Factory Technical Manual For John Deere Diesel Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 421
Number: CTM20 (november 1995)
Model
John Deere Diesel Engine
Series 500
6101
SN -499999
Contents
SAFETY
-GENERAL INFORMATION
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Engine Model Designation
Engine Nameplate Information
6101 Engine Application Chart
Basic 6101 Engine Specifications
-FUELS, LUBRICANTS, AND COOLANT
Diesel Fuel
Lubricity of Diesel Fuels
Engine Break-In Oil
Diesel Engine Oil
OILSCAN® and COOLSCAN
Alternative and Synthetic Lubricants
Grease
Engine Coolant Requirements
Recommended Engine Coolant
Engine Coolant Specifications
Replenishing Supplemental Coolant Additives
Operating in Tropical Conditions
Flush and Service Cooling System
Disposing of Coolant
-ENGINE MOUNTING
Engine Repair Stand
Safety Precautions
Install 500 Series Adapters on Repair Stand
Engine Lifting Procedure
Clean Engine
Mount Engine on Repair Stand
Disconnect Turbocharger Oil Inlet Line
-ENGINE REBUILD GUIDE
6101 Engine Disassembly Sequence
Sealant Application Guidelines
6101 Engine Assembly Sequence
-CYLINDER HEAD AND VALVES
Special or Essential Tools
Service Equipment and Tools
Other Material
Specifications
Torques
Disconnect Turbocharger Oil Inlet Line
Check and Adjust Valve Clearance
Measure Valve Lift
Remove Cylinder Head and Valves
Check Valve Height in Relation to Cylinder Head
Disassemble and Inspect Rocker Arm Shaft Assembly
Assemble Rocker Arm Shaft Assembly Make Preliminary Valve Checks
Remove Valve Assembly
Inspect Valve Springs
Inspect Spring Caps, Wear Caps and Valve Rotators
Clean Valves
Measure Valves
Inspect and Clean Cylinder Head
Check Cylinder Head Combustion Face Flatness
Measure Cylinder Head Thickness
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Replace Valve Guides
Clean and Inspect Valve Seats
Measure Valve Seats
Grind Valve Seats
Replace Valve Seat Inserts
Recheck Valve Height in Relation to Cylinder Head
Install Oversize Valve Seat Inserts
Clean and Inspect Cylinder Head Nozzle Bore
Clean and Inspect Nozzle Seating Surface
Clean and Inspect Push Rods
Clean and Inspect Cylinder Head Cap Screws
Inspect Ventilator Assembly
Inspect and Clean Exhaust Manifold
Clean and Inspect Top Deck of Cylinder Block
Measure Cylinder Liner Height
Install Valve Assembly
Install Cylinder Head
Tighten Cylinder Head Cap Screws
TORCUE-TURN Method for Proper Cylinder Head Torque
Install Rocker Arm Assembly
Complete Final Assembly on Injection Pump Side
Complete Final Assembly on Exhaust Manifold Side
Perform Engine Break-In
-CYLINDER BLOCK, LINERS, PISTONS AND RODS
Special or Essential Tools
Other Material
Service Equipment and Tools
Specifications
Preliminary Liner, Piston, and Rod Checks
Disconnect Turbocharger Oil Inlet Line
Remove Pistons and Connecting Rods
Measure Cylinder Liner Standout (Height Above Block)
Remove Cylinder Liners
Remove Piston Rings
Clean Pistons
Visually Inspect Pistons
Clean Cylinder Liners
Visually Inspect Cylinder Liners
Check Piston Ring Groove Wear
Install Piston Pin in Piston
Measure Piston OD
Determine Piston-to-Liner Clearance
Measure Oil Control Ring Groove
Measure Cylinder Liners
Deglaze Cylinder Liners
Inspect and Measure Connecting Rod Bearings
Inspect Connecting Rod and Cap
Inspect Piston Pins and Bushings
Remove Piston Pin Bushing
Clean and Inspect Piston Pin Bushing Bore
Install Piston Pin Bushing in Rod
Complete Disassembly of Cylinder Block (if required)
Remove and Clean Piston Cooling Orifices
Inspect and Clean Cylinder Block
Clean Cylinder Liner O-Ring Bores in Block
Measure Cylinder Block
Install Piston Cooling Orifices and Galley Plugs
Recheck Cylinder Liner Standout (Height Above Block)
Measure Liner Flange Thickness
Install Liner Shims—If Required
Install Cylinder Liner O-Rings and Packings
Install Cylinder Liners
Install Pistons and Connecting Rods
TORGUE-TURN Connecting Rod Cap Screws
Check Engine Rotation for Excessive Tightness
Complete Final Assembly
-CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
Special or Essential Tools
Shop Equipment and Tools
Other Material
Specifications
Torques
Crankshaft and Main Bearing Failure
Analysis
Disconnect Turbocharger Oil Inlet Line
Replace Crankshaft Rear Oil Seal and Wear Sleeve
Remove Fan Drive Assembly (If Equipped)
Inspect Vibration Damper
Remove Damper/Pulley Assembly
Remove Crankshaft Front Oil Seal (Timing Gear Cover Installed)
Remove Crankshaft Front Wear Sleeve (Cover Installed/Removed)
Install Crankshaft Front Wear Sleeve (Timing Gear Cover Installed)
Install Crankshaft Front Oil Seal (Timing Gear Cover Installed)
Remove Timing Gear Cover
Check Crankshaft End Play
Check Flywheel Housing Face Runout
Check Flywheel Face Flatness
Remove Flywheel and Flywheel Housing
Inspect and Repair Flywheel
Replace Flywheel Ring Gear
Remove Rear Oil Seal Housing
Remove Rear Oil Seal Housing and Wear Sleeve (Engine Disassembled)
Remove Crankshaft Main Bearings
Check Main Bearing Clearance
Remove Crankshaft
Inspect Crankshaft
Measure Assembled ID of Bearings and OD of Crankshaft Journals
Measure Assembled ID of Main Bearing Caps (Without Bearings)
Crankshaft Grinding Guidelines
Crankshaft Grinding Specifications
Thrust Bearing New Part Specifications Replace Crankshaft Gear
Replace (Crankshaft) Oil Pump Drive Gear
Inspect Thrust Bearings
Remove and Clean Piston Cooling Orifices
Install Main Bearing Inserts in Block
Install Crankshaft
Install Oil Pump and Check Drive Gear-to-Crankshaft Clearance
Install Crankshaft Rear Oil Seal Housing
Check Oil Seal Housing Runout
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly
Install Crankshaft Front Wear Sleeve
Install Timing Gear Cover
Install Crankshaft Front Oil Seal In Timing Gear Cover
Install Damper Pulley Assembly
Install Fan Drive Assembly
Install Flywheel Housing and Flywheel
Complete Final Assembly
-CAMSHAFT AND TIMING GEAR TRAIN
Special or Essential Tools
Specifications
Disconnect Turbocharger Oil Inlet Line
Measure Valve Lift
Remove Fan Drive Assembly (If Equipped)
Remove Damper/Pulley Assembly
Remove Timing Gear Cover
Remove Front Wear Sleeve (Timing Gear Cover Removed)
Remove Front Oil Seal (Timing Gear Cover Removed)
Check Camshaft End Play
Measure Camshaft Drive Gear-to-Crankshaft Gear Minimum Backlash
Remove Camshaft
Remove Camshaft Gear, Spacer, and Thrust Plate
Measure Thrust Plate and Spacer
Inspect Camshaft
Measure Camshaft Journal OD and Bushing ID
Measure Camshaft Lobe Lift
Remove, Inspect, and Measure Camshaft Followers
Assemble Camshaft
Service Camshaft Bushings Using JDE6 Camshaft Bushing Replacement Set
Service Camshaft Bushings Using JDG405 Camshaft Bushing Service Set
Install Camshaft
Install Timing Gear Cover
Install Crankshaft Front Wear Sleeve (Timing Gear Cover Installed)
Install Crankshaft Front Oil Seal (Timing Gear Cover Installed)
Complete Final Assembly
-LUBRICATION SYSTEM
Other Material
Specifications
Diagnosing Lubrication System Malfunctions
Disconnect Turbocharger Oil Inlet Line
Drain Engine Oil, Coolant and Remove Oil Pan
Engine Oil Bypass Valve Housing, Oil Cooler and Oil Filtration System
Remove Oil Bypass Valve Housing and Oil Cooler Assembly
Remove and Inspect Oil Cooler Bypass and Oil Filter Bypass Valves
Assemble Bypass Valve Housing and Oil Cooler Assembly
Install Oil Bypass Valve Housing and Oil Cooler Assembly
Remove, Disassemble, Inspect, and Install Oil Pressure Reg Valve
Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash
Engine Oil Pump Assembly
Remove Engine Oil Pump
Inspect and Clean Oil Pump
Check Drive Shaft End Play
Check Drive Shaft Side Movement
Check Pumping Gear Backlash
Inspect Oil Pump Drive Gear
Adjust Oil Pump Set Screw
Install Engine Oil Pump
Install Oil Pan
-COOLING SYSTEM
Special or Essential Tools
Other Material
Specifications
Service Equipment and Tools
Diagnosing Cooling System Malfunctions
General Cooling System Information
Remove and Install Heavy Duty Fan Drive Assembly
Remove Fan Drive Bearings
Install Fan Drive Bearings
Remove Water Pump—6101AT001 Engines
Remove Water Pump—6101HRW01, 02 Engines
Water Pump Assembly
Disassemble Water Pump
Measure Bearing Bore in Water Pump Housing
Assemble Water Pump
Install Water Pump—6101AT001 Engines
Install Water Pump—6101HRW01, 02 Engines
Remove Water Manifold
Inspect and Clean Water Manifold
Install Water Manifold
Remove Thermostats
Install Thermostats
Remove Coolant Filter Conditioner
Inspect Coolant Filter Conditioner Components
Install Coolant Filter Conditioner
Complete Final Assembly
Check and Adjust V-Belt Tension
Remove Coolant Heater—If Equipped
Install Coolant Heater—If Equipped
-AIR INTAKE AND EXHAUST SYSTEM
Special or Essential Tools
Specifications
Other Material
Extending Turbocharger Life
Remove Turbocharger
Diagnosing Turbocharger Malfunctions
Turbocharger Seven-Step Inspection
A—Compressor Housing Inlet and Compressor Wheel
B—Compressor Housing Outlet
C—Turbine Housing Inlet
D—Turbine Housing Outlet and Turbine Wheel
E—External Center Housing and Joints
F—Internal Center Housing
G—Turbo Bench Test
Perform Radial Bearing Clearance Test (Garret/Ai Research T45)
Perform Axial End Play Bearing Test (Garret/Ai Research T45)
Perform Radial Bearing Clearance Test (Schwitzer S3A)
Perform Axial End Play Bearing Test (Schwitzer S3A)
Disassemble and Inspect Turbocharger (Garrett/Ai Research T45)
Replace Center Housing and Rotating Assembly
Disassemble and Inspect Turbocharger (Schwitzer S3A)
Replace Center Housing and Rotating Assembly
Prelube Turbocharger
Install Turbocharger
Remove Aftercooler Assembly and Intake Manifold (6101A Engines)
Inspect and Repair Aftercooler (6101A Engines)
Inspect and Repair Intake Manifold (6101A Engines)
Install Intake Manifold and Aftercooler Assembly (6101A Engines)
Install Aftercooler Cover (6101A Engines)
Remove, Inspect, and Install Intake Manifold (6101H Engines)
Remove, Inspect, and Install Exhaust Manifold Assembly
-FUEL SYSTEM
Special or Essential Tools
Other Material
Specifications
Relieve System Pressure
Replace Rectangular Final Fuel Filter
Replace Fuel Check Valve Assembly
Remove Fuel Supply Pump
Test Fuel Supply Pump For Leaks
Disassemble Fuel Supply Pump
Inspect and Repair Fuel Supply Pump
Assemble Fuel Supply Pump
Install Fuel Supply Pump
General Information For Aneroid (if Equipped)
Repair Aneroid—Mechanical Governors Only
Remove Hydraulic Aneroid Activator—Mechanical Governor
Disassemble and Clean Hydraulic Aneroid Activator
Assemble and Install Hydraulic Aneroid Activator
Service Injection Pump Overflow Valve
Remove Fuel Injection Pump
Repair Fuel Injection Pump
Install Fuel Injection Pump
Remove Fuel Injection Nozzles
Diagnose Injection Nozzle Malfunction
Test Fuel Injection Nozzles
Perform Opening Pressure Test
Fuel Injection Nozzle Specifications
Perform Leakage Test
Test Nozzle Chatter and Spray Pattern
Disassemble Fuel Injection Nozzle
Clean and Inspect Fuel Injection Nozzle Assembly
Perform Nozzle Slide Test
Clean Spray Orifices
Inspect Nozzle Holder
Inspect Gland Nut
Assemble Fuel Injection Nozzle
Adjust Fuel Injection Nozzles
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Nozzle Seating Surface
Install Fuel Injection Nozzles
Install Fuel Leak-off and Fuel Delivery Line Assemblies
-ENGINE TUNE-UP AND BREAK-IN
Effects of Altitude and Temperature on Engine Performance
Preliminary Engine Testing
General Tune-Up Recommendations
Dynamometer Test
Engine Break-In Guidelines
Engine Break-In Instructions
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check and Service Cooling System
Check Electrical System
-ENGINE SYSTEM OPERATION AND TESTS
Special or Essential Tools
Engine Test Specifications
General Description
Engine Sectional View
How the Lubrication System Works
Head Gasket Joint Construction and Operation
Diagnosing Head Gasket Joint Failures
Head Gasket Inspection and Repair Sequence
Diagnosing Engine Malfunctions
Test Engine Compression Pressure
Check Engine Oil Pressure
Measure Engine Crankcase Pressure (Blow-By)
Pressure Test Cooling System and Radiator Cap
Inspect Thermostat and Test Opening Temperature
-AIR INTAKE SYSTEM OPERATION AND TESTS
Special or Essential Tools
Air Intake and Exhaust System Test Specifications
Diagnosing Air Intake Malfunctions
How the Air Intake and Exhaust System Works
Air Cleaner Operation
Diagnosing Turbocharger Malfunctions
How the Turbocharger Works
How the Turbocharger is Lubricated
How the Aftercooler Works—6101A
Check Intake Manifold Pressure (Turbo Boost)
Air Filter Restriction Indicator Switch Test
-FUEL SYSTEM OPERATION AND TESTS
Special or Essential Tools
Service Equipment and Tools
Fuel System Test Specifications
Fuel Injection Pump Specifications
Fuel System Operation
Diagnose Fuel System Malfunctions
Supply Pump Operation
Diagnosing Mechanical Fuel Supply Malfunctions
Test Fuel Supply Pump for Leaks
Check Supply Pump Operation
Service Supply Pump
Rectangular Final Filter Operation
Bleed Fuel System
In-Line Fuel Injection Pump Operation
Diagnose In-Line Fuel Injection Pump Malfunctions
Check and Adjust Injection Pump Timing
Check Fast Idle Speed
Check and Adjust Engine Slow Idle
How the Aneroid Works—Mechanical Governors Only
Diagnose Aneroid Malfunction
How the Hydraulic Aneroid Activator Works
Diagnose Malfunctions—Hydraulic Aneroid Activator
Fuel Injection Nozzles—General Information
Fuel Injection Nozzle Operation
Diagnose Malfunctions—Fuel Injection Nozzle
Test Fuel Injection Nozzles (Engine Running)
Fuel Drain Back Test Procedure
-DEALER FABRICATED TOOLS
How to Make Tools
Cylinder Liner Holding Fixture
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