John Deere 6076 Repair Manual

Series 400

6076

Diesel Engines

Serial Number

(500000- )

COMPONENT TECHNICAL MANUAL pЙкбЙл=QMM=SMTS=aбЙлЙд=bеЦбеЙл=pЙкб~д kмгДЙк=ERMMMMMJ=F

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Deere Power Systems Group

CTM42 (24MAR95)

LITHO IN U.S.A.

ENGLISH

D C T

C T M 4 2 2 4 M A R 9 5

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 -19-22MAY92
CTM42 (24MAR95)	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.

•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.

•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.

•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.

•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.

TIME TRAC® is a registered trademark of Stanadyne Automotive Corp.	RG,CTM42,DPS -19-21MAR95

CTM42 (24MAR95)	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
Group 00—Safety
Safety . . . . . . . . . . . . . . . . . . . . . .	. . . . . 00-1
Group 01—General Information
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . .	. . . . . 01-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . .	. . . . . 01-2
Engine Model Designation . . . . . . . . .	. . . . . 01-3
Engine Serial Number Plate Information	. . . . . 01-4
Engine Application Chart . . . . . . . . . . .	. . . . 01-5
Engine Application Chart . . . . . . . . . . .	. . . . 01-6
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . . . . . . . . . . . . . . . . .	. . . . 02-1
Lubricity of Diesel Fuels . . . . . . . . . . .	. . . . 02-1
Engine Break-In Oil . . . . . . . . . . . . . .	. . . . 02-2
Engine Oil . . . . . . . . . . . . . . . . . . . .	. . . . 02-3
Oilscan and Coolscan . . . . . . . . . . . . .	. . . . 02-4
Grease . . . . . . . . . . . . . . . . . . . . . . .	. . . . 02-4
Alternative and Synthetic Lubricants . . .	. . . . 02-5
Engine Coolant Requirements . . . . . . .	. . . . 02-5
Recommended Engine Coolant . . . . . . .	. . . . 02-7
Engine Coolant Specifications . . . . . . .	. . . . 02-8
Replenish Supplemental Coolant
Additives Between Coolant Changes	. . . . 02-10
Operating in Tropical Conditions . . . . . .	. . . 02-11
Flush and Service Cooling System . . . .	. . . 02-12
Disposing of Coolant . . . . . . . . . . . . .	. . . 02-13
Group 03—Engine Mounting
Engine Repair Stand . . . . . . . . . . . . .	. . . . 03-1
Safety Precautions . . . . . . . . . . . . . . .	. . . . 03-2
Install 400 Series Adapters on Repair
Stand . . . . . . . . . . . . . . . . . . . . . .	. . . . 03-2
Engine Lifting Procedure . . . . . . . . . . .	. . . . 03-3
Clean Engine . . . . . . . . . . . . . . . . . .	. . . . 03-4
Disconnect Turbocharger Oil Inlet Line	. . . . . 03-4
Mount Engine On Repair Stand . . . . . .	. . . . 03-5

		Page
				00
	Group 04—Engine Rebuild Guide
	6076 Engine Disassembly Sequence . .	. . . . . 04-1
				01
	Sealant Application Guidelines . . . . . .	. . . . . 04-2
	6076 Engine Assembly Sequence . . . . .	. . . . 04-4
	Group 05—Cylinder Head and Valves
				02
	Special or Essential Tools	05-1
	Service Equipment and Tools	05-3
	Other Material . . . . . . . . . . . . . . . . . .	. . . . 05-4
	Cylinder Head and Valves Specifications	. . . . 05-5		03
	. . . .Check and Adjust Valve Clearance	. . . . 05-7
	. . . . . . . . . . . . . . . .Check Valve Lift	. . . . 05-9
	Remove Cylinder Head . . . . . . . . . . . .	. . . 05-10
				04
	Disassemble and Inspect Rocker Arm
	Shaft Assembly . . . . . . . . . . . . . . .	. . . 05-12
	Assemble Rocker Arm Shaft Assembly	. . . . 05-14
	Measure Valve Recess	05-14
				05
	Preliminary Cylinder Head and Valve
	Checks	05-15
	Remove Valve Assembly . . . . . . . . . . .	. . . 05-16
	. . .Inspect and Measure Valve Springs	. . . 05-17		10
	Inspect Valve Rotators and Wear Caps	. . . . 05-17
	. . . . . . . . . . . . . . . . . . .Clean Valves	. . . 05-18
	Inspect and Measure Valves . . . . . . . .	. . . 05-18
				15
	Grind Valves . . . . . . . . . . . . . . . . . . .	. . . 05-19
	Inspect and Clean Cylinder Head . . . . .	. . . 05-19
	Check Cylinder Head Combustion Face
	Flatness	05-20
				16
	Measure Cylinder Head Thickness	05-21
	Clean Valve Guides	05-22
	Measure Valve Guides . . . . . . . . . . . .	. . . 05-22
	. . . . . . . . . . . . . .Knurl Valve Guides	. . . 05-23		20
	. . . . . .Clean and Inspect Valve Seats	. . . 05-23
	. . . . . . . . . . . . .Measure Valve Seats	. . . 05-24
	Grind Valve Seats . . . . . . . . . . . . . . .	. . . 05-25
				25
	Remove Valve Seat Inserts and Measure
	Bores . . . . . . . . . . . . . . . . . . . . . .	. . . 05-26
	Install Valve Seat Inserts . . . . . . . . . . .	. . . 05-27
				30
	Continued on next page

	All information, illustrations and specifications in this manual are based on		35
	the latest information available at the time of publication. The right is
	reserved to make changes at any time without notice.
	CTM42-19-24MAR95
			100
	COPYRIGHT© 1995
	DEERE & COMPANY
	Moline, Illinois
	All rights reserved
			105
	A John Deere ILLUSTRUCTION™ Manual
	Previous Editions
	Copyright 1992, 1991 Deere & Company

CTM42 (24MAR95)

i

6076 Diesel Engines—S.N. (500000— )

160101

PN=438

Contents

			Page
	00	Inspect and Clean Cylinder Head Nozzle
		. . . . . . . . . . . . . . . . . . . . . . . . . .Bore	05-27
		Clean and Inspect Push Rods	05-28
	01
		Inspect and Clean Ventilator Outlet Hose . . .	05-28
		Clean and Inspect Top Deck of Cylinder
		Block . . . . . . . . . . . . . . . . . . . . . . . . .	05-29
	02	Measure Cylinder Liner Standout (Height
		. . . . . . . . . . . . . . . . . . . .above Block)	05-30
		. . . . . . . . . . . . .Assemble Valve Assembly	05-31
		Install Cylinder Head . . . . . . . . . . . . . . . .	05-32
	03
		Cylinder Head Cap Screw Types . . . . . . . .	05-33
		Clean, Inspect and Install Cylinder Head
		Cap Screws . . . . . . . . . . . . . . . . . . . . .	05-34
		Torque-To-Yield Special Flanged-Head
	04
		. . . . . . . . . . . . . . . . . . . . .Cap Screws	05-36
		. . . . . . . . . . .Install Rocker Arm Assembly	05-37
		Complete Final Assembly Of Injection
	05
		Pump Side . . . . . . . . . . . . . . . . . . . . . .	05-38
		Complete Final Assembly On Exhaust
		. . . . . . . . . . . . . . . . . . . .Manifold Side	05-39
		Perform Engine Break-In	05-42
	10
		Group 10—Cylinder Block, Liners, Pistons and
		Rods
	15
		Special or Essential Tools . . . . . . . . . . . . .	. 10-1
		Service Equipment and Tools . . . . . . . . . . .	. 10-3
		. . . . . . . . . . . . . . . . . . . . . .Other Material	10-3
		Cylinder Block, Liners, Pistons, and Rods
	16
		. . . . . . . . . . . . . . . . . . . . .Specifications	10-4
		Preliminary Liner, Piston, and Rod
		Checks . . . . . . . . . . . . . . . . . . . . . . . . .	10-8
	20	Remove Pistons and Connecting Rods . . . . . 10-9
		Measure Cylinder Liner Standout (Height
		. . . . . . . . . . . . . . . . . . . .above Block)	10-12
		Remove Cylinder Liners	10-13
	25
		Deglazing Cylinder Liners	10-14
		Clean Cylinder Liners	10-15
		Disassemble and Clean Piston . . . . . . . . . .	10-15
	30	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
	35
		Visually Inspect Cylinder Liners	10-19
		Cylinder Liner Manufacturing Date Code
		Explanation . . . . . . . . . . . . . . . . . . . . .	10-20
	100	. . . . . . . . . . . . . .Measure Piston Skirt OD	10-21
		. . . . . . . . . . . . .Measure Cylinder Liner ID	10-22
		. . . . . . . .Measure Liner Flange Thickness	10-22
		Inspect and Measure Connecting Rod
	105
		Bearings . . . . . . . . . . . . . . . . . . . . . . .	10-23
		Inspect Rod and Cap . . . . . . . . . . . . . . . .	10-24

	Page
Inspect Piston Pins and Bushings . . . . . . . .	10-26
Remove Piston Pin Bushing . . . . . . . . . . . .	10-27
Clean and Inspect Piston Pin Bushing
Bore in Rod . . . . . . . . . . . . . . . . . . . . .	10-27
Install Piston Pin Bushing in Connecting
Rod . . . . . . . . . . . . . . . . . . . . . . . . . .	10-28
Complete Disassembly of Cylinder Block
(If Required) . . . . . . . . . . . . . . . . . . . . .	10-29
Remove and Clean Piston Cooling
Orifices . . . . . . . . . . . . . . . . . . . . . . . .	10-29
Inspect and Clean Cylinder Block . . . . . . . .	10-30
Clean O-Ring Bore . . . . . . . . . . . . . . . . . .	10-32
Measure Cylinder Block . . . . . . . . . . . . . .	10-32
Install Piston Cooling Orifices and Gallery
Plugs . . . . . . . . . . . . . . . . . . . . . . . . .	10-34
Recheck Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . .	10-35
Install Liner Shims—If Required . . . . . . . . .	10-36
Install Cylinder Liner O-Rings and
Packings . . . . . . . . . . . . . . . . . . . . . . .	10-37
Install Cylinder Liners . . . . . . . . . . . . . . . .	10-38
Install Pistons and Connecting Rods . . . . . .	10-40
Torque-Turn Connecting Rod Cap Screws. . .	10-43
Check Engine Rotation for Excessive
Tightness . . . . . . . . . . . . . . . . . . . . . . .	10-43
Complete Final Assembly . . . . . . . . . . . . .	10-44
Group 15—Crankshaft, Main Bearings and
Flywheel
Special or Essential Tools . . . . . . . . . . . . .	. 15-1
Service Equipment and Tools . . . . . . . . . . .	. 15-4
Other Material . . . . . . . . . . . . . . . . . . . . . .	15-5
Crankshaft, Main Bearings, and Flywheel
Specifications . . . . . . . . . . . . . . . . . . . . .	15-6
Failure Analysis . . . . . . . . . . . . . . . . . . . . .	15-8
Remove Crankshaft Rear Oil Seal
Housing
(With Oil Seal Housing Installed) . . . . . . . .	15-9
Install Crankshaft Rear Oil Seal and
Wear Sleeve
(Without Engine Disassembly) . . . . . . . . .	15-11
Inspect Vibration Damper . . . . . . . . . . . . .	15-12
Check Crankshaft End Play . . . . . . . . . . . .	15-13
Remove Damper Pulley . . . . . . . . . . . . . .	15-14
Remove Front Oil Seal
(With Timing Gear Cover Installed on
Engine) . . . . . . . . . . . . . . . . . . . . . .	15-16

Continued on next page

CTM42 (24MAR95)

ii

6076 Diesel Engines—S.N. (500000— )

160101

PN=439

Contents

Page

Page

Remove Front Wear Sleeve
(With Timing Gear Cover Installed or
Removed) . . . . . . . . . . . . . . . . . . . . .	15-17
Install Front Wear Sleeve
(With Timing Gear Cover Installed) . . . . .	15-17
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . . .	15-18
Replace Timing Gear Cover
(6076HRW33, 34, and 35 Engines)
—Engine Installed in Vehicle . . . . . . . . . .	15-19
Remove Timing Gear Cover . . . . . . . . . . .	15-20
Inspect, Measure and Repair Flywheel . . . .	15-20
Check Flywheel Housing Face Run-Out . . . . 15-21
Check Flywheel Face Flatness . . . . . . . . . .	15-21
Check Pilot Bearing Bore Concentricity . . . .	15-22
Remove Flywheel . . . . . . . . . . . . . . . . . .	15-22
Remove SAE 1 and SAE 2 Flywheel
Housing . . . . . . . . . . . . . . . . . . . . . . . .	15-23
Remove SAE 3 Flywheel Housing . . . . . . . .	15-23
Replace Flywheel Ring Gear . . . . . . . . . . .	15-24
Replace Rear Oil Seal Housing
(6076HRW33, 34, and 35 Engines)
—Engines Installed in Vehicle . . . . . . . . .	15-25
Remove Rear Oil Seal Housing and
Wear Sleeve
(With Engine Disassembled) . . . . . . . . . .	15-26
Remove Crankshaft Main Bearings . . . . . . .	15-27
Check Main Bearing Clearance . . . . . . . . .	15-28
Remove Crankshaft . . . . . . . . . . . . . . . . .	15-29
Inspect Crankshaft . . . . . . . . . . . . . . . . . .	15-30
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals . . . . . . . . . . .	15-32
Main Bearing Cap Line Bore
Specifications . . . . . . . . . . . . . . . . . . . .	15-33
Crankshaft Grinding Guidelines . . . . . . . . . .	15-34
Thrust Bearing New Part Specifications . . . .	15-36
Crankshaft Grinding Specifications . . . . . . .	15-37
Replace Crankshaft Oil Pump Drive Gear . . .	15-38
Replace Crankshaft Gear . . . . . . . . . . . . .	15-39
Inspect Thrust Bearings . . . . . . . . . . . . . .	15-40
Remove and Clean Piston Cooling
Orifices . . . . . . . . . . . . . . . . . . . . . . . .	15-40
Install Main Bearings and Crankshaft . . . . . .	15-41
Install Crankshaft Rear Oil Seal Housing . . .	15-43
Check Oil Seal Housing Runout . . . . . . . . .	15-45
Crankshaft Rear Oil Seal And Wear
Sleeve Handling Precautions . . . . . . . . . .	15-46
Install Crankshaft Rear Oil Seal and
Wear Sleeve Assembly . . . . . . . . . . . . .	15-47
Install Timing Gear Cover . . . . . . . . . . . . .	15-48

	. . . . . . . . . . . . .Install Front Wear Sleeve	15-48		110
	Install Front Oil Seal
	(With Timing Gear Cover Installed) . . . . .	15-49
	Install Damper Pulley Assembly	15-49
				115
	Install SAE 3 Flywheel Housing	15-50
	Install Flywheel . . . . . . . . . . . . . . . . . . . .	15-51
	Install SAE 1 and SAE 2 Flywheel
	. . . . . . . . . . . . . . . . . . . . . . . .Housing	15-51		199
	. . . . . . . . . . . . .Complete Final Assembly	15-52
	Group 16—Camshaft and Timing Gear Train
				INDX
	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
	Group 20—Lubrication System
	Other Material . . . . . . . . . . . . . . . . . . . . . .	20-1
	Lubrication System Specifications . . . . . . . . .	20-1
	Drain Engine Oil and Remove Oil Pan . . . . . .	20-2
	Oil Filter and Oil Conditioning Housing
	Assembly . . . . . . . . . . . . . . . . . . . . . . . .	20-3

Continued on next page

CTM42 (24MAR95)

iii

6076 Diesel Engines—S.N. (500000— )

160101

PN=440

Contents

				Page
			Remove Oil Filter and Oil Conditioning
	110
			Housing . . . . . . . . . . . . . . . . . . . . . . . .	. 20-4
			Inspect and Replace Oil Filter Adapter . . . . . .	20-4
			Remove, Inspect, and Install Valves from
			Oil Conditioning Housing	20-5
	115
			Install Oil Filter and Oil Conditioning
			Housing	20-6
			Remove Engine Oil Cooler . . . . . . . . . . . . .	20-7
	199		Clean, Inspect, and Install Engine Oil
			. . . . . . . . . . . . . . . . . . . . . . . . . .Cooler	20-8
			Check Crankshaft Gear-To-Oil Pump
			Drive Gear Backlash	20-9
	INDX
			Remove Engine Oil Pump	20-9
			Inspect and Clean Oil Pump . . . . . . . . . . .	20-10
			Check Drive Shaft End Play . . . . . . . . . . .	20-11
			Check Drive Shaft Side Movement . . . . . . .	20-11
			Check Pumping Gear Backlash . . . . . . . . .	20-12
			Inspect Oil Pump Drive Gear . . . . . . . . . . .	20-12
			Install Engine Oil Pump . . . . . . . . . . . . . . .	20-13
			Install Oil Pan . . . . . . . . . . . . . . . . . . . . .	20-14
			Tighten cap screws on front frame/oil
			sump . . . . . . . . . . . . . . . . . . . . . . . . .	20-15

Group 25—Cooling System

Special or Essential Tools . . . . . . . . . . . . . . 25-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 25-2 Cooling System Specifications . . . . . . . . . . . 25-3 Service Equipment and Tools . . . . . . . . . . . . 25-5 Replace Bearings in Standard Duty,

Adjustable Fan Drive Assembly . . . . . . . . . 25-6 Replace Bearings in Heavy Duty,

Adjustable Fan Drive Assembly . . . . . . . . . 25-8 Water Manifold Mounted Fixed Fan Drive

Assembly . . . . . . . . . . . . . . . . . . . . . . . 25-10 Replace Bearing in Injection Pump Drive

Gear Mounted Fan Drive . . . . . . . . . . . . 25-12 Inspect and Check Belt Tensioner Spring

Tension . . . . . . . . . . . . . . . . . . . . . . . . 25-13 Replace Belt Tensioner Assembly . . . . . . . . 25-14 Remove Water Pump . . . . . . . . . . . . . . . . 25-14 Disassemble Water Pump . . . . . . . . . . . . . 25-15 Inspect Water Pump Parts . . . . . . . . . . . . . 25-18 Assemble Water Pump . . . . . . . . . . . . . . . 25-19 Install Water Pump . . . . . . . . . . . . . . . . . . 25-21 Remove and Test Thermostats . . . . . . . . . . 25-22 Install Thermostats . . . . . . . . . . . . . . . . . . 25-23 Remove Water Manifold . . . . . . . . . . . . . . 25-23 Install Water Manifold . . . . . . . . . . . . . . . . 25-24 Remove Coolant Heater . . . . . . . . . . . . . . 25-24 Install Coolant Heater . . . . . . . . . . . . . . . . 25-25 Complete Final Assembly . . . . . . . . . . . . . 25-26

	Page
Fan Belt Tension Specifications . . . . .	. . . . 25-26
Group 30—Air Intake And Exhaust System
Special or Essential Tools . . . . . . . . .	. . . . . 30-1
Other Material . . . . . . . . . . . . . . . . .	. . . . . 30-2
Air Intake and Exhaust System
Specifications . . . . . . . . . . . . . . . . .	. . . . 30-2
Extending Turbocharger Life . . . . . . . .	. . . . 30-4
Remove Turbocharger . . . . . . . . . . . .	. . . . 30-6
Turbocharger Failure Analysis . . . . . . .	. . . . 30-8
Turbocharger Seven-Step Inspection . . .	. . . 30-10
Perform Radial Bearing Clearance Test	. . . . 30-15
Perform Axial Bearing End Play Test . . .	. . . 30-16
Repair Turbocharger . . . . . . . . . . . . . .	. . . 30-16
Disassemble Turbocharger . . . . . . . . .	. . . 30-17
Clean and Inspect Turbine and
Compressor Housings . . . . . . . . . . .	. . . 30-18
Replace Center Housing Assembly and
Assemble Turbocharger . . . . . . . . . .	. . . 30-19
Prelube Turbocharger . . . . . . . . . . . . .	. . . 30-20
Install Turbocharger . . . . . . . . . . . . . .	. . . 30-20
Remove, Inspect, and Install Intake
Manifold . . . . . . . . . . . . . . . . . . . .	. . . 30-22
Remove Vertically-Mounted Aftercooler
and Intake Manifold . . . . . . . . . . . . .	. . . 30-23
Remove and Disassemble
Horizontally-Mounted Aftercooler
Assembly . . . . . . . . . . . . . . . . . . . .	. . . 30-25
Inspect and Repair Aftercooler . . . . . . .	. . . 30-26
Inspect and Repair Intake Manifold and
Cover . . . . . . . . . . . . . . . . . . . . . .	. . . 30-26
Install Intake Manifold and
Vertically-Mounted Aftercooler . . . . . .	. . . 30-27
Assemble and Install
Horizontally-Mounted Aftercooler
Assembly . . . . . . . . . . . . . . . . . . . .	. . . 30-29
Remove, Inspect, and Install Exhaust
Manifold . . . . . . . . . . . . . . . . . . . .	. . . 30-31
Group 35—Fuel System
Special or Essential Tools . . . . . . . . . .	. . . . 35-1
Other Material . . . . . . . . . . . . . . . . . .	. . . . 35-4
Diesel Fuel System Specifications . . . . .	. . . . 35-4
Relieve Fuel System Pressure . . . . . . .	. . . . 35-6
Replace Rectangular Fuel Filter Element	. . . . 35-6
Replace Fuel Check Valve . . . . . . . . .	. . . . 35-7
Remove Round Fuel Filter Element . . . .	. . . . 35-8
Identification of fuel supply and fuel
injection pumps . . . . . . . . . . . . . . .	. . . . 35-9
Remove Mechanical Fuel Supply Pump	. . . . 35-10

Continued on next page

CTM42 (24MAR95)

iv

6076 Diesel Engines—S.N. (500000— )

160101

PN=441

Contents

Page

Page

Test Mechanical Fuel Supply Pump for
Leaks . . . . . . . . . . . . . . . . . . . . . . . . .	35-11
Disassemble Mechanical Fuel Supply
Pump (Nippondenso) . . . . . . . . . . . . . . .	35-12
Inspect and Repair Mechanical Fuel
Supply Pump (Nippondenso) . . . . . . . . . .	35-14
Assemble Mechanical Fuel Supply Pump
(Nippondenso) . . . . . . . . . . . . . . . . . . .	35-15
Disassemble Mechanical Fuel Supply
Pump (Robert Bosch) . . . . . . . . . . . . . .	35-16
Inspect and Repair Mechanical Fuel
Supply Pump (Robert Bosch) . . . . . . . . .	35-17
Assemble Mechanical Fuel Supply Pump
(Robert Bosch) . . . . . . . . . . . . . . . . . . .	35-18
Install Mechanical Fuel Supply Pump . . . . .	35-18
Remove and Install Electric Fuel Supply
Pump . . . . . . . . . . . . . . . . . . . . . . . . .	35-19
Clean or Replace Electric Fuel Supply
Pump Filter Screen . . . . . . . . . . . . . . . .	35-20
Repair Aneroid . . . . . . . . . . . . . . . . . . . .	35-21
Remove Hydraulic Aneroid Activator . . . . . .	35-21
Disassemble and Clean Hydraulic
Aneroid Activator Parts . . . . . . . . . . . . .	35-22
Assemble and Install Hydraulic Aneroid
Activator . . . . . . . . . . . . . . . . . . . . . . .	35-22
Service Injection Pump Overflow Valve . . . .	35-22
Remove and Install Fuel Shutoff Solenoid . . .	35-24
Identification of In-Line Injection Pumps . . . .	35-25
Remove In-Line Fuel Injection Pump . . . . . .	35-26
Install In-Line Fuel Injection Pump . . . . . . .	35-29
Remove Rotary Fuel Injection
Pump—Stanadyne DB4 . . . . . . . . . . . . .	35-33
Install Rotary Fuel Injection
Pump—Stanadyne DB4 . . . . . . . . . . . . .	35-34
Remove Fuel Injection Nozzles . . . . . . . . .	35-37
Diagnose Injection Nozzle Malfunction . . . . .	35-40
Test Fuel Injection Nozzles . . . . . . . . . . . .	35-42
Perform Opening Pressure Test . . . . . . . . .	35-43
Injection Nozzle Specifications . . . . . . . . . .	35-44
Perform Nozzle Leakage Test . . . . . . . . . .	35-45
Perform Chatter and Spray Pattern Test . . .	35-46
Disassemble Fuel Injection Nozzle . . . . . . .	35-47
Clean and Inspect Fuel Injection Nozzle
Assembly . . . . . . . . . . . . . . . . . . . . . . .	35-49
Perform Nozzle Slide Test . . . . . . . . . . . . .	35-50
Clean Spray Orifices . . . . . . . . . . . . . . . . .	35-50
Inspect Nozzle Holder . . . . . . . . . . . . . . . .	35-51
Inspect Gland Nut . . . . . . . . . . . . . . . . . .	35-53
Assemble Fuel Injection Nozzle . . . . . . . . .	35-54
Adjust Injection Nozzles . . . . . . . . . . . . . .	35-57

Inspect and Clean Cylinder Head Nozzle

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 35-58

Inspect and Clean Nozzle Seating

Surface . . . . . . . . . . . . . . . . . . . . . . . . 35-59

Install Fuel Injection Nozzles . . . . . . . . . . . 35-59

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

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

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

CTM42 (24MAR95)

v

6076 Diesel Engines—S.N. (500000— )

160101

PN=442

Contents

Page

Page

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

How the Hydraulic Aneroid Activator
Works . . . . . . . . . . . . . . . . . . . . . . . .	115-44
Diagnose Malfunctions—Hydraulic
Aneroid Activator . . . . . . . . . . . . . . . .	115-45
Fuel Injection Nozzles—General
Information . . . . . . . . . . . . . . . . . . . . .	115-46
Fuel Injection Nozzle Operation . . . . . . . .	115-47
Diagnose Malfunctions—Fuel Injection
Nozzle . . . . . . . . . . . . . . . . . . . . . . .	115-48
Test Fuel Injection Nozzles (Engine
Running) . . . . . . . . . . . . . . . . . . . . . .	115-49
Fuel Drain Back Test Procedure . . . . . . . .	115-49

Group 199—Dealer Fabricated Tools

How to Make Tools . . . . . . . . . . . . . . . . . 199-1 Cylinder Liner Holding Fixture . . . . . . . . . . 199-1

Index

CTM42 (24MAR95)

vi

6076 Diesel Engines—S.N. (500000— )

160101

PN=443

HANDLE FLUIDS SAFELY—AVOID FIRES

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.

Do not store oily rags; they can ignite and burn spontaneously.

PREVENT BATTERY EXPLOSIONS

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.

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.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

CTM42 (24MAR95)

00-1

Group 00

Safety

00

1

TS227 -UN-23AUG88

DX,FLAME -19-04JUN90

TS204 -UN-23AUG88

DX,SPARKS -19-03MAR93

TS291 -UN-23AUG88

DX,FIRE2 -19-03MAR93

6076 Diesel Engines—S.N. (500000— )

160101

PN=6

Safety/Safety

PREVENT ACID BURNS

00

2 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.

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 -UN-23AUG88

DX,POISON -19-21APR93

CTM42 (24MAR95)	00-2	6076 Diesel Engines—S.N. (500000— )
		160101

PN=7

Safety/Safety

AVOID HIGH-PRESSURE FLUIDS

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.

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.

CTM42 (24MAR95)

00-3

00

3

X9811 -UN-23AUG88

DX,FLUID -19-03MAR93

TS206 -UN-23AUG88

DX,WEAR -19-10SEP90

6076 Diesel Engines—S.N. (500000— )

160101

PN=8

Safety/Safety

SERVICE MACHINES SAFELY

00

4 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.

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.

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.

CTM42 (24MAR95)

00-4

TS228 -UN-23AUG88

DX,LOOSE -19-04JUN90

TS220 -UN-23AUG88

DX,AIR -19-04JUN90

T6642EJ -UN-18OCT88

DX,CLEAN -19-04JUN90

6076 Diesel Engines—S.N. (500000— )

160101

PN=9

Safety/Safety

REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust.

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.

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.

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.

CTM42 (24MAR95)

00-5

00

5

TS220 -UN-23AUG88

DX,PAINT -19-03MAR93

TS953 -UN-15MAY90

DX,TORCH -19-03MAR93

TS223 -UN-23AUG88

DX,LIGHT -19-04JUN90

6076 Diesel Engines—S.N. (500000— )

160101

PN=10

Safety/Safety

USE PROPER LIFTING EQUIPMENT

00

6 Lifting heavy components incorrectly can cause severe 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.

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.

CTM42 (24MAR95)

00-6

TS226 -UN-23AUG88

DX,LIFT -19-04JUN90

TS218 -UN-23AUG88

DX,SERV -19-03MAR93

6076 Diesel Engines—S.N. (500000— )

160101

PN=11

Safety/Safety

USE PROPER TOOLS

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.

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

00

7

TS779 -UN-08NOV89

DX,REPAIR -19-04JUN90

TS1133 -UN-26NOV90

DX,DRAIN -19-03MAR93

6076 Diesel Engines—S.N. (500000— )

160101

PN=12

Safety/Safety

	LIVE WITH SAFETY
00	Before returning machine to customer, make sure
8
	machine is functioning properly, especially the safety
	systems. Install all guards and shields.
		-19-07OCT88
		TS231
	DX,LIVE	-19-25SEP92

CTM42 (24MAR95)	00-8	6076 Diesel Engines—S.N. (500000— )
		160101

PN=13

Group 01

General Information

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

01

1

TS1162 -19-04MAR91

		Grade 1				Grade 2b			Grade 5, 5.1, or 5.2					Grade 8 or 8.2
Size	Lubricateda		Drya		Lubricateda		Drya		Lubricateda		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	3.7	2.8	4.7	3.5	6	4.5	7.5	5.5	9.5	7	12	9	13.5	10	17	12.5
5/16	7.7	5.5	10	7	12	9	15	11	20	15	25	18	28	21	35	26
3/8	14	10	17	13	22	16	27	20	35	26	44	33	50	36	63	46
7/16	22	16	28	20	35	26	44	32	55	41	70	52	80	58	100	75
1/2	33	25	42	31	53	39	67	50	85	63	110	80	120	90	150	115
9/16	48	36	60	45	75	56	95	70	125	90	155	115	175	130	225	160
5/8	67	50	85	62	105	78	135	100	170	125	215	160	240	175	300	225
3/4	120	87	150	110	190	140	240	175	300	225	375	280	425	310	550	400
7/8	190	140	240	175	190	140	240	175	490	360	625	450	700	500	875	650
1	290	210	360	270	290	210	360	270	725	540	925	675	1050	750	1300	975
1-1/8	400	300	510	375	400	300	510	375	900	675	1150	850	1450	1075	1850	1350
1-1/4	570	425	725	530	570	425	725	530	1300	950	1650	1200	2050	1500	2600	1950
1-3/8	750	550	950	700	750	550	950	700	1700	1250	2150	1550	2700	2000	3400	2550
1-1/2	1000	725	1250	925	990	725	1250	930	2250	1650	2850	2100	3600	2650	4550	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.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

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.

bGrade 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.

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.

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.

DX,TORQ1 -19-20JUL94

CTM42 (24MAR95)	01-1	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

01

2

TS1163 -19-04MAR91

		Class 4.8				Class 8.8 or 9.8					Class 10.9				Class 12.9
Size	Lubricateda		Drya		Lubricateda		Drya			Lubricateda		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	4.8	3.5	6	4.5	9	6.5	11		8.5	13	9.5	17	12	15	11.5	19	14.5
M8	12	8.5	15	11	22	16	28		20	32	24	40	30	37	28	47	35
M10	23	17	29	21	43	32	55		40	63	47	80	60	75	55	95	70
M12	40	29	50	37	75	55	95		70	110	80	140	105	130	95	165	120
M14	63	47	80	60	120	88	150		110	175	130	225	165	205	150	260	190
M16	100	73	125	92	190	140	240		175	275	200	350	255	320	240	400	300
M18	135	100	175	125	260	195	330		250	375	275	475	350	440	325	560	410
M20	190	140	240	180	375	275	475		350	530	400	675	500	625	460	800	580
M22	260	190	330	250	510	375	650		475	725	540	925	675	850	625	1075	800
M24	330	250	425	310	650	475	825		600	925	675	1150	850	1075	800	1350	1000
M27	490	360	625	450	950	700	1200		875	1350	1000	1700	1250	1600	1150	2000	1500
M30	675	490	850	625	1300	950	1650		1200	1850	1350	2300	1700	2150	1600	2700	2000
M33	900	675	1150	850	1750	1300	2200		1650	2500	1850	3150	2350	2900	2150	3700	2750
M36	1150	850	1450	1075	2250	1650	2850		2100	3200	2350	4050	3000	3750	2750	4750	3500
DO NOT use these values if a different torque value									Make sure fasteners threads are clean and that you
or tightening procedure is given for a specific									properly start thread engagement. This will prevent
application. Torque values listed are for general use									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									to approximately 50 percent of the dry torque shown
loads. Always replace shear bolts with identical									in the chart, applied to the nut, not to the bolt head.
property class.									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.	DX,TORQ2	-19-20JUL94

CTM42 (24MAR95)	01-2	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:

6076HH030 Engine

6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders 076 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter displacement H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aspiration code H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End user code 030 . . . . . . . . . . . . . . . . . . . . . . . . . . Application code

Aspiration Code

A . . . . . . . . . . . . . . . . . Turbocharged and air-to-coolant aftercooled H . . . . . . . . . . . . . . . . . . . . Turbocharged and air-to-air aftercooled T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged

End User Code

DW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Davenport

F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM

H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvester

N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Des Moines

RW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tractor

T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dubuque

Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zweibrucken

01

3

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
	IMPORTANT: The engine serial number plate can be
		easily destroyed. Remove the plate or
01		record the information elsewhere,
4		before “hot tank” cleaning the block.
	• 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:
	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.

CTM42 (24MAR95)

01-4

RG5804 -UN-12AUG91

RG,CTM42,G1,2 -19-14FEB95

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

COMBINES—HARVESTER WORKS

CTS Rice Combine* . . . . . . . . . . . . . . . . . . . . . . . 6076HH030 2056 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AZ031 2058 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AZ030 2064 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AZ030 2066 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HZ031

9500* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HH031, 6076HH032 9600* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HH030, 6076HH031

COMBINES—ZWEIBRUCKEN

2056 Hillmaster . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AZ031

2058 Hillmaster . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AZ030

2064 Hillmaster . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AZ030

2066 Hillmaster . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HZ031

01

5

FORAGE HARVESTERS—ZWEIBRUCKEN

6610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HZ030

COTTON PICKER—DES MOINES

9960** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AN030 9965 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6067AN031

TRACTORS—WATERLOO

7700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076TRW31 7800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076TRW30 8100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HRW33 8200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HRW34 8300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076HRW35 8560 4-Wheel Drive*** . . . . . . . . . . . . . . . . . . . . . 6076HRW30 8570 4-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 6076HRW32

*Beginning with combine serial number (645000— )

**Above P.I.N. 4001

*** Beginning with tractor serial number (5000— )	RG,CTM42,G1,3 -19-16AUG94

CTM42 (24MAR95)	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.	Engine Model
01	LOADERS—DUBUQUE
6
	. . . . . . . . . . . . . . . . . .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		• Sulfur Content
diesel fuel available in your area.		— Sulfur content should not exceed 0.5%. Sulfur
		content less than 0.05% is preferred.
In general, diesel fuels are blended to satisfy the low		— If diesel fuel with sulfur content greater than 0.5%
temperature requirements of the geographical area in		is used, reduce the service interval for engine oil and
which they are marketed.		filter changes by 50%.
		— DO NOT use diesel fuel with sulfur content greater
					02
Diesel fuels specified to EN 590 or ASTM D975 are		than 1.0%.
					1
recommended.
		Bio-diesel fuels meeting DIN 51606 or equivalent
In all cases, the fuel must meet the following		specification may be used.
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		Fuel lubricity should pass a minimum of 3300 gram
proper operation and durability of fuel injection system		load level as measured by the BOCLE scuffing test.
components.
		ASTM D975 and EN 590 specifications do not require
Diesel fuels for highway use in the United States now		fuels to pass a fuel lubricity test. Diesel fuels meeting
require sulfur content less than 0.05%. Diesel fuel in		U.S. Military Specification VV—F—800E pass a fuel
the European Union will require sulfur content less		lubricity test.
than 0.05% by 1 October 1996.
		If fuel of low or unknown lubricity is used, add John
Experience shows that some low sulfur diesel fuels		Deere ALL-SEASON DIESEL FUEL CONDITIONER
may have inadequate lubricity and their use may		or equivalent at the specified concentration.
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.
			RG,FUEL5 -19-22FEB95
CTM42 (24MAR95)	02-1		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	IMPORTANT: Do not use John Deere PLUS-50 oil
		ENGINE BREAK-IN OIL. During the break-in period,	or engine oils meeting API CG4,
		add John Deere ENGINE BREAK-IN OIL as needed	API CF4, or CCMC D5 performance
		to maintain the specified oil level.	levels during the first 100 hours of
			operation of a new or rebuilt engine.
		Change the oil and filter after the first 100 hours of	These oils will not allow the engine
		operation of a new or rebuilt engine.	to break-in properly.
	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.
			DX,ENOIL4 -19-17OCT94

CTM42 (24MAR95)	02-2	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®

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®

Other oils may be used if they meet one or more of the following:

•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

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%.

02

3

TS1619 -UN-12SEP94

DX,ENOIL -19-16SEP94

CTM42 (24MAR95)	02-3	6076 Diesel Engines—S.N. (500000— )
		160101

PN=22

Fuels, Lubricants, and Coolant/Grease

OILSCAN® AND COOLSCAN™

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

4Check with your John Deere dealer for the availability of OILSCAN and COOLSCAN kits.

T6828AB -UN-15JUN89

T6829AB -UN-18OCT88

DX,OILSCAN -19-16APR92

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.

CTM42 (24MAR95)

02-4

TS1622 -UN-02NOV94

DX,GREA1 -19-02NOV94

6076 Diesel Engines—S.N. (500000— )

160101

PN=23