John Deere Engines Series 500, 6101 Components Technical Manual (CTM61)
John Deere Engines Series 500, 6101 Components Technical Manual (CTM61)
CTM61 - John Deere Series 500, 6101 Engine (500000-) Components Technical Manual.pdf
Complete service technical manual with Electrical Wiring Diagrams for John Deere Engines Series 500, 6101, with all the shop information to maintain, diagnostic, repair, rebuild like professional mechanics.
John Deere Engines Series 500, 6101 Components Technical 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.
Total Pages: 792 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS - Expanded View
00 - Safety
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Dispose of Waste Properly
Handle Fluids Safely-Avoid Fires
Illuminate Work Area Safely
Live With Safety
Practice Safe Maintenance
Prepare for Emergencies
Prevent Acid Burns
Prevent Battery Explosions
Remove Paint Before Welding or Heating
Service Machines Safely
Use Proper Lifting Equipment
Use Proper Tools
Wear Protective Clothing
Work in Clean Area
Work in Ventilated Area
01 - General Information
Engine Application Chart
Engine Model Designation
Engine Serial Number Plate Information
Metric Bolt and Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
02 - Fuels, Lubricants, and Coolant
Check Effectiveness of Coolant Solution
Diesel Engine Oil
Diesel Fuel
Disposing of Coolant
Engine Coolant Requirements
Engine Coolant Specifications
Flushing and Servicing Cooling System
Grease
John Deere Engine Cooling Fluid
OILSCAN® and CoolScan™
Replenishing Supplemental Coolant Additives (SCA's) Between Coolant Changes
03 - Engine Mounting
Clean Engine
Disconnect Turbocharger Oil Inlet Line
Engine Lifting Procedure
Engine Repair Stand
Install 500 Series Engine Adapters On Repair Stand
Mount Engine On Repair Stand
Safety Precautions
04 - Engine Rebuid Guide
6101 Engine Assembly Sequence
6101 Engine Disassembly Sequence
Sealant Application Guidelines
05 - Cylinder Head & Valves
Assemble Rocker Arm Shaft Assembly
Assemble Valve Assembly
Check and Adjust Valve Clearance
Check Cylinder Head Combustion Face Flatness
Check Valve Lift
Clean and Inspect Crankcase Ventilation Assembly
Clean and Inspect Push Rods
Clean and Inspect Top Deck of Cylinder Block
Clean and Inspect Valve Seats
Clean Valve Guides
Clean Valves
Complete Final Assembly On Exhaust Manifold Side
Complete Final Assembly On Injection Pump Side
Cylinder Head and Valves Specifications
Diagnosing Malfunctions
Disassemble and Inspect Rocker Arm Shaft Assembly
Grind Valve Seats
Grind Valves
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Cylinder Head
Inspect and Measure Valves
Inspect and Measure Valve Springs
Inspect Wear Caps and Valve Rotators
Install Cylinder Head
Install Rocker Arm Assembly
Install Valve Seat Inserts (Standard or Oversize)
Knurl Valve Guides
Measure Cylinder Head Thickness
Measure Cylinder Liner Standout (Height Above Block)
Measure Valve Guides
Measure Valve Recess in Cylinder Head
Measure Valve Seat Bores In Cylinder Head
Measure Valve Seats
Other Material
Perform Engine Break-In
Remove Cylinder Head and Valves
Remove Valve Assembly
Remove Valve Seat Inserts
Replace Valve Guides
Service Equipment and Tools
Special or Essential Tools
Tighten Flanged-Head Cylinder Head Cap Screws (With Flat Washers)
Torque-Turn Flanged-Head Cylinder Head Cap Screws
100 - Engine Tune-Up & Break-In
Altitude Compensation Guideline
Check Air Intake System
Check and Service Cooling System
Check Crankcase Ventilation System
Check Electrical System
Check Exhaust System
Dynamometer Test
Dynamometer Test Specifications [ Average power ratings are given; allow ±5 for maximum and minimum power
Engine Break-In Guidelines
General Tune-Up Recommendations
Perform Engine Break-In
Preliminary Engine Testing
105 - Engine System Operation & Tests
Check Engine Oil Pressure
Diagnosing Engine Malfunctions
Diagnosing Head Gasket Joint Failures
Engine Sectional View
Engine Test Specifications
General Engine Description
Head Gasket Inspection and Repair Sequence
Head Gasket Joint Construction and Operation
How the Cooling System Works
How the Lubrication System Works
Inspect Thermostat and Test Opening Temperature
Measure Engine Crankcase Pressure (Blow-By)
Pressure Test Cooling System and Radiator Cap
Special or Essential Tools
Test Engine Compression Pressure
10 - Cylinder Block, Liners, Pistons & Rods
Check Engine Rotation for Excessive Tightness
Check Piston Ring Groove Wear
Clean and Inspect Piston Pin Bushing Bore In Connecting Rod
Clean Cylinder Liner O-Ring Bore
Clean Cylinder Liners
Clean Pistons
Complete Disassembly of Cylinder Block (If Required)
Complete Final Assembly
Cylinder Block, Liners, Pistons, and Rods Specifications
Cylinder Liner Manufacturing Date Code Explanation
Deglaze Cylinder Liners
Determine Piston-to-Liner Clearance
Inspect and Clean Cylinder Block
Inspect and Measure Connecting Rod Bearings
Inspect Piston Pins and Bushings
Inspect Rod and Cap
Install Cylinder Liner O-Rings and Packings
Install Cylinder Liners
Install Liner Shims-If Required
Install Piston Cooling Orifices and Galley Plugs
Install Piston Pin Bushing In Connecting Rod
Install Piston Pin In Piston
Install Pistons and Connecting Rods
Measure Cylinder Block
Measure Cylinder Liners
Measure Cylinder Liner Standout (Height Above Block)
Measure Liner Flange Thickness
Measure Oil Control Ring Groove
Measure Piston Protrusion
Measure Piston Skirt OD
Other Material
Piston and Liner Identification Markings
Preliminary Liner, Piston, and Rod Checks
Recheck Cylinder Liner Standout (Height Above Block)
Remove and Clean Piston Cooling Orifices
Remove Cylinder Liners
Remove Piston Pin Bushing
Remove Piston Rings
Remove Pistons and Connecting Rods
Service Equipment and Tools
Special or Essential Tools
Use Torque-Turn Method for Proper Torque
Visually Inspect Cylinder Liners
Visually Inspect Pistons
110 - Air Intake System Operation & Tests
Air Cleaner Operation
Air Intake and Exhaust System Test Specifications
Check Intake Manifold Pressure (Turbo Boost)
Diagnosing Air Intake Malfunctions
Diagnosing Turbocharger Malfunctions
How the Aftercooler Works-6101A Engines
How the Air Intake and Exhaust System Works
How the Turbocharger is Lubricated
How the Turbocharger Works
Special or Essential Tools
115 - Fuel System Operation & Tests
Bleed the Fuel System
Check and Adjust Engine Slow Idle Speed
Check and Adjust Injection Pump Timing
Check Fast Idle Speed
Check Mechanical Fuel Supply Pump Operation
Diagnose Aneroid Malfunction
Diagnose Fuel System Malfunctions
Diagnose In-Line Fuel Injection Pump Malfunctions
Diagnose Malfunctions-Fuel Injection Nozzle
Diagnose Malfunctions-Hydraulic Aneroid Activator
Diagnosing Mechanical Fuel Supply Pump Malfunctions
Fuel Drain Back Test Procedure
Fuel Injection Nozzle Operation
Fuel Injection Nozzles-General Information
Fuel Injection Pump Specifications
Fuel Shut-Off Solenoid Linkage Adjustment
Fuel Shut-Off Solenoid Operational Check
Fuel Shut-Off Solenoid Resistance Test
Fuel System Operation
Fuel System Test Specifications
How the Aneroid Works-Mechanical Governors Only
How the Hydraulic Aneroid Activator Works-Mechanical Governors Only
In-Line Fuel Injection Pump Operation
Mechanical Fuel Supply Pump Operation
Rectangular Final Fuel Filter Operation
Round Primary Fuel Filter _ Water Separator Operation
Service Equipment and Tools
Service Mechanical Fuel Supply Pump
Special or Essential Tools
Test Fuel Injection Nozzles (Engine Running)
Test Mechanical Fuel Supply Pump for Leaks
119 - Dealer Fabricated Tools
Fabricated Tools-Cylinder Liner Holding Fixture
How to Make Tools
15 - Crankshaft, Main Bearings, and Flywheel
Check Crankshaft End Play
Check Flywheel Face Flatness
Check Flywheel Housing Face Runout
Check Main Bearing Clearance
Check Oil Seal Housing Runout
Check Pilot Bearing Bore Concentricity
Complete Final Assembly
Crankshaft Grinding Guidelines
Crankshaft Grinding Specifications
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
Disconnect Turbocharger Oil Inlet Line
Failure Analysis
Group 15-Crankshaft, Main Bearings, and Flywheel Specifications
Inspect Crankshaft
Inspect, Measure, and Repair Flywheel
Inspect Thrust Bearings
Inspect Vibration Damper
Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)_{2640}
Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
Install Crankshaft Front Wear Sleeve
Install Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed On Engine)
Install Crankshaft
Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly
Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly (Without Engine Disassembly)
Install Crankshaft Rear Oil Seal Housing
Install Damper Pulley and Vibration Damper
Install Flywheel Housing and Flywheel
Install Main Bearing Inserts In Block
Install Oil Pump and Check Drive Gear-to-Crankshaft Clearance
Install Timing Gear Cover
Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journals
Measure Assembled I.D. of Main Bearing Caps (Without Bearings)
Other Material
Remove and Clean Piston Cooling Orifices
Remove Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
Remove Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed or Removed)
Remove Crankshaft Main Bearings
Remove Crankshaft
Remove Crankshaft Rear Oil Seal and Wear Sleeve (With Oil Seal Housing Installed)
Remove Flywheel and Flywheel Housing
Remove Rear Oil Seal Housing and Wear Sleeve (With Engine Disassembled)
Remove Timing Gear Cover
Remove Vibration Damper and Pulley
Replace Crankshaft Gear
Replace Crankshaft Oil Pump Drive Gear
Replace Flywheel Ring Gear
Service Equipment and Tools
Special or Essential Tools
Thrust Bearing New Part Specifications
16 - Camshaft and Timing Gear Train
Assemble Camshaft
Camshaft and Timing Gear Train Specifications
Check Camshaft End Play
Check Valve Lift
Complete Final Assembly
Inspect and Measure Camshaft
Install Camshaft
Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
Install Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed On Engine)
Install Timing Gear Cover
Measure Camshaft Drive Gear-to-Crankshaft Gear Backlash
Measure Camshaft Journal O.D. and Bushing I.D
Measure Camshaft Lobe Lift
Measure Thrust Plate and Spacer
Other Material
Remove Camshaft Gear, Spacer, and Thrust Plate
Remove Camshaft
Remove, Inspect, and Measure Camshaft Followers
Remove Timing Gear Cover
Remove Vibration Damper and Pulley
Service Camshaft Bushings Using JDG602 Adapter Set
Service Camshaft Bushings Using JDG606 Adapter Set
Special or Essential Tools
20 - Lubrication System
Adjust Oil Pump Set Screw
Assemble Bypass Valve Housing and Oil Cooler Assembly
Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash
Check Drive Shaft End Play
Check Drive Shaft Side Movement
Check Pumping Gear Backlash
Diagnosing Lubrication System Malfunctions
Drain Engine Oil, Coolant, and Remove Oil Pan
Engine Oil Bypass Valve Housing, Oil Cooler, and Combination Filter
Engine Oil Bypass Valve Housing, Oil Cooler, and Dual Filter System
Engine Oil Pump Assembly
Inspect and Clean Oil Pump
Inspect Oil Pump Drive Gear
Install Engine Oil Pump
Install Oil Bypass Valve Housing and Oil Cooler Assembly
Install Oil Pan
Lubrication System General Information
Lubrication System Specifications
Other Material
Remove and Inspect Oil Cooler Bypass and Oil Filter Bypass Valves
Remove, Disassemble, Inspect, and Install Oil Pressure Regulating Valve and Housing
Remove Engine Oil Pump
Remove Oil Bypass Valve Housing and Oil Cooler Assembly
Replace Bypass Oil Check Valve On Combination Filter System
Replace Bypass Oil Check Valve On Dual Filter System
25 - Cooling System
Air Intake Manifold Mounted Coolant Filter Conditioner Assembly
Assemble Water Pump
Check and Adjust V-Belt Tension
Complete Final Assembly
Coolant Conditioner Filter General Information
Cooling System Specifications
Diagnosing Cooling System Malfunctions
Disassemble Water Pump
General Cooling System Information
Inspect and Clean Water Manifold
Install Coolant Heater-If Equipped
Install Fan Drive Bearings
Install Thermostats
Install Water Manifold
Install Water Pump
Intergal (Air Intake) Coolant Filter Conditioner Assembly
Measure Bearing Bore In Water Pump Housing
Other Material
Remove and Install Air Intake Manifold Coolant Filter Conditioner Assembly
Remove and Install Heavy Duty Fan Drive Assembly
Remove and Install Intergal (Air Intake) Coolant Filter Conditioner Assembly
Remove and Install Water Manifold Mounted Coolant Filter Conditioner Assembly
Remove and Test Thermostats
Remove Coolant Heater-If Equipped
Remove Fan Drive Bearings
Remove Water Manifold
Remove Water Pump
Replace Fan Belt Tightener Bearings
Service Equipment and Tools
Special or Essential Tools
Water Manifold Mounted Coolant Filter Conditioner Assembly
Water Pump Assembly
30 - Air Intake & Exhaust System
Air Intake and Exhaust System Specifications
Diagnosing Turbocharger Malfunctions
Disassemble and Inspect Turbocharger
Extending Turbocharger Life
Inspect and Repair Aftercooler (6101A Engines)
Inspect and Repair Intake Manifold-6101H Engines
Install Aftercooler Cover (6101A Engines)
Install Intake Manifold and Aftercooler Assembly (6101A Engines)
Install Turbocharger
Other Material
Perform Axial End Play Bearing Test
Perform Radial Bearing Clearance Test
Prelube Turbocharger
Remove Aftercooler Assembly and Intake Manifold (6101A Engines)
Remove and Install Intake Manifold (6101H Engines)
Remove, Inspect, and Install Exhaust Manifold Assembly
Remove Turbocharger
Replace Center Housing and Rotating Assembly
Special or Essential Tools
Turbocharger Seven-Step Inspection
35 - Fuel System
Adjust Fuel Injection Nozzles
Assemble and Install Hydraulic Aneroid Activator-Mechanical Governors Only
Assemble Fuel Injection Nozzle
Assemble Fuel Supply Pump
Clean and Inspect Fuel Injection Nozzle Assembly
Clean Spray Orifices
Diagnose Injection Nozzle Malfunction
Disassemble and Clean Hydraulic Aneroid Activator Parts-Mechanical Governors Only
Disassemble Fuel Injection Nozzle
Disassemble Fuel Supply Pump
Fuel Injection Nozzle Specifications
Fuel System Specifications
General Information for Aneroid-Mechanical Governors Only
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Nozzle Seating Surface
Inspect and Repair Fuel Supply Pump
Inspect Gland Nut
Inspect Nozzle Holder
Install Fuel Injection Nozzles
Install Fuel Injection Pump
Install Fuel Leak-Off and Fuel Delivery Line Assemblies
Install Fuel Shutoff Solenoid-Mechanical Governors Only
Install Fuel Supply Pump
Make Chatter and Spray Pattern Test
Other Material
Perform Leakage Test
Perform Nozzle Slide Test
Perform Opening Pressure Test
Relieve System Pressure
Remove Fuel Injection Nozzles
Remove Fuel Injection Pump
Remove Fuel Shut-Off Solenoid-Mechanical Governors Only
Remove Fuel Supply Pump
Remove Hydraulic Aneroid Activator-Mechanical Governors Only
Repair Aneroid-Mechanical Governors Only
Repair Fuel Injection Pump
Replace Fuel Check Valve Assembly
Replace Primary Fuel Filter _ Water Separator-If Equipped
Replace Rectangular Final Fuel Filter
Service Overflow Valve
Special or Essential Tools
Test Fuel Injection Nozzles
Test Fuel Supply Pump for Leaks
