleaner restricted or dirty
Excessive resistance in air intake system
Improper crankcase oil
Improper fuel
Restricted exhaust system
Fuel System Malfunction - See Group 115
Fuel filter restricted
Defective fuel supply pump
Defective fuel injection pump
Fuel injection pump incorrectly timed
Faulty injection nozzles
Plugged fuel tank vent
Basic Engine Problem
Engine overheated
Engine clutch slipping
Defective cylinder head gasket
Lobes of camshaft worn
Improper valve clearance
Improper valve timing
Burnt, damaged or stuck valves
Weak valve springs
Piston rings and cylinder liners excessively worn
Engine compression too low
Improper coolant temperature
S11,22010,BO
CTM42 (24MAR95)
105-18
-19-18AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=367
Engine System Operation and Test/Diagnosing Engine Malfunctions
DIAGNOSING ENGINE MALFUNCTIONS—CONTINUED
• Engine Overheats
• Low Oil Pressure
Service Problem
Lack of coolant in cooling system
Radiator core and/or side screens dirty
Cooling system limed up
Engine overloaded
Too low crankcase oil level
Improper fuel
Basic Engine Problem
Loose or defective fan belt
Defective thermostat(s)
Damaged cylinder head gasket
Defective water pump
Defective radiator cap
Fuel System Malfunction - See Group 115
Fuel injection pump delivers too much fuel
Fuel injection pump incorrectly timed
Service Problem
Low crankcase oil level
Improper crankcase oil
Defective oil pressure warning switch or engine oil
pressure indicator light
Basic Engine Problem
Leakage at internal oil passages
Defective oil pump
Excessive main and connecting rod bearing
clearance
Improper regulating valve adjustment
Piston cooling orifice missing
Plugged oil pump intake screen
• Excessive Oil Consumption
Basic Engine Problem
Oil control rings worn or broken
Scored cylinder liners or pistons
Excessive resistance in air intake system
Oil flow through oil passages restricted
Worn valve guides or stems
Excessive oil pressure
Piston ring grooves excessively worn
Piston rings sticking in ring grooves
Insufficient piston ring tension
Piston ring gaps not staggered
Excessive main or connecting rod bearing
clearance
Front and/or rear crankshaft oil seal faulty
Glazed cylinder liners (insufficient load during
engine break-in)
Service Problem
Too low viscosity crankcase oil
Crankcase oil level too high
External oil leaks
• High Oil Pressure
Basic Engine Problem
Oil pressure regulating valve bushing loose
(wanders)
Improperly operating regulating valve
Stuck or damaged filter bypass valve
• Excessive Fuel Consumption
Service Problem
Improper grade of fuel
Engine overloaded
Air cleaner restricted or dirty
Basic Engine Problem
Compression too low
Fuel System Malfunction - See Group 115
Leaks in fuel system
Fuel injection nozzles dirty or faulty
Fuel injection pump defective (delivers too much
fuel)
Fuel injection pump incorrectly timed
Improper valve clearance
• Black or Grey Exhaust Smoke
Service Problem
Excess fuel
Engine overloaded
Air cleaner restricted or dirty
Defective muffler (causing back-pressure)
Fuel System Malfunction - See Group 115
Fuel injection nozzles dirty or faulty
Incorrect engine timing
105
19
S11,22010,BP
CTM42 (24MAR95)
105-19
-19-29OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=368
Engine System Operation and Test/Diagnosing Engine Malfunctions
DIAGNOSING ENGINE MALFUNCTIONS—CONTINUED
• White Exhaust Smoke
• Detonation or Pre-Ignition
Basic Engine Problem
Engine compression too low
Defective thermostat(s) (does not close)
Fuel System Malfunction - See Group 115
Defective fuel injection nozzles
Fuel injection pump incorrectly timed
Service Problem
Improper fuel
Basic Engine Problem
Oil picked up by intake air stream (intake manifold)
Fuel System Malfunction - See Group 115
Dirty or faulty fuel injection nozzles
Incorrect fuel injection pump timing
Fuel injection nozzle tip holes enlarged
Fuel injection nozzle tips broken
Carbon build-up in compression chamber
Faulty injection pump
Service Problem
Improper fuel
• Coolant in Crankcase
Basic Engine Problem
Cylinder head gasket defective
Cylinder head or block cracked
Cylinder liner seals leaking
• Water Pump Leaking
Seal ring or pump shaft worn
• Abnormal Engine Noise
• Coolant Temperature Below Normal
Basic Engine Problem
Low engine oil level
Worn main or connecting rod bearings
Excessive crankshaft end play
Loose main and connecting rod bearing caps
Foreign material in combustion chamber
Worn piston pin bushings and pins
Scored pistons
Worn main or connecting rod bearings
Worn timing gears
Incorrect engine timing
Excessive valve clearance
Worn cam followers
Bent push rods
Worn camshaft
Worn rocker arm shaft
Insufficient engine lubrication
Worn turbocharger bearings
Crankshaft oil pump drive gear worn or broken
Crankshaft vibration damper worn or separated
Fuel System Malfunction - See Group 115
Fuel injection pump incorrectly timed
Defective thermostat(s)
Coolant temperature gauge defective
• Engine Vibrating
Fan blades bent or broken
Water pump shaft worn
105
20
CTM42,G105,19 -19-29OCT92
CTM42 (24MAR95)
105-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=369
Engine System Operation and Test/Test Engine Compression Pressure
RG4118
-UN-27OCT88
TEST ENGINE COMPRESSION PRESSURE
IMPORTANT: Compression pressures are affected
by the cranking speed of the engine.
Before beginning test, insure that
batteries are fully charged and
injection nozzle area is thoroughly
cleaned.
NOTE: Pressure given was taken at 300 m (1000 ft)
above sea level. A 3.6 percent reduction in
gauge pressure will result for each additional
300 m (1000 ft) of altitude.
All cylinder pressures should be approximately
alike. There should be less than 340 kPa (3.4
bar) (50 psi) difference between cylinder
pressures.
1. Start engine and run at rated speed until it warms
up to normal operating temperature. (From a cold
start, operate engine 10—15 minutes at slow idle.)
2. Remove injection lines, leak-off lines, and injection
nozzles. See Group 35.
3. Install the JT01675A Nozzle adapter and JT01677
Adapter Nut (A) into injection nozzle bore. Tighten
adapter nut to 80 N·m (60 lb-ft).
4. Connect JT01682 Gauge and Hose Assembly (B)
to nozzle adapter.
5. Pull fuel shut-off knob all the way out, if equipped,
and close fuel shut-off valve.
8. Crank engine over and record compression reading
again.
If pressure is higher than 2790 kPa (27.9 bar) (405
psi), worn or stuck rings are indicated. Either replace
piston rings or install new piston and liner set as
needed. See Group 10.
If pressure is below 2380 kPa (23.8 bar) (345 psi), it
is possible that valves are worn or sticking.
Recondition cylinder head as needed. See Group 05.
6. Crank engine over at 275—325 rpm cranking
speed and record compression readings.
ENGINE COMPRESSION
Engine
7. If pressure is much lower than shown, remove
gauge and apply oil to ring area of piston through
injection nozzle bore. Do not use too much oil and do
not get oil on valves.
Compression Pressure
9. Measure compression pressure in all remaining
cylinders and compare readings. Recondition power
cylinders and valves as required.
6076 . . . . . . . . . . . . . . . . . . . 2380—2790 kPa (23.8—27.9 bar)
(345—405 psi)
105
21
S55,22005,I
CTM42 (24MAR95)
105-21
-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=370
Engine System Operation and Test/Check Engine Oil Pressure
CHECK ENGINE OIL PRESSURE
NOTE: JDG782 Oil Galley Plug Tool must be used to
remove galley plugs on current engine.
1. Remove pipe plug (A) from main oil gallery and install
No. 0070 (D1) Fitting (A), No. 2106 (19-HP) Hose (B),
and JT05472* Gauge (C).
IMPORTANT: To achieve an accurate oil pressure
reading, warm up engine to 115˚C
(240˚F).
-UN-20AUG91
2. Measure engine oil pressure.
OIL PRESSURE SPECIFICATIONS
RG5924
Minimum No Load at 850 rpm
(Slow Idle) . . . . . . . . . . . . . . . . . . . . . 138 kPa (1.4 bar) (20 psi)
Maximum Full Load at 1800—2200 rpm
(Rated Speed) . . . . . . . . . . . . . . . . . . . 400 kPa (4.0 bar) (58 psi)
NOTE: The regulating valve is designed so that
adjustment of oil pressure should not be required.
* Part of JT05470 (D15027NU) Universal Pressure Test Kit
RG,CTM42,105,9A-19-14FEB95
105
22
CTM42 (24MAR95)
105-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=371
Engine System Operation and Test/Check Engine Oil Pressure
RG6558
RG6557
-UN-20JAN93
-UN-20JAN93
PRESSURE TEST COOLING SYSTEM AND RADIATOR CAP
N
Test Cooling System:
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
Shut off engine. Only remove filler cap
when cool enough to touch with bare
hands. Slowly loosen cap to first stop to
relieve pressure before removing
completely.
NOTE: Engine should be warmed up to test overall
cooling system.
1. Allow engine to cool, then carefully remove radiator
cap.
2. Fill radiator with coolant to the normal operating
level.
IMPORTANT: DO NOT apply excessive pressure to
cooling system, doing so may
damage radiator and hoses.
Test Radiator Cap:
1. Remove radiator cap and attach to D05104ST
Tester as shown.
2. Pressurize cap to 50 kPa (0.5 bar) (7 psi)*. Gauge
should hold pressure for 10 seconds within the
normal range if cap is acceptable.
If gauge does not hold pressure, replace radiator cap.
3. Remove the cap from gauge, turn it 180˚, and
retest cap. This will verify that the first measurement
was accurate.
3. Connect gauge and adapter to radiator filler neck.
Pressurize cooling system to 50 kPa (0.5 bar) (7
psi)*.
4. With pressure applied, check all cooling system
hose connections, radiator, and overall engine for
leaks.
If leakage is detected, correct as necessary and
pressure test system again.
If no leakage is detected, but the gauge indicated a
drop in pressure, coolant may be leaking internally
within the system or at the block-to-head gasket.
Have your servicing dealer or distributor correct this
problem immediately.
*Test pressures recommended are for all Deere OEM cooling systems.
On specific vehicle applications, test cooling system and pressure cap
according to the recommended pressure for that vehicle.
CTM42 (24MAR95)
105-23
105
23
RG18293,6
-19-14OCT94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=372
Engine System Operation and Test/Inspect Thermostat and Test Opening Temperature
INSPECT THERMOSTAT AND TEST
OPENING TEMPERATURE
Visually inspect thermostat for corrosion or damage.
Replace as necessary.
• Test thermostat as follows:
N
CAUTION: DO NOT allow thermostat or
thermometer to rest against the side or bottom
of container when heating water. Either may
rupture if overheated.
-UN-17SEP91
1. Suspend thermostat and a thermometer in a container
of water.
RG5971
2. Stir the water as it heats. Observe opening action of
thermometer and compare temperatures with
specification given in chart below.
NOTE: Due to varying tolerances of different suppliers,
initial opening and full open temperatures may
vary slightly from specified temperatures.
THERMOSTAT TEST SPECIFICATIONS
Rating
71˚C
77˚C
82˚C
89˚C
90˚C
92˚C
96˚C
99˚C
(160˚F)
(170˚F)
(180˚F)
(192˚F)
(195˚F)
(197˚F)
(205˚F)
(210˚F)
Initial Opening
(Range)
69—72˚C (156—162˚F)
74—78˚C (166—172˚F)
80—84˚C (175—182˚F)
86—90˚C (187—194˚F)
89—93˚C (192—199˚F)
89—93˚C (193—200˚F)
94—97˚C (201—207˚F)
96—100˚C (205—212˚F)
Full Open
(Nominal)
84˚C (182˚F)
89˚C (192˚F)
94˚C (202˚F)
101˚C (214˚F)
103˚C (218˚F)
105˚C (221˚F)
100˚C (213˚F)
111˚C (232˚F)
3. Remove thermostat and observe its closing action as
it cools. In ambient air the thermostat should close
completely. Closing action should be smooth and slow.
4. If any thermostat is defective on a multiple thermostat
engine, replace all thermostats.
CTM42,G105,13 -19-13MAY93
105
24
CTM42 (24MAR95)
105-24
6076 Diesel Engines—S.N. (500000—
)
160101
PN=373
Group 110
Air Intake System Operation and Test
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
110
1
-19-05JUN91
A—JT03092 Gauge *
-UN-15DEC88
B—JT03017 Hose and Connector *
C—Connector
Used with above hose
and gauge to check
intake manifold pressure
at aneroid.
R28266
1/8 in. Pipe Nipple
1/4 in.—1/8 in. Pipe Reducer
1/8 NPT-7/16-20 UNC Adapter
D—“T” Fitting
D—JT03104 Fitting*
Used with above hose
and gauge to check
intake manifold pressure
at aftercooler on 6076A
Engines.
* Part of JT05412 Universal Pressure Test Kit
S55,23005,A
CTM42 (24MAR95)
110-1
-19-16SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=374
Air Intake System Operation and Test/Air Intake and Exhaust System Test Specifications
AIR INTAKE AND EXHAUST SYSTEM TEST SPECIFICATIONS
Air Intake Manifold Pressure (Turbo-Boost)
110
2
Engine
Application
6076ADW30 .
6076ADW31(a)
6076ADW31(b)
6076ADW32 .
6076AF030 . .
6076AF030 . .
6076AF030 . .
6076AF030 . .
6076AF030 . .
6076AF030 . .
6076AN030 . .
6076AN031 . .
6076AT030 . .
6076AZ030 . .
6076AZ031 . .
6076HF030 . .
6076HF030 . .
6076HH030(a)
6076HH030(b)
6076HH031(a)
6076HH031(b)
6076HH032(a)
6076HH032(b)
6076HRW32 .
6076HZ030 . .
6076HZ031 . .
6076TDW30 . .
6076TF030 . .
6076TF030 . .
6076TRW30 . .
6076TRW31 . .
Fuel Injection
Pump Part No.
.
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RE55529
RE47396
RE47396
RE55711
RE47395
RE47396
RE48642
RE48643
RE50748
RE55292
RE47394
RE50748
RE46898
RE47398
RE52038
RE47396
RE47410
RE47396
RE47396
RE44518
RE44518
RE47396
RE47396
RE47396
RE47549
RE47399
RE54248
RE48640
RE48641
RE41833
RE41233
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104—122
100—116
119—139
111—125
119—133
156—176
161—179
168—192
158—174
179—201
156—176
158—174
152—172
170—188
120—136
164—182
169—187
145—151
146—150
118—130
118—130
145—151
146—150
158—162
140—156
170—188
95—113
115—127
131—149
95—113
130—154
(bar)
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1.0—1.2
1.0—1.1
1.2—1.4
1.1—1.3
1.2—1.3
1.6—1.8
1.6—1.8
1.7—1.9
1.6—1.7
1.8—2.0
1.6—1.8
1.6—1.7
1.5—1.7
1.7—1.9
1.2—1.4
1.6—1.8
1.7—1.9
1.4—1.5
1.4—1.5
1.2—1.3
1.2—1.3
1.4—1.5
1.4—1.5
1.5—1.6
1.4—1.6
1.7—1.9
1.0—1.1
1.2—1.3
1.3—1.5
1.0—1.1
1.3—1.5
(psi)
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15—18
15—17
17—20
16—18
17—19
23—26
23—26
24—28
23—25
26—29
23—26
23—25
22—25
25—27
17—20
24—26
25—27
21—22
21—22
17—19
17—19
21—22
21—22
22—23
20—23
25—27
14—16
17—18
19—22
14—16
19—22
RG,CTM42,G110,1-19-17MAR95
CTM42 (24MAR95)
110-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=375
Air Intake System Operation and Test/Diagnosing Air Intake Malfunctions
DIAGNOSING AIR INTAKE MALFUNCTIONS
Symptom
Problem
Solution
Engine Starts Hard or Won’t Start
Air leak on suction side of system
Check hose and pipe connections
for tightness; repair as required
(See Group 30).
Erratic Engine Operation
Air leak on suction side of system
Check hose and pipe connections
for tightness; repair as required
(See Group 30).
Engine Emits Excessive Black
Smoke
Air cleaner element restricted
Clean or replace elements (See
operator’s manual).
Turbocharger defective
Repair or replace (See Group 30).
Air leak in manifold
Check hose and pipe connections
for tightness; repair as required
(See Group 30).
Engine Idles Poorly
Air leak on suction side of system
Check hose and pipe connections
for tightness; repair as required
(See Group 30).
Engine Does Not Develop Full
Power
Air cleaner restricted
Clean or replace elements (See
operator’s manual).
Air leak on suction side of system
Check hose and pipe connections
for tightness; repair as required
(See Group 30).
Turbocharger defective
Repair or replace (See Group 30).
Manifold pressure pipe to aneroid
loose or broken
Check hose and pipe connections
for tightness; repair as required
(See Group 30).
Air leak in manifold
Check intake manifold gasket and
manifold; repair as required (See
Group 30).
Turbocharger “Screams”
S11,23005,AJ
CTM42 (24MAR95)
110-3
110
3
-19-16SEP92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=376
Air Intake System Operation and Test/Air Cleaner Operation
HOW THE AIR INTAKE AND EXHAUST SYSTEM WORKS
On 6076H Engines, an air-to-air aftercooler cools the
turbocharger compressor discharge air by routing it
through a heat exchanger before it enters the engine.
The heat exchanger uses no liquid coolant but relies
on air flow to cool the charge air.
This increased volume of air, when combined with a
predetermined quantity of additional fuel, enables
more power to be produced.
Exhaust, as it is expelled out the exhaust elbow,
drives the turbocharger to deliver a larger quantity of
air to meet the engine requirements than what could
be delivered under naturally aspirated
(non-turbocharged) conditions.
On 6076A Engines, intake air, which has been
compressed (and heated) by the turbocharger, flows
around the aftercooler and lowers the air temperature
as much as 27—32˚C (80—90˚F) before entering the
engine cylinders. Lowering the air temperature makes
the air more dense and permits an even greater
volume of air to be delivered to engine cylinders for
combustion.
RG,CTM42,110,3 -19-29OCT92
AIR CLEANER OPERATION
-UN-14DEC88
Dust-laden air enters the air cleaner inlet (A) and is
forced into a high-speed centrifugal motion.
Most of the dust settles out of the air (before it enters
the filter elements) and falls to the bottom of the air
cleaner body. It is expelled to the outside of the air
cleaner (B) through a rubber valve, which automatically
ejects the dust and keeps it from accumulating inside the
air cleaner body.
As the intake air is drawn through the primary element
(C) and a secondary (safety) element (D), the remaining
dust particles are retained in the primary element to
permit only clean air to enter the intake manifold.
The safety element retains the dust that would otherwise
pass into the engine if the primary element should
rupture.
R28270
110
4
Engine suction draws dust-laden outside air through
an air inlet stack into the air cleaner. Air is filtered
through dry type primary and secondary (safety) filter
elements in the air cleaner canister. Clean air travels
through the air intake hose to the turbocharger and
intake manifold to the engine.
A—Air Inlet
B—Dust Outlet
C—Primary Element
D—Secondary (Safety) Element
E—Air Outlet
See your operator’s manual for recommended service
intervals.
S11,23005,AO
CTM42 (24MAR95)
110-4
-19-04FEB93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=377
Air Intake System Operation and Test/Air Cleaner Operation
AIR FILTER RESTRICTION INDICATOR
SWITCH TEST
-UN-09DEC88
1. Remove air filter restriction indicator switch from air
intake piping.
T6188AQ
2. Install pipe nipple (C), tee fitting (B), and gauge (A)
from D05022ST Water Vacuum Gauge Kit into air filter
restriction indicator hole. Install air filter restriction
indicator into tee fitting.
3. Start engine and slowly cover the air cleaner inlet with
a piece of paper or cardboard.
4. Air restriction indicator must show red at 5.6—6.8 kPa
(56—68 mbar) (22.7—27.3 in. water) (1.6—2.0 in. hg)
vacuum.
If air restriction indicator shows red at any other value
than listed above, install a new indicator.
RG,CTM6,G110,1 -19-14AUG91
CTM42 (24MAR95)
110-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=378
110
5
Air Intake System Operation and Test/Diagnosing Turbocharger Malfunctions
DIAGNOSING TURBOCHARGER MALFUNCTIONS
110
6
Before replacing the turbocharger, determine what
caused the failure of the defective unit, and correct
the condition. This will prevent an immediate repeat
failure of the replacement unit. Refer to Air Intake
and Exhaust System Group 30 for repair information.
• Oil In Manifold Or Dripping From Housing:
Excessive crankcase pressure.
Air intake restriction.
Drain tube restriction.
Damaged or worn journal bearings.
Unbalance of rotating assembly:
Damage to turbine or compressor wheel
or blade.
Dirt or carbon build-up on wheel or blade.
Bearing wear.
Oil starvation or insufficient lubrication.
Shaft seals worn.
• Noise Or Vibration*:
Bearings not lubricated (insufficient oil
pressure).
Air leak in engine intake or exhaust manifold.
Improper clearance between turbine wheel
and turbine housing.
Broken blades (or other wheel failures).
• Turbine Wheel Drag:
• Engine Will Not Deliver Rated Power:
Carbon build-up behind turbine wheel caused by
coked oil or combustion deposits.
Dirt build-up behind compressor wheel caused by
air intake leaks.
Bearing seizure or dirty, worn bearings caused
by excessive temperatures, unbalanced wheel,
dirty oil, oil starvation, or insufficient
lubrication.
Clogged manifold system.
Foreign material lodged in compressor, impeller,
or turbine.
Excessive dirt build-up in compressor.
Leak in engine intake or exhaust manifold.
Leak in intake manifold-to-aneroid pipe.
Rotating assembly bearing failure.
Damaged compressor or turbine blades.
• Oil On Compressor Wheel Or In Compressor
Housing (Oil Being Pushed or Pulled Through
Center Housing):
Excessive crankcase pressure.
Air intake restriction.
Drain tube restriction.
*Do not confuse the whine heard during run down with noise which
indicates a bearing failure.
CTM42 (24MAR95)
110-6
S11,23005,K
-19-18AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=379
Air Intake System Operation and Test/How The Turbocharger is Lubricated
HOW THE TURBOCHARGER WORKS
The turbocharger, which is baically an air pump that is
driven by exhaust gases, allows the engine to produce
added power without increasing displacement.
Turbochargers are specially matched for the power ratio
requirements of each specific application.
110
7
-UN-14DEC88
Exhaust gases from the engine pass through the turbine
housing (B) causing the turbine wheel (A) to rotate
before the exhaust gas is discharged to the atmosphere.
The turbine wheels mounted on a shaft (F) to drive the
compressor wheel (D) which is also mounted on the
shaft.
R28273
As the compressor wheel rotates in the compressor
housing (E), an increased volume of (compressed) inlet
air is drawn into the housing and delivered to the intake
manifold (through an aftercooler or heat exchanger, if so
equipped).
A—Turbine Wheel
B—Turbine Housing
C—Center Housing
D—Compressor Wheel
E—Compresssor Housing
F—Shaft
All rotating components of the turbocharger are
lubricated within the center housing (C).
RG,CTM86,G110,3-19-16SEP94
HOW THE TURBOCHARGER IS
LUBRICATED
RG4646
The Garrett/AiResearch turbocharger contains two
floating bearings and the Schwitzer turbocharger contains
a single floating bearing. These bearings have clearance
between the bearing OD and the housing bore as well
as clearance between the bearing ID and the shaft OD.
These clearances are lubricated by the oil supply (E)
and the bearings are protected by a cushion of oil.
Discharge oil (F) drains by gravity from the bearing
housing to the engine crankcase.
-UN-29AUG94
Engine oil under pressure from the engine lubrication
system is pumped through a passage in the bearing
housing and directed to the bearings (A), thrust plate (B),
and thrust sleeve (C). Oil is sealed from the compressor
and turbine by a piston ring (D) at both ends of the
bearing housing.
Schwitzer Turbocharger Lubrication
A—Bearing(s)
B—Thrust Plate
C—Thrust Sleeve
D—Piston Ring
E—Pressure Oil
F—Discharge Oil
S11,3005,JE
CTM42 (24MAR95)
110-7
-19-16AUG94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=380
Air Intake System Operation and Test/How The Aftercooler Works—6076A Engines
HOW THE AFTERCOOLER WORKS—6076A ENGINES
RG5856
-UN-13AUG91
110
8
A—Heated Air
B—Cooled Air
NOTE: On some applications, aftercooler may be
mounted horizontally on engine. Specifications
are the same regardless of how aftercooler is
mounted.
Air entering intake manifold has been compressed
(and heated) by turbocharger. As this heated and
compressed air (A) enters intake manifold, it flows
around aftercooler before going to engine cylinders.
C—Engine Coolant
The aftercooler functions as a heat exchanger,
lowering intake air (B) temperature as much as
35˚—47˚C (95˚—116˚F). Lowering air temperature
makes air more dense, permitting an even greater
volume (compared with not having an aftercooler) to
be delivered to engine cylinders. This increased
volume of air, when combined with a predetermined
quantity of additional fuel, enables more power to be
produced.
Engine coolant (C) circulates through aftercooler core
and carries heat out of aftercooler. Extreme care
must be used to insure engine coolant does not leak
into intake manifold, resulting in possible damage to
engine.
RG,CTM42,G30,43-19-29OCT92
CTM42 (24MAR95)
110-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=381
Air Intake System Operation and Test/Check Intake Manifold Pressure (Turbocharger Boost)
CHECK INTAKE MANIFOLD PRESSURE (TURBOCHARGER BOOST)
NOTE: For each vehicle application, refer to the
appropriate machine technical manual for
intake manifold pressure specifications.
• If boost pressure is too high, remove and test fuel
injection pump for high fuel delivery.
110
9
• If boost pressure is too low, check for the following:
Intake manifold pressure (turbocharger boost) can be
checked at intake manifold and aneroid.
IMPORTANT: Engine speed and load should be
stabilized before taking readings on
gauge. Be sure that gauge works
properly.
Pressure checks are only a guide to
determine if there is an engine
problem (valve leakage, defective
nozzles, etc.). Low readings are not
a valid reason for increasing
injection pump fuel delivery. Pump
adjustment should be within
specification as established by an
authorized repair station.
—Restriction in air cleaner.
—Leak in air intake between turbocharger and
cylinder head.
—Defective turbocharger.
—Leak in exhaust manifold gasket.
—Leak in fuel control pipe.
—Restricted fuel filter elements.
—Incorrect fast idle adjustment.
—Incorrect injection pump timing.
—Faulty fuel supply pump.
—Low compression pressure.
—Faulty fuel injection nozzles.
—Carbon build-up in turbocharger.
—Turbocharger compressor or turbine wheel rubbing
housing.
—Low fuel injection pump delivery.
—Restricted exhaust.
RG,CTM42,110,6 -19-16AUG94
CTM42 (24MAR95)
110-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=382
Air Intake System Operation and Test/Check Intake Manifold Pressure (Turbocharger Boost)
• At Aneroid (If Equipped):
-UN-19AUG91
1. Remove aneroid line (A) from aneroid (B).
2. Install a 1/8-in. pipe nipple and “T” fitting (C) into
aneroid with a 1/4-in. to 1/8-in. pipe reducer (D).
RG5920
3. Connect aneroid line to “T” fitting.
4. Attach 1/8-in. NPT to 7/16-20 UNC Adapter (E) and
JT03017 Hose (F) to JD03092 Pressure Gauge (G).
5. With engine at operating temperature, connect to a
dynamometer. Operate engine at rated full load speed.
Observe pressure readings.
6. Remove test equipment and reinstall aneroid line.
A—Aneroid Line
B—Aneroid
C—T-Fitting
D—1/4—1/8 in. Pipe Reducer
E—Adapter
F—JT03017 Hose
G—JT03092 Pressure Gauge
RG,CTM42,G110,8-19-29OCT92
• At Intake Manifold:
6076A engine shown, use same procedure for 6076T
and 6076H.
1. Remove ether aid starting line (A), if equipped, nozzle
adapter and plug from intake manifold cover.
-UN-14DEC88
2. Install JT03104 Fitting (B) into cover.
3. Install a JT03017 Hose (C) with an accurate 0—400
kPa (0—4 bar) (0—60 psi) pressure gauge (D).
4. With engine at operating temperature, connect
machine to a dynamometer. Operate engine at rated full
load speed. Observe pressure reading.
5. Remove test equipment and reinstall ether starting aid
line.
RG4130
110
10
A—Ether Starting Aid
B—JT03104 Fitting
C—JD03017 Hose
D—JT03092 Pressure Gauge
RG,CTM42,110,7 -19-29OCT92
CTM42 (24MAR95)
110-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=383
Group 115
Fuel System Operation and Test
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the
U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS
-19-05JUN91
115
1
TIME TRAC® Kit .. JT07158
(FKM10429)
Used to perform the dynamic timing of engines.
• JT07158 Kit consists of the following:
26932 Meter
Magnetic Pickup
Transducer Cable
28037 SOI Clamp Assembly
28062 Instruction Booklet
Specification Sheet
JT07155 9/16 in. SOI Sensor
29361 Single Carton
29361 6-Pack Carton
JDE81-4 Timing Pin
JDG793 Magnetic Pickup Adapter
26924 Carry Case
-UN-09FEB95
consists of the following:
Meter
Timing Light
Transducer Cable
Sensor Clamp
6 mm Clamp-on Transducer
Sensor
Carrying Case
Instruction Manual
RG7246
• FKM10429 Kit
FKM10429-1
FKM10429-2
FKM10429-3
FKM10429-4
FKM10429-5
FKM10429-6
FKM10429-7
FKM10429-8
TIME TRAC® is a registered trademark of Stanadyne Automotive Corp.
RG,JT07158
-19-18FEB95
RG,JDG820
-19-14FEB95
-UN-10AUG94
Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820
RG7056
Used to rotate engine to check damper radial runout and
time engine. JDE81-1 may be used also if JDG820 is
not available.
CTM42 (24MAR95)
115-1
6076 Diesel Engines—S.N. (500000—
)
160101
PN=384
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
RG5068
-UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train.
S53,JDE814A
-19-08AUG94
115 FUEL SYSTEM TEST SPECIFICATIONS
2
ITEM
SPECIFICATIONS
Mechanical Fuel Supply Pump Minimum Output Pressure . . . . . 200 kPa (2.0 bar) (29.0 psi)
Hydraulic Aneroid Activator Operating
Pressure (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 48—75 kPa (0.5—0.8 bar) (7—11 psi)
Fuel Injection Pump Timing-to-Engine . . . . . . . . . . . . . . . . . . TDC
Engine Speeds (RPM)*
TORQUES
In-Line Injection Pump Drive Gear-to-Pump Hub:
A Pumps . . . . . . . . . . . . . . . . . . . . . . . . . .
P Pumps . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Injection Pump Gear-to-Pump Hub . . . . . .
Rotary Injection Pump-to-Cylinder Block Stud Nuts
Injection Pump Drive Gear Cover . . . . . . . . . . .
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* For each application, refer to the appropriate machine technical
manual for slow idle, fast idle, and rated speed specifications.
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. 47 N·m
. 61 N·m
130 N·m
. 27 N·m
. 27 N·m
(35
(45
(95
(20
(20
lb-ft)
lb-ft)
lb-ft)
lb-ft)
lb-ft)
RG,CTM42,115,1 -19-12JUL94
CHECK AND ADJUST ROTARY FUEL
INJECTION PUMP DYNAMIC TIMING USING
JT07158 TIME TRAC KIT
The JT07158 Time Trac Kit electronically indicates start
of injection with respect to piston top dead center (TDC),
and allows accurate setting of injection pump timing to
provide optimum power, smoke, and exhaust emissions.
Timing engines with this timing kit improves consistency
between engines and helps to control cylinder firing
pressures which can be a factor in head gasket failures
as well as improve overall engine efficiencies.
RG,CTM42,115,46-19-14FEB95
CTM42 (24MAR95)
115-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=385
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
• Install JT07158 Time Trac Kit:
-UN-06FEB95
IMPORTANT: All transducers and sensors must be
installed at nozzle end of No. 1 fuel
injection line. If access to No. 1 line is
restricted, sensor can be installed on
No. 6 injection line.
RG7285
Remove all paint from injection line
where clamp-on transducer will be
installed and be sure this location is
thoroughly clean.
1. On engines with optional JT07155 In-Line SOI Sensor
(A) installed between injection nozzle and fuel delivery
line, install JT07173 SOI Clamp Assembly (B) onto clean
sensor and tighten securely.
-UN-13FEB95
2. On engines without optional JT07155 In-Line Sensor,
install JT07177 6 mm (green) Clamp-on Transducer (E)
onto clean, paint-free injection line and tighten securely.
RG7286
3. Assemble red lead of JT07172 Transducer Cable (C)
onto in-line sensor or transducer, however equipped.
4. Attach spring clip to a solid ground. Plug connector
into JT07170 meter port marked SR.
A—JT07155 In-Line SOI Sensor
B—JT07173 SOI Clamp Assembly
C—JT07172 Transducer Cable
D—Fuel Injection (Delivery) Line
E—JT07177 6 mm (Green) Clamp-on Transducer
RG,CTM42,115,50-19-17MAR95
CTM42 (24MAR95)
115-3
6076 Diesel Engines—S.N. (500000—
)
160101
PN=386
115
3
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
6. Install JDG821 Magnetic Pick-up Adapter (B) into
flywheel housing. Lightly tap adapter to lock into position.
Insert probe of magnetic pick-up (A) into adapter until it
contacts the flywheel. Pull probe back out to provide
0.64 mm (0.025 in.) air gap.
7. Plug magnetic pick-up adapter connector into JT07170
meter port marked MP.
RG7288
115
4
-UN-07FEB95
5. Use JDE81-4 Timing Pin in flywheel timing hole (C) to
ensure engine is NOT stopped at TDC. Magnetic pick-up
probe will enter TDC timing hole in flywheel and be
damaged when engine is started. An air gap of 0.64 mm
(0.025 in.) is recommended between tip of probe and
flywheel face.
A—Magnetic Pick-up
B—JDG821 Magnetic Pick-up Adapter
C—Flywheel Timing Hole
RG,CTM42,115,47-19-17MAR95
CTM42 (24MAR95)
115-4
6076 Diesel Engines—S.N. (500000—
)
160101
PN=387
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
• Check Injection Pump Rated Load Dynamic Timing:
1. Engine OFF. Push ON/CLEAR button.
Display shows: R=0
RG7031
-UN-27SEP94
115
5
2. Push MAG PROBE button.
Display shows: Trig Level: 30%
RG7032
-UN-27SEP94
3. Change to 70% and push ENTER.
RG,CTM8,G115,23-19-02FEB95
CTM42 (24MAR95)
115-5
6076 Diesel Engines—S.N. (500000—
)
160101
PN=388
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
Display shows: Offset: 20.0˚
4. Change to offset 0˚ and push ENTER.
RG7033
-UN-27SEP94
115
6
Display shows: Calibrate?
RG7129
-UN-06OCT94
5. Start engine and push ENTER.
RG,CTM8,G115,24-19-02FEB95
CTM42 (24MAR95)
115-6
6076 Diesel Engines—S.N. (500000—
)
160101
PN=389
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
6. Run engine at 1300 rpm. Push ENTER.
Display shows: Calibrating then Engine RPM and timing.
NOTE: If display shows NO PROBE, the magnetic
pick-up probe has not been installed properly [air
gap exceeds 0.64 mm (0.025 in.)] or there is
debris on the back of the flywheel. Check for
proper air gap or to clean the back side of the
flywheel, insert a soft wooden dowel into the
engine timing pin hole with the engine running at
low idle speed to clean the debris from flywheel.
115
7
7. Warm engine to normal operating temperature, check
slow and fast idle rpm. See FUEL INJECTION PUMP
SPECIFICATIONS earlier in this group. Adjust speeds as
necessary.
RG,CTM8,G115,25-19-02FEB95
CTM42 (24MAR95)
115-7
6076 Diesel Engines—S.N. (500000—
)
160101
PN=390
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
8. Run engine at wide open throttle (WOT) and load
engine down gradually to rated speed rpm.
RG7037
115
8
-UN-27SEP94
IMPORTANT: Many machines have hydraulic pumps
that have adequate flow to load engine
well below rated load rpm. Some
equipment may need to be driven in
high gear or pull a load to bring engine
speed to rated load rpm.
NOTE: A negative timing value indicates the clamp-on
sensor signal is not adequate. Check sensor and
lines for cleanliness and proper installation.
9. Record engine speed (rpm) and timing degrees.
IMPORTANT: Stop engine prior to making timing
adjustments. Injection pump can seize
if adjustment is made with engine
running.
10. Stop engine.
If dynamic timing reading is more than 8 degrees
retarded with pump flange and front plate timing marks
at original location as shipped from factory, this may
indicate the pump advance is not functioning. Check the
following:
• Change fuel filter(s)
• Check transfer pump for positive fuel pressure to
injection pump
• Check camshaft movement on injection pumps with
rectangular timing window.
• Check pump drive shaft-to-gear key or pin to ensure
key or pin has not sheared.
• If none of the above checks are conclusive, remove
pump and have necessary repairs made at an authorized
diesel repair station.
RG,CTM8,G115,26-19-02FEB95
CTM42 (24MAR95)
115-8
6076 Diesel Engines—S.N. (500000—
)
160101
PN=391
Fuel System Operation and Test/Check and Adjust Rotary fuel pump Dynamic Timing
• Adjust Injection Pump Dynamic Timing:
1. Loosen injection pump mounting flange nuts and
adjust pump timing.
To advance pump timing, rotate top of pump clockwise
view from rear (flywheel end) of engine. To retard timing,
rotate top of pump counterclockwise. Pump flange
movement of 1.524 mm (0.060 in.) is equivalent to 2
degrees of engine timing.
-UN-26OCT92
115
9
RG6465
2. Tighten injection pump mounting flange nuts to 47
N·m (35 lb-ft). Start engine and check injection pump
dynamic timing again. Adjust timing as needed.
3. Grind away original timing mark and stamp new timing
mark onto injection pump flange so timing mark (A)
aligns after all final adjustments have been made and
satisfactory engine performance is achieved.
RG,CTM42,115,48-19-14FEB95
CTM42 (24MAR95)
115-9
6076 Diesel Engines—S.N. (500000—
)
160101
PN=392
Fuel System Operation and Test/Fuel System Operation—In-Line Fuel Injection Pump
FUEL SYSTEM OPERATION—IN-LINE FUEL INJECTION PUMP
RG6665
-UN-13MAR93
115
10
A—Fuel Filter
B—Check Valve Assembly
C—Pump Plungers
D—Fuel Galley
E—Supply Pump
F—Injection Pressure Lines
G—Nozzles
H—Leak-Off Line
The supply pump (E) draws fuel from the vented fuel
tank through the primary filter (K).
The supply pump pressurizes the fuel so that it flows
through the filter (A) to the injection pump galley (D).
Supply pump output pressure will vary depending on
load and application.
The galley is kept full by the supply pump. Injection
pump plungers (C) further pressurize the fuel.
Injection pressure lines (F) route the fuel to the
nozzles (G).
CTM42 (24MAR95)
I—Fuel Shut-off Solenoid
J—Supply Pump Outlet
K—Round Primary
Filter/Water Separator
L—Injection Pressure
M—Supply Pump Pressure
N—Fuel Return
O—Gravity Pressure
The high pressure fuel opens the nozzle valve and
forces fuel out the small orifices in the nozzle tip.
This atomizes the fuel as it enters the combustion
chamber.
There are two sources of excess fuel incorporated
into the system. The supply pump supplies more fuel
to the pump than is required by the engine, and the
nozzle requires excess fuel to lubricate the nozzle
valve. A leak-off line (H) returns this excess fuel to
the tank from both the pump and nozzles.
RG,CTM42,115,3 -19-07APR93
115-10
6076 Diesel Engines—S.N. (500000—
)
160101
PN=393
Fuel System Operation and Test/Fuel System Operation—Rotary Fuel Injection Pump
FUEL SYSTEM OPERATION—ROTARY FUEL INJECTION PUMP
RG6454
-UN-22OCT92
115
11
A—Electric Fuel Supply
Pump
B—Fuel Filter
C—Fuel Injection Pump
D—Injection Pressure Lines
E—Fuel Injection Nozzles
F—Fuel Inlet Line
The electric fuel supply pump (A) draws fuel from the
tank and pressurizes it. This pressure permits the fuel
to flow through the filter (B) and charge the transfer
pump of the injection pump (C).
With the fuel injection pump charged with fuel by the
fuel supply pump, the injection pump plungers
pressurize the fuel to approximately 50 000 kPa (500
bar) (7255 psi). Injection pressure lines (D) are used
to route this high pressure fuel to the fuel injection
nozzles (E).
Fuel enters the injection nozzle at a pressure which
easily overcomes the pressure required to open the
nozzle valve. When the nozzle valve opens, fuel is
forced out through the orifices in the nozzle tip and
atomizes as it enters the combustion chamber.
G—Fuel Supply Pump
Pressure
H—Fuel Injection Pump
Pressure
I—Fuel Return (Leak-off) Line
Pressure
Incorporated into the fuel system is a means of
returning excess (or unused) fuel back to the fuel
tank. Excess fuel comes from two sources:
1. Fuel Injection Pump: A quantity of fuel greater than
that required by the engine is supplies to the fuel
injection pump.
2. Fuel Injection Nozzles: A small amount of fuel
seeps past the nozzle valve for lubrication purposes.
To get the excess fuel back to the tank, a return line
from the injection pump is connected to the middle of
the nozzle leak-off line. Fuel from both sources is
then returned to the tank by a return pipe connected
to the front end of the leak-off pipe.
RG,CTM42,115,33-19-28OCT92
CTM42 (24MAR95)
115-11
6076 Diesel Engines—S.N. (500000—
)
160101
PN=394
Fuel System Operation and Test/Diagnose Fuel System Malfunctions
DIAGNOSE FUEL SYSTEM MALFUNCTIONS
NOTE: The following diagnostics apply to either standard
mechanical in-line or rotary fuel pumps, or
electronic governor type fuel pumps. See CTM11
for additional electronic pump diagnostics.
115
12
Symptom
Problem
Solution
Fuel Not Reaching Injection
Nozzles
Fuel filter restricted
Replace fuel filter (See Group 35)
Fuel line restricted
Clean lines as required
Fuel too heavy at low temperatures
Use correct grade of fuel (See
Group 02)
Air in system
Correct problem and bleed fuel
system (this group)
Fuel tank valve shut off
Open fuel tank valve
Low supply pump pressure
Check fuel lines for restrictions;
check pump output pressure (this
group)
Fuel too heavy at low temperature
Use correct grade of fuel (See
Group 02)
Injection nozzles faulty or sticking
Repair or replace as required (See
Group 35)
Incorrect timing
Adjust timing (this group)
Faulty injection pump
Repair or replace
Water in fuel
Drain water from fuel (or separator
if equipped). Install new filter (See
Group 35)
Fuel filter restricted
Replace fuel filters (See Group 35)
Low supply pump pressure
Check pump output pressure. (See
this group)
Injection pump return fuel line or
fittings restricted
Clean lines as required
Low cetane fuel
Use correct grade of fuel (See
Group 02)
Broken starting fuel control shaft
spring
Repair (See Group 35)
Engine Starts Hard or Won’t Start
Continued on next page
CTM42 (24MAR95)
115-12
6076 Diesel Engines—S.N. (500000—
)
160101
PN=395
Fuel System Operation and Test/Diagnose Fuel System Malfunctions
Symptom
Engine Starts and Stops
Erratic Engine Operations
Engine Emits Excessive Black
Smoke
Problem
Solution
Injection pump drive gear teeth
worn or broken
Check timing gear backlash and
check for failed crankshaft vibration
damper.
Air in system
Correct problem and bleed fuel
system (See this group)
Fuel filter restricted
Replace fuel filter (See Group 35)
Fuel lines restricted
Clean lines as required
Water in fuel
Drain water from fuel, (or separator
if equipped). Install new filter (See
Group 35)
Injection pump return fuel line or
fittings restricted
Clean lines as required
Fuel filter restricted
Replace fuel filter (See Group 35)
Fuel too heavy at low temperatures
Use correct grade of fuel (See
Group 02)
Injection nozzles faulty or sticking
Repair (See Group 35)
Fuel lines restricted
Clean as required
Incorrect timing
Adjust timing (this group)
Governor faulty
Repair (See Group 35)
Water in fuel
Drain water from fuel (or separator,
if equipped). Install new filter
Injection pump return fuel line or
fittings restricted
Clean lines as required
Low cetane fuel
Use correct grade of fuel (See
Group 02)
Injection nozzle return lines
restricted
Clean lines as required
Injection nozzles faulty or sticking
Repair (See Group 35)
Injection pump timing incorrect
Adjust timing (this group)
Low cetane fuel
Use correct grade of fuel (See
Group 02)
115
13
Continued on next page
CTM42 (24MAR95)
115-13
6076 Diesel Engines—S.N. (500000—
)
160101
PN=396
Fuel System Operation and Test/Diagnose Fuel System Malfunctions
Symptom
115
14
Engine Emits Excessive Blue or
White Smoke
Engine Idles Poorly
Engine Does Not Develop Full
Power
Problem
Solution
Over-fueling
Repair and adjust (See Group 35)
Aneroid defective
Repair and adjust (See Group 35)
Cranking speed too low
Check batteries and electrical
system
Injection pump timing incorrect
Adjust timing (this group)
Injection nozzles faulty or sticking
Repair (See Group 35)
Excessive wear in liners and/or
piston rings stuck
See Group 10
Incorrect cetane fuel for ambient
temperature
Use correct grade of fuel (See
Group 02)
Engine running too “cold”
Check thermostat (See Group 25)
Injection nozzles faulty or sticking
Repair (See Group 35)
Incorrect timing
Adjust timing (this group)
Pump slow idle speed not correctly
adjusted
Adjust slow idle speed (this group)
Fuel lines restricted
Clean as required
Water in fuel
Drain water from filter, (or separator
if equipped). Install new filters (See
Group 35)
Injection pump return lines or
fittings restricted
Clean as required
Injection nozzle return lines clogged
Clean as required
Low cetane fuel
Use correct grade of fuel (See
Group 02)
Low cetane fuel
Use correct grade of fuel (See
Group 02)
Incorrect timing
Adjust timing (this Group)
Injection pump or governor faulty
Repair (See Group 35)
Fuel filter clogged
Replace fuel filter (See Group 35)
Continued on next page
CTM42 (24MAR95)
115-14
6076 Diesel Engines—S.N. (500000—
)
160101
PN=397
Fuel System Operation and Test/Diagnose Fuel System Malfunctions
Symptom
Engine Does Not Develop Full
Power
Problem
Solution
Injection nozzles faulty or sticking
Repair (See Group 35)
Injection pump return fuel line or
fittings restricted
Clean as required
Water in fuel (or gasoline in fuel)
Drain water or replace with clean
fuel Install new filters (this Group)
Incorrect fast idle speed
Adjust speed (this Group)
Manifold pressure pipe to aneroid
loose or broken
Repair as required
Fuel shut-off cable improperly
adjusted
Adjust
115
15
RG,CTM42,115,2 -19-28OCT92
CTM42 (24MAR95)
115-15
6076 Diesel Engines—S.N. (500000—
)
160101
PN=398
Fuel System Operation and Test/Mechanical Fuel Supply Pump Operation Operation
MECHANICAL FUEL SUPPLY PUMP OPERATION
RG5926
-UN-19AUG91
115
16
A—Fuel Inlet
B—Plunger
C—Fuel Outlet
D—Hand Primer
Nippondenso pump shown
The plunger-type Robert Bosch or Nippondenso fuel
supply pump is used on 6076 engines. It is mounted
on the side of the injection pump housing and is
driven by the injection pump camshaft. Fuel enters
the supply pump at (A), is pressurized by the plunger
(B), and discharged through outlet (C). The hand
primer (D) provides manual pump operation for
bleeding the fuel system.
RG,CTM42,115,4 -19-28OCT92
CTM42 (24MAR95)
115-16
6076 Diesel Engines—S.N. (500000—
)
160101
PN=399
Fuel System Operation and Test/Mechanical Fuel Supply Pump Operation Operation
MECHANICAL FUEL SUPPLY PUMP OPERATION—CONTINUED
RG5787
-UN-06AUG91
115
17
A—Camshaft
B—Roller Tappet
C—Pressure Spindle
D—Plunger
E—Plunger Spring
F—Suction Chamber
G—Pressure Valve
H—Pressure Chamber
I—Suction Valve
J—Fuel Inlet
K—Hand Primer Pump
L—Fuel Outlet
As the pump camshaft (A) rotates toward the “high
cam” intermediate stroke position (M), the roller
tappet (B) and pressure spindle (C) cause the
plunger (D) to move against and compress the
plunger spring (E).
Plunger movement forces the fuel out of the suction
chamber (F), through the pressure valve (G), and into
the pressure chamber (H). The amount of fuel
discharged from the suction chamber is equal to the
amount of fuel delivered for each stroke of the
plunger. Towards the end of the intermediate stroke,
the spring-loaded pressure valve closes again.
As the camshaft rotates toward the “low cam” or
suction and discharge position (N), plunger spring
pressure causes the plunger, pressure spindle, and
roller tappet to follow the camshaft.
M—Intermediate Stroke
Position
N—Suction and Discharge
Stroke Position
Movement of the plunger pushes the fuel from the
pressure chamber, and delivers it to the fuel filters
and injection pump. At the same time, plunger suction
pressure is permitting fuel to enter the suction
chamber through the suction valve (I). With the
suction chamber charged with fuel, the pumping cycle
begins again.
Fuel is allowed to flow in around the pressure spindle
to lubricate the spindle as it moves back and forth in
housing. To prevent the fuel from entering the pump
crankcase, a rubber O-ring is positioned in the
spindle bore of housing at the roller tappet end.
Unscrewing the knurled knob on the hand primer
pump (K) and pulling upward causes the suction
valve to open and fuel to flow into the suction
chamber. When the hand plunger is pushed
downward, the suction valve closes, and fuel is
forced out of the pressure valve.
RG,CTM42,115,5 -19-28OCT92
CTM42 (24MAR95)
115-17
6076 Diesel Engines—S.N. (500000—
)
160101
PN=400
Fuel System Operation and Test/Diagnosing Mechanical Fuel Supply Pump Malfunctions
DIAGNOSING MECHANICAL FUEL SUPPLY PUMP MALFUNCTIONS
IMPORTANT: Visually inspect the fuel inlet fitting
and pump filter for possible
plugging before disassembling to
determine cause of malfunction.
115
18
Symptom
Problem
Solution
Low Supply Pump Output
Pressure or Pump Not
Functioning Correctly
Restriction at fuel inlet fitting.
Thoroughly clean fuel tank, lines,
filters, and inlet fitting.
Hand primer not screwed down
tight, allowing dirt to enter hand
primer plunger chamber
(Nippondenso pumps only).
Advise customer to tighten hand
primer after use.
Worn or pitted valves caused by
foreign material lodging in valve.
Replace valves as required.
Missing or broken spring(s).
Replace spring(s).
Broken spindle.
Replace pump.
Out of fuel.
Add fuel to fuel tank.
Fuel shut off at tank.
Open fuel shut off valve.
Restricted fuel line.
Clean as required.
Air leak in fuel line between pump
and tank.
Repair as required.
Loose or damaged fuel line
connetions.
Repair.
Hand primer left in upward position
(Nippondenso pump only)
Bleed fuel system, gently push hand
primer down and tighten securely.
Worn or damaged valve
assemblies/
Repair or replace.
Broken valve spring(s)
Repair or replace.
RG,CTM42,G35,48-19-28OCT92
CTM42 (24MAR95)
115-18
6076 Diesel Engines—S.N. (500000—
)
160101
PN=401
Fuel System Operation and Test/Test Mechanical Fuel Supply Pump for Leaks
DIAGNOSE MECHANICAL FUEL SUPPLY PUMP MALFUNCTION—CONTINUED
Symptom
Problem
Solution
Diesel Fuel Leaking Into Injection
Pump Crankcase
Worn spindle and/or pump housing.
Replace pump.
Defective O-ring seal.
Replace O-ring seal.
Supply Pump Will Not Pump on
P-Size Pump
Supply pump from A-Series
Injection pump may have been
installed.
Install correct supply pump on
injection pump.
Supply Pump Mounting Flange
Breaks When Mounted on A-Size
Pump and Operated
Supply pump from P-Series
Injection pump may have been
installed.
Install correct supply pump on
injection pump.
115
19
RG,CTM42,115,21-19-28OCT92
TEST MECHANICAL FUEL SUPPLY PUMP
FOR LEAKS
Fuel delivery pressure should be checked before
removing supply pump from injection pump. (See
CHECK MECHANICAL FUEL SUPPLY PUMP
OPERATION, in Group 115.)
1. Connect compressed air line (A) to a pressure gauge
(B) and to supply pump inlet fitting. Air line should have
a regulating valve to control pressure.
-UN-19AUG91
2. Cap or plug supply pump outlet fitting (C).
3. Submerge supply pump in a container of clean diesel
fuel. Regulate air pressure to 200 kPa (2.0 bar) (29 psi).
RG5894
4. Move roller tappet (Nippondenso pumps) or spindle
(Bosch pumps) in and out by hand. No air bubbles
should appear around roller tappet or spindle bore.
NOTE: If bubbles appear, it is an indication that either
the O-ring seal is defective or spindle or tappet is
worn (or possibly both).
IMPORTANT: Serious injection pump or engine
damage could occur, if enough diesel
fuel leaks past spindle and seal. Fuel
leakage past spindle dilutes engine oil.
RG,CTM42,G35,9 -19-28OCT92
CTM42 (24MAR95)
115-19
6076 Diesel Engines—S.N. (500000—
)
160101
PN=402
Fuel System Operation and Test/Check Mechanical Fuel Supply Pump Operation
CHECK MECHANCIAL FUEL SUPPLY PUMP
OPERATION
• Test fuel supply pump and hand primer for leaks:
RG5903
115
20
-UN-19AUG91
NOTE: The following test procedures can best be
performed under moderate air temperature
conditions to reduce electrical loads when
cranking the engine is required.
1. Make a preliminary inspection of supply pump.
Thoroughly clean area around pump. All connections
must be tight and not leaking.
2. Start engine and bring to operating temperature.
Shut-off engine.
NOTE: If fuel leaks around a Nippondenso hand primer
that is screwed down tight when engine is
running, replace the hand primer.
Robert Bosch hand primers (A) are spring loaded
to remain in the fully extended position. If fuel
leaks around a Bosch hand primer while seated
in the extended position, replace the hand primer.
3. Check operation of hand primer. With engine shut-off,
unscrew knob (Nippondenso only) and operate hand
primer through several strokes. Moderate to heavy
leakage of fuel between plunger and barrel indicates seal
is defective. Replace hand primer.
NOTE: Appearance of a slight quantity of fuel around the
plunger is normal.
IMPORTANT: On Nippondenso pumps, be sure hand
primer is seated all the way down in
barrel before tightening to prevent
internal thread damage.
4. On Nippondenso pumps only, tighten hand primer
knob, but do not overtighten. If knob will not tighten
(indicating internal thread damage), replace hand primer.
RG,CTM42,115,6 -19-17MAR95
CTM42 (24MAR95)
115-20
6076 Diesel Engines—S.N. (500000—
)
160101
PN=403
Fuel System Operation and Test/Check Mechanical Fuel Supply Pump Operation
• Test operation of suction side of pump:
• Test operation of discharge side of pump:
1. Disconnect suction and discharge lines at pump.
1. Suction line must be connected and discharge
(pressure) line disconnected.
2. Drain all fuel from pump by operating hand primer.
Then reconnect suction line to pump.
3. Operate hand primer until fuel flows from pump
outlet (discharge). Fuel should flow within 15—25
strokes. If not, the suction line may be obstructed or
leaking air; (replace in-line filter when used).
NOTE: When operating hand primer, a moderate
resistance should be felt. When only a slight
resistance (or no resistance) occurs, replace
hand primer or repair pump (valves may be
defective).
2. Tighten hand primer (Nippondenso only) and place
injection pump fuel shut-off control in “STOP” position
to prevent engine from starting.
115
21
3. Crank engine with starting motor. Fuel should flow
from pump outlet within 10 seconds. If not, the
suction line may be obstructed or leaking air; (replace
in-line filter when used).
If fuel does not flow, and if no leak or obstruction is
found, pump is defective. Repair or replace pump.
(See Group 35.)
S11,23010,FJ
-19-14FEB95
• Test pump output pressure while cranking engine:
1. Connect a 0—400 kPa (0—4 bar) (0—60 psi)
pressure gauge to one end of a pressure hose about
250—300 mm (10—12 in.) long. Connect other end of
hose to pump outlet. All air must be out of system.
IMPORTANT: The starting motor must crank the
engine at normal cranking speed. Use
booster batteries if necessary.
-UN-19AUG91
2. Crank engine for 10 seconds with starting motor
(approximately 300 engine rpm). Supply pump minimum
outlet pressure should be 200 kPa (2.0 bar) (29.0 psi).
RG5927
3. Compare measured output with the minimum pressure
specifications.
If pressure is below the minimum specified and if no
obstruction or leak is found, repair or replace the pump.
RG,CTM42,115,7 -19-17MAR95
CTM42 (24MAR95)
115-21
6076 Diesel Engines—S.N. (500000—
)
160101
PN=404
Fuel System Operation and Test/Service Mechanical Fuel Supply Pump
SERVICE MECHANICAL FUEL SUPPLY
PUMP
NOTE: Gaining access to the valves on Robert Bosch
supply pump requires removal and disassembly
of the supply pump, (See Group 35).
-UN-14DEC88
1. To gain access to the valves on Nippondenso supply
pump, remove hand primer, banjo fitting, and plug from
top of supply pump (shown removed).
2. Remove valves (B) and springs (A).
3. Inspect valves and valve seats for foreign material,
wear or pitting. Valve springs must not be cracked or
broken.
RG78153D1
115
22
Nippondenso pump
4. Reassemble parts, open tank shut-off valve, and
check operation. If the pump operation is still not normal,
the pump will have to be repaired or replaced. (See
Group 35.)
RG,CTM42,115,8 -19-28OCT92
CTM42 (24MAR95)
115-22
6076 Diesel Engines—S.N. (500000—
)
160101
PN=405
Fuel System Operation and Test/Electric Fuel Supply Pump Operation
ELECTRIC FUEL SUPPLY PUMP OPERATION
RG6450
-UN-15OCT92
115
23
A—Fuel Inlet
B—Fuel Outlet
The electric supply pump is used on 6076 Engines
equipped with the rotary fuel injection pump.
As the coil is energized, the plunger is forced down.
When the coil de-energizes, a spring forces the
plunger back up creating a vacuum. The vacuum
draws fuel in through the inlet valve and fills the
plunger area. This fuel is then forced out the top of
the pump on the subsequent stroke. Maximum
pressure delivered by this pump is 69 kPa (0.7 bar)
(10 psi) at 2.8 A.
Operation of the pump can be determined by listening
for a “clicking” sound when the key is “ON”. A sharp
clicking is an indication that there is no fuel getting to
the pump. Fuel flowing through the pump muffles the
clicking sound. If no clicking sound is heard, check
wiring harness for 12 v. If pumps clicks once then
quits, there is most likely an electrical problem in the
pump and the pump will have to be replaced, as it is
not repairable.
RG,CTM42,115,24-19-28OCT92
CTM42 (24MAR95)
115-23
6076 Diesel Engines—S.N. (500000—
)
160101
PN=406
Fuel System Operation and Test/Diagnose Electric Fuel Supply Pump Malfunction
DIAGNOSE ELECTRIC FUEL SUPPLY PUMP MALFUNCTION
Symptom
Problem
Solution
Low Supply Pump Pressure or
Pump Not Functioning Correctly
Out of fuel
Add fuel to fuel tank.
Fuel shut off at tank
Open fuel shut-off valve.
Restricted fuel line
Clean as required.
Air leak in fuel line between pump
and tank
Repair as required.
Loose or damaged fuel line
connections
Repair.
115
24
RG,CTM42,115,25-19-28OCT92
CTM42 (24MAR95)
115-24
6076 Diesel Engines—S.N. (500000—
)
160101
PN=407
Fuel System Operation and Test/Test Electric Fuel Supply Pump Output Pressure and Flow
TEST ELECTRIC FUEL SUPPLY PUMP FOR
OUTPUT PRESSURE AND FLOW
-UN-26OCT92
• Output Pressure Test:
1. Bleed fuel system. See BLEED FUEL SYSTEM later
in this group.
RG6481
2. Put key in “ON” position.
3. Connect pressure gauge to one end of pressure hose.
Connect other end of hose to pump outlet.
4. Measure output pressure.
ELECTRIC FUEL SUPPLY PUMP OUTPUT PRESSURE
Normal . . . . . . . . . . . . . . . . 62—69 kPa (0.62—0.69 bar) 9—10 psi
If output pressure is low, it may be the result of a
partially obstructed supply pump filter screen. See
CLEAN OR REPLACE ELECTRIC FUEL SUPPLY
FILTER SCREEN in Group 35.
• Flow Test:
A clean fuel supply and a 12v power supply is needed
for this test.
1. Disconnect fuel inlet line from supply line.
2. Connect pressure hose to pump inlet. Submerge the
other end of hose in clean fuel.
3. With key in “ON” position, supply pumps should pump
3 qts. of fuel in 1 minute or 45 gallons per hour.
If pump does not meet these specifications, see
DIAGNOSING ELECTRIC SUPPLY PUMP
MALFUNCTIONS earlier in this group.
RG,CTM42,115,26-19-02NOV92
CTM42 (24MAR95)
115-25
6076 Diesel Engines—S.N. (500000—
)
160101
PN=408
115
25
115
26
-UN-04DEC91
RW19613
1. Observe fuel shut-off lever (A) when key switch is
turned from “OFF” to “START” (engine running at slow
idle) and then released to “ON” position.
RW19612
FUEL SHUT-OFF SOLENOID OPERATIONAL
CHECK
-UN-04DEC91
Fuel System Operation and Test/Test Electric Fuel Supply Pump Output Pressure and Flow
2. Fuel shut-off lever should move from “NO FUEL”
position (B) to “RUN” position (C) when starting motor
begins to crank. The lever should remain at the “RUN”
position after key switch is released to “ON” position.
If fuel shut-off lever returns to “NO FUEL” position with
key switch at “ON” position, check for:
—Loss of battery voltage to fuel shutoff winding. Check
voltage and wiring connection to solenoid.
—Binding of fuel shut-off lever, solenoid rod or linkage
does not allow solenoid to lock in position. Repair or
replace linkage.
—Torn or leaking rubber boot allowing dirt or moisture to
enter at spring end of solenoid rod.
—Improperly adjusted fuel shut-off solenoid linkage. See
FUEL SHUT-OFF SOLENOID LINKAGE
ADJUSTMENT, later in this group.
3. Start engine and run at slow idle. Turn key switch to
“OFF” position.
4. Fuel shut-off lever should move to “NO FUEL” position
and engine should stop.
If the solenoid stops just short of the “NO FUEL”
position, slight adjustment of the linkage is required. See
FUEL SHUT-OFF SOLENOID LINKAGE ADJUSTMENT,
later in this group.
If engine continues to run with key switch at “OFF”
position, unplug shut-off solenoid 3-way connector.
—If solenoid moves lever to “NO FUEL” position,
problem is in the electrical circuit.
—If solenoid does not shut off fuel to engine, check
linkage for binding or excessive tightness.
Replacement service kit is available with a swivel rod
which is less sensitive to misalignment and binding.
RG,CTM61,115,29-19-13MAY93
CTM42 (24MAR95)
115-26
6076 Diesel Engines—S.N. (500000—
)
160101
PN=409
Fuel System Operation and Test/Fuel Shut-Off Solenoid Resistance Test
FUEL SHUT-OFF SOLENOID RESISTANCE
TEST
1. Disconnect shut-off solenoid 3-way WEATHER
PACK™ connector.
2. Measure “PULL” coil resistance between black lead
wire “C” and white lead wire “B”.
115
27
3. Measure “HOLD” coil resistance between black lead
wire “C” and red lead wire “A”.
Replace solenoid if resistance is not within specification
given below.
PULL AND HOLD COIL RESISTANCE SPECIFICATIONS
Hold Coil
Resistance
(Ohms)
12-Volt System:
RE53507, RE55415 . . . . . . 0.187—0.281
RE53559 . . . . . . . . . . . . . 0.140—0.210
10.04—12.27
6.63—8.11
24-Volt System:
RE54747, RE55416 . . . . . . 0.735—0.899
RE53560 . . . . . . . . . . . . . 0.560—0.684
37.22—45.49
24.35—29.76
WEATHER PACK is a trademark of Packard Electric.
-UN-04DEC91
RG,CTM42,115,45-19-16AUG94
FUEL SHUT-OFF SOLENOID LINKAGE
ADJUSTMENT
RW19614
Shut-off solenoid linkage is factory adjusted and usually
will not require additional field adjustment. ALWAYS
check linkage and lever for alignment and binding before
making adjustments.
-UN-04DEC91
Pull Coil
Resistance
(Ohms)
RW19615
Solenoid
Part Number
1. Thoroughly lubricate all linkage and lever pivot points.
2. If necessary, adjust linkage (A) so that lever (B)
contacts stop (C) with key switch “OFF” and engine not
running.
A—Link
B—Lever
C—Stop
D—Stop
3. Start engine and run at slow idle. Lever should
contact stop (D) or nearly contact when the lever is
being pushed up.
RG,CTM61,115,30-19-13MAY93
CTM42 (24MAR95)
115-27
6076 Diesel Engines—S.N. (500000—
)
160101
PN=410
Fuel System Operation and Test/Round (Final) Fuel Filter Operation
RECTANGULAR FUEL FILTER OPERATION
-UN-28APR89
Since water and other contaminants may settle to the
bottom of the sediment bowl, a drain plug (F) is provided
to permit their removal.
R26812
An air vent (C) enables air in the fuel system to be
expelled to the outside through the filters when bleed
plug is removed.
A—Inlet
B—Outlet
C—Air Vent
D—Second Stage Filtering Media
E—First Stage Filtering Media
F—Drain Plug
G—Sediment Bowl
RG,CTM42,115,27-19-28OCT92
ROUND (FINAL) FUEL FILTER OPERATION
Fuel enters the filter at the inlet (A), then flows through a
primary filter (B) and a secondary filter (C) before exiting
filter through outlet (D) to the fuel injection pump. The
filter elements are housed in a sediment bowl attached
to the base with a threaded (detent) ring.
Since water and contaminants settle at the bottom of the
sediment bowl, a drain plug (E) is provided.
Air in the system can be expelled through the air vent
when bleed screw is loosened.
-UN-13OCT92
A—Fuel Inlet
B—Primary Filter
C—Secondary Filter
D—Fuel Outlet
E—Drain Plug
RG6444
115
28
Fuel enters the filter at (A) and flows through a first
stage filtering media (E) and a second stage filtering
media (D) before flowing through outlet (B) to the
injection pump. The filtering media is housed in the
metal sediment bowl (G) and epoxied to the bowl as one
assembly.
RG,CTM42,115,28-19-28OCT92
CTM42 (24MAR95)
115-28
6076 Diesel Engines—S.N. (500000—
)
160101
PN=411
Fuel System Operation and Test/Bleed the Fuel System
BLEED THE FUEL SYSTEM
-UN-23AUG88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
115
29
X9811
N
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline,
Illinois, or other knowledgeable medical
source.
Whenever the fuel system has been opened up for
service (lines disconnected or filters removed), it will be
necessary to bleed air from the system.
The fuel system may be bled at one of several locations.
On some engine applications it may be necessary to
consult your operator’s manual and choose the location
best for your engine/machine application.
S11,0408,AC
-19-18APR94
A. At Rectangular Fuel Filter:
1. Loosen bleed plug (A) on fuel filter base.
RG5870
-UN-19AUG91
NOTE: When bleeding the fuel system on engines
equipped with electronic governors, the key
switch must be at the ’ON’ position so the fuel
shutoff valve will be open to allow fuel flow.
RG,CTM42,G35,6 -19-02OCT92
CTM42 (24MAR95)
115-29
6076 Diesel Engines—S.N. (500000—
)
160101
PN=412
Fuel System Operation and Test/Bleed the Fuel System
2. Unscrew hand primer on fuel supply pump until it can
be pulled by hand (Nippondenso pumps only).
IMPORTANT: On Nippondenso pumps, be sure hand
primer is all the way down in barrel
before tightening to prevent internal
thread damage.
RG5903
3. Operate the hand primer (A) on fuel supply pump until
a smooth flow of fuel, free of bubbles, comes out of the
filter plug hole.
Bosch Pump Shown
4. Simultaneously stroke the hand primer down and
close the filter port plug. This prevents air from entering
the system. Tighten plug securely. DO NOT overtighten.
5. Lock hand primer in position (Nippondenso pumps
only).
NOTE: If the engine will not start, it may be necessary to
loosen the fuel pipes at the injection nozzles to
bleed air from system. Put the hand throttle in
slow idle position. Push the engine fuel shut-off
control knob all the way in. Turn the engine with
the starter until fuel without air flows from the
loose fuel pipe connections. Tighten the
connections.
RG,CTM42,115,9 -19-28OCT92
B. At Round Fuel Filter:
-UN-26OCT92
NOTE: This procedure is for engine applications with
electric fuel supply pumps.
1. Open air bleed vent screw two full turns by hand.
2. Turn key switch “ON” until a noticeable amount of fuel
and air comes out of vent opening. Close vent screw
when fuel starts to flow.
RG6482
115
30
-UN-19AUG91
NOTE: Robert Bosch supply pumps use a hand primer
that is spring loaded and remains fully extended
during normal engine operation.
RG,CTM42,G35,93-19-02NOV92
CTM42 (24MAR95)
115-30
6076 Diesel Engines—S.N. (500000—
)
160101
PN=413
Fuel System Operation and Test/Bleed the Fuel System
C. At Fuel Injection Pump:
NOTE: This procedure is for engine applications with
electric fuel supply pumps.
1. Loosen fuel return line at fuel injection pump.
115
31
RG6483
-UN-26OCT92
2. Turn key switch “ON”. As soon as fuel flow is free
from air bubbles, tighten fuel return line.
RG,CTM42,G35,94-19-02NOV92
D. At Fuel Injection Nozzles:
1. Place throttle lever in fast idle position.
-UN-26OCT92
2. Using two open-end wrenches, loosen fuel line
connection at No. 1 injection nozzle.
3. Crank engine with starting motor (but do not start
engine), until fuel free from bubbles flows out of
loosened connection. Retighten connection.
RG6484
4. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
RG,CTM42,G35,95-19-28OCT92
CTM42 (24MAR95)
115-31
6076 Diesel Engines—S.N. (500000—
)
160101
PN=414
Fuel System Operation and Test/Diagnose In-Line Fuel Injection Pump Malfunctions
DIAGNOSE IN-LINE FUEL INJECTION PUMP MALFUNCTIONS
Symptom
Problem
Solution
Engine Starts Hard or Won’t Start
Incorrect fuel shut-off lever position
(pump control rack not moving all
the way forward)
Adjust shut-off cable as required.
Defective injection pump
Remove pump from engine and
repair (see Group 35)
Injection pump not correctly timed
Check pump timing
Slow idle stop screw improperly
adjusted
Recheck stop screw adjustment
Supplementary idling spring
improperly adjusted
Recheck adjustment
Defective injection pump
Remove pump from engine and
repair (See Group 35)
Pump not properly timed
Check timing
Defective injection pump
Remove pump from engine and
repair (See Group 35)
115
32
Slow Idle Speed Irregular
Engine Horsepower Low
RG,CTM42,115,51-19-17MAR95
CTM42 (24MAR95)
115-32
6076 Diesel Engines—S.N. (500000—
)
160101
PN=415
Fuel System Operation and Test/In-Line Fuel Injection Pump Operation
IN-LINE FUEL INJECTION PUMP
OPERATION
Filtered fuel under pressure by the supply pump fills the
injection pump fuel gallery (G). As the camshaft rotates,
roller tappets (C) riding on the camshaft (B) lobes
operate the plungers (F) to supply high pressure fuel
through the delivery valves (H) to the injection nozzles.
115
33
A governor-operated control rack (D) is connected to the
control sleeves (E) and plungers to regulate the quantity
of fuel delivered to the engine.
RG4650
-UN-14DEC88
Engine lubricating oil is piped to the injection pump
crankcase (A) to provide splash lubrication of the
working parts. Two drain holes at the front end of the
pump determine the level of oil maintained in the
crankcase. Excess oil drains out these holes and returns
back to the engine through the timing gear housing.
A—Crankcase
B—Camshaft
C—Roller Tappet
D—Control Rack
E—Control Sleeve
F—Plunger
G—Fuel Gallery
H—Delivery Valve
I—Delivery Pipe
J—Injection Pressure
K—Supply Pump Pressure
L—Engine Lubricating Oil
S11,23010,GF1 -19-14FEB95
CTM42 (24MAR95)
115-33
6076 Diesel Engines—S.N. (500000—
)
160101
PN=416
Fuel System Operation and Test/Check Fast Idle Speed—In-Line Fuel Injection Pump
CHECK FAST IDLE SPEED—IN-LINE FUEL
INJECTION PUMP
NOTE: The governor control lever on injection pump may
be inboard (next to engine block) or outboard
(away from engine block), depending upon
engine application.
RG3600
115
34
-UN-14DEC88
1. Remove speed control rod. With the engine running,
move governor control lever (A) against the fast idle stop
screw (B).
2. Using a tachometer, check fast idle speed to see if it
is within specification.
NOTE: For each application, refer to the appropriate
machine technical manual for fast idle speed
specifications.
If fast idle speed must be adjusted, see your authorized
diesel repair station.
NOTE: For some applications such as generator sets,
special equipment may be required for fast idle
adjustment in conjunction with droop adjustment.
See your OEM dealer or John Deere Engine
Distributor.
RG,CTM42,115,14-19-28OCT92
CTM42 (24MAR95)
115-34
6076 Diesel Engines—S.N. (500000—
)
160101
PN=417
Fuel System Operation and Test/Check and Adjust Engine Slow Idle Speed—In-Line Fuel Injection Pump
CHECK AND ADJUST SLOW IDLE
SPEED—IN-LINE FUEL INJECTION PUMP
(Robert Bosch)
-UN-23AUG91
If slow idle stop screw and bumper
spring screw are not adjusted
according to instruction, engine
damage could result because of
overspeeding.
CAUTION: ALWAYS STOP ENGINE before
making adjustments.
1. With the engine running, pull the governor control
lever rearward to the slow idle speed position. Check
and adjust slow idle speed to specification.
NOTE: For each application, refer to the appropriate
machine technical manual for slow idle speed
specifications.
RG5943
N
RG5942
IMPORTANT: Minor adjustment of the slow idle
speed may be made with the bumper
spring screw. However, it should not be
used by itself to change engine speed
more than 50 rpm, as overspeeding of
the engine may result.
-UN-23AUG91
NOTE: Both the slow idle stop screw (A) and the
bumper spring screw (B) may be used to adjust
the slow idle speed.
(Nippondenso)
A—Slow Idle Stop Screw
B—Bumper Spring Screw
C—Lock Nut
D—Lock Nut
RG,CTM42,115,34-19-16AUG94
CTM42 (24MAR95)
115-35
6076 Diesel Engines—S.N. (500000—
)
160101
PN=418
115
35
Fuel System Operation and Test/Check and Adjust Engine Slow Idle Speed—In-Line Fuel Injection Pump
NOTE: On Nippondenso first remove slow idle stop
screw cover.
4. Turn the bumper spring adjusting screw in to increase
engine speed a maximum of 50 rpm to desired slow idle
speed.
For example, to obtain an 850 rpm slow idle speed, use
the slow idle stop screw to set speed at approximately
800 rpm. Then increase speed to 850 rpm using the
bumper spring adjusting screw.
RG5943
3. Loosen lock nut (D) and adjust slow idle stop screw
(A) to obtain an idle speed 50 rpm less that the desired
slow idle speed setting.
Robert Bosch (Nippondenso similar)
A—Slow Idle Stop Screw
B—Bumper Spring Adjusting Screw
C—Lock Nut
D—Lock Nut
NOTE: Increasing the slow idle speed a slight amount
above the specified speed range may help to
reduce engine surge (or hunting). If this occurs,
use the procedure given above; but do not
exceed 850 rpm.
RG,CTM42,115,35-19-16AUG94
-UN-14DEC88
5. If engine surging or hunting persists at slow idle, the
bumper spring (A) and adjustment screw (B) may need
to be replaced with a new one. Remove the pump from
the engine and have it repaired by an authorized diesel
repair station (ADS shop). See Group 35 for fuel
injection pump removal and installation.
6. Again check the fast and slow idle speeds. Readjust,
slow idle speed if not correct.
R28387N
115
36
-UN-23AUG91
2. Loosen lock nut (C) and back out the bumper spring
adjusting screw (B) three turns.
7. Check all adjusting screw lock nuts for tightness.
Install covers (and copper washers) on slow idle stop
screw and idling spring adjusting screw (on Nippondenso
Pumps).
8. Connect fuel shut-off cable and speed control rod.
RG,CTM42,115,36-19-16AUG94
CTM42 (24MAR95)
115-36
6076 Diesel Engines—S.N. (500000—
)
160101
PN=419
Fuel System Operation and Test/Check and Adjust Engine Slow Idle Speed—In-Line Fuel Injection Pump
115
37
CTM42 (24MAR95)
115-37
6076 Diesel Engines—S.N. (500000—
)
160101
PN=420
Fuel System Operation and Test/Rotary Fuel Injection Pump Operation—Stanadyne DB4
ROTARY FUEL INJECTION PUMP OPERATION—STANADYNE DB4
RG4910
-UN-14DEC88
115
38
1—Drive Shaft
2—Distributor Rotor
3—Hydraulic Head
4—Delivery Valve
5—Supply Pump
6—Pressure Regulator
7—Discharge Fitting
8—Metering Valve
9—Pumping Plungers
10—Internal Cam Ring
11—Governor
12—Governor Weights
13—Advance
14—Drive Shaft Bushing
15—Housing
The main rotating components are the drive shaft (1),
distributor rotor (2), supply pump (5), and the
governor (11).
The drive shaft engages the distributor rotor in
hydraulic head (3). The drive end of rotor
incorporates two pumping plungers (9).
The plungers are actuated toward each other
simultaneously by an internal cam ring (10) through
rollers (16) and shoes which are carried in slots at
drive end of the rotor. The number of cam lobes
normally equal the number of engine cylinders.
16—Rollers
17—Supply Pump Inlet
18—Charging Ports
19—Throttle Lever
The supply pump at rear of rotor is a positive
displacement vane-type pump enclosed in the end
cap. The end cap also houses supply pump inlet
(17), fuel strainer and pressure regulator (6). Supply
pump pressure is automatically compensated for
viscosity effects due to temperature changes and fuel
grade variations.
The distributor rotor incorporates two charging ports
(18) and a single axial bore (passage) with one
discharge port to serve all head outlets (7) to the
injection lines. The rotor rotates in bore of hydraulic
head. Metering valve (8) bore, charging ports and
discharge fittings are located in the head.
RG,CTM42,115,29-19-28OCT92
CTM42 (24MAR95)
115-38
6076 Diesel Engines—S.N. (500000—
)
160101
PN=421
Fuel System Operation and Test/Rotary Fuel Injection Pump Operation—Stanadyne DB4
(Refer to illustration on previous page).
This pump contains its own mechanical governor. The
centrifugal force of the weights (12) in their retainer is
transmitted through a sleeve to a governor arm and
through a positive linkage to the metering valve. The
metering valve can be closed to shut off fuel through
a solid linkage by an independently operated shut-off
lever.
The automatic speed advance (13), advances or
retards (hydraulically) the beginning of fuel delivery
from the pump. The advance responds to changes in
speed only, or to a combination of speed and load
changes.
Fuel is drawn from the supply tank through filters into
the pump inlet through the inlet filter screen by the
vane type fuel transfer pump. Some fuel is bypassed
through the pressure regulator assembly to the
suction side.
Fuel under transfer pump pressure flows through the
center of the transfer pump rotor, past the rotor
retainer into a circular groove on the rotor. It then
flows through a connecting passage in the head to
the automatic advance and up through a radial
passage and then through a connecting passage to
the metering valve. The radial position of the
metering valve, controlled by the governor, regulates
flow of the fuel into the radial charging passages
which incorporates the head charging ports.
As the rotor revolves, the two rotor inlet passages
register with the charging ports in the hydraulic head,
allowing fuel to flow into the pumping chamber. With
further rotation, the inlet passages move out of
registry and the discharge port of the rotor registers
with one of the head outlets. While the discharge port
is opened, the rollers contact the cam lobes forcing
the plungers together. Fuel trapped between the
plungers is then pressurized and delivered by the
nozzle to the combustion chamber.
115
39
Self-lubrication is an inherent feature of the pump’s
design. As fuel at transfer pump pressure reaches the
charging ports, slots on the rotor shank allow fuel and
any entrapped air to flow into the pump housing
cavity.
Additionally, an air vent passage in the hydraulic
head connects the outlet side of the transfer pump
with the pump housing. This allows air and some fuel
to be bled back to the fuel tank via the return line.
The fuel thus bypassed fills the housing, lubricates
the internal components, cools and carries off any
small air bubbles. The pump operates with the
housing completely full of fuel; there are no dead air
spaces anywhere within the pump.
RG,CTM8,G115,3 -19-06FEB95
CTM42 (24MAR95)
115-39
6076 Diesel Engines—S.N. (500000—
)
160101
PN=422
Fuel System Operation and Test/Diagnose Rotary Fuel Injection Pump Malfunctions
DIAGNOSE ROTARY FUEL INJECTION PUMP MALFUNCTIONS
Symptom
Problem
Solution
Engine Starts Hard or
Won’t Start
Shut-off solenoid not functioning
properly; or wiring lead loose
or broken
Repair.
Injection pump not correctly timed
Check pump timing (refer to this group).
Defective injection pump
Remove pump from engine and repair.
Automatic advance faulty or
not operating
Adjust or repair.
Nozzle faulty or sticking
Repair (See Group 35).
Automatic advance faulty
or not operating
Inspect and adjust or repair.
Injection pump not properly
timed
Check pump timing (refer to this group).
Defective injection pump
Remove pump and repair.
Pump not properly timed
Check timing (refer to this group).
Insufficient throttle arm travel
Inspect and adjust.
Automatic advance faulty or
not operating
Adjust or repair.
Nozzle faulty or sticking
Repair (See Group 35)
Defective injection pump
Remove pump and repair.
115
40
Slow Idle Speed
Irregular
Engine Horsepower Low
RG,CTM42,115,30-19-28OCT92
CTM42 (24MAR95)
115-40
6076 Diesel Engines—S.N. (500000—
)
160101
PN=423
Fuel System Operation and Test/Check and Adjust Engine Speeds on Rotary Pump
CHECK AND ADJUST ENGINE SPEEDS ON ROTARY PUMP—STANADYNE DB4
RG6485
-UN-26OCT92
115
41
A—Fast Idle Adjusting Screw
B—Slow Idle Adjusting Screw
NOTE: Before adjusting engine speed, make sure
engine has reached its normal operating
temperature.
Adjust slow idle speed if necessary as detailed below.
5. Move throttle lever to the fast idle position against
adjusting screw stop.
• Check Slow and Fast Idle Speeds:
1. Start engine and run at 50% load and rated speed
until engine reaches normal operating temperature.
2. Stop engine and disconnect speed control rod or
cable from injection pump throttle lever.
3. Start engine and run at slow idle and no-load until
engine stabilizes. Move injection pump throttle lever
to slow idle position against adjusting screw stop.
4. Measure engine speed using a tachometer.
Compare reading with specification.
6. Read and record engine speed using a
tachometer. Compare readings with specifications.
IMPORTANT: If fast idle is not within
specification, have an authorized
diesel repair station, servicing
dealer, or engine distributor adjust
as necessary.
• Adjust Slow Idle Speed:
1. Hold pump throttle lever against slow idle stop.
2. Loosen slow idle adjusting screw lock nut. Turn
adjusting screw clockwise to increase speed and
counterclockwise to decrease speed.
RG,CTM42,115,32-19-14FEB95
CTM42 (24MAR95)
115-41
6076 Diesel Engines—S.N. (500000—
)
160101
PN=424
Fuel System Operation and Test/How the Aneroid Works—In-Line Injection Pumps
HOW THE ANEROID WORKS (IF
EQUIPPED)—IN-LINE INJECTION PUMPS
Intake manifold pressure (created by the turbocharger)
enters aneroid at (A). It is directed to upper side of
diaphragm chamber (C) and exerts pressure on
diaphragm (D).
When the pressure rises to about 100 kPa (1 bar) (15
psi), or about 1000 engine rpm under moderate to heavy
loads, spring pressure (E) is overcome. Diaphragm then
moves adjusting shaft screw (F) downward.
Arm (G) has two “legs”. The inner leg bears on the flat
surface of adjusting shaft screw (F). The outer leg bears
against a block riveted to the control rack (H).
Downward movement of the adjusting shaft causes arm
to rotate on starting fuel control shaft (I), permitting
control rack to move its normal amount.
If the intake manifold pressure is below 100 kPa (1 bar)
(15 psi) because of low engine speed, or is under light
load at higher engine speeds, the aneroid spring
pressure is greater than the intake manifold pressure. As
a result, the control rack travel is limited (therefore, fuel
delivery is limited) by the arm and adjusting shaft.
-UN-14DEC88
NOTE: Diaphragm adjusting screw (B) regulates the
minimum fuel delivery quantity at a specified rpm
and zero pressure acting on the diaphragm. The
diaphragm spring determines acceleration time
(the greater the spring tension, the greater the
manifold pressure required to overcome spring
tension; hence, a slower acceleration).
R27340N
115
42
A—Intake Manifold Pressure Opening
B—Adjusting Screw
C—Diaphragm Chamber
D—Diaphragm
E—Spring
F—Adjusting Shaft Screw
G—Arm
H—Control Rack
I—Starting Fuel Shaft
Aneroid control will be in effect until the manifold
pressure is high enough to overcome diaphragm spring
pressure.
A hydraulic aneroid activator (described in this group) is
used to control the lever arm engagement with the
control rack by moving the starting fuel control shaft in or
out.
During starting, the hydraulic aneroid activator
disengages the lever arm from the control rack block to
permit the rack to move all the way forward to the
starting fuel delivery position.
S11,23010,IU
CTM42 (24MAR95)
115-42
-19-14FEB95
6076 Diesel Engines—S.N. (500000—
)
160101
PN=425
Fuel System Operation and Test/Diagnose Aneroid Malfunctions
DIAGNOSE ANEROID MALFUNCTION
Symptom
Problem
Solution
Slow Engine Acceleration
Loose pipe or broken connection at
inlet fitting
Repair as required. (See Group 35)
Aneroid cover cracked around inlet
fitting
Repair as required. (See Group 35)
Defective diaphragm
Repair as required. (See Group 35)
Aneroid not correctly adjusted
Remove injection pump (See Group
35) and adjust on test stand.
Aneroid not correctly adjusted
Remove injection pump. (See Group
35) and adjust on test stand.
Excessive Smoke When
Accelerating Engine
S11,23010,IV
Use information contained in the chart above to help
diagnose aneroid malfunctions.
See Group 35 for instructions on how to repair and
adjust the aneroid.
The aneroid controls fuel delivery when intake
manifold pressure is about 100 kPa (1 bar) (15 psi)
or less. Therefore, all final adjustments are to be
made on the test stand with aneroid mounted on
injection pump.
115
43
-19-17MAR92
IMPORTANT: Correct aneroid adjustments are
essential for satisfactory engine
performance. Whenever the aneroid
has been disassembled or the
adjustments have been altered, the
injection pump (including aneroid)
must be calibrated on the test stand
by an authorized diesel injection
repair station before releasing the
pump for service.
S11,23010,IV1 -19-09SEP91
CTM42 (24MAR95)
115-43
6076 Diesel Engines—S.N. (500000—
)
160101
PN=426
Fuel System Operation and Test/How the Hydraulic Aneroid Activator Works
HOW THE HYDRAULIC ANEROID
ACTIVATOR WORKS (IF EQUIPPED)
-UN-14DEC88
Engine lubricating oil is piped from the oil filter body to
operate the activator. This oil is then piped to the
injection pump housing to lubricate the internal working
parts.
Engine oil upon starting the engine is routed to the
aneroid activator housing (I) through a banjo connector
(A), special screw (B), and an orifice in the capillary
valve (E) to head of piston (F).
Whenever the engine oil pressure is about 60 kPa (0.6
bar) (9 psi) or higher, the piston will overcome resistance
of piston spring (G) and move the starting fuel control
shaft (H) inward to provide aneroid control.
R27342N
115
44
The hydraulic aneroid activator mounts on the inboard
side of the governor housing. It has an internal piston (F)
that is operated by engine oil pressure to hydraulically
move the starting fuel control shaft inward for aneroid
control.
A—Activator Banjo Connector
B—Special Screw
C—Capillary Valve Spring
D—Restrictor Wire
E—Capillary Valve
F—Piston
G—Piston Spring
H—Starting Fuel Control Shaft
I—Activator Housing
Loss of oil pressure permits a return spring on the
starting fuel control shaft to hold the lever arm out of
engagement with the control rack. This prevents the
aneroid from limiting rack travel.
A restrictor wire (D) is inserted in the capillary valve for
two reasons.
(1) To retard engagement of the aneroid when engine is
cold.
(2) To help maintain an open passage in the capillary
valve (oil pressure action moves the wire enough to
prevent orifice from plugging).
The length of time required to achieve aneroid control
depends on the ambient air temperature and the
viscosity of the engine oil. Warm ambient air
temperatures will permit the aneroid to activate in a few
seconds. Cold temperatures may delay activation for
several minutes.
S11,23010,AB
CTM42 (24MAR95)
115-44
-19-28OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=427
Fuel System Operation and Test/Diagnose Malfunctions—Hydraulic Aneroid Activator
The following table gives the approximate ambient
temperature-engagement time based on different engine
lubricating oil viscosities:
Ambient Temp.
˚C (˚F)
Engine
Crankcase
Oil
Engagement
in Seconds
(Approx.)
-1 (30)
-18 (1)
-29 (-20)
SAE 30
10W-20
5W-20
86
255
360
115
45
S11,23010,AC
-19-16AUG94
DIAGNOSE MALFUNCTIONS—HYDRAULIC ANEROID ACTIVATOR
Symptom
Problem
Solution
Engine Starts Hard
Broken return spring on starting fuel
control shaft.
Repair (See Group 35)
Retaining ring missing from starting
fuel control shaft.
Repair (See Group 35)
Check for restriction in oil supply
passages to activator piston.
Disassemble activator (See Group
35)
Excessive Smoke When
Accelerating Engine
S11,23010,IW
CTM42 (24MAR95)
115-45
-19-28OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=428
Fuel System Operation and Test/Fuel Injection Nozzles—General Information
FUEL INJECTION NOZZLES—GENERAL INFORMATION
RG5929
-UN-19AUG91
115
46
A—Fuel Inlet
B—Leak-Off Connection
C—O-Ring
D—Dowel Pin
E—Intermediate Plate
F—Nozzle Retaining Nut
G—Washer
H—Nozzle
J—Valve
K—Spring Seat
L—Spring
M—Shims
N—Gland Nut
O—Fuel Passage
P—Edge-Type Filter
Q—Nozzle Holder
Nippondenso Shown (Bosch Similar)
An edge-type filter (P) is placed in the fuel inlet of the
nozzle holder. Its purpose is to prevent coarse,
foreign particles from damaging the nozzle assembly
or plugging the orifices. Finer particles pass through
the filter without harm. The filter is not removable.
The nozzle valve (J) is held on its seat by a spring
(L). Shims (M) are used to regulate the nozzle
opening pressure.
The nozzle (H) and valve fit together by precision
lapping. These parts are referred to as a nozzle
assembly, and are not serviced separately.
Correct alignment of the nozzle assembly with its
holder is essential so that the atomized fuel will be
sprayed into the combustion chamber at the angle
and location intended by design. KDEL and KDAL
holders use an intermediate plate (E) with dowel pins
(D) on both sides to insure alignment.
To provide a seal between the injection nozzle and
the engine cylinder head, a steel washer (G) is used
at the base of the nozzle retaining nut.
The fuel injection nozzle is fastened to the engine
cylinder head by a gland nut (N). The gland nut also
functions as a jack screw to raise the injection nozzle
out of cylinder head during removal.
A retaining nut (F) is used to fasten the nozzle
assembly to the holder body. The diameter of the
holder body is 21 mm, and from this dimension the
fuel injection nozzles are known as 21 mm nozzles.
RG,CTM42,115,22-19-28OCT92
CTM42 (24MAR95)
115-46
6076 Diesel Engines—S.N. (500000—
)
160101
PN=429
Fuel System Operation and Test/Fuel Injection Nozzle Operation
FUEL INJECTION NOZZLE OPERATION
Fuel lines (A) deliver the fuel to injection nozzles. Fuel
enters the injection nozzle inlet (B), and passes through
the edge-type filter (C). Coarse foreign particles are
retained by the filter.
115
47
A passage (D) routes fuel through the nozzle holder to
the nozzle valve (E). The nozzle valve is lifted instantly
off its seat by the high pressure inlet fuel acting on an
annulus in the valve.
NOTE: Since the nozzle valve opening pressure is
considerably lower than the injection pump output
pressure, the inlet fuel pressure easily overcomes
the resistance of the nozzle valve spring (G).
When the nozzle valve opens, a definite quantity of fuel
(determined by the injection pump output for each
plunger stroke) is forced out through orifices (F). The
fuel becomes finely atomized as it is sprayed into the
combustion chamber at high velocity.
-UN-29AUG94
The nozzle assembly is lubricated by a small amount of
fuel which seeps between the lapped surfaces of the
nozzle and valve which accumulates around the spring
(G, refer to previous illustrations).
RG4651
The leakage fuel is routed out the nozzle holder through
a leak-off connector (H) and returned back to the fuel
tank by means of a leak-off pipe (I).
Fuel Flow Through KDEL Injection Nozzle
A—Fuel Delivery Line
B—Fuel Inlet
C—Edge-Type Filter
D—Fuel Passage
E—Nozzle Valve
F—Orifices
G—Nozzle Valve Spring
H—Leak-Off Connector
I—Leak-Off Pipe
J—Engine Cylinder Head
K—High Pressure Fuel
L—Low Pressure (Return) Fuel
S55,23010,P
CTM42 (24MAR95)
115-47
-19-16SEP94
6076 Diesel Engines—S.N. (500000—
)
160101
PN=430
Fuel System Operation and Test/Diagnose Malfunctions—Fuel Injection Nozzle
DIAGNOSE MALFUNCTIONS—FUEL INJECTION NOZZLE
Fuel injection nozzles are usually removed from the
engine when there is a noticeable loss of power or
excessive smoking.
115
48
Listed in the following chart are various malfunctions
which may occur on the 21 mm nozzles. Only
possible defects related to these nozzles are listed.
Failures in other components of the fuel injection
system are listed under their respective headings in
this group.
See Group 35 for repair information.
Symptom
Problem
Solution
Engine Has Low Horsepower
Nozzle orifices plugged
Repair (See Group 35)
Incorrect nozzle valve opening
pressure
Adjust (See Group 35)
Broken or damaged parts
Repair as required (See Group 35)
a.
b.
c.
d.
Engine Emits Too Much Smoke
Broken nozzle valve spring
Cracked or split nozzle tip
Cracked or split nozzle body
Internal leak
Wrong nozzle and valve in holder
Install correct nozzle assembly (See
Group 35)
Nozzle loose in cylinder head
Make sure R84472 Steel Washer is
installed on tip end of injection
nozzle. Tighten to specified torque
(See Group 35)
Nozzle orifices plugged
Repair (See Group 35 Diesel Fuel
System)
Broken or damaged parts
Repair as required (See Group 35)
Diesel Fuel System
a.
b.
c.
d.
Broken nozzle valve spring
Cracked or split nozzle tip
Cracked or split nozzle body
Internal leak
Wrong nozzle and valve in holder
Install nozzle assembly (See Group
35 Diesel Fuel System)
Worn nozzle valve seal
Replace nozzle assembly (See
Group 35 Diesel Fuel System)
RG,CTM42,115,23-19-28OCT92
CTM42 (24MAR95)
115-48
6076 Diesel Engines—S.N. (500000—
)
160101
PN=431
Fuel System Operation and Test/Fuel Drain Back Test Procedure
TEST FUEL INJECTION NOZZLES (ENGINE RUNNING)
1. Operate engine at intermediate speed and no load.
2. Slowly loosen the fuel pressure line at one of the
nozzles until fuel escapes at the connection (fuel not
opening nozzle valve).
NOTE: The injection nozzle before and/or after nozzle
being checked could be the faulty nozzle.
• If engine speed changes, the injection nozzle is
probably working satisfactory.
• If engine speed does not change, a nozzle is faulty
and must be checked and repaired (or replaced).
115
49
3. Repeat test for each remaining nozzle assembly.
4. Remove faulty injection nozzles and repair as
required. See Group 35.
S11,23010,HR
FUEL DRAIN BACK TEST PROCEDURE
Fuel draining back through the fuel system may
cause hard starting. This procedure will determine if
air is entering the system at connections and allowing
fuel to siphon back to the fuel tank.
N
-19-18APR94
CAUTION: Maximum air pressure should be
100 kPa (1 bar) (15 psi) when performing
this test.
5. Apply liquid soap and water solution to all joints
and connections in the fuel system and inspect for
leaks.
1. Disconnect fuel supply line and fuel return line at
fuel tank.
IMPORTANT: Fuel return line MUST extend below
fuel level in fuel tank before
performing this test. Fill fuel tank if
necessary.
NOTE: Connections may allow air to enter the system
without allowing fuel to leak out.
6. If any leaks are found, take necessary steps to
repair.
2. Drain all fuel from the system, including the fuel
transfer pump, fuel injection pump, fuel filters, and
water separator (if equipped).
7. Reconnect supply and return lines and prime
system.
3. Securely plug off the end of the fuel return pipe.
8. Start engine and run for approximately 10 minutes.
4. Using a low pressure air source, pressurize the
fuel system at the fuel supply line.
9. Allow engine to sit overnight and try starting the
following morning.
S11,23010,JA
CTM42 (24MAR95)
115-49
-19-28OCT92
6076 Diesel Engines—S.N. (500000—
)
160101
PN=432
Fuel System Operation and Test/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
RG5753
-UN-05AUG91
115
50
A—Droop Adjusting Screw
B—Governor Housing
C—Droop Adjusting Screw
Access Plug
D—Throttle Lever
E—Slow Idle (Adjusting)
Screw
F—Idle (Bumper) Spring
G—Mechanical Shutoff Lever
This instruction covers step-by-step adjustment
procedures for changing 6076 Gen Set Engine rated
speed from 1800 RPM (60 Hz) to 1500 RPM (50 Hz)
while maintaining the desired speed regulation.
IMPORTANT: Only qualified technicians should
attempt the adjustments covered in
this instruction. If qualifications are
in doubt, have your nearest ADS
repair shop perform these
adjustments.
To assure specified power and
governing during engine operation,
the throttle lever must be fixed
against the fast idle (stop) screw
(H).
H—Fast Idle (Stop) Screw
To assure specified governing, the
fast idle screw and bumper spring
screw (F) must be readjusted any
time the droop screw (A) is
adjusted.
If an electric shutoff solenoid is
connected to the shutoff lever (G)
by rigid linkage, it must be adjusted
to provide a gap of 0.0762 mm
(0.003 in.), (one paper thickness)
between the lever and stop. Too
much gap will limit rack travel, no
gap will bind the lever shaft. If
flexible linkage is used, it should be
adjusted for no gap.
RG,GENSET4,1
CTM42 (24MAR95)
115-50
-19-11FEB93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=433
Fuel System Operation and Test/Fuel Drain Back Test Procedure
CHANGE ENGINE RATED SPEED FROM
1800 RPM TO 1500 RPM AND ADJUST
DROOP
1. Start engine and apply 50% load at rated speed until
it reaches operating temperature. Remove cap nuts from
adjusting screws before making adjustments.
115
51
2. When the engine has reached normal operating
temperature, adjust fast idle (stop) screw (A) clockwise
(CW) to 1500 rpm (50 Hz) with 100 % (full) load.
3. Remove load and back out the idle (bumper) spring
screw (E), while observing the corresponding drop in
engine rpm’s until engine quits losing speed.
4. Screw in idle (bumper) spring screw until engine
speed increases 5—10 rpm.
-UN-05AUG91
5. Check for specified no-load (frequency). If governor
regulation is within 5—7% range, proceed to Step 8.
6. If governor regulation is above 7% or below 5%, stop
engine and remove droop adjusting screw access plug
(B, shown removed) from top of governor housing.
a. Back out slow idle (adjusting) screw (D) and and
bumper screw. Pull back on throttle lever (F, toward
rear of governor housing) by hand until the droop
adjusting screw (C) inside housing can be adjusted
through the access plug hole.
b. Screw the droop screw in (CW), counting the turns
until screw bottoms out. Then, return screw to
original setting.
c. Screw in the droop screw (CW) no more than 1/2 turn
(two clicks) at a time to reduce governor droop. CCW
no more than two clicks at a time to increase
governor droop (to reduce governor sensitivity).
d. Replace access plug in top of governor housing. Start
engine, apply full (100%) load, and readjust high
idle adjusting screw until 1500 rpm (50 Hz) is
obtained at the specified power.
e. Screw in idle (bumper) spring until engine speed
increases 5—10 rpm.
RG5752
NOTE: A noticable click will occur at each 1/4 turn of
droop adjusting screw. One click CW will
increase no-load speed approximately 10 rpm,
counter-clockwise (CCW) will reduce speed by 10
rpm. Maximum 24 clicks out, minimum 4 clicks
out with final setting.
A—Fast Idle (Stop) Screw
B—Droop Adjusting Screw Access Plug Location
C—Droop Adjusting Screw
D—Slow Idle (Adjusting) Screw
E—Idle (Bumper) Spring
F—Throttle Lever
G—Mechanical Shutoff Lever
7. Repeat Steps 6 (a—d) until governor regulation is
within the 5—7% range.
Replace all cap nuts onto adjusting screws and tighten
lock nuts securely.
RG,GENSET4,3
CTM42 (24MAR95)
115-51
-19-11FEB93
6076 Diesel Engines—S.N. (500000—
)
160101
PN=434
Fuel System Operation and Test/Fuel Drain Back Test Procedure
115
52
CTM42 (24MAR95)
115-52
6076 Diesel Engines—S.N. (500000—
)
160101
PN=435
Group 199
Dealer Fabricated Tools
HOW TO MAKE TOOLS
These tools can be made in a service shop using
common shop tools and locally obtained materials.
S55,DFRG
199
1
-19-01DEC89
T36748N
-UN-24OCT88
DFRG3—CYLINDER LINER HOLDING FIXTURE
1—254.0 mm (10 in.)
2—127.0 mm (5 in.)
3—38.1 mm (1.5 in.)
4—405.4 mm (16 in.)
5—330.2 mm (13 in.)
6—9.52 mm (0.38 in.)
7—12.7 mm (0.5 in.)
8—31.8 mm (1.25 in.)
9—63.5 mm (2.5 in.)
10—25.4 mm (1 in.)
11—6.35 mm (0.25 in.)
12—152.4 mm (6 in.)
13—0.328 in. Drill Through
14—5/16 in.—18 Tap
15—2 used
16—304.8 mm (12 in.)
17—5/16 in—18 Tap
18—69.85 mm (2.75 in.)
Radius
19—101.6 mm (4 in.)
20—111.25 mm (4.38 in.)
21—60.45 mm (2.38 in.)
22—5/16 in. x 1 in. Cap
Screw
23—38.1 mm (1.5 in.) Angle
Iron
S55,DFRG3
CTM42 (24MAR95)
199-1
-19-23FEB87
6076 Diesel Engines—S.N. (500000—
)
160101
PN=436
Dealer Fabricated Tools/Cylinder Liner Holding Fixture
199
2
CTM42 (24MAR95)
199-2
6076 Diesel Engines—S.N. (500000—
)
160101
PN=437
Index
Page
A
Additives
Coolant . . . . . . . . . . . . . . .
Aftercooler
Inspect . . . . . . . . . . . . . . .
Install horizontally-mounted . .
Install vertically-mounted . . .
Remove horizontally-mounted
Remove vertically-mounted . .
Repair . . . . . . . . . . . . . . . .
Air cleaner
Operation . . . . . . . . . . . . .
Air intake cover
Inspect . . . . . . . . . . . . . . .
Air intake manifold pressure
Aneroid . . . . . . . . . . . . . . .
Intake manifold . . . . . . . . . .
Air intake system
Check . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . .
General information . . . . . . .
Specifications . . . . . . . . . . .
Altitude compensation . . . . . . .
Aneroid
Diagnostics . . . . . . . . . . . .
General information . . . . . . .
Repair . . . . . . . . . . . . . . . .
Aneroid, hydraulic activator
Clean . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . .
Disassemble . . . . . . . . . . .
General information . . . . . . .
Install . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . .
Aneroid, hydrualic activator
Assemble . . . . . . . . . . . . .
. . . . . . . . . 02-10
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30-26
30-29
30-27
30-25
30-23
30-26
. . . . . . . . . 110-4
. . . . . . . . . 30-26
. . . . . . . . . 110-9
. . . . . . . . 110-10
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100-7
110-3
110-4
. 30-2
100-1
. . . . . . . . 115-43
. . . . . . . . 115-42
. . . . . . . . . 35-21
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. 35-22
115-45
. 35-22
115-44
. 35-22
. 35-21
. . . . . . . . . 35-22
B
Bearing cap, main
Measure line bore . . . . . .
Bearings
Failure analysis . . . . . . .
Measure assembled ID . .
Bearings, connecting rod
Inspect and measure . . . .
Bearings, flywheel, crankshaft
Final assembly . . . . . . . .
. . . . . . . . . . . 15-33
. . . . . . . . . . . . 15-8
. . . . . . . . . . . 15-32
. . . . . . . . . . . 10-23
. . . . . . . . . . . 15-52
Page
Bearings, main
Check clearance . . . . . . . .
Install . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . .
Bearings, thrust
Specifications . . . . . . . . . .
Belt tensioner . . . . . . . . . . .
Belt, fan
Tension specifications . . . .
Block, cylinder
Clean and inspect top deck
Disassemble . . . . . . . . . .
Inspect and clean . . . . . . .
Measure . . . . . . . . . . . . .
Break-In Engine Oil . . . . . . .
Break-in, engine
Guidelines . . . . . . . . . . . .
Perform . . . . . . . . . . . . . .
Bushing, piston pin
Remove . . . . . . . . . . . . .
Bushings, camshaft
Service (using JDG602) . . .
Service (using JDG606) . . .
Bushings, piston pin
Inspect . . . . . . . . . . . . . .
Bypass valve, oil filter
Remove, inspect, and install
. . . . . . . . . . 15-28
. . . . . . . . . . 15-41
. . . . . . . . . . 15-27
. . . . . . . . . . 15-36
. . . . . . . . . . 25-13
. . . . . . . . . . 25-26
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05-29
10-29
10-30
10-32
. 02-2
. . . . . . . . . . 100-5
. . . . . 05-42, 100-6
. . . . . . . . . . 10-27
. . . . . . . . . . 16-15
. . . . . . . . . . 16-17
. . . . . . . . . . 10-26
. . . . . . . . . . . 20-5
C
Camshaft
Assemble . . . . . . . . . . . .
End play . . . . . . . . . . . . .
Inspect . . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . .
Measure drive gear backlash
Remove . . . . . . . . . . . . .
Specifications . . . . . . . . . .
Camshaft bushing ID
Measure . . . . . . . . . . . . .
Camshaft bushings
Service (using JDG602) . . .
Service (using JDG606) . . .
Camshaft followers
Inspect and measure . . . . .
Camshaft gears
Install . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . .
Camshaft journal OD
Measure . . . . . . . . . . . . .
Index-1
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16-14
. 16-7
16-12
16-18
. 16-8
. 16-9
. 16-4
. . . . . . . . . . 16-13
. . . . . . . . . . 16-15
. . . . . . . . . . 16-17
. . . . . . . . . . 16-12
. . . . . . . . . . 16-14
. . . . . . . . . . 16-11
. . . . . . . . . . 16-13
160101
PN=444
INDX
1
Index
Page
INDX
2
Camshaft lobe lift
Measure . . . . . . . . . . . . .
Camshaft thrust washers
Measure . . . . . . . . . . . . .
Cap screws, cylinder head
Clean, inspect and install . .
TORQUE-TO-YIELD . . . . .
TORQUE-TURN . . . . . . . .
Types . . . . . . . . . . . . . . .
Cap, main bearing
Measure line bore . . . . . . .
Check valve, fuel filter
Replace . . . . . . . . . . . . . .
Compression pressure, engine
Test . . . . . . . . . . . . . . . .
Connecting rod bearings
Inspect and measure . . . . .
Connecting rods
Failure analysis . . . . . . . .
Inspect rod and cap . . . . .
Install . . . . . . . . . . . . . . .
Preliminary checks . . . . . .
Remove . . . . . . . . . . . . .
Coolant
Additives . . . . . . . . . . . . .
Disposing . . . . . . . . . . . .
Products . . . . . . . . . . . . .
Recommended . . . . . . . . .
Requirements . . . . . . . . . .
Tropical . . . . . . . . . . . . . .
Coolant heater
Install . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . .
Coolant, engine . . . . . . . . . .
Coolant, engine
Specifications . . . . . . . . . .
Cooler, oil
Clean, inspect, and install . .
Remove . . . . . . . . . . . . .
Cooling orifices, piston
Remove and clean . . . . . .
Cooling system
Flush . . . . . . . . . . . . . . .
Flush and service . . . . . . .
How it works . . . . . . . . . .
Pressure test . . . . . . . . . .
Specifications . . . . . . . . . .
Cover, timing gear
Install . . . . . . . . . . . . . . .
Install with engine installed .
. . . . . . . . . . 16-13
. . . . . . . . . . 16-11
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05-34
05-36
05-35
05-33
. . . . . . . . . . 15-33
. . . . . . . . . . . 35-7
. . . . . . . . . 105-21
. . . . . . . . . . 10-23
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. 10-8
10-24
10-40
. 10-8
. 10-9
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02-10
02-13
. 02-7
. 02-7
. 02-5
02-11
. . . . . . . . . . 25-25
. . . . . . . . . . 25-24
. . . . . . . . . . . 02-5
. . . . . . . . . . . 02-8
. . . . . . . . . . . 20-8
. . . . . . . . . . . 20-7
. . . . . . . . . . 15-40
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. 100-8
. 02-12
105-10
105-23
. . 25-3
. . . . . 15-20, 15-48
. . . . . . . . . . 15-19
Cover, timing gear—Continued
Remove . . . . . . . . . . . . . . . . . .
Remove with engine installed . . . .
Crankcase ventilation system
Check . . . . . . . . . . . . . . . . . . . .
Crankshaft
Grinding specifications . . . . . . . . .
Inspect . . . . . . . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . . .
Crankshaft end play
Check . . . . . . . . . . . . . . . . . . . .
Crankshaft gear
Replace . . . . . . . . . . . . . . . . . . .
Crankshaft gear-to-oil pump drive gear
Check backlash . . . . . . . . . . . . .
Crankshaft pulley
Remove . . . . . . . . . . . . . . . . . .
Crankshaft rear oil seal
Install . . . . . . . . . . . . . . . . . . . .
Crankshaft rear oil seal & wear sleeve
Handling precautions . . . . . . . . . .
Install (w/o engine disassembly) . .
Crankshaft rear oil seal housing
Install . . . . . . . . . . . . . . . . . . . .
Crankshaft, journals
Measure OD . . . . . . . . . . . . . . .
Crankshaft, main bearings, flywheel
Final assembly . . . . . . . . . . . . . .
Crankshaft, rear oil seal
Remove . . . . . . . . . . . . . . . . . .
Cylinder block
Clean and inspect top deck . . . . .
Disassemble . . . . . . . . . . . . . . .
Inspect and clean . . . . . . . . . . . .
Measure . . . . . . . . . . . . . . . . . .
Cylinder head
Check flatness . . . . . . . . . . . . . .
Check valve lift . . . . . . . . . . . . . .
Clean and inspect push rods . . . .
Clean and inspect valve seats . . . .
Clean valve guides . . . . . . . . . . .
Clean valves . . . . . . . . . . . . . . .
Failure analysis . . . . . . . . . . . . .
Final assembly . . . . . . . . . . . . . .
Grind valve seats . . . . . . . . . . . .
Inspect and clean . . . . . . . . . . . .
Inspect and clean nozzle bore . . . .
Inspect rotators and wear caps . . .
Inspect valve springs . . . . . . . . . .
Index-2
Page
. . . . . 15-20
. . . . . 15-19
. . . . . 100-7
.....
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15-41,
.....
15-37
15-30
15-42
15-29
. . . . . 15-13
. . . . . 15-39
. . . . . . 20-9
. . . . . . 16-7
. . . . . 15-47
. . . . . 15-46
. . . . . 15-11
. . . . . 15-43
. . . . . 15-32
. . . . . 15-52
. . . . . . 15-9
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05-29
10-29
10-30
10-32
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. . . 05-20
05-9, 16-6
. . . 05-28
. . . 05-23
. . . 05-22
. . . 05-18
. . . 05-15
. . . 05-38
. . . 05-25
. . . 05-19
. . . 05-27
. . . 05-17
. . . 05-17
160101
PN=445
Index
Cylinder head—Continued
Inspect ventilator outlet hose . . .
Install . . . . . . . . . . . . . . . . . .
Install rocker arm assembly . . .
Measure valve guides . . . . . . .
Measure valve recess . . . . . . .
Measure valve seats . . . . . . . .
Measure valves . . . . . . . . . . .
Preliminary checks . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Remove valve seat inserts . . . .
TORQUE-TO-YIELD cap screws
TORQUE-TURN cap screws . . .
Valve clearance adjustment . . .
Cylinder head cap screws
Clean, inspect and install . . . . .
Types . . . . . . . . . . . . . . . . . .
Cylinder head gasket
Failure diagnostics . . . . . . . . .
Joint construction . . . . . . . . . .
Joint operation . . . . . . . . . . . .
Cylinder liner
Deglaze . . . . . . . . . . . . . . . . .
Measure height . . . . . . . . . . . .
Cylinder liner height
Recheck . . . . . . . . . . . . . . . .
Cylinder liners
Clean . . . . . . . . . . . . . . . . . .
Date code . . . . . . . . . . . . . . .
Failure analysis . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . .
Install liner shims . . . . . . . . . .
Install O-rings and packings . . .
Measure . . . . . . . . . . . . . . . .
Measure flange thickness . . . . .
Preliminary checks . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Cylinder liners Inspect . . . . . . . . .
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Page
Page
05-28
05-32
05-37
05-22
05-14
05-24
05-18
05-15
05-10
05-26
05-36
05-35
. 05-7
Diesel Fuel
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . 02-1
Drive, fan
Replace bearings . . . . . . . . . 25-6, 25-8, 25-10
Dynamometer test
Procedure . . . . . . . . . . . . . . . . . . . . . . 100-4
. . . . . . . 05-34
. . . . . . . 05-33
. . . . . . 105-14
. . . . . . 105-12
. . . . . . 105-12
. . . . . . . 10-14
. . 05-30, 10-12
. . . . . . . 10-35
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10-15
10-20
. 10-8
10-38
10-36
10-37
10-22
10-22
. 10-8
10-13
10-19
D
Damper pulley
Remove . . . . . . .
Damper, vibration
Inspect . . . . . . . .
Remove . . . . . . .
Diagnostics
Air intake system .
Engine . . . . . . . .
Head gasket failure
Diesel Engine Oil . . .
Diesel fuel . . . . . . .
. . . . . . . . . . . . . . . . 15-14
. . . . . . . . . . . . . . . . 15-12
. . . . . . . . . . . . . . . . . 16-7
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. 110-3
105-18
105-14
. . 02-3
. . 02-1
E
Electrical system
Check . . . . . . . . . . . . . . . . . . .
Elevations
Compensation guideline . . . . . . .
Engine
Assembly Sequence . . . . . . . . .
Check for excessive tightness . . .
Cleaning . . . . . . . . . . . . . . . . .
Coolant . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . .
Disassembly Sequence . . . . . . .
Dynamometer test . . . . . . . . . . .
General tune-up recommendations
Lifting . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . .
Preliminary testing . . . . . . . . . . .
Repair stand . . . . . . . . . . . . . .
Repair stand adapters . . . . . . . .
Sealant Guidelines . . . . . . . . . .
Serial number plate . . . . . . . . . .
Engine break-in
Perform . . . . . . . . . . . . . . . . . .
Engine break-in guidelines . . . . . . .
Engine compression pressure
Test . . . . . . . . . . . . . . . . . . . .
Engine coolant
Disposing . . . . . . . . . . . . . . . .
Products . . . . . . . . . . . . . . . . .
Requirements . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . .
Engine oil
Break-In . . . . . . . . . . . . . . . . .
Diesel . . . . . . . . . . . . . . . . . . .
Drain . . . . . . . . . . . . . . . . . . .
Engine oil pressure
Check . . . . . . . . . . . . . . . . . . .
Engine test specifications . . . . . . .
Exhaust manifold
Inspect . . . . . . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Index-3
. . . . . 100-10
. . . . . . 100-1
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. . . . . 04-4
. . . . 10-43
. . . . . 03-4
02-5, 02-13
. . . 105-18
. . . . . 04-1
. . . . 100-4
. . . . 100-3
. . . . . 03-3
. . . . . 03-5
. . . . 100-2
. . . . . 03-1
. . . . . 03-2
. . . . . 04-2
. . . . . 01-4
. 05-42, 100-6
. . . . . . 100-5
. . . . . 105-21
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02-13
. 02-7
. 02-5
. 02-8
. . . . . . . 02-2
. . . . . . . 02-3
. . . . . . . 20-2
. . . . . 105-22
. . . . . . 105-3
. . . . . . 30-31
. . . . . . 30-31
. . . . . . 30-31
160101
PN=446
INDX
3
Index
Page
Exhaust system
Check . . . . . . . . . . . . . . . . . . . . . . . . . 100-8
General information . . . . . . . . . . . . . . . . 110-4
Specifications . . . . . . . . . . . . . . . . . . . . . 30-2
F
INDX
4
Failure analysis
Head gasket . . . . . . . . . . . . . . . . . . . 105-14
Fan belt
Tension specifications . . . . . . . . . . . . . . 25-26
Fan drive
Replace bearings . . . . . . . . . . . . . . . . . 25-10
Fan drive assembly
Replace bearings . . . . . . . . . . . . . . 25-6, 25-8
Fan pulley
Replace bearing . . . . . . . . . . . . . . . . . . 25-12
Filter, oil
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Filter, rectangular fuel
Operation . . . . . . . . . . . . . . . . . . . . . 115-28
Replace . . . . . . . . . . . . . . . . . . . . . . . . . 35-6
Filter, round fuel
Bleed fuel system . . . . . . . . . . . . . . . . 115-30
Replace . . . . . . . . . . . . . . . . . . . . . . . . . 35-8
Filter,oil
Remove . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Flywheel
Check face flatness . . . . . . . . . . . . . . . . 15-21
Inspect and measure . . . . . . . . . . . . . . . 15-20
Install . . . . . . . . . . . . . . . . . . . . . . . . . 15-51
Remove . . . . . . . . . . . . . . . . . . . . . . . 15-22
Ring gear, replace . . . . . . . . . . . . . . . . . 15-24
Flywheel housing
Check face runout . . . . . . . . . . . . . . . . . 15-21
Remove SAE 1 and SAE 2 . . . . . . . . . . 15-23
Remove SAE 3 . . . . . . . . . . . . . . . . . . 15-23
Flywheel housing (SAE 1 & SAE 2)
Install . . . . . . . . . . . . . . . . . . . . . . . . . 15-51
Flywheel housing (SAE 3)
Install . . . . . . . . . . . . . . . . . . . . . . . . . 15-50
Flywheel, main bearings, crankshaft
Final assembly . . . . . . . . . . . . . . . . . . . 15-52
Followers, camshaft
Inspect and measure . . . . . . . . . . . . . . . 16-12
Front frame/oil sump Tighten cap screws . . . 20-15
Front oil seal
Install (timing cover installed) . . . . 15-18, 15-49,
16-21
Remove (timing cover installed) . . . . . . . . 15-16
Page
Front wear sleeve
Install (timing cover installed) . . .
Remove (timing cover installed) . .
Fuel
Diesel . . . . . . . . . . . . . . . . . . .
Lubricity . . . . . . . . . . . . . . . . .
Fuel filter check valve
Replace . . . . . . . . . . . . . . . . . .
Fuel filter, rectangular
Operation . . . . . . . . . . . . . . . .
Replace . . . . . . . . . . . . . . . . . .
Fuel filter, round
Bleed fuel system . . . . . . . . . . .
Replace . . . . . . . . . . . . . . . . . .
Fuel injection nozzle
Clean and inspect seating surface
General information . . . . . . . . . .
Operation . . . . . . . . . . . . . . . .
Fuel injection nozzle bore
Clean and inspect . . . . . . . . . . .
Inspect and clean . . . . . . . . . . .
Fuel injection nozzles
Adjustment . . . . . . . . . . . . . . . .
Assemble . . . . . . . . . . . . . . . .
Bleed system . . . . . . . . . . . . . .
Chatter and spray test . . . . . . . .
Clean . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . .
Disassemble . . . . . . . . . . . . . .
Inspect . . . . . . . . . . . . . . . . . .
Inspect holder . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Leakage test . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Slide test . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . .
Test opening pressure . . . . . . . .
Test, engine running . . . . . . . . .
Fuel injection pump
Diagnose malfunctions . . . . . . . .
Identification . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . .
Service overflow valve . . . . . . . .
Fuel injection pump, in-line
Fast idle speed, check . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Slow idle speed, check and adjust
Index-4
. . . . . . 15-17
. . . . . . 15-17
. . . . . . . 02-1
. . . . . . . 02-1
. . . . . . . 35-7
. . . . . 115-28
. . . . . . . 35-6
. . . . . 115-30
. . . . . . . 35-8
. . . . . . 35-59
. . . . . 115-46
. . . . . 115-47
. . . . . . 35-58
. . . . . . 05-27
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. . . . 35-57
. . . . 35-54
. . . 115-31
. . . . 35-46
35-49, 35-50
. . . . . 35-40
. . . . 115-48
. . . . . 35-47
35-49, 35-53
. . . . . 35-51
. . . . . 35-59
. . . . . 35-45
. . . . . 35-37
. . . . . 35-50
. . . . . 35-44
. . . . . 35-42
. . . . . 35-43
. . . . 115-49
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115-32
. . 35-9
115-33
. 35-22
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115-34
. 35-29
. 35-26
115-35
160101
PN=447
Index
Page
Fuel injection pump, rotary
Check and adjust engine speeds
Diagnose malfunctions . . . . . . .
Operation . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Fuel shut-off solenoid
Linkage adjustment . . . . . . . . .
Operational check . . . . . . . . . .
Resistance test . . . . . . . . . . . .
Fuel shutoff solenoid
Bracket, remove and install . . . .
Remove and install . . . . . . . . .
Fuel supply pump
Diagnostics . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . .
Fuel supply pump, electric
Clean or replace filter screen . .
Operation . . . . . . . . . . . . . . .
Remove and install . . . . . . . . .
Test output pressure and flow . .
Fuel supply pump, mechanical
Assemble (Bosch) . . . . . . . . . .
Assemble (Nippondenso) . . . . .
Check operation . . . . . . . . . . .
Disassemble (Bosch) . . . . . . . .
Disassemble (Nippondenso) . . .
General information . . . . . . . . .
Inspect (Bosch) . . . . . . . . . . .
Inspect (Nippondenso) . . . . . . .
Install . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . .
Fuel system
Bleed . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . .
Fuel drain back test . . . . . . . . .
Specifications . . . . . . . . . . . . .
Fuel system, in-line pump
General information . . . . . . . . .
Fuel system, rotary pump
General information . . . . . . . . .
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115-41
115-40
115-38
. 35-33
. . . . . . 115-27
. . . . . . 115-26
. . . . . . 115-27
. . . . . . . 35-24
. . . . . . . 35-24
. . . . . . 115-18
. . . . . . . . 35-9
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. 35-20
115-23
. 35-19
115-25
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. . . . . 35-18
. . . . . 35-15
. . . . 115-20
. . . . . 35-16
. . . . . 35-12
. . . . 115-16
. . . . . 35-17
. . . . . 35-14
. . . . . 35-18
. . . . . 35-10
. . . . 115-22
35-11, 115-19
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. . . 115-29
. . . 115-12
. . . 115-49
35-4, 115-2
. . . . . . 115-10
. . . . . . 115-11
G
Gasket, head
Diagnosing failures . . . . . . . . . . . .
Inspection and repair . . . . . . . . . . .
Joint construction and operation . . .
Gear
Flywheel ring, replace . . . . . . . . . .
. . . 105-14
. . . 105-17
. . . 105-12
. . . . 15-24
Page
Gear backlash
Camshaft-to-crankshaft . . . . . . . . .
Gear cover
Install . . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . . .
Gear, crankshaft
Replace . . . . . . . . . . . . . . . . . . .
Gear, oil pump drive
Inspect . . . . . . . . . . . . . . . . . . .
Gear, Oil Pump Drive (Crankshaft)
Replace . . . . . . . . . . . . . . . . . . .
Gears
Camshaft, remove . . . . . . . . . . . .
Gears, camshaft
Install . . . . . . . . . . . . . . . . . . . .
Grease
Extreme pressure and multipurpose
Grinding, crankshaft
Guidelines . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . .
Guides, valve
Clean . . . . . . . . . . . . . . . . . . . .
Knurl . . . . . . . . . . . . . . . . . . . .
Measure . . . . . . . . . . . . . . . . . .
. . . . . . 16-8
. . . . . 16-20
. . . . . . 16-7
. . . . . 15-39
. . . . . 20-12
. . . . . 15-38
. . . . . 16-11
. . . . . 16-14
. . . . . . 02-4
. . . . . 15-34
. . . . . 15-37
. . . . . 05-22
. . . . . 05-23
. . . . . 05-22
H
Head, cylinder
Check flatness . . . . . . . . . . .
Clean and inspect push rods .
Clean and inspect valve seats .
Clean valve guides . . . . . . . .
Failure analysis . . . . . . . . . .
Final assembly . . . . . . . . . . .
Gasket failure diagnostics . . . .
Gasket joint construction . . . .
Gasket joint operation . . . . . .
Grind valve seats . . . . . . . . .
Inspect and clean . . . . . . . . .
Inspect rotators and wear caps
Install . . . . . . . . . . . . . . . . .
Install rocker arm assembly . .
Measure valve guides . . . . . .
Measure valve recess . . . . . .
Measure valve seats . . . . . . .
Measure valves . . . . . . . . . .
Preliminary checks . . . . . . . .
Remove . . . . . . . . . . . . . . .
Remove valve seat inserts . . .
Index-5
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. 05-20
. 05-28
. 05-23
. 05-22
. 05-15
. 05-38
105-14
105-12
105-12
. 05-25
. 05-19
. 05-17
. 05-32
. 05-37
. 05-22
. 05-14
. 05-24
. 05-18
. 05-15
. 05-10
. 05-26
160101
PN=448
INDX
5
Index
INDX
6
Head, cylinder—Continued
TORQUE-TO-YIELD cap screws .
TORQUE-TURN cap screws . . . .
Valve clearance adjustment . . . .
Heater, coolant
Install . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Hose, ventilator outlet
Inspect . . . . . . . . . . . . . . . . . .
Housing, crankshaft rear oil
Install . . . . . . . . . . . . . . . . . . .
Housing, flywheel
Check face runout . . . . . . . . . . .
Remove SAE 1 and SAE 2 . . . .
Remove SAE 3 . . . . . . . . . . . .
Housing, flywheel (SAE 1 & SAE 2)
Install . . . . . . . . . . . . . . . . . . .
Housing, flywheel (SAE 3)
Install . . . . . . . . . . . . . . . . . . .
Housing, oil conditioning
Assembly . . . . . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Housing, oil conditioning housing
Remove . . . . . . . . . . . . . . . . .
Housing, oil seal
Check runout . . . . . . . . . . . . . .
Housing, rear oil seal
Remove . . . . . . . . . . . . . . . . .
Page
. . . . . . 05-36
. . . . . . 05-35
. . . . . . . 05-7
. . . . . . 25-25
. . . . . . 25-24
. . . . . . 05-28
. . . . . . 15-43
. . . . . . 15-21
. . . . . . 15-23
. . . . . . 15-23
. . . . . . 15-51
. . . . . . 15-50
. . . . . . . 20-3
. . . . . . . 20-6
. . . . . . . 20-4
. . . . . . 15-45
. . . . . . 15-25
I
Inch torque values . . . . . . . . .
Injection nozzle
Adjustment . . . . . . . . . . . . .
General information . . . . . . .
Operation . . . . . . . . . . . . .
Injection nozzle bore
Clean and inspect . . . . . . . .
Inspect and clean . . . . . . . .
Injection nozzle seating surface
Clean and inspect . . . . . . . .
Injection nozzles
Assemble . . . . . . . . . . . . .
Bleed system . . . . . . . . . . .
Chatter and spray test . . . . .
Clean . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . .
Disassemble . . . . . . . . . . .
Inspect . . . . . . . . . . . . . . .
. . . . . . . . . . 01-1
. . . . . . . . . 35-57
. . . . . . . . 115-46
. . . . . . . . 115-47
. . . . . . . . . 35-58
. . . . . . . . . 05-27
. . . . . . . . . 35-59
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. . . . . 35-54
. . . . 115-31
. . . . . 35-46
35-49, 35-50
. . . . . 35-40
. . . . 115-48
. . . . . 35-47
35-49, 35-53
Injection nozzles—Continued
Inspect holder . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Leakage test . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Slide test . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . .
Test opening pressure . . . . . . . .
Test, engine running . . . . . . . . .
Injection pump
Bleed system . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . .
Service overflow valve . . . . . . . .
Injection pump, in-line
Fast idle speed, check . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Slow idle speed, check and adjust
Injection pump, in-line fuel
Remove . . . . . . . . . . . . . . . . .
Injection pump, rotary fuel
Remove . . . . . . . . . . . . . . . . .
Inserts, valve seat
Install . . . . . . . . . . . . . . . . . . .
Replace . . . . . . . . . . . . . . . . . .
Intake manifold
Check pressure . . . . . . . . . . . .
Inspect . . . . . . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Remove, inspect, and install . . . .
Repair . . . . . . . . . . . . . . . . . . .
Intake system, air
Check . . . . . . . . . . . . . . . . . . .
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. 35-51
. 35-59
. 35-45
. 35-37
. 35-50
. 35-44
. 35-42
. 35-43
115-49
. . . . . 115-31
. . . . . . . 35-9
. . . . . . 35-22
. . . . . 115-34
. . . . . . 35-29
. . . . . 115-35
. . . . . . 35-26
. . . . . . 35-33
. . . . . . 05-27
. . . . . . 05-26
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30-27,
30-23,
.....
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110-9
30-26
30-29
30-25
30-22
30-26
. . . . . . 100-7
L
Lift, valve
Check . . . . . . . .
Liner, cylinder
Deglaze . . . . . . .
Measure height . .
Recheck height . .
Liners, cylinder
Clean . . . . . . . .
Date code . . . . .
Failure analysis .
Inspect . . . . . . .
Install . . . . . . . .
Install liner shims
Index-6
. . . . . . . . . . . . . . 05-9, 16-6
. . . . . . . . . . . . . . . . . 10-14
. . . . . . . . . . . . 05-30, 10-12
. . . . . . . . . . . . . . . . . 10-35
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10-15
10-20
. 10-8
10-19
10-38
10-36
160101
PN=449
Index
Liners, cylinder—Continued
Install O-rings and packings
Measure . . . . . . . . . . . . .
Measure flange thickness . .
Preliminary checks . . . . . .
Remove . . . . . . . . . . . . .
Lubricant
Alternative . . . . . . . . . . . .
Synthetic . . . . . . . . . . . . .
Lubrication system
How it works . . . . . . . . . .
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10-37
10-22
10-22
. 10-8
10-13
. . . . . . . . . . . 02-5
. . . . . . . . . . . 02-5
. . . . . . . . . . 105-6
M
Main bearing cap
Measure line bore . . . . . . . . . .
Main bearings
Check clearance . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Main bearings, flywheel, crankshaft
Final assembly . . . . . . . . . . . .
Manifold, intake
Check pressure . . . . . . . . . . .
Manifold, water
Install . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Metric torque values . . . . . . . . . .
. . . . . . . 15-33
. . . . . . . 15-28
. . . . . . . 15-41
. . . . . . . 15-27
. . . . . . . 15-52
. . . . . . . 110-9
. . . . . . . 25-24
. . . . . . . 25-23
. . . . . . . . 01-2
N
Nozzle bore
Clean and inspect . . . . .
Nozzle bore, fuel injection
Inspect and clean . . . . .
Nozzle, fuel injection
Clean and inspect seating
General information . . . .
Operation . . . . . . . . . .
Nozzles, fuel injection
Bleed system . . . . . . . .
Chatter and spray test . .
Clean . . . . . . . . . . . . .
Diagnosis . . . . . . . . . .
Disassemble . . . . . . . .
Inspect . . . . . . . . . . . .
Inspect holder . . . . . . .
Install . . . . . . . . . . . . .
Leakage test . . . . . . . .
. . . . . . . . . . . . 35-58
. . . . . . . . . . . . 05-27
surface . . . . . . 35-59
. . . . . . . . . . . 115-46
. . . . . . . . . . . 115-47
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115-31
. 35-46
. 35-49
. 35-40
. 35-47
. 35-49
. 35-51
. 35-59
. 35-45
Page
Nozzles, fuel injection—Continued
Remove . . . . . . . . . . . . . . . . . . . . . . . 35-37
Slide test . . . . . . . . . . . . . . . . . . . . . . . 35-50
Test, engine running . . . . . . . . . . . . . . 115-49
O
Oil
Filter . . . . . . . . . . . . . . . . . . . . . .
Oil conditioning housing
Install . . . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . . . .
Oil conditioning housing assembly . . . .
Oil cooler
Clean, inspect, and install . . . . . . . .
Remove . . . . . . . . . . . . . . . . . . .
Oil filter
Install . . . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . . . .
Oil filter adapter
Replace . . . . . . . . . . . . . . . . . . . .
Oil filter assembly . . . . . . . . . . . . . .
Oil filter bypass valve
Remove, inspect, and install . . . . . .
Oil pan
Install . . . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . . . .
Oil pressure
Check . . . . . . . . . . . . . . . . . . . . .
Oil pressure regulating valve
Remove, inspect, and install . . . . . .
Oil pump
Check drive shaft endplay . . . . . . .
Check pumping gear backlash . . . . .
Check shaft side movement . . . . . .
Inspect and clean . . . . . . . . . . . . .
Inspect drive gear . . . . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . . . .
Oil Pump Drive Gear (Crankshaft)
Replace . . . . . . . . . . . . . . . . . . . .
Oil pump drive gear-to crankshaft gear
Check backlash . . . . . . . . . . . . . .
Oil seal housing runout
Check . . . . . . . . . . . . . . . . . . . . .
Oil seal housing, crankshaft rear
Install . . . . . . . . . . . . . . . . . . . . .
Oil seal housing, rear
Remove . . . . . . . . . . . . . . . . . . .
Oil seal, crankshaft rear
Install . . . . . . . . . . . . . . . . . . . . .
Index-7
. . . . . 20-4
. . . . . 20-6
. . . . . 20-4
. . . . . 20-3
. . . . . 20-8
. . . . . 20-7
. . . . . 20-6
. . . . . 20-4
. . . . . 20-4
. . . . . 20-3
. . . . . 20-5
. . . . 20-14
. . . . . 20-2
. . . 105-22
. . . . . 20-5
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20-11
20-12
20-11
20-10
20-12
20-13
. 20-9
. . . . 15-38
. . . . . 20-9
. . . . 15-45
. . . . 15-43
. . . . 15-25
. . . . 15-47
160101
PN=450
INDX
7
Index
Page
Oil seal, front
Install (timing cover installed) . . . . 15-18, 15-49,
16-21
Remove (timing cover installed) . . . . . . . . 15-16
Oil seal, rear, and wear sleeve
Install (w/o engine disassembly) . . . . . . . 15-11
Oil, engine
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Orifices, piston cooling
Install . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Remove and clean . . . . . . . . . . . . . . . . 10-29
INDX
8
P
Pan, oil
Install . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . .
Pilot bearing
Check bore concentricity . . . .
Pin, piston
Install in piston . . . . . . . . . . .
Piston
Measure oil control ring groove
Piston cooling orifices
Install . . . . . . . . . . . . . . . . .
Remove and clean . . . . . . . .
Piston pin
Install in piston . . . . . . . . . . .
Piston pin bushing
Install . . . . . . . . . . . . . . . . .
Piston Pin Bushing
Remove . . . . . . . . . . . . . . .
Piston pin bushing bore
Clean and inspect . . . . . . . . .
Piston ring groove
Check wear . . . . . . . . . . . . .
Piston rings
Remove . . . . . . . . . . . . . . .
Piston skirt OD
Measure . . . . . . . . . . . . . . .
Piston-to-liner clearance
Determine . . . . . . . . . . . . . .
Pistons
Clean . . . . . . . . . . . . . . . . .
Failure analysis . . . . . . . . . .
Inspect . . . . . . . . . . . . . . . .
Inspect pins and bushings . . .
Install . . . . . . . . . . . . . . . . .
Preliminary checks . . . . . . . .
Remove . . . . . . . . . . . . . . .
. . . . . . . . 20-14
. . . . . . . . . 20-2
. . . . . . . . 15-22
. . . . . . . . 10-18
. . . . . . . . 10-18
. . . . . . . . 10-34
. . . 10-29, 15-40
. . . . . . . . 10-18
. . . . . . . . 10-28
. . . . . . . . 10-27
. . . . . . . . 10-27
. . . . . . . . 10-17
. . . . . . . . 10-15
. . . . . . . . 10-21
. . . . . . . . 10-21
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10-15
. 10-8
10-16
10-26
10-40
. 10-8
. 10-9
Page
Pressure, engine compression
Test . . . . . . . . . . . . . . . . . . .
Pressure, engine oil
Check . . . . . . . . . . . . . . . . . .
Pulley, crankshaft
Remove . . . . . . . . . . . . . . . .
Pulley, damper
Remove . . . . . . . . . . . . . . . .
Pulley, fan
Replace bearing . . . . . . . . . . .
Pump, electric fuel supply
Diagnose malfunction . . . . . . . .
Test output pressure and flow . .
Pump, fuel injection
Bleed system . . . . . . . . . . . . .
Diagnose malfunctions . . . . . . .
Identification . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . .
Service overflow valve . . . . . . .
Pump, in-line fuel injection
Remove . . . . . . . . . . . . . . . .
Pump, mechanical fuel supply
Identification . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Pump, oil
Check drive shaft endplay . . . .
Check pumping gear backlash . .
Check shaft side movement . . .
Inspect and clean . . . . . . . . . .
Inspect drive gear . . . . . . . . . .
Install . . . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . . . .
Pump, rotary fuel injection . . . . . .
Pump, rotary fuel injection
Diagnose malfunctions . . . . . . .
Operation . . . . . . . . . . . . . . .
Pump, rotary fuel injection pump
Check and adjust engine speeds
Pump, water
Assemble . . . . . . . . . . . . . . .
Disassemble . . . . . . . . . . . . .
Inspect . . . . . . . . . . . . . . . . .
Push rods
Clean and inspect . . . . . . . . . .
. . . . . . 105-21
. . . . . . 105-22
. . . . . . . . 16-7
. . . . . . . 15-14
. . . . . . . 25-12
. . . . . . 115-24
. . . . . . 115-25
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115-31
115-32
. . 35-9
115-33
. 35-22
. . . . . . . 35-26
. . . . . . . . 35-9
. . . . . . . 35-10
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20-11
20-12
20-11
20-10
20-12
20-13
. 20-9
35-33
. . . . . . 115-40
. . . . . . 115-38
. . . . . . 115-41
. . . . . . . 25-19
. . . . . . . 25-15
. . . . . . . 25-18
. . . . . . . 05-28
R
Radiator cap
Pressure test . . . . . . . . . . . . . . . . . . . 105-23
Radiator, cap
Pressure test . . . . . . . . . . . . . . . . . . . 105-23
Index-8
160101
PN=451
Index
Page
Rear crankshaft oil seal housing
Install . . . . . . . . . . . . . . . . . . .
Rear oil seal and crankshaft
Handling precautions . . . . . . . . .
Rear oil seal and wear sleeve
Install (w/o engine disassembly) .
Rear oil seal housing
Remove with engine disassembled
Regulating valve, oil pressure
Remove, inspect, and install . . . .
Ring gear, flywheel
Replace . . . . . . . . . . . . . . . . . .
Rings, piston
Remove . . . . . . . . . . . . . . . . .
Rocker arm assembly
Install . . . . . . . . . . . . . . . . . . .
Rocker arm shaft assembly
Assemble . . . . . . . . . . . . . . . .
Disassemble and inspect . . . . . .
Rod bearings
Inspect and measure . . . . . . . . .
Rods, connecting
Failure analysis . . . . . . . . . . . .
Inspect rod and cap . . . . . . . . .
Rods, Connecting
Install . . . . . . . . . . . . . . . . . . .
Rods, connecting
Preliminary checks . . . . . . . . . .
Remove . . . . . . . . . . . . . . . . .
Rotary fuel injection pump
Check and adjust engine speeds .
Diagnose malfunctions . . . . . . . .
Operation . . . . . . . . . . . . . . . .
Rotary Injection pump
Dynamic timing . . . . . . . . . . . . .
. . . . . . 15-43
. . . . . . 15-46
. . . . . . 15-11
. . . . . . 15-26
. . . . . . . 20-5
. . . . . . 15-24
. . . . . . 10-15
. . . . . . 05-37
. . . . . . 05-14
. . . . . . 05-12
. . . . . . 10-23
. . . . . . . 10-8
. . . . . . 10-24
. . . . . . 10-40
. . . . . . . 10-8
. . . . . . . 10-9
. . . . . 115-41
. . . . . 115-40
. . . . . 115-38
. . . . . . 115-2
S
Seal, crankshaft rear oil
Handling precautions . . . . . . .
Install . . . . . . . . . . . . . . . . .
Install (w/o engine disassembly)
Remove . . . . . . . . . . . . . . .
Seal, front oil
Install (timing cover installed) .
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15-46
15-47
15-11
. 15-9
. . . 15-18, 15-49,
16-21
Remove (timing cover installed) . . . . . . . . 15-16
Seal, rear oil housing
Remove . . . . . . . . . . . . . . . . . . . . . . . 15-25
Sealant guidelines . . . . . . . . . . . . . . . . . . . 04-2
Page
Seats, valve
Clean and inspect . . . . . . . . . . . .
Grind . . . . . . . . . . . . . . . . . . . .
Measure . . . . . . . . . . . . . . . . . .
Serial Number Plate . . . . . . . . . . . .
Shaft, rocker arm assembly
Disassemble and inspect . . . . . . .
Shims, cylinder liner
Install . . . . . . . . . . . . . . . . . . . .
Shut-off solenoid, fuel
Linkage adjustment . . . . . . . . . . .
Operational check . . . . . . . . . . . .
Resistance test . . . . . . . . . . . . . .
Skirt, piston
Measure OD . . . . . . . . . . . . . . .
Sleeve, front wear
Install . . . . . . . . . . . . . . . . . . . .
Install (timing cover installed) . . . .
Remove (timing cover installed) . . .
Sleeve, rear wear
Install . . . . . . . . . . . . . . . . . . . .
Remove (with engine disassembled)
Sleeve, wear
Remove . . . . . . . . . . . . . . . . . .
Solenoid, fuel shut-off
Linkage adjustment . . . . . . . . . . .
Operational check . . . . . . . . . . . .
Resistance test . . . . . . . . . . . . . .
Solenoid, fuel shutoff
Remove and install . . . . . . . . . . .
Specifications
Air intake system . . . . . . . . . . . .
Block, Liners, Pistons, and Rods . .
Camshaft and timing gear train . . .
Coolant . . . . . . . . . . . . . . . . . . .
Cooling system . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . .
Crankshaft grinding . . . . . . . . . . .
Cylinder Head and Valves . . . . . .
Exhaust system . . . . . . . . . . . . .
Flywheel . . . . . . . . . . . . . . . . . .
Fuel injection nozzles . . . . . . . . .
Fuel system . . . . . . . . . . . . . . . .
Intake manifold pressure . . . . . . .
Lubrication System . . . . . . . . . . .
Main Bearings . . . . . . . . . . . . . .
Specifications,
Engine test . . . . . . . . . . . . . . . .
Springs, valve
Inspect . . . . . . . . . . . . . . . . . . .
Index-9
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05-23
05-25
05-24
. 01-4
. . . . . 05-12
. . . . . 10-36
. . . . 115-27
. . . . 115-26
. . . . 115-27
. . . . . 10-21
. . . . . 15-48
. . . . . 15-17
. . . . . 15-17
. . . . . 15-47
. . . . . 15-26
. . . . . 15-25
. . . . 115-27
. . . . 115-26
. . . . 115-27
. . . . . 35-24
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. . . . . 30-2
. . . . . 10-4
. . . . . 16-4
. . . . . 02-8
. . . . . 25-3
. . . . . 15-6
. . . . 15-37
. . . . . 05-5
. . . . . 30-2
. . . . . 15-6
. . . . 35-44
35-4, 115-2
. . . . 110-9
. . . . . 20-1
. . . . . 15-6
. . . . . 105-3
. . . . . 05-17
160101
PN=452
INDX
9
Index
Page
INDX
10
Supply pump, electric fuel
Clean or replace filter screen
Diagnose malfunction . . . . . .
Operation . . . . . . . . . . . . .
Remove and install . . . . . . .
Test output pressure and flow
Supply pump, fuel
Diagnostics . . . . . . . . . . . .
Supply pump, mechanical fuel
Assemble (Bosch) . . . . . . . .
Assemble (Nippondenso) . . .
Check operation . . . . . . . . .
Disassemble (Bosch) . . . . . .
Disassemble (Nippondenso) .
General information . . . . . . .
Identification . . . . . . . . . . . .
Inspect (Bosch) . . . . . . . . .
Inspect (Nippondenso) . . . . .
Install . . . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . .
Synthetic Lubricants . . . . . . . .
System, cooling
Flush . . . . . . . . . . . . . . . .
How it works . . . . . . . . . . .
System, crankcase ventilation
Check . . . . . . . . . . . . . . . .
System, electrical
Check . . . . . . . . . . . . . . . .
System, lubrication
How it works . . . . . . . . . . .
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. 35-20
115-24
115-23
. 35-19
115-25
. . . . . . . . 115-18
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. . . . . 35-18
. . . . . 35-15
. . . . 115-20
. . . . . 35-16
. . . . . 35-12
. . . . 115-16
. . . . . . 35-9
. . . . . 35-17
. . . . . 35-14
. . . . . 35-18
. . . . . 35-10
. . . . 115-22
35-11, 115-19
. . . . . . . 02-5
. . . . . . . . . 100-8
. . . . . . . . 105-10
. . . . . . . . . 100-7
. . . . . . . . 100-10
. . . . . . . . . 105-6
T
Temperature compensation .
Test specifications
Engine . . . . . . . . . . . . .
Thermostat
Inspect and test . . . . . . .
Thermostats
Install . . . . . . . . . . . . . .
Remove and test . . . . . .
Thrust bearings
Specifications . . . . . . . . .
Thrust washers, camshaft
Measure . . . . . . . . . . . .
Timing gear cover
Install . . . . . . . . . . . . . .
Install with engine installed
. . . . . . . . . . . 100-1
Timing gear cover—Continued
Remove . . . . . . . . . . . . . . . . .
Remove with engine installed . . .
Timing gear train
Specifications . . . . . . . . . . . . . .
Torque values
Inch . . . . . . . . . . . . . . . . . . . .
Metric . . . . . . . . . . . . . . . . . . .
TORQUE-TO-YIELD
Cylinder head cap screws . . . . .
TORQUE-TURN
Cylinder head cap screws . . . . .
Tune-up
Preliminary engine testing . . . . . .
Tune-Up Recommendations . . . . . .
Turbocharger
Assemble . . . . . . . . . . . . . . . .
Axial bearing end play test . . . . .
Boost pressure at aneroid . . . . .
Boost pressure at intake manifold
Clean compressor housing . . . . .
Clean turbine housing . . . . . . . .
Diagnostics . . . . . . . . . . . . . . .
Disassemble . . . . . . . . . . . . . .
Extending life . . . . . . . . . . . . . .
Failure analysis . . . . . . . . . . . .
General information . . . . . . . . . .
Inspect compressor housing . . . .
Inspect turbine housing . . . . . . .
Install . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . .
Prelube . . . . . . . . . . . . . . . . . .
Radial bearing clearance test . . .
Remove . . . . . . . . . . . . . . . . .
Replace center housing assembly
Seven-step inspection . . . . . . . .
Turbocharger boost
Check . . . . . . . . . . . . . . . . . . .
Page
. . 15-20, 16-7
. . . . . . 15-19
. . . . . . . 16-4
. . . . . . . 01-1
. . . . . . . 01-2
. . . . . . 05-36
. . . . . . 05-35
. . . . . . 100-2
. . . . . . 100-3
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. 30-19
. 30-16
. 110-9
110-10
. 30-18
. 30-18
. 110-6
. 30-17
. . 30-4
. . 30-8
. 110-7
. 30-18
. 30-18
. 30-20
. 110-7
. 30-20
. 30-15
. . 30-6
. 30-19
. 30-10
. . . . . . 110-9
. . . . . . . . . . . 105-3
V
. . . . . . . . . . 105-24
. . . . . . . . . . . 25-23
. . . . . . . . . . . 25-22
. . . . . . . . . . . 15-36
. . . . . . . . . . . 16-11
. 15-20, 15-48, 16-20
. . . . . . . . . . . 15-19
Valve assembly
Assemble . . . . .
Valve clearance
Check and adjust
Valve guides
Knurl . . . . . . . .
Measure . . . . . .
Valve lift
Check . . . . . . . .
Valve recess
Measure . . . . . .
Index-10
. . . . . . . . . . . . . . . . . 05-31
. . . . . . . . . . . . . . . . . . 05-7
. . . . . . . . . . . . . . . . . 05-23
. . . . . . . . . . . . . . . . . 05-22
. . . . . . . . . . . . . . 05-9, 16-6
. . . . . . . . . . . . . . . . . 05-14
160101
PN=453
Index
Page
Valve seat inserts
Install . . . . . . . . . . . . . . .
Replace . . . . . . . . . . . . . .
Valve seats
Clean and inspect . . . . . . .
Grind . . . . . . . . . . . . . . .
Measure . . . . . . . . . . . . .
Valve springs
Inspect . . . . . . . . . . . . . .
Measure . . . . . . . . . . . . .
Specifications . . . . . . . . . .
Valve, oil cooler bypass
Remove, inspect, and install
Valve, oil filter bypass
Remove, inspect, and install
Valve, oil pressure regulating
Remove, inspect, and install
Valve, rotators
Inspect . . . . . . . . . . . . . .
Valves
Clean . . . . . . . . . . . . . . .
Failure analysis . . . . . . . .
Grind . . . . . . . . . . . . . . .
Measure . . . . . . . . . . . . .
Preliminary checks . . . . . .
Remove valve assembly . . .
Valves guides
Clean . . . . . . . . . . . . . . .
Ventilation system, crankcase
Check . . . . . . . . . . . . . . .
Ventilator outlet hose
Inspect and clean . . . . . . .
Vibration damper
Inspect . . . . . . . . . . . . . .
Remove . . . . . . . . . . . . .
. . . . . . . . . . 05-27
. . . . . . . . . . 05-26
. . . . . . . . . . 05-23
. . . . . . . . . . 05-25
. . . . . . . . . . 05-24
Page
Wear sleeve, front
Install . . . . . . . . . . . . . . . . . . . .
Install (timing cover installed) . . . .
Remove (timing cover installed) . . .
Wear sleeve, rear
Install . . . . . . . . . . . . . . . . . . . .
Remove (with engine disassembled)
. . . . . 15-48
. . . . . 15-17
. . . . . 15-17
. . . . . 15-47
. . . . . 15-26
. . . . . . . . . . 05-17
. . . . . . . . . . 05-17
. . . . . . . . . . 05-17
. . . . . . . . . . . 20-5
INDX
11
. . . . . . . . . . . 20-5
. . . . . . . . . . . 20-5
. . . . . . . . . . 05-17
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05-18
05-15
05-19
05-18
05-15
05-16
. . . . . . . . . . 05-22
. . . . . . . . . . 100-7
. . . . . . . . . . 05-28
. . . . . . . . . . 15-12
. . . . . . . . . . . 16-7
W
Water manifold
Install . . . . .
Remove . . .
Water pump
Assemble . .
Disassemble
Inspect . . . .
Install . . . . .
Remove . . .
Wear caps
Inspect . . . .
Wear sleeve
Remove . . .
. . . . . . . . . . . . . . . . . . . . 25-24
. . . . . . . . . . . . . . . . . . . . 25-23
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25-19
25-15
25-18
25-21
25-14
. . . . . . . . . . . . . . . . . . . . 05-17
. . . . . . . . . . . . . . . . . . . . 15-25
Index-11
160101
PN=454
Index
INDX
12
Index-12
160101
PN=455