John Deere CTM42 TECHNICAL MANUAL

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Page 1

Series 400

6076

Diesel Engines

Serial Number

(500000- )

COMPONENT TECHNICAL MANUAL

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DCTCTM4 2 24MAR9 5

Deere Power Systems Group

CTM42 (24MAR95)

LITHO IN U.S.A.

ENGLISH

Page 2

FOREWORD

Introduction

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

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

Page 3

Page 4

Page 5

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.

• 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.

CTM42 (24MAR95) 6076 Diesel Engines—S.N. (500000— )

• 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

Page 6

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

Page 7

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

Group 04—Engine Rebuild Guide

6076 Engine Disassembly Sequence . . . . . . . 04-1

Sealant Application Guidelines . . . . . . . . . . . 04-2

6076 Engine Assembly Sequence . . . . . . . . . 04-4

Group 05—Cylinder Head and Valves

Special or Essential Tools . . . . . . . . . . . . . . 05-1

Service Equipment and Tools . . . . . . . . . . . . 05-3

Other Material . . . . . . . . . . . . . . . . . . . . . . 05-4

Cylinder Head and Valves Specifications . . . . 05-5

Check and Adjust Valve Clearance . . . . . . . . 05-7

Check Valve Lift . . . . . . . . . . . . . . . . . . . . 05-9

Remove Cylinder Head . . . . . . . . . . . . . . . 05-10

Disassemble and Inspect Rocker Arm

Shaft Assembly . . . . . . . . . . . . . . . . . . 05-12

Assemble Rocker Arm Shaft Assembly . . . . 05-14

Measure Valve Recess . . . . . . . . . . . . . . . 05-14

Preliminary Cylinder Head and Valve

Checks . . . . . . . . . . . . . . . . . . . . . . . . 05-15

Remove Valve Assembly . . . . . . . . . . . . . . 05-16

Inspect and Measure Valve Springs . . . . . . 05-17

Inspect Valve Rotators and Wear Caps . . . . 05-17

Clean Valves . . . . . . . . . . . . . . . . . . . . . . 05-18

Inspect and Measure Valves . . . . . . . . . . . 05-18

Grind Valves . . . . . . . . . . . . . . . . . . . . . . 05-19

Inspect and Clean Cylinder Head . . . . . . . . 05-19

Check Cylinder Head Combustion Face

Flatness . . . . . . . . . . . . . . . . . . . . . . . 05-20

Measure Cylinder Head Thickness . . . . . . . 05-21

Clean Valve Guides . . . . . . . . . . . . . . . . . 05-22

Measure Valve Guides . . . . . . . . . . . . . . . 05-22

Knurl Valve Guides . . . . . . . . . . . . . . . . . 05-23

Clean and Inspect Valve Seats . . . . . . . . . 05-23

Measure Valve Seats . . . . . . . . . . . . . . . . 05-24

Grind Valve Seats . . . . . . . . . . . . . . . . . . 05-25

Remove Valve Seat Inserts and Measure

Bores . . . . . . . . . . . . . . . . . . . . . . . . . 05-26

Install Valve Seat Inserts . . . . . . . . . . . . . . 05-27

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.

CTM42-19-24MAR95

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTION™ Manual

CTM42 (24MAR95) i 6076 Diesel Engines—S.N. (500000— )

Previous Editions

160101

PN=438

100

105

Page 8

Contents

Inspect and Clean Cylinder Head Nozzle

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 05-27

Clean and Inspect Push Rods . . . . . . . . . . 05-28

Inspect and Clean Ventilator Outlet Hose . . . 05-28 Clean and Inspect Top Deck of Cylinder

Block . . . . . . . . . . . . . . . . . . . . . . . . . 05-29

Measure Cylinder Liner Standout (Height

above Block) . . . . . . . . . . . . . . . . . . . . 05-30

Assemble Valve Assembly . . . . . . . . . . . . . 05-31

Install Cylinder Head . . . . . . . . . . . . . . . . 05-32

Cylinder Head Cap Screw Types . . . . . . . . 05-33

Clean, Inspect and Install Cylinder Head

Cap Screws . . . . . . . . . . . . . . . . . . . . . 05-34

Torque-To-Yield Special Flanged-Head

Cap Screws . . . . . . . . . . . . . . . . . . . . . 05-36

Install Rocker Arm Assembly . . . . . . . . . . . 05-37

Complete Final Assembly Of Injection

Pump Side . . . . . . . . . . . . . . . . . . . . . . 05-38

Complete Final Assembly On Exhaust

Manifold Side . . . . . . . . . . . . . . . . . . . . 05-39

Perform Engine Break-In . . . . . . . . . . . . . . 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

100

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

Page 9

Contents

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

Page

Install Front Wear Sleeve . . . . . . . . . . . . . 15-48

Install Front Oil Seal

(With Timing Gear Cover Installed) . . . . . 15-49

Install Damper Pulley Assembly . . . . . . . . . 15-49

Install SAE 3 Flywheel Housing . . . . . . . . . 15-50

Install Flywheel . . . . . . . . . . . . . . . . . . . . 15-51

Install SAE 1 and SAE 2 Flywheel

Housing . . . . . . . . . . . . . . . . . . . . . . . . 15-51

Complete Final Assembly . . . . . . . . . . . . . 15-52

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

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

110

115

199

INDX

CTM42 (24MAR95) iii 6076 Diesel Engines—S.N. (500000— )

160101

PN=440

Page 10

Contents

Remove Oil Filter and Oil Conditioning

110

Housing . . . . . . . . . . . . . . . . . . . . . . . . . 20-4

Inspect and Replace Oil Filter Adapter . . . . . . 20-4

Remove, Inspect, and Install Valves from

115

Oil Conditioning Housing . . . . . . . . . . . . . 20-5

Install Oil Filter and Oil Conditioning

Housing . . . . . . . . . . . . . . . . . . . . . . . . . 20-6

Remove Engine Oil Cooler . . . . . . . . . . . . . 20-7

Clean, Inspect, and Install Engine Oil

199

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

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Page 11

Contents

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

Page

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

Page 12

Contents

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

Page

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

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Page 13

HANDLE FLUIDS SAFELY—AVOID FIRES

Group 00

Safety

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.

00 1

TS227 -UN-23AUG88

DX,FLAME -19-04JUN90

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.

TS204 -UN-23AUG88

DX,SPARKS -19-03MAR93

TS291 -UN-23AUG88

DX,FIRE2 -19-03MAR93

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Page 14

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.

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.

Safety/Safety

DX,POISON -19-21APR93

TS203 -UN-23AUG88

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

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Page 15

AVOID HIGH-PRESSURE FLUIDS

Safety/Safety

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.

DX,FLUID -19-03MAR93

TS206 -UN-23AUG88

DX,WEAR -19-10SEP90

CTM42 (24MAR95) 00-3 6076 Diesel Engines—S.N. (500000— )

160101

PN=8

Page 16

SERVICE MACHINES SAFELY

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.

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.

TS220 -UN-23AUG88

DX,AIR -19-04JUN90

T6642EJ -UN-18OCT88

DX,CLEAN -19-04JUN90

CTM42 (24MAR95) 00-4 6076 Diesel Engines—S.N. (500000— )

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Page 17

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.

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.

DX,LIGHT -19-04JUN90

CTM42 (24MAR95) 00-5 6076 Diesel Engines—S.N. (500000— )

160101

PN=10

TS953 -UN-15MAY90

TS223 -UN-23AUG88

Page 18

USE PROPER LIFTING EQUIPMENT

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.

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.

DX,SERV -19-03MAR93

TS218 -UN-23AUG88

CTM42 (24MAR95) 00-6 6076 Diesel Engines—S.N. (500000— )

160101

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Page 19

USE PROPER TOOLS

Safety/Safety

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.

TS1133 -UN-26NOV90

DX,DRAIN -19-03MAR93

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Page 20

LIVE WITH SAFETY

Before returning machine to customer, make sure

machine is functioning properly, especially the safety systems. Install all guards and shields.

Safety/Safety

TS231 -19-07OCT88

DX,LIVE -19-25SEP92

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160101

PN=13

Page 21

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

Group 01

General Information

01 1

TS1162 -19-04MAR91

Grade 1 Grade 2

Size Lubricated

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

Dry

Lubricated

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.

Dry

Grade 5, 5.1, or 5.2 Grade 8 or 8.2

Lubricated

Dry

Lubricated

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

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.

“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.

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.

DX,TORQ1 -19-20JUL94

CTM42 (24MAR95) 01-1 6076 Diesel Engines—S.N. (500000— )

160101

PN=14

Page 22

General Information/Metric Bolt and Cap Screw Torque Values

METRIC BOLT AND CAP SCREW TORQUE VALUES

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

TS1163 -19-04MAR91

Size Lubricated

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 23172921433255406347806075559570

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 or tightening procedure is given for a specific application. Torque values listed are for general use

Dry

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

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.

“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.

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Page 23

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

01 3

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

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

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

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

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

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

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

Application Code

30, 31, etc.

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Page 24

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

• 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

record the information elsewhere, before “hot tank” cleaning the block.

RG5804 -UN-12AUG91

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

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Page 25

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

FORAGE HARVESTERS—ZWEIBRUCKEN

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

01 5

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

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Page 26

General Information/Engine Application Chart

ENGINE APPLICATION CHART—CONTINUED

John Deere Industrial Equipment Applications

Machine Model No. 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

OEM APPLICATIONS

Machine Model No. Engine Model

Marine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AFM030

OEM Repower . . . . . . . . . . . . . . . . . . . . . . . . . . 6076AF030

6076HF030 6076TF030

RG,CTM42,G1,3B -19-16AUG94

RG,CTM42,G1,3A -19-16AUG94

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Page 27

DIESEL FUEL

Group 02

Fuels, Lubricants, and Coolant

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.

RG,FUEL5 -19-22FEB95

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Page 28

ENGINE BREAK-IN OIL

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.

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.

DX,ENOIL4 -19-17OCT94

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Page 29

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

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Page 30

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.

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.

DX,OILSCAN -19-16APR92

DX,GREA1 -19-02NOV94

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Page 31

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.

ENGINE COOLANT REQUIREMENTS

Synthetic lubricants may be used if they meet the performance requirements listed in this manual.

02 5

DX,ALTER -19-01FEB94

RG6258 -UN-22APR92

A—Quality Water B—Ethylene Glycol Concentrate C—Supplemental Coolant Additives

(Antifreeze) (SCA’s)

Engine Coolant

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

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.

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 -19-10OCT94

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Page 32

Fuels, Lubricants, and Coolant/Engine Coolant Requirements

ENGINE COOLANT REQUIREMENTS—CONTINUED

A—Cylinder Liner Walls B—Engine Coolant C—Vapor Bubbles

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.

RG6263 -UN-22APR92

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.

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Page 33

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 FREEZE PROTECTION LIMIT

40 -24˚ C (-12˚ F) 50 -37˚ C (-34˚ F) 60 -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.

02 7

RG,COOL2,CTM -19-23FEB95

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Page 34

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.

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

Parts Grains Per Per

Item Million Gallon

Chlorides (maximum) . . . . . . . . . . . . . . . . . 40 2.5

Sulfates (maximum) . . . . . . . . . . . . . . . . . . 100 5.9

Total Dissolved Solids (maximum) . . . . . . . . . 340 20

Total Hardness (maximum) . . . . . . . . . . . . . 170 10

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.

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Fuels, Lubricants, and Coolant/Engine Coolant Specifications

ENGINE COOLANT SPECIFICATIONS—CONTINUED

02 9

RG7298 -UN-13FEB95

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.

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.

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.

John Deere Liquid Coolant Conditioner is available in the following sizes:

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.

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.

Contact your authorized servicing dealer or engine distributor, if there are further questions.

—TY16004 473 mL (16 oz) container —TY16005 3.8 L (1 US gal) container

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Fuels, Lubricants, and Coolant/Replenish Supplemental Coolant Additives Between Coolant Changes

REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCA’S) BETWEEN COOLANT CHANGES

02 10

RG6261 -UN-22APR92

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.

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.

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.

RG6262 -UN-22APR92

IMPORTANT: ALWAYS maintain coolant at correct

level and concentration. DO NOT operate engine without coolant for even a few minutes.

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.

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Page 37

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 -19-23FEB95

02 11

CTM42 (24MAR95) 02-11 6076 Diesel Engines—S.N. (500000— )

160101

PN=30

Page 38

Fuels, Lubricants, and Coolant/Flush and Service Cooling System

FLUSH AND SERVICE COOLING SYSTEM

02 12

TS281 -UN-23AUG88

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 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.

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.

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) 02-12 6076 Diesel Engines—S.N. (500000— )

RG,COOL,REQ8B -19-17AUG94

160101

PN=31

Page 39

Fuels, Lubricants, and Coolant/Disposing of Coolant

DISPOSING OF COOLANT

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.

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.

02 13

TS1133 -UN-26NOV90

RG,COOL5 -19-01SEP94

CTM42 (24MAR95) 02-13 6076 Diesel Engines—S.N. (500000— )

160101

PN=32

Page 40

02 14

Fuels, Lubricants, and Coolant/Disposing of Coolant

CTM42 (24MAR95) 02-14 6076 Diesel Engines—S.N. (500000— )

160101

PN=33

Page 41

ENGINE REPAIR STAND

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.

Group 03

Engine Mounting

03 1

RG4929 -UN-15DEC88

S11,2000,EM -19-08MAR94

CTM42 (24MAR95) 03-1 6076 Diesel Engines—S.N. (500000— )

160101

PN=34

Page 42

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 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.

• 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.

• 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.

• 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

INSTALL 400 SERIES ADAPTERS ON REPAIR STAND

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).

S11,2000,FB -19-08MAR94

CTM42 (24MAR95) 03-2 6076 Diesel Engines—S.N. (500000— )

160101

PN=35

RG4930 -UN-15DEC88

Page 43

Engine Mounting/Engine Lifting Procedure

ENGINE LIFTING PROCEDURE

03 3

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.

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).

RG5788 -UN-09AUG91

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.

RG,CTM42,G3,1 -19-23MAR95

CTM42 (24MAR95) 03-3 6076 Diesel Engines—S.N. (500000— )

160101

PN=36

Page 44

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.

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.

S11,2000,EC -19-20AUG92

DISCONNECT TURBOCHARGER OIL INLET LINE

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.

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.

RG5323 -UN-06DEC88

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

Page 45

Engine Mounting/Mount Engine On Repair Stand

MOUNT ENGINE ON REPAIR STAND

03 5

RG5965 -UN-05SEP91

NOTE: If starting motor is to be removed from

engine, remove before mounting engine onto repair stand.

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.

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).

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

Page 46

Engine Mounting/Mount Engine On Repair Stand

CTM42 (24MAR95) 03-6 6076 Diesel Engines—S.N. (500000— )

160101

PN=39

Page 47

6076 ENGINE DISASSEMBLY SEQUENCE

Group 04

Engine Rebuild Guide

The following sequence is suggested when complete disassembly for overhaul is required. Refer to the appropriate repair group when removing individual engine components.

NOTE: Remove starting motor before mounting

engine into repair stand.

1. Drain all coolant and engine oil. Check engine oil for metal contaminates.

2. Remove turbocharger oil inlet line.

3. Remove breather hose.

4. Remove fan pulley and water manifold assembly.

5. Remove turbocharger exhaust elbow and connector. Remove turbocharger.

NOTE: DO NOT damage option code label (if

equipped), when removing rocker arm cover.

6. Remove rocker arm cover.

7. Remove rocker arm assembly and push rods. Identify parts for re-assembly.

8. Remove alternator and mounting brackets.

9. Remove front crankshaft pulley and damper assembly.

10. Remove fuel injection lines and injection nozzles.

11. Remove water pump.

12. Remove engine oil filter and oil conditioning housing.

13. Remove injection pump gear cover and remove injection pump. Remove fuel filter and mounting base.

14. On 6076A Engines, remove aftercooler cover and aftercooler assembly.

15. Remove exhaust manifold and air intake manifold.

16. Remove turbocharger oil return line.

17. Remove cylinder head with valve assembly. Remove head gasket.

18. On SAE No. 3 flywheel housings, remove flywheel then remove flywheel housing.

19. On SAE No. 1 and 2 flywheel housings, remove flywheel housing and then remove flywheel.

20. Roll engine over and remove oil pan and engine oil pump assembly.

21. Remove front timing gear cover.

22. Rotate engine to vertical position. Remove pistons and connecting rods. Identify for re-assembly. Perform wear checks with PLASTIGAGE™.

NOTE: Perform wear check on main bearing surfaces

with PLASTIGAGE, when removing main bearing caps.

23. Remove main bearing caps. Remove crankshaft and main bearings. Identify for re-assembly.

24. Remove camshaft and cam followers. Identify for re-assembly.

25. Rotate engine and remove liners and their O-ring seals. Mark liners for reassembly in same bore from which removed.

26. Remove piston cooling orifices.

27. Remove cylinder block plugs and engine serial number plate, if block is to be put in a “hot tank”.

28. Refer to appropriate group for inspection and repair of engine components.

04 1

PLASTIGAGE™ is a trademark of the Perfect Circle Division of Dana Corp.

CTM42 (24MAR95) 04-1 6076 Diesel Engines—S.N. (500000— )

RG,CTM42,G4,1 -19-24SEP91

160101

PN=40

Page 48

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.

• LOCTITE 242 Thread Lock & Sealer (Medium

Strength) (blue):

TY9370 6 ml. (0.2 oz) tube T43512 50 ml. (1.7 oz) bottle

—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.

• 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)

—Threaded nipples and elbows in water pump housing

—Temperature sending unit

—Oil pan (drain hose and drain valve)

—Connectors: turbocharger oil supply and drain lines.

—Adapter fitting for turbocharger oil inlet line

• LOCTITE 609 Retaining Compound (green):

—Oil pressure sending unit

• LOCTITE 271 Thread Lock & Sealer (High

Strength) (clear):

TY9371 6 ml. (0.2 oz) tube T43513 50 ml. (1.7 oz) bottle

—Studs: Injection pump-to-block and exhaust manifold-to-turbocharger.

—Oil filter adapter.

—Steel cap plugs: cylinder block, cylinder head, and water pump

• LOCTITE 515 Flexible Sealant:

TY6304 50 ml. (1.7 oz) bottle

—Water pump and water manifold gaskets

T43515 50 ml. (1.7 oz) bottle

—Crankshaft rear oil seal/wear sleeve, crankshaft front wear sleeve

• PERMATEX® AVIATION (Form-A-Gasket No. 3):

TY6299 227 g (8 oz) container

—Timing gear cover-to oil pan

—Flywheel housing-to-oil pan

—Camshaft bore steel cap plug

RG,CTM42,G4,2 -19-17MAR95

CTM42 (24MAR95) 04-2 6076 Diesel Engines—S.N. (500000— )

160101

PN=41

Page 49

Engine Rebuild Guide/Sealant Application Guidelines

SEALANT APPLICATION GUIDELINES—CONTINUED

• AR31790 SCOTCH-GRIP® EC-1099 Plastic

• PT569 NEVER-SEEZ® COMPOUND:

Adhesive:

PT569 227 g (8 oz) Brush PT506 453 g (16 oz) Spray

—Cap Screws: exhaust manifold, turbocharger-to-exhaust manifold.

—Gland nut threads and fuel injection nozzle barrel.

LOCTITE® and PERMATEX® are registered trademarks of Loctite Corporation.

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.

AR31790 118 ml (4 oz)

—Rocker arm cover gasket

• FEL-PRO® C-670 Molybdenum Disulfide Paste

—Camshaft nose (gear installation)

04 3

RG,CTM42,G4,5 -19-16AUG94

CTM42 (24MAR95) 04-3 6076 Diesel Engines—S.N. (500000— )

160101

PN=42

Page 50

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.

1. Install all plugs in cylinder block that were removed to service block. Install engine serial number plate.

2. Install clean piston cooling orifices.

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.

4. Install main bearings and crankshaft. Rotate crankshaft to assure correct assembly. Check crankshaft end play.

5. If installing new piston/liner kits, assemble the respective connecting rods.

12. Install flywheels:

SAE 1 or SAE 2: Flywheel goes on before housing.

SAE 3: Housing goes on before flywheel.

13. Install cylinder head, push rods, and rocker arm assembly. Measure valve lift and adjust valve clearance.

14. Install rocker arm cover. Install breather hose.

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.

18. Install aftercooler assembly on 6076A Engines.

19. Install turbocharger with elbow and oil lines.

20. Install water pump.

6. Install engine oil pump assembly.

7. Install crankshaft rear oil seal housing, oil seal, and wear sleeve.

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.

11. Install engine oil conditioning assembly, if removed.

21. Install injection nozzles and line assembly.

22. Install front pulley and damper as an assembly.

23. Install alternator. Install fan pulley assembly.

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.

RG,CTM42,G4,3 -19-14FEB95

CTM42 (24MAR95) 04-4 6076 Diesel Engines—S.N. (500000— )

160101

PN=43

Page 51

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).

Spring Compression Tester . . . . . . . . . D01168AA

Test valve spring compression.

Valve Inspection Center . . . . . . . . . . . . D05058ST

Check valves for out-of round.

End Brush . . . . . . . . . . . . . . . . . . . . . D17024BR

Cylinder Head and Valves

RG5061 -UN-23AUG88

RG5062 -UN-23AUG88

RG5063 -UN-23AUG88

Group 05

DX,TOOLS -19-05JUN91

S53,D01168,AA -19-13MAR92

S53,D05058,ST -19-02APR87

05 1

Clean valve seat and bores.

Nozzle Thread Cleaning Brush . . . . . . . . . D17030BR

Used to clean nozzle threads in cylinder head.

Dial Indicator . . . . . . . . . . . . . (English, in.) D17526CI

or (Metric, mm ) D17527CI

Use with JDG451 to measure valve recess and cylinder liner height-to-cylinder block top deck.

S53,D17024,BR -19-26JAN87

RG5099 -UN-23AUG88

S53,D17030,BR -19-16FEB87

RG6246 -UN-27MAR92

RG,D17526CI -19-29OCT92

RG5064 -UN-23AUG88

Valve Guide Knurler Kit . . . . . . . . . . . . . . . JT05949

Knurl valve guides.

S53,D20002,WI -19-16SEP92

CTM42 (24MAR95) 05-1 6076 Diesel Engines—S.N. (500000— )

160101

PN=44

Page 52

Cylinder Head and Valves/Special or Essential Tools

Valve Seat Pilot Driver . . . . . . . . . . . . . . . . JDE7

Install replacement valve seat inserts. Use with JDG605.

Flywheel Turning Tool . . . . . . . . . . . . . . . . . JDG820

Used to rotate engine to check damper radial runout and time engine. JDE81-1 may be used also if JDG820 is not available.

Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4

RG5065 -UN-23AUG88

S53,JDE7A -19-04FEB93

RG7056 -UN-10AUG94

RG,JDG820 -19-14FEB95

RG5068 -UN-23AUG88

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.

Valve Seat Puller . . . . . . . . . . . . . . . . . JDE41296

Remove valve seats.

Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDF5

Used to restore nozzle threads in cylinder head.

Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG681A

Used to restore threaded holes in cylinder block for cylinder head cap screws.

RG,JDE814,86 -19-14FEB95

RG5071 -UN-23AUG88

S53,JDE,41296 -19-26JAN87

RG5100 -UN-23AUG88

S53,JDF5 -19-08MAR94

RG5100 -UN-23AUG88

RG,JDG681A -19-17MAR95

CTM42 (24MAR95) 05-2 6076 Diesel Engines—S.N. (500000— )

160101

PN=45

Page 53

Cylinder Head and Valves/Service Equipment and Tools

Valve Seat Installer . . . . . . . . . . . . . . . . JDG605

Install intake and exhaust valve seat inserts. Use with JDE7.

Nozzle Seat Reamer . . . . . . . . . . . . . . . . . . JDG609

Used to clean carbon from nozzle seats in cylinder head.

SERVICE EQUIPMENT AND TOOLS

RG5240 -UN-23AUG88

S53,JDG605 -19-25MAR91

RG5289 -UN-23AUG88

S53,JDG609 -19-02DEC87

05 3

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 -19-08FEB94

CTM42 (24MAR95) 05-3 6076 Diesel Engines—S.N. (500000— )

160101

PN=46

Page 54

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

CTM42 (24MAR95) 05-4 6076 Diesel Engines—S.N. (500000— )

160101

PN=47

Page 55

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.) 12.65 mm (0.498 in.)

Exhaust . . . . . . . . . . . . . . . . . . 14.52—14.70 mm (0.572—0.579 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 . . . . . . . . . . 52.5 mm @ 345—399 N (2.07 in. @ 78—90 lb-force) ——

Exhaust . . . . . . . . . . 54.5 mm @ 284—338 N (2.15 in. @ 64—76 lb-force) ——

Valve Open-Intake . . . . . . . . . . . 38.1 mm @ 810—880 N (1.50 in. @ 182—198 lb-force) ——

Exhaust . . . . . . . . . . 38.5 mm @ 797—867 N (1.52 in. @ 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.) ——

05 5

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.) 4.62 mm (0.182 in.)

Exhaust . . . . . . . . . . . . . . . . . . 1.19—1.70 mm (0.047—0.067 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

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Page 56

Cylinder Head and Valves/Cylinder Head and Valves Specifications

CYLINDER HEAD AND VALVES SPECIFICATIONS—CONTINUED

ITEM 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-to-

Combustion Face) . . . . . . . . . . . . . . . . 155.45—155.71 mm (6.120—6.130 in.) ——

Minimum Acceptable Thickness . . . . . . . . 154.69 mm (6.09 in.) ——

Maximum Acceptable Head Out-of-Flat

(Entire Length or Width) . . . . . . . . . . . . 0.102 mm (0.0040 in.) ——

Combustion Face Surface

Finish (Surface Grind Only) . . . . . . . . . . 60—110AA ——

Maximum Wave Depth . . . . . . . . . . . . . 0.008 mm (0.0003 in.) ——

Maximum Material Removal for

Resurfacing Head . . . . . . . . . . . . . . . . 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)

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Page 57

Cylinder Head and Valves/Check and Adjust Valve Clearance

CHECK AND ADJUST VALVE CLEARANCE

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.

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.

RG5790 -UN-09AUG91

05 7

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.

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.”

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Page 58

Cylinder Head and Valves/Check and Adjust Valve Clearance

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.)

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.

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).

RG5241 -UN-06DEC88RG4295 -19-21AUG91

8. Recheck clearance on all valves again after locknut is tightened.

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Page 59

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.

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.

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.

05 9

RG5789 -UN-09AUG91

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.

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Page 60

Cylinder Head and Valves/Remove Cylinder Head

REMOVE CYLINDER HEAD

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.

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.

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.)

2. Remove water manifold (A) and all coolant piping. (See Cooling System, Group 25.)

TS281 -UN-23AUG88RG5792 -UN-09AUG91

3. Remove turbocharger (B) and exhaust elbow (E). (See Air Intake and Exhaust System, Group 30.)

4. On 6076A Engines, remove aftercooler assembly (D).

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.)

A—Water Manifold B—Turbocharger C—Intake Manifold D—Aftercooler Assembly E—Exhaust Elbow

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Page 61

Cylinder Head and Valves/Remove Cylinder Head

7. Remove fuel injection lines (A) and nozzles (B). (See Fuel System, Group 35.)

8. Remove rocker arm cover (C) and ventilator outlet hose assembly.

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.

RG5887 -UN-13AUG91

RG,CTM42,G5,7 -19-22AUG91

RG5793 -UN-09AUG91

10. Remove all 12 push rods and identify for reassembly.

NOTE: Clean and inspect push rods as explained later in

this group.

05 11

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Page 62

Cylinder Head and Valves/Disassemble and Inspect Rocker Arm Shaft Assembly

11. Remove all 26 cylinder head cap screws.

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.

RG5245 -UN-06DEC88

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.

DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY

NOTE: Make preliminary inspection during disassembly.

Look for: —Worn or scored rocker arms, shaft, and shaft support. —Weak or broken springs —Lube oil restriction

1. Remove plugs (A) and washers (B) from ends of rocker arm shaft.

S11,2005,MT -19-16AUG94

RG3801 -UN-23FEB89

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.

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Page 63

Cylinder Head and Valves/Disassemble and Inspect Rocker Arm Shaft Assembly

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.

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.

5. Clean all rocker arm parts with clean solvent. Dry with compressed air.

6. Check for cups or concave wear (A) on ends of rocker arms where they contact wear caps.

7. Examine spacer springs on shaft between rocker arms. Be sure they are strong enough to exert a positive pressure on rocker arms.

RG3802 -UN-23FEB89

05 13

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

R26131 -UN-09DEC88

to check for bends or distortion. Replace parts as necessary.

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Page 64

Cylinder Head and Valves/Measure Valve Recess

ASSEMBLE ROCKER ARM SHAFT ASSEMBLY

1. Assemble parts on rocker arm shaft opposite removal procedure.

Make sure rocker arm shaft end plugs (A) are firmly seated against end of shaft, and washers (B) are installed on shaft.

MEASURE VALVE RECESS

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.

RG3801 -UN-23FEB89

S11,0401,O -19-08MAR94

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.)

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.)

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Page 65

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.

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.

• 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).

• 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.

• 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.

• 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:

05 15

Worn valve guides. Bent valves. Debris passed through valve train.

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Page 66

Cylinder Head and Valves/Remove Valve Assembly

REMOVE VALVE ASSEMBLY

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.

1. Compress JDE138 Valve Spring Compressor (A) over valve.

2. Remove retaining locks (B).

3. Remove valve spring compressor.

05 16

4. Remove valve rotators (A) and valve springs (B).

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S11,0401,Q -19-14FEB95

5. Remove exhaust valve stem shields.

6. Remove valves (C) from cylinder head.

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Page 67

Cylinder Head and Valves/Inspect Valve Rotators and Wear Caps

INSPECT AND MEASURE VALVE SPRINGS

1. Inspect valve springs for alignment, wear and damage.

2. Put springs on a flat surface to see that they are square and parallel.

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.

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.)

RG2732 -UN-23FEB89T82054 -UN-08NOV88

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.)

INSPECT VALVE ROTATORS AND WEAR CAPS

1. Insure that valve rotators (A), if equipped, will turn freely. Replace if defective.

2. Replace valve wear caps (B) if pitted or worn.

3. Inspect valve retainer locks for excessive wear. Replace as needed.

05 17

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Page 68

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.

05 18

INSPECT AND MEASURE VALVES

S11,0401,U -19-13MAR92

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

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.)

RG,CTM42,G5,12 -19-03MAY93

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Page 69

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.

VALVE FACE RUNOUT SPECIFICATION

Maximum permissible runout of

valve face . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

GRIND (REFACE) VALVES

IMPORTANT: Valve grinding should only be done by

experienced personnel familiar with equipment and capable of maintaining required specifications.

If necessary to reface valve, grind valve face to an angle of 29.25˚ ± 0.25˚ (A).

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S11,2005,IZ -19-14FEB95

05 19

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.

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.

RG5247 -UN-12AUG91

S11,2005,MG -19-20JUL94

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Page 70

Cylinder Head and Valves/Check Cylinder Head Combustion Face Flatness

CHECK CYLINDER HEAD COMBUSTION FACE FLATNESS

Check cylinder head flatness using D05012ST Precision Straightedge and feeler gauge. Check lengthwise, crosswise, and diagonally in several places.

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

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.)

05 20

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Page 71

Cylinder Head and Valves/Measure Cylinder Head Thickness

MEASURE CYLINDER HEAD THICKNESS

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.

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.

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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.)

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Page 72

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.

NOTE: A few drops of light oil or kerosene will help to

fully clean the guide.

05 22

MEASURE VALVE GUIDES

RG5346 -UN-06DEC88

S11,2005,MY -19-28OCT92

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.)

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.

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Page 73

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.

A—Knurler B—Reamer C—Speed Reducer D—Lubricant

CLEAN AND INSPECT VALVE SEATS

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.

3. Check entire combustion face for rust, scoring, pitting or cracks.

S11,0401,Z -19-08MAR94

S11,0401,AA -19-28OCT92

R26141 -UN-09DEC88

05 23

R26142N -UN-09DEC88

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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 Angle (B) . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚ ±0.50˚

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.)

05 24

Maximum Valve Seat Runout . . . . . . . . . . . . 0.051 mm (0.0020 in.)

A—Valve Seat Insert B—Valve Seat Angle C—Valve Seat Width D—Valve Seat Runout

RG5248 -UN-06DEC88

S11,2005,MI -19-16SEP94

CTM42 (24MAR95) 05-24 6076 Diesel Engines—S.N. (500000— )

160101

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Page 75

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.

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.

R26143N -UN-09DEC88

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.

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.

2. ALWAYS measure valve seat runout after grinding using D11010KW Eccentrimeter.

VALVE SEAT SPECIFICATIONS

A—Valve Seat Insert

B—Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚ ±0.50˚

C—Valve Seat Width

—Exhaust . . . . . . . . . . . . . . . . . . 2.0—3.8 mm (0.079—0.150 in.)

—Intake . . . . . . . . . . . . . . . . . . . 1.4—3.8 mm (0.055—0.150 in.)

D—Maximum Valve Seat Runout . . . . . . . . . . 0.051 mm (0.0020 in.)

RG5248 -UN-06DEC88

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 -19-28OCT92

CTM42 (24MAR95) 05-25 6076 Diesel Engines—S.N. (500000— )

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Page 76

Cylinder Head and Valves/Remove Valve Seat Inserts and Measure Bores

REMOVE VALVE SEAT INSERTS AND MEASURE BORES IN CYLINDER HEAD

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.

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.

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

05 26

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.

RG5306 -UN-06DEC88

S11,2005,ML -19-28OCT92

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Page 77

Cylinder Head and Valves/Inspect and Clean Cylinder Head Nozzle Bore

INSTALL VALVE SEAT INSERTS

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.

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.)

INSPECT AND CLEAN CYLINDER HEAD NOZZLE BORE

RG5249 -UN-06DEC88

S11,2005,MM -19-28OCT92

05 27

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.

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.

RG5251 -UN-14DEC88

RG,CTM42,G5,14 -19-08FEB94

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Page 78

Cylinder Head and Valves/Inspect and Clean Ventilator Outlet Hose

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.

5. Clean nozzle seating surface by using the JDG609 Nozzle Seat Reamer (A) to remove carbon.

6. Blow out debris with compressed air and thoroughly clean all nozzle bores.

05 28

RG5252 -UN-06DEC88

RG,CTM42,G5,15 -19-22AUG91

CLEAN AND INSPECT PUSH RODS

1. Clean push rods with solvent and compressed air.

2. Check push rods for straightness by rolling on a flat surface.

3. Inspect contact ends for wear and damage.

4. Replace defective push rods.

INSPECT AND CLEAN VENTILATOR OUTLET HOSE

1. Check ventilator outlet hose (A) on rocker arm cover for bent or damaged condition. Replace if necessary.

2. Clean ventilator hose if restricted.

RG5253 -UN-06DEC88

S11,2005,NU -19-23AUG91

T81233 -UN-01NOV88

S11,2005,JN -19-24APR92

RG,CTM42,G5,9 -19-28OCT92

CTM42 (24MAR95) 05-28 6076 Diesel Engines—S.N. (500000— )

160101

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RG5797 -UN-12AUG91

Page 79

Cylinder Head and Valves/Clean and Inspect Top Deck of Cylinder Block

CLEAN AND INSPECT TOP DECK OF CYLINDER BLOCK

1. Remove gasket material, rust, carbon, and other foreign material from top deck. Gasket surface must be clean.

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.

6. Install new cylinder head locating dowel pins in cylinder block.

RG5796 -UN-12AUG91

05 29

RG,CTM42,G5,17 -19-17MAR95

CTM42 (24MAR95) 05-29 6076 Diesel Engines—S.N. (500000— )

160101

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Page 80

Cylinder Head and Valves/Measure Cylinder Liner Standout (Height above Block)

MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)

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).

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 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 . . . . . . . . . . . . . . . . . . 0.050—0.127 mm

(0.002—0.005 in.)

RG5829 -UN-12AUG91RG5813 -UN-08MAR94

A—Cylinder Liner B—Dial Indicator C—Liner Height D—Cylinder Block

RG,CTM42,G5,31 -19-16AUG94

CTM42 (24MAR95) 05-30 6076 Diesel Engines—S.N. (500000— )

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Page 81

Cylinder Head and Valves/Assemble Valve Assembly

ASSEMBLE VALVE ASSEMBLY

1. Apply AR44402 Valve Stem Lubricant or clean engine oil to valve stems and guides.

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.

NOTE: There is no top or bottom to valve springs; they

may be installed either way.

RG3806 -UN-23FEB89

S11,0401,AK -19-28OCT92

05 31

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.

4. Install valve rotators (A) on springs and valves (C).

5. Install valve stem shields on exhaust valve stems.

6. Compress valve springs with JDE138 Valve Spring Compressor (A) and install retainer locks (B).

NOTE: Install wear caps just before installing rocker arm

assembly.

RG3804 -UN-23FEB89

RG,CTM42,G5,28 -19-28OCT92

RG3803 -UN-23FEB89

RG,CTM42,G5,29 -19-28OCT92

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Page 82

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.

Repeat procedure for all remaining valves. Remember valve stem seals are installed onto exhaust valve stems only.

8. Measure valve recess as directed earlier in this group.

INSTALL CYLINDER HEAD

IMPORTANT: ALWAYS thoroughly inspect new

cylinder head gasket for possible manufacturing imperfections. Return

05 32

any gasket that does not pass inspection.

RG3807 -UN-23FEB89

RG,CTM42,G5,30 -19-28OCT92

Be sure cylinder head and block gasket surfaces are clean, dry, and free of any oil.

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.

RG5245 -UN-06DEC88

RG,CTM42,G5,40 -19-14FEB95

CTM42 (24MAR95) 05-32 6076 Diesel Engines—S.N. (500000— )

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Page 83

Cylinder Head and Valves/Cylinder Head Cap Screw Types

CYLINDER HEAD CAP SCREW TYPES

A—ASTM Grade 180 Flanged-Head B—Flanged-Head Marked

RG7226 -UN-22JUL94

“SPECIAL”

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.

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.

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.

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.

05 33

RG,CTM42,G5,41 -19-14FEB95

CTM42 (24MAR95) 05-33 6076 Diesel Engines—S.N. (500000— )

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Page 84

Cylinder Head and Valves/Clean, Inspect and Install Cylinder Head Cap Screws

CLEAN, INSPECT AND INSTALL CYLINDER HEAD CAP SCREWS

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.

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.

RG4471 -UN-28FEB94

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 Location on Cylinder Head

134 mm (5.2 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3, 4, 5, 6, 7

149 mm (5.9 in.) . . . . . . . . . . . . . . . . . . . . . . . . 23, 25, 17, 21, 19

175 mm (6.9 in.) . . . . . . . . . . . . . . . . . . 1, 15, 14, 13, 12, 11, 10, 8

203 mm (8.0 in.) . . . . . . . . . . . . . . . . . . . . 16, 20, 22, 18, 26, 24, 9

RG,CTM42,G5,42 -19-17MAR95

CTM42 (24MAR95) 05-34 6076 Diesel Engines—S.N. (500000— )

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Page 85

Cylinder Head and Valves/Clean, Inspect and Install Cylinder Head Cap Screws

TORQUE-TURN FLANGED-HEAD CAP SCREWS—GRADE 180

Arrow (A) points toward front of engine.

• Using line scribe method to TORQUE-TURN

cylinder head cap screws:

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 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.

4. Make 90˚ reference marks (A,B) on socket.

RG7136 -UN-21FEB94

RG4471 -UN-28FEB94RG7138 -UN-28FEB94

05 35

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:

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— )

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Page 86

Cylinder Head and Valves/Torque-To-Yield Special Flanged-Head Cap Screws

TORQUE-TO-YIELD FLANGED-HEAD CAP SCREWS—GRADE 180 MARKED “SPECIAL”

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).

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.

05 36

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.

RG4471 -UN-28FEB94RG7139 -UN-01MAY94

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˚.

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˚.

RG,CTM1,G5,4 -19-09AUG94

CTM42 (24MAR95) 05-36 6076 Diesel Engines—S.N. (500000— )

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Page 87

Cylinder Head and Valves/Install Rocker Arm Assembly

INSTALL ROCKER ARM ASSEMBLY

1. Install push rods (A) in holes from which removed.

2. Install wear caps (B) on valves, making certain caps rotate freely.

3. Make sure spring pin (A) engages with hole (B) in shaft.

RG3809 -UN-23FEB89

S11,2005,HT -19-12JUL94

05 37

4. Install shaft clamps (B) and all six cap screws (A). Tighten cap screws to 75 N·m (55 lb-ft).

RG3810 -UN-23FEB89

RG5793 -UN-09AUG91

RG,CTM42,G5,20 -19-07AUG91

CTM42 (24MAR95) 05-37 6076 Diesel Engines—S.N. (500000— )

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Page 88

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.

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.).

4. Install fuel injection nozzles (E), leak-off lines (D) and fuel injection lines (C). (See INSTALL FUEL INJECTION NOZZLES in Group 35.)

RG5798 -UN-12AUG91

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.)

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

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Page 89

Cylinder Head and Valves/Complete Final Assembly On Exhaust Manifold Side

COMPLETE FINAL ASSEMBLY ON EXHAUST MANIFOLD SIDE

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.

1. Install front exhaust manifold using new gaskets. Do not tighten cap screws until sealing ring (A) and rear exhaust manifold is installed.

2. Install rear exhaust manifold using new gaskets and sealing ring.

RG5799 -UN-12AUG91RG5800 -UN-12AUG91RG6338 -UN-03AUG92

05 39

3. Tighten cap screws in sequence shown in bottom illustration to 47 N·m (35 lb-ft).

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— )

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Page 90

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).

6. On 6076T Engines, install intake coupling (B). Do not tighten clamps.

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

05 40

9. On 6076A Engines, use new gaskets (A) and install intake manifold (B). Tighten cap screws to 47 N·m (35 lb-ft).

RG5801 -UN-12AUG91

RG,CTM42,G5,23 -19-16AUG94

RG,CTM42,G5,24 -19-22AUG91

10. On 6076A Engines, using new gaskets and O-rings, install aftercooler and cover (A). (See INSTALL INTAKE MANIFOLD AND AFTERCOOLER in Group 30.)

RG,CTM42,G5,25 -19-06SEP91

CTM42 (24MAR95) 05-40 6076 Diesel Engines—S.N. (500000— )

160101

PN=83

RG5802 -UN-13AUG91

RG5803 -UN-13AUG91

Page 91

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.)

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.)

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.)

A—Water Inlet Hose B—Aneroid Line C—Water Outlet Tube and Hose D—Turbocharger

RG,CTM42,G5,32 -19-28OCT92

RG5885 -UN-13AUG91

05 41

CTM42 (24MAR95) 05-41 6076 Diesel Engines—S.N. (500000— )

160101

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Page 92

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.)

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— )

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Page 93

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).

Cylinder Liner Puller . . . . . . . . . . . . . . D01062AA

(or D01073AA)

Remove cylinder liners.

Group 10

DX,TOOLS -19-05JUN91

RG5019 -UN-23AUG88

S53,D01062,AA -19-07AUG91

Flexible Cylinder Hone . . . . . . . . . . . . D17005BR

Hone cylinder liners.

O-Ring Groove Cleaning Brush . . . . . . . D17015BR

Clean cylinder liner O-ring groove in block.

Dial Indicator . . . . . . . . . . . . . (English, in.) D17526CI

or (Metric, mm ) D17527CI

RG5074 -UN-23AUG88

10 1

S53,D17005,BR -19-07APR88

RG5075 -UN-23AUG88

S53,D17015,BR -19-25MAR91

Use with JDG451 to measure valve recess and cylinder liner height-to-cylinder block top deck.

RG,D17526CI -19-29OCT92

CTM42 (24MAR95) 10-1 6076 Diesel Engines—S.N. (500000— )

160101

PN=86

RG6246 -UN-27MAR92

Page 94

Cylinder Block, Liners, Pistons and Rods/Special or Essential Tools

Ring Groove Wear Gauge . . . . . . . . . . . . . JDE55

Check wear of keystone ring groove on pistons.

Piston Ring Expander . . . . . . . . . . . . . . . . JDE93

Remove and install piston rings.

Piston Ring Compressor . . . . . . . . . . . . . . JDE96

Compress rings while installing pistons.

RG5076 -UN-23AUG88

S53,JDE55 -19-25MAR91

RG5077 -UN-23AUG88

S53,JDE93 -19-17FEB87

RG5031 -UN-23AUG88

S53,JDE96 -19-25MAR87

Connecting Rod Bushing Service Set . . . . . JDE98A

Remove and install connecting rod bushings.

Set consists of:

1—Cup . . . . . . . . . . . . . . . . . . . . . . . JDE98-1

2—Driver . . . . . . . . . . . . . . . . . . . . . . JDE98-2

3—Pilot . . . . . . . . . . . . . . . . . . . . . . . JDE98-3

4—Driver . . . . . . . . . . . . . . . . . . . . . . JDE98-4

5—Driver . . . . . . . . . . . . . . . . . . . . . . JDE98-5

6—Pilot . . . . . . . . . . . . . . . . . . . . . . . JDE98-6

7—Driver . . . . . . . . . . . . . . . . . . . . . . JDE98-7

8—Cup . . . . . . . . . . . . . . . . . . . . . . . JDE98-8

9—Pilot . . . . . . . . . . . . . . . . . . . . . . . JDE98-9

10—Remover Bushing . . . . . . . . . . . . JDE98-10

Forcing Screw . . . . . . . . . . . . . . . . STD36104

Connecting Rod Bushing Service Set . . . . . JDG337

Use with JDE98A Bushing Service Set to remove and install connecting rod bushings.

RG5078 -UN-16FEB94

S53,JDE98A -19-16AUG94

RG5079 -UN-25JUN94

S53,JDG337,A -19-29JUL94

CTM42 (24MAR95) 10-2 6076 Diesel Engines—S.N. (500000— )

160101

PN=87

Page 95

Cylinder Block, Liners, Pistons and Rods/Other Material

Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG681A

Used to restore threaded holes in cylinder block for cylinder head cap screws.

Torque Angle Gauge . . . . . . . . . . . . . . . . . . JT05993

Used to TORQUE-TURN flanged-head cylinder head and connecting rod cap screws.

RG5100 -UN-23AUG88

RG,JDG681A -19-17MAR95

RG5698 -UN-27AUG90

RG,JT05993 -19-22AUG91

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

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.

10 3

S11,2010,BS -19-08AUG94

CTM42 (24MAR95) 10-3 6076 Diesel Engines—S.N. (500000— )

160101

PN=88

Page 96

Cylinder Block, Liners, Pistons and Rods/Cylinder Block, Liners, Pistons, and Rods Specifications

CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS

ITEM SPECIFICATION WEAR LIMIT

Cylinder Liner Height

Above Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050—0.127 mm ——

(0.002—0.005 in.) ——

Maximum Piston Protrusion Above Block . . . . . . . . . . . 0.051—0.787 mm ——

(0.002—0.031 in.) —— Piston Oil Control Ring-to-

Groove Clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.064—0.102 mm 0.165 mm

(0.0025—0.0040 in.) (0.0065 in.) Piston Compression Ring End Gap: 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.) ——

Piston OD: —19.1 mm (0.75 in.) from Bottom of Skirt

Engine Serial No. . . . . . . . . . . . . . . . . . . . . . . . . 115.771—115.789 mm ——

(4.5579—4.5586 in.)

Piston-to-Liner Clearance at Bottom of Skirt:

Engine Serial No. . . . . . . . . . . . . . . . . . . . . . . . . 0.076—0.124 mm 0.152 mm

(0.0030—0.0049 in.) (0.0060 in.)

Cylinder Liner ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 115.865—115.895 mm ——

(4.5616—4.5628 in.) ——

OD . . . . . . . . . . . . . . . . . . . . . . . . . 127.94—128.24 mm ——

(5.037—5.049 in.) ——

Cylinder Liner Thickness . . . . . . . . . . . . . . . . . . . . . 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.) ——

RG,CTM42,G10,25-19-17MAR95

CTM42 (24MAR95) 10-4 6076 Diesel Engines—S.N. (500000— )

160101

PN=89

Page 97

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

Cylinder Liner Maximum

Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 mm ——

(0.0020 in.) ——

Cylinder Liner Counterbore Depth . . . . . . . . . . . . . 8.105—8.155 mm ——

(0.319—0.321 in.) ——

Cylinder Liner Flange Thickness . . . . . . . . . . . . . . 8.175—8.225 mm ——

(0.322—0.324 in.) ——

Cylinder Liner Flange OD . . . . . . . . . . . . . . . . . . 135.105—135.130 mm ——

(5.319—5.321 in.) —— Outer Diameter of Liner:

at Upper Bore . . . . . . . . . . . . . . . . . . . . . . . . 129.085—129.135 mm ——

(5.082—5.084 in.) ——

at Lower Bore . . . . . . . . . . . . . . . . . . . . . . . . 125.042—125.122 mm ——

(4.923—4.926 in.) —— Upper Bore Diameter in Block For

Seating Liners . . . . . . . . . . . . . . . . . . . . . . . . 129.155—129.205 mm ——

(5.085—5.087 in.) —— Lower Bore Diameter in Block for

Seating Liners . . . . . . . . . . . . . . . . . . . . . . . . 125.133—125.183 mm ——

(4.9265—4.9285 in.) —— Liner-to-Block Clearance:

at Upper Bore . . . . . . . . . . . . . . . . . . . . . . . . 0.026—0.126 mm ——

(0.001—0.005 in.) ——

at Lower Bore . . . . . . . . . . . . . . . . . . . . . . . . 0.012—0.140 mm ——

(0.0005—0.0055 in.) ——

10 5

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.) ——

RG,CTM42,G10,29-19-16AUG94

CTM42 (24MAR95) 10-5 6076 Diesel Engines—S.N. (500000— )

160101

PN=90

Page 98

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

Rod Pin-to-Bushing Oil Clearance . . . . . . . . . . . . . 0.042—0.084 mm 0.102 mm

(0.0017—0.0033 in.) (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.) ——

Centerline of Main Bearing Bore-to-

Top Deck of Cylinder Block . . . . . . . . . . . . . . . 352.35—352.50 mm ——

(13.872—13.878 in.) ——

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.) ——

Camshaft Bushing ID . . . . . . . . . . . . . . . . . . . . . 67.076—67.102 mm ——

(2.6408—2.6418 in.) ——

Cylinder Block Top Deck: 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.) ——

Centerline of Rod Pin Bore-to-Centerline

of Crankshaft Journal Bore . . . . . . . . . . . . . . . . 222.20—222.30 mm ——

(8.748—8.752 in.) ——

RG,CTM42,G10,20-19-14FEB95

CTM42 (24MAR95) 10-6 6076 Diesel Engines—S.N. (500000— )

160101

PN=91

Page 99

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 * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 lb-ft)

Final (All Cap Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N·m (55 lb-ft)

Plus 90—100˚

Piston Cooling Orifices into Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6—12.4 N·m

(85—110 lb-in.)

Cylinder Liner Cap Screws

(for Checking Liner Standout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N·m (50 lb-ft)

* See INSTALL PISTONS AND CONNECTING RODS, later in this group, before tightening cap screws.

RG,CTM42,G10,39-19-16AUG94

10 7

CTM42 (24MAR95) 10-7 6076 Diesel Engines—S.N. (500000— )

160101

PN=92

Page 100

Cylinder Block, Liners, Pistons and Rods/Preliminary Liner, Piston, and Rod Checks

PRELIMINARY LINER, PISTON AND ROD CHECKS

• Scuffed or Scored Pistons:

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.

• Worn or Broken Compression Rings:

Insufficient lubrication. Insufficient cooling. Improper ring installation.

Improper combustion.

Improper timing. Abrasives in combustion chamber.

• Clogged Oil Control Ring:

Improper oil. Excessive Blow-by. Contaminated oil. Improper periodic service. Low operating temperature.

• Dull Satin Finish and Fine Vertical Scratches on Rings:

• Stuck Rings:

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:

Insufficient cooling.

• Broken Connecting Rod:

Inadequate piston-to-liner clearance. Worn connecting rod bearing. Distorted cylinder liner. Piston pin failure.

• Piston Pin and Snap Ring Failure:

Misaligned connecting rod. Excessive crankshaft end play. Incorrect snap rings.

• Mottled, Grayish or Pitted Compression Rings:

Internal coolant leaks.

Dirt and abrasive in air intake system.

CTM8,GR10,37 -19-17AUG94

CTM42 (24MAR95) 10-8 6076 Diesel Engines—S.N. (500000— )

160101

PN=93

John Deere CTM42 TECHNICAL MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual