John Deere PowerTech 6101 10.1L Diesel Engine Component Technical Manual CTM61

John Deere PowerTech 6101 10.1L Diesel Engine Component Technical Manual CTM61
Language: English
Format: PDF
Document: Component Technical Manual
Machine: Diesel Engine
Machine Model: 6101AF010, 6101AT011, 6101AT012, 6101HF010, 6101HRW10, 6101HRW11, 6101HZ011
Pages: 607 Pages
Part Number: CTM61

Contents:
Foreword
  Safety
     Handle Fluids Safely-Avoid Fires
     Prevent Battery Explosions
     Prepare for Emergencies
     Prevent Acid Burns
     Avoid High-Pressure Fluids
     Wear Protective Clothing
     Service Machines Safely
     Work in Ventilated Area
     Work in Clean Area
     Remove Paint Before Welding or Heating
     Avoid Heating Near Pressurized Fluid Lines
     Illuminate Work Area Safely
     Use Proper Lifting Equipment
     Practice Safe Maintenance
     Use Proper Tools
     Dispose of Waste Properly
     Live With Safety
  General Information
     Unified Inch Bolt and Cap Screw Torque Values
     Metric Bolt and Cap Screw Torque Values
     Engine Machine Model Designation
     Engine Serial Number Plate Information
     Engine Application Chart
  Fuels, Lubricants, and Coolant
     Diesel Fuel
     Diesel Engine Oil
     OILSCANOILSCAN is a trademark of Deere & Company. and CoolScanCoolScan is a trademark of Deere & Company.
     Grease
     Engine Coolant Requirements
     Engine Coolant Specifications
     John Deere Engine Cooling Fluid
     Check Effectiveness of Coolant Solution
     Replenishing Supplemental Coolant Additives (SCA`s) Between Coolant Changes
     Flushing and Servicing Cooling System
     Disposing of Coolant
  Engine Mounting
     Engine Repair Stand
     Safety Precautions
     Install 500 Series Engine Adapters On Repair Stand
     Engine Lifting Procedure
     Clean Engine
     Disconnect Turbocharger Oil Inlet Line
     Mount Engine On Repair Stand
  Engine Rebuild Guide
     6101 Engine Disassembly Sequence
     Sealant Application Guidelines
     6101 Engine Assembly Sequence
  Cylinder Head and Valves
     Special or Essential Tools
     Cylinder Head and Valves Specifications
     Service Equipment and Tools
     Other Material
     Check and Adjust Valve Clearance
     Check Valve Lift
     Remove Cylinder Head and Valves
     Disassemble and Inspect Rocker Arm Shaft Assembly
     Assemble Rocker Arm Shaft Assembly
     Measure Valve Recess in Cylinder Head
     Diagnosing Malfunctions
     Remove Valve Assembly
     Inspect and Measure Valve Springs
     Inspect Wear Caps and Valve Rotators
     Clean Valves
     Inspect and Measure Valves
     Grind Valves
     Inspect and Clean Cylinder Head
     Check Cylinder Head Combustion Face Flatness
     Measure Cylinder Head Thickness
     Clean Valve Guides
     Measure Valve Guides
     Knurl Valve Guides
     Replace Valve Guides
     Clean and Inspect Valve Seats
     Measure Valve Seats
     Grind Valve Seats
     Remove Valve Seat Inserts
     Measure Valve Seat Bores In Cylinder Head
     Install Valve Seat Inserts (Standard or Oversize)
     Inspect and Clean Cylinder Head Nozzle Bore
     Clean and Inspect Push Rods
     Clean and Inspect Crankcase Ventilation Assembly
     Clean and Inspect Top Deck of Cylinder Block
     Measure Cylinder Liner Standout (Height Above Block)
     Assemble Valve Assembly
     Install Cylinder Head
     Tighten Flanged-Head Cylinder Head Cap Screws (With Flat Washers)
     Torque-Turn Flanged-Head Cylinder Head Cap Screws
     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
     Service Equipment and Tools
     Other Material
     Cylinder Block, Liners, Pistons, and Rods Specifications
     Preliminary Liner, Piston, and Rod Checks
     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
     Piston and Liner Identification Markings
     Check Piston Ring Groove Wear
     Install Piston Pin In Piston
     Measure Piston Skirt OD
     Determine Piston-to-Liner Clearance
     Measure Oil Control Ring Groove
     Measure Cylinder Liners
     Deglaze Cylinder Liners
     Inspect and Measure Connecting Rod Bearings
     Inspect Rod and Cap
     Inspect Piston Pins and Bushings
     Remove Piston Pin Bushing
     Clean and Inspect Piston Pin Bushing Bore In Connecting Rod
     Install Piston Pin Bushing In Connecting Rod
     Complete Disassembly of Cylinder Block (If Required)
     Remove and Clean Piston Cooling Orifices
     Inspect and Clean Cylinder Block
     Clean Cylinder Liner O-Ring Bore
     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
     Cylinder Liner Manufacturing Date Code Explanation
     Install Cylinder Liners
     Install Pistons and Connecting Rods
     Use Torque-Turn Method for Proper Torque
     Check Engine Rotation for Excessive Tightness
     Measure Piston Protrusion
     Complete Final Assembly
  Crankshaft, Main Bearings and Flywheel
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Group 15-Crankshaft, Main Bearings, and Flywheel Specifications
     Failure Analysis
     Disconnect Turbocharger Oil Inlet Line
     Remove Crankshaft Rear Oil Seal and Wear Sleeve (With Oil Seal Housing Installed)
     Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly (Without Engine Disassembly)
     Inspect Vibration Damper
     Remove Vibration Damper and Pulley
     Remove Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
     Remove Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed or Removed)
     Install Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed On Engine)
     Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
     Remove Timing Gear Cover
     Check Crankshaft End Play
     Inspect, Measure, and Repair Flywheel
     Check Flywheel Housing Face Runout
     Check Flywheel Face Flatness
     Check Pilot Bearing Bore Concentricity
     Remove Flywheel and Flywheel Housing
     Replace Flywheel Ring Gear
     Remove Rear Oil Seal Housing and Wear Sleeve (With Engine Disassembled)
     Remove Crankshaft Main Bearings
     Check Main Bearing Clearance
     Remove Crankshaft
     Replace Crankshaft Gear
     Inspect Crankshaft
     Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journals
     Measure Assembled I.D. of Main Bearing Caps (Without Bearings)
     Crankshaft Grinding Guidelines
     Crankshaft Grinding Specifications
     Thrust Bearing New Part Specifications
     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 (With Timing Gear Cover Installed On Engine)
     Install Damper Pulley and Vibration Damper
     Install Flywheel Housing and Flywheel
     Complete Final Assembly
  Camshaft and Timing Gear Train
     Special or Essential Tools
     Other Material
     Camshaft and Timing Gear Train Specifications
     Check Valve Lift
     Check Camshaft End Play
     Remove Vibration Damper and Pulley
     Remove Timing Gear Cover
     Measure Camshaft Drive Gear-to-Crankshaft Gear Backlash
     Remove Camshaft
     Remove Camshaft Gear, Spacer, and Thrust Plate
     Measure Thrust Plate and Spacer
     Inspect and Measure Camshaft
     Measure Camshaft Journal O.D. and Bushing I.D.
     Measure Camshaft Lobe Lift
     Remove, Inspect, and Measure Camshaft Followers
     Assemble Camshaft
     Service Camshaft Bushings Using JDG602 Adapter Set
     Service Camshaft Bushings Using JDG606 Adapter Set
     Install Camshaft
     Install Timing Gear Cover
     Install Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed On Engine)
     Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
     Complete Final Assembly
  Lubrication System
     Other Material
     Lubrication System Specifications
     Diagnosing Lubrication System Malfunctions
     Drain Engine Oil, Coolant, and Remove Oil Pan
     Lubrication System General Information
     Engine Oil Bypass Valve Housing, Oil Cooler, and Dual Filter System
     Replace Bypass Oil Check Valve On Dual Filter System
     Engine Oil Bypass Valve Housing, Oil Cooler, and Combination Filter
     Replace Bypass Oil Check Valve On Combination Filter 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 Regulating Valve and Housing
     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
     Cooling System 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
     Water Pump Assembly
     Disassemble Water Pump
     Measure Bearing Bore In Water Pump Housing
     Assemble Water Pump
     Install Water Pump
     Remove Water Manifold
     Inspect and Clean Water Manifold
     Install Water Manifold
     Remove and Test Thermostats
     Install Thermostats
     Coolant Conditioner Filter General Information
     Intergal (Air Intake) Coolant Filter Conditioner Assembly
     Remove and Install Intergal (Air Intake) Coolant Filter Conditioner Assembly
     Air Intake Manifold Mounted Coolant Filter Conditioner Assembly
     Remove and Install Air Intake Manifold Coolant Filter Conditioner Assembly
     Water Manifold Mounted Coolant Filter Conditioner Assembly
     Remove and Install Water Manifold Mounted Coolant Filter Conditioner Assembly
     Complete Final Assembly
     Check and Adjust V-Belt Tension
     Replace Fan Belt Tightener Bearings
     Remove Coolant Heater-If Equipped
     Install Coolant Heater-If Equipped
  Air Intake and Exhaust System
     Special or Essential Tools
     Other Material
     Air Intake and Exhaust System Specifications
     Extending Turbocharger Life
     Remove Turbocharger
     Diagnosing Turbocharger Malfunctions
     Turbocharger Seven-Step Inspection
     Perform Radial Bearing Clearance Test
     Perform Axial End Play Bearing Test
     Disassemble and Inspect Turbocharger
     Replace Center Housing and Rotating Assembly
     Prelube Turbocharger
     Install Turbocharger
     Remove and Install Intake Manifold (6101H Engine)
     Inspect and Repair Intake Manifold-6101H Engine
     Remove Aftercooler Assembly and Intake Manifold (6101A Engine)
     Inspect and Repair Aftercooler (6101A Engine)
     Install Intake Manifold and Aftercooler Assembly (6101A Engine)
     Install Aftercooler Cover (6101A Engine)
     Remove, Inspect, and Install Exhaust Manifold Assembly
  Fuel System
     Special or Essential Tools
     Other Material
     Fuel System Specifications
     Relieve System Pressure
     Replace Rectangular Final Fuel Filter
     Replace Fuel Check Valve Assembly
     Replace Primary Fuel Filter/Water Separator-If Equipped
     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-Mechanical Governors Only
     Repair Aneroid-Mechanical Governors Only
     Remove Hydraulic Aneroid Activator-Mechanical Governors Only
     Disassemble and Clean Hydraulic Aneroid Activator Parts-Mechanical Governors Only
     Assemble and Install Hydraulic Aneroid Activator-Mechanical Governors Only
     Service Overflow Valve
     Remove Fuel Shut-Off Solenoid-Mechanical Governors Only
     Install Fuel Shutoff Solenoid-Mechanical Governors Only
     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
     Make Chatter and Spray Pattern Test
     Disassemble Fuel Injection Nozzle
     Clean and Inspect Fuel Injection Nozzle Assembly
     Perform Nozzle Slide Test
     Clean Spray Orifices
     Inspect Nozzle Holder
     Inspect Gland Nut
     Assemble Fuel Injection Nozzle
     Adjust 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
     Altitude Compensation Guideline
     Preliminary Engine Testing
     General Tune-Up Recommendations
     Dynamometer Test
     Dynamometer Test Specifications Average power ratings are given; allow ±5% for maximum and minimum power. Specifications given are for OEM applications only. Refer to your machine technical manual for engine speeds that are different from those preset at 
     Engine Break-In Guidelines
     Perform Engine Break-In
     Check Crankcase Ventilation System
     Check Air Intake System
     Check Exhaust System
     Check and Service Cooling System
     Check Electrical System
  Engine System Operation and Test
     Special or Essential Tools
     Engine Test Specifications
     Engine Sectional View
     General Engine Description
     How the Lubrication System Works
     How the Cooling 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 Test
     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 Engine
     Check Intake Manifold Pressure (Turbo Boost)
  Fuel System Operation and Test
     Special or Essential Tools
     Service Equipment and Tools
     Fuel System Test Specifications
     Fuel Injection Pump Specifications Engine speeds listed are as preset to factory specification. In most cases, slow idle speed will be reset depending upon specific vehicle application requirements. Refer to your machine technical manual for engine speeds
     Fuel System Operation
     Diagnose Fuel System Malfunctions
     Mechanical Fuel Supply Pump Operation
     Diagnosing Mechanical Fuel Supply Pump Malfunctions
     Test Mechanical Fuel Supply Pump for Leaks
     Check Mechanical Fuel Supply Pump Operation
     Service Mechanical Fuel Supply Pump
     Fuel Shut-Off Solenoid Operational Check
     Fuel Shut-Off Solenoid Resistance Test
     Fuel Shut-Off Solenoid Linkage Adjustment
     Rectangular Final Fuel Filter Operation
     Round Primary Fuel Filter/Water Separator Operation
     Bleed the 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 Speed
     How the Aneroid Works-Mechanical Governors Only
     Diagnose Aneroid Malfunction
     How the Hydraulic Aneroid Activator Works-Mechanical Governors Only
     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
     Fabricated Tools-Cylinder Liner Holding Fixture