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.
This is the safety-alert symbol. When you see
N
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.
current CTM obsolete. Discard
CTM42, dated 02 NOV 92. Please
copy this page and route through
your service department.
• Engine application charts updated to include the
latest product models. See ENGINE APPLICATION
CHART in Group 01.
• Engine coolant information revised. See ENGINE
COOLANT RECOMMENDATIONS in Group 02.
• 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.
• 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.
• 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.
• Information and specifications for fan drive assembly
with press-fit fan spacer added to Group 25.
• Torque specifications for turbocharger oil inlet line
added to Group 30.
• Information to help identify A-Series and P-Series
fuel injection pumps and fuel supply pumps added to
Group 35.
• 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.
• 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.
• Camshaft lobe lift specifications and valve lift
specifications revised in Group 16.
TIME TRAC® is a registered trademark of Stanadyne Automotive Corp.
• 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.
RG,CTM42,DPS -19-21MAR95
®
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.
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.
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.
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.
00
3
X9811 -UN-23AUG88
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
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.
Tie long hair behind your head. Do not wear a necktie,
4
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.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
WORK IN VENTILATED AREA
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.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
Safety/Safety
TS228 -UN-23AUG88
DX,LOOSE -19-04JUN90
WORK IN CLEAN AREA
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.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose
of paint and solvent properly.
00
5
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.
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
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.
TS220 -UN-23AUG88
DX,PAINT -19-03MAR93
DX,TORCH -19-03MAR93
ILLUMINATE WORK AREA SAFELY
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.
Lifting heavy components incorrectly can cause severe
6
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
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.
Safety/Safety
TS226 -UN-23AUG88
DX,LIFT -19-04JUN90
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.
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on
machine.
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
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.
DISPOSE OF WASTE PROPERLY
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.
00
7
TS779 -UN-08NOV89
DX,REPAIR -19-04JUN90
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.
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.
b
a
Dry
a
Grade 5, 5.1, or 5.2Grade 8 or 8.2
Lubricated
a
Dry
a
Lubricated
a
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.
Dry
a
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.
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.
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.
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.
Tighten toothed or serrated-type lock nuts to the full
torque value.
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
Dry
a
Lubricated
a
Dry
a
Lubricated
a
Dry
a
Lubricated
a
Dry
a
Make sure fasteners threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steel-type lock nuts
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical
property class.
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.
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.
General Information/Engine Serial Number Plate Information
ENGINE SERIAL NUMBER PLATE
INFORMATION
IMPORTANT: The engine serial number plate can be
easily destroyed. Remove the plate or
01
4
• Engine Serial Number (A)
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:
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.
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
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.
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.
• 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%.
Bio-diesel fuels meeting DIN 51606 or equivalent
specification may be used.
RG,FUEL1 -19-22FEB95
02
1
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.
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.
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.
Fuels, Lubricants, and Coolant/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.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
02
2
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.
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.
OILSCAN and COOLSCAN are John Deere sampling
programs to help you monitor machine performance and
identify potential problems before they cause serious
damage.
Oil and coolant samples should be taken from each
system prior to its recommended change interval.
02
4
Check with your John Deere dealer for the availability of
OILSCAN and COOLSCAN kits.
T6828AB -UN-15JUN89T6829AB -UN-18OCT88
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
Greases meeting Military Specification MIL-G-10924F
may be used as arctic grease.