Complete All Inclusive Component Technical Manual with electrical wiring diagrams for John Deere PowerTech 8.1 L Diesel Engines, with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere Base Engine Technical Manual - PowerTech 8.1L Diesel Engines workshop technical service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

ctm86 - PowerTech 8.1 L Diesel Engines Base Engine - (Worldwide Edition) Component Technical Manual.PDF
ctm86 - PowerTech 8.1 L Diesel Engines Base Engine - (Worldwide Edition) Component Technical Manual.epub

Total Pages: 767 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle etc.
Language: English

ctm86 - PowerTech™ 8.1 LDiesel EnginesBase Engine -: (Worldwide Edition)
Component Technical Manual

Table of Contents

Foreword

About this Manual

Identification Views Serial Number ( —199,999) Non Emissions Certified, and Tier I Emissions Certified Engines

Identification Views Serial Number (200,000— ) Tier II Emissions Certified Engines

Section 01: General

Group 000: Safety

Handle Fluids Safely—Avoid Fires

Handle Starting Fluid Safely

Handling Batteries Safely

Prepare for Emergencies

Avoid High-Pressure Fluids

Wear Protective Clothing

Service Machines Safely

Work In Ventilated Area

Work in Clean Area

Install Fan Guards

Avoid Hot Parts

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Use Proper Lifting Equipment

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

Use Proper Tools

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 001: Engine Identification

Engine Model Designation

Engine Serial Number Plate Information

Engine Option Code Label

Group 002: Fuels, Lubricants and Coolant

Diesel Fuel

Diesel Fuel Additive Products

Bio-Diesel Fuel

Lubricity of Diesel Fuel

Handling and Storing Diesel Fuel

Testing Diesel Fuel

Fuel Filters

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I

Alternative and Synthetic Lubricants

Mixing of Lubricants

OILSCAN OILSCAN is a registered trademark of Deere & Company. and CoolScan CoolScan is a registered trademark of Deere & Company.

Grease

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Diesel Engine Coolants, Supplemental Additive Information

Testing Diesel Engine Coolant

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

Operating in Warm Temperature Climates

Flush and Service Cooling System

Disposing of Coolant

Section 02: Repair and Adjustments

Group 010: Engine Rebuild

Engine Overhaul Guidelines

Engine Repair Stand

Safety Precautions

Install Adapters on Engine Repair Stand

Engine Lifting Procedure

Clean Engine

Disconnect Turbocharger Oil Inlet Line

Mount Engine on Repair Stand

Engine Disassembly Sequence for Overhaul

Sealant Application Guidelines

6081 Engine Assembly Sequence After Overhaul

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

General Tune-Up Recommendations

Group 020: Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Check and Adjust Valve Clearance Serial Number ( —199,999)

Check Valve Lift Serial Number ( —199,999)

Remove Cylinder Head Serial Number ( —199,999)

Head Gasket Inspection and Repair Sequence Serial Number ( —199,999)

Disassemble and Inspect Rocker Arm Shaft Assembly Serial Number ( —199,999)

Assemble Rocker Arm Shaft Assembly Serial Number ( —199,999)

Measure Valve Recess Serial Number ( —199,999)

Preliminary Cylinder Head and Valve Checks Serial Number ( —199,999)

Remove Valve Assembly Serial Number ( —199,999)

Inspect and Measure Valve Springs Serial Number ( —199,999)

Inspect Valve Spring Caps, Wear Caps, and Retainer Locks Serial Number ( —199,999)

Clean Valves Serial Number ( —199,999)

Inspect and Measure Valves Serial Number ( —199,999)

Grind (Reface) Valves Serial Number ( —199,999)

Inspect and Clean Cylinder Head Serial Number ( —199,999)

Check Cylinder Head Combustion Face Flatness Serial Number ( —199,999)

Measure Cylinder Head Thickness Serial Number ( —199,999)

Clean Valve Guides Serial Number ( —199,999)

Measure Valve Guides Serial Number ( —199,999)

Knurl Valve Guides Serial Number ( —199,999)

Clean and Inspect Valve Seats Serial Number ( —199,999)

Measure Valve Seats Serial Number ( —199,999)

Grind Valve Seats Serial Number ( —199,999)

Remove Valve Seat Inserts Serial Number ( —199,999)

Install Valve Seat Inserts Serial Number ( —199,999)

Inspect and Clean Cylinder Head Nozzle Bore Serial Number ( —199,999)

Clean and Inspect Push Rods Serial Number ( —199,999)

Clean and Inspect Top Deck of Cylinder Block Serial Number ( —199,999)

Measure Cylinder Liner Standout (Height Above Block) Serial Number ( —199,999)

Assemble Valve Assembly Serial Number ( —199,999)

Install Cylinder Head and Cap Screws Serial Number ( —199,999)

Torque-to-Yield Flanged-Head Cap Screws—Grade 180 Marked “SPECIAL” Serial Number ( —199,999)

Install Rocker Arm Assembly Serial Number ( —199,999)

Inspect and Clean Ventilator Outlet Hose Serial Number ( —199,999)

Complete Final Assembly of Injection Pump Side of Engine Serial Number ( —199,999)

Complete Final Assembly on Exhaust Manifold Side of Engine Serial Number ( —199,999)

Perform Engine Break-In Serial Number ( —199,999)

Group 021: Cylinder Head and Valves Repair and Adjustment S. N. (200,000— )

Check Valve Clearance — Serial Number (200,000— )

Adjust Valve Clearance Serial Number (200,000— )

Check Valve Lift Serial Number (200,000— )

Remove Cylinder Head Serial Number (200,000— )

Diagnosing Head Gasket Joint Failures - Serial Number (200,000— )

Head Gasket Diagnostic Charts - Serial Number (200,000— )

Head Gasket Inspection and Repair Sequence - Serial Number (200,000— )

Inspect Rocker Arm Assembly - Serial Number (200,000— )

Disassemble and Assemble Rocker Arm Assembly - Serial Number (200,000— )

Measure Valve Recess - Serial Number (200,000— )

Preliminary Cylinder Head and Valve Checks - Serial Number (200,000— )

Remove Valve Assembly - Serial Number (200,000— )

Inspect and Measure Valve Springs - Serial Number (200,000— )

Inspect Valve Spring Caps, Wear Caps, and Retainer LocksSerial Number (200,000— )

Clean Valves - Serial Number (200,000— )

Inspect and Measure Valves - Serial Number (200,000— )

Inspect and Measure Valves - Serial Number (200,000— )

Grind (Reface) Valves - Serial Number (200,000— )

Inspect and Clean Cylinder Head - Serial Number (200,000— )

Check Cylinder Head Combustion Face Flatness - Serial Number (200,000— )

Measure Cylinder Head Thickness - Serial Number (200,000— )

Clean Valve Guides - Serial Number (200,000— )

Measure Valve Guides - Serial Number (200,000— )

Knurl Valve Guides - Serial Number(200,000— )

Clean and Inspect Valve Seats - Serial Number (200,000— )

Measure Valve Seats - Serial Number (200,000— )

Grind Valve Seats - Serial Number (200,000— )

Remove Valve Seat Inserts and Measure Bores in Cylinder Head - Serial Number (200,000— )

Install Valve Seat Inserts - Serial Number (200,000— )

Inspect and Clean Cylinder Head Nozzle Bore - Serial Number (200,000— )

Clean and Inspect Push Rods - Serial Number (200,000— )

Clean and Inspect Top Deck of Cylinder Block - Serial Number (200,000— )

Measure Cylinder Liner Standout (Height Above Block) - Serial Number (200,000— )

Assemble Valve Assembly - Serial Number (200,000— )

Install Cylinder Head and Cap Screws - Serial Number (200,000— )

Torque-to-Yield Flanged-Head Cap Screws—Grade 180 Marked “SPECIAL” - Serial Number (200,000— )

Install Rocker Arm Assembly - Serial Number (200,000— )

Inspect and Clean Ventilator Outlet Hose - Serial Number (200,000— )

Complete Final Assembly of Fuel Pump Side of Engine - Serial Number (200,000— )

Complete Final Assembly on Exhaust Manifold Side of Engine - Serial Number (200,000— )

Perform Engine Break-In - Serial Number (200,000— )

Cylinder Head—Preparation and Measurement

Cylinder Head — Thickness Measurement

Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment

Preliminary Liner, Piston, and Rod Checks

Connecting Rods—General Information

Remove Pistons and Connecting Rod Assemblies

Measure Cylinder Liner Standout (Height Above Block)

Install Liner Shims—If Required

Remove Cylinder Liners

Deglaze Cylinder Liners

Cylinder Liner — Cleaning

Disassemble Piston and Rod Assembly

Clean Pistons

Visually Inspect Pistons

Check Piston Ring Groove Wear

Inspect Piston Pin and Bore

Visually Inspect Cylinder Liners

Cylinder Liner Manufacturing Date Code Explanation

Determine Piston-to-Liner Clearance

Inspect Rod and Cap

Inspect Piston Pins and Bushings

Remove Piston Pin Bushing, Clean and Inspect Pin Bore

Measure Liner Flange

Inspect and Measure Connecting Rod Bearings

Piston Pin Bushing — Installation

Complete Disassembly of Cylinder Block (If Required)

Remove and Clean Piston Cooling Orifices

Clean Cylinder Block

Cylinder Block — Inspect and Reclaim

Measure Cylinder Block

Install Piston Cooling Orifices and Gallery Plugs

Install Packing on Cylinder Liner and O-Rings in Block

Install Cylinder Liner in Block

Install Piston and Connecting Rod

Connecting Rod Cap Screw — Torque Procedure

Check Engine Rotation for Excessive Tightness

Complete Final Assembly

Group 040: Crankshaft, Main Bearings and Flywheel Repair and Adjustment

Crankshaft and Main Bearing Failure Analysis

Crankshaft Rear Oil Seal and Wear Sleeve General Information

Remove Crankshaft Rear Oil Seal and Wear Sleeve

Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions

Install Crankshaft Rear Oil Seal and Wear Sleeve

Crankshaft Dual Damper — Removal

Install Unitized Front Crankshaft Oil Seal

Inspect Vibration Damper

Check Crankshaft End Play

Remove Crankshaft Vibration Damper

Remove Crankshaft Front Oil Seal and Wear Sleeve

Remove and Install Timing Gear Cover—Engine Installed in Vehicle (8000 Series Tractors)

Remove Timing Gear Cover—Engine Removed

Inspect and Measure Flywheel

Check Flywheel Housing Face Runout

Check Flywheel Face Flatness

Check Pilot Bearing Bore Concentricity

Remove Flywheel

Remove SAE 1 Flywheel Housing

Remove SAE 2 and 3 Flywheel Housing

Replace Flywheel Ring Gear

Remove and Install Rear Oil Seal Housing—Engine Installed in Vehicle (8000 Series Tractors)

Remove Rear Oil Seal Housing—Engine Removed

Remove Main Bearing Caps

Check Main Bearing Oil Clearance

Remove Connecting Rod Caps and Remove Crankshaft

Crankshaft — Inspection

Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journals

Main Bearing Cap Line Bore Specifications

Thrust Bearing New Part Specifications

Crankshaft Grinding Guidelines

Crankshaft Grinding Specifications

Replace Crankshaft Gear

Inspect Thrust Bearings

Remove and Clean Piston Cooling Orifices

Install Main Bearings and Crankshaft

Install Crankshaft Rear Oil Seal Housing

Check Crankshaft Rear Oil Seal Housing Runout

Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions

Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly

Install Timing Gear Cover

Install Front Wear Sleeve

Install Crankshaft Front Oil Seal

Install Unitized Front Crankshaft Oil Seal

Install Vibration Damper

Crankshaft Dual Damper — Installation

Install SAE 2 and 3 Flywheel Housing

Install Flywheel & Flex Plates - Option Code 1502

Install Flywheel

Install SAE 1 Flywheel Housing

Complete Final Assembly

Group 050: Camshaft and Timing Gear Train Repair and Adjustment

Check Camshaft End Play and Measure Gear Backlash

Remove Vibration Damper and Timing Gear Cover

Remove, Inspect, and Install Crankshaft Gear-Driven Auxiliary Drive—If Equipped

Remove Camshaft

Remove Camshaft Gears

Measure Thrust Washer Thickness

Inspect and Measure Camshaft Followers

Visually Inspect Camshaft

Measure Camshaft Journal O.D. and Bushing I.D.

Measure Camshaft Lobe Lift

Install Camshaft Gears

Service Camshaft Bushings Using JDG602 Adapter Set

Service Camshaft Bushings Using JDG606 Adapter Set

Install Camshaft

Install Thrust Washer and Timing Gear Cover

Complete Final Assembly

Group 060: Lubrication System Repair and Adjustment

Diagnosing Lubrication System Malfunctions

Oil Filter Base and Oil Pressure Regulating Valve Housing Assembly

Top-Load Oil Filter Assembly

Remote Oil Filter Assembly

Changing Top-Load Oil Filter

Remove and Install Oil Filter Base and Oil Pressure Regulating Valve Housing

Engine Oil Cooler Assembly

Remove, Inspect, and Install Engine Oil Cooler

Remove, Inspect, and Install Oil Pressure Regulating Valve, Oil Filter Bypass Valve, and Oil Cooler Bypass Valve

Remove Oil Pressure Regulating Valve — Top Load Oil Filter

Install Oil Pressure Regulating Valve — Top Load Oil Filter

Remove Engine from 8000 Tractors for Access to Engine Oil Pump

Remove Oil Pan

Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash

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

Remove and Install Oil Pump Outlet Tube and Oil Cooler Crossover Tube Adapter

Remove, Inspect, and Install Oil Pump Pickup Tube

Install Engine Oil Pan

Tighten Cap Screws on Front Frame/Oil Sump (8000 Series Tractors)

Group 070: Cooling System Repair and Adjustment

Inspect Fan Hub & Replace Bearings in Heavy-Duty, Adjustable Fan Drive Assembly

Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive Assembly

Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive Assembly

Fan Drive Assembly

Checking Belt Tensioner Spring Tension and Belt Wear

Inspect and Install Fan Assembly

Visually Inspect Coolant Pump

Remove Coolant Pump Assembly

Install Coolant Pump Assembly

Replace Bypass Tube Seal in Coolant Pump Cover

Remove and Test Thermostats

Remove Coolant Manifold

Install Thermostats

Install Coolant Manifold

Remove and Install Coolant Temperature Switch

Servicing of Engine Coolant Heater

Complete Final Assembly

Group 080: Air Intake and Exhaust System Repair and Adjustment

Extending Turbocharger Life

Remove Turbocharger

Turbocharger Failure Analysis

Turbocharger Inspection

Perform Radial Bearing Clearance Test

Repair Turbocharger

Prelube Turbocharger

Install Turbocharger

Turbocharger Break-In

Recommendations for Turbocharger Use

Remove, Inspect, and Install Exhaust Manifold

Remove, Inspect, and Install Intake Manifold (6081T and 6081H Engines)

Remove Vertically-Mounted Aftercooler and Intake Manifold (6081A Engines)

Remove and Disassemble Horizontally-Mounted Aftercooler (6081A Engines)

Inspect and Repair Aftercooler (6081A Engines)

Inspect and Repair Intake Manifold and Air Intake Cover (6081A Engines)

Install Intake Manifold and Vertically-Mounted Aftercooler (6081A Engines)

Assemble and Install Horizontally-Mounted Aftercooler Assembly (6081A Engines)

Servicing of Air Heater (If Equipped)

Group 100: OEM Starting and Charging Systems Repair and Adjustment

Remove and Install Alternator (OEM Engines)

Remove and Install Starter Motor (OEM Engines)

Section 03: Theory of Operation

Group 120: Base Engine Operation

Engine Sectional View Serial Number ( —199,999)

Engine Sectional View Serial Number (200,000— )

General Engine Operation

Lubrication System Operation

Cooling System Operation

Head Gasket Joint Construction and Operation

Air Intake and Exhaust System Operation

Turbocharger Operation

Wastegate Operation

How the Turbocharger is Lubricated

Section 04: Diagnostics

Group 150: Observable Diagnostics and Tests

About This Group of the Manual

8.1L - L1 - Excessive Oil Consumption

Engine Oil Consumption

8.1L - L2 - Engine Oil Pressure Low

8.1L - L3 - Engine Oil Pressure High

8.1L - L4 - Soot or Sludge in Oil

8.1L - C1 - Engine Coolant Temperature Above Normal

8.1L - C2 - Engine Coolant Temperature Below Normal

8.1L - C3 - Coolant In Oil or Oil In Coolant

8.1L - C4 - Coolant Leaking from Weep Hole

Test Engine Compression Pressure For Tier 1 (ESN — 199,999) / Tier 2 (ESN 200,000 —) Engines

Check Engine Cranking Speed

Check Engine Oil Pressure

Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)

Check for Turbocharger Oil Seal Leak

Inspect Thermostat and Test Opening Temperature

Pressure Test Cooling System and Radiator Cap

Test For Engine Coolant Leakage

Check for Head Gasket Failures

Measure Intake Manifold Pressure (Turbo Boost)

Check for Intake and Exhaust Restrictions

Test for Intake Air Leaks

Check for Exhaust Air Leaks (Turbocharged Engines)

Test Turbocharger Wastegate Actuator

Adjust Turbocharger Wastegate Actuator

Excessive Engine Vibration

Section 05: Tools and Other Materials

Group 170: Repair Tools and Other Materials

Group 020 — Cylinder Head and Valves Essential Tools S. N. ( —199,999)

Group 020 — Cylinder Head and Valves Service Equipment and Tools S. N.( —199,999)

Group 020 — Cylinder Head and Valves Other Materials S. N. ( —199,999)

Group 021 — Cylinder Head and Valves S. N. (200,000— ) Essential Tools

Group 021 — Cylinder Head and Valves S. N. (200,000— ) Service Equipment and Tools

Group 021 — Cylinder Head and Valves S. N. (200,000— ) Other Materials

Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential Tools

Group 030 — Cylinder Block, Liners, Pistons, and Rods Other Materials

Group 040 — Crankshaft, Main Bearings and Flywheel Essential Tools

Group 040 — Crankshaft, Main Bearings and Flywheel Service Equipment and Tools

Group 040 — Crankshaft, Main Bearings and Flywheel Other Materials

Group 050 — Camshaft and Timing Gear Train Essential Tools

Group 050 — Camshaft and Timing Gear Train Other Materials

Group 060 — Lubrication System Other Materials

Group 070 — Cooling System Essential Tools

Group 070 — Cooling System Other Materials

Group 080 — Air Intake and Exhaust System Essential Tools

Group 080 — Air Intake and Exhaust System Other Materials

Group 100 — Starting and Charging Systems Essential Tools

75240

Group 180: Diagnostic Service Tools

Base Engine Diagnostic Tools

Group 190: Dealer Fabricated Service Tools

How to Make Tools

DFRG3

Section 06: Specifications

Group 200: Repair and General OEM Specifications

General OEM Engine Specifications

General OEM Engine Specifications—Continued

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Group 020 — Cylinder Head and Valves S. N. ( —199,999) Repair Specifications

Group 021 — Cylinder Head and Valves S. N. (200,000— ) Repair Specifications

Group 030 — Cylinder Block, Liners, Pistons and Rods Repair Specifications

Group 040 — Crankshaft, Main Bearings and Flywheel Repair Specifications

Group 050 — Camshaft and Timing Gear Train Repair Specifications

Group 060 — Lubrication System Repair Specifications

Group 070 — Cooling System Repair Specifications

Group 080 — Air Intake and Exhaust System Repair Specifications

Group 100 — OEM Starting and Charging Systems Repair Specifications

Group 210: Diagnostic Specifications

Group 150 — Base Engine Diagnostic Specifications (Includes Dynamometer Specifications (OEM) and Turbocharger Boost Specifications)

Dynamometer Test Specifications

Intake Manifold Pressure (Turbocharger Boost) Specifications

Effects of Altitude and Temperature on Engine Performance