John Deere 6101 10.1L (Series 500) Diesel Engines (SN. from 500000) Engine Technical Manual (CTM61)

Table of Contents:
   Introduction
      Foreword
      About This Manual
      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 Model Designation
         Engine Serial Number Plate Information
         Engine Application Chart
      Fuels, Lubricants, and Coolant
         Diesel Fuel
         Diesel Engine Oil
         OILSCAN and CoolScan
         Grease
         Engine Coolant Requirements
         Engine Coolant Specifications
         John Deere Engine Cooling Fluid
         Check Effectiveness of Coolant Solution
         Replenishing Supplemental Coolant Additives (SCAs) 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
         Engine Disassembly Sequence
         Sealant Application Guidelines
         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
         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
         Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed On Engine)
         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 Engines)
         Inspect and Repair Intake Manifold-6101H Engines
         Remove Aftercooler Assembly and Intake Manifold (6101A Engines)
         Inspect and Repair Aftercooler (6101A Engines)
         Install Intake Manifold and Aftercooler Assembly (6101A Engines)
         Install Aftercooler Cover (6101A Engines)
         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
         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 Engines
         Check Intake Manifold Pressure (Turbo Boost)
      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
         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