John Deere PowerTech 8.1 L Diesel Engines Mechanical Fuel Systems Workshop Service Repair manual with Electrical Wiring Diagrams (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

John Deere PowerTech 8.1 L Diesel Engines Mechanical Fuel Systems contains high quality images, circuit diagrams, instructions to help you to maintenance, troubleshoot, diagnose, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, cross links for easy navigation.

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Category: CTM - Component Technical Manual
Language: English Spanish French German Italian Russian Portuguese
Published on 2017/11/04

TABLE OF CONTENTS
Section 01: General
  Group 000: Safety...8
    Handle Fluids Safely—Avoid Fires...11
    Handle Starting Fluid Safely...12
    Handling Batteries Safely...13
    Prepare for Emergencies...16
    Avoid High-Pressure Fluids...17
    Wear Protective Clothing...18
    Service Machines Safely...19
    Work In Ventilated Area...20
    Work in Clean Area...21
    Remove Paint Before Welding or Heating...22
    Avoid Heating Near Pressurized Fluid Lines...23
    Illuminate Work Area Safely...24
    Use Proper Lifting Equipment...25
    Construct Dealer-Made Tools Safely...26
    Practice Safe Maintenance...27
    Use Proper Tools...29
    Decommissioning — Proper Recycling and Disposal of Fluids and Components...30
    Live With Safety...31
  Group 001: Engine Identification...8
    Engine Model Designation...33
    Engine Serial Number Plate Information...34
    Engine Option Code Label...36
  Group 002: Fuels, Lubricants and Coolant...8
    Diesel Fuel...38
    Bio-Diesel Fuel...39
    Lubricity of Diesel Fuel...41
    Testing Diesel Fuel...42
    Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III...43
    Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I...45
    Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I...47
    Alternative and Synthetic Lubricants...48
    Mixing of Lubricants...49
    OILSCAN OILSCAN is a registered trademark of Deere & Company. and CoolScan CoolScan is a registered trademark of Deere & Company...9
    Grease...51
    Diesel Engine Coolant (engine with wet sleeve cylinder liners)...52
    Diesel Engine Coolants, Supplemental Additive Information...54
    Testing Diesel Engine Coolant...56
    Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes...57
    Operating in Warm Temperature Climates...59
    Flush and Service Cooling System...60
    Disposing of Coolant...62
Section 02: Repair and Adjustment...63
  Group 090: Mechanical Fuel System Repair and Adjustments...63
    Relieve Fuel System Pressure...66
    Replace Rectangular Fuel Filter Element...67
    Replace Fuel Filter Check Valve...69
    Replace Primary (Round) Fuel Filter/Water Separator...70
    Identification of Fuel Supply Pumps...72
    Remove Fuel Supply Pump (Bosch and Nippondenso)...73
    Inspect Fuel Supply Pump...74
    Install Fuel Supply Pump (Bosch and Nippondenso)...75
    Install Fuel Supply Pump (Motorpal)...76
    Repair Injection Pump Aneroid (Bosch and Nippondenso)—If Equipped...77
    Remove Hydraulic Aneroid Activator (Bosch and Nippondenso)—If Equipped...78
    Disassemble, Clean, Assemble and Install Hydraulic Aneroid Activator Parts (Bosch and Nippondenso)—If Equipped...79
    Service Injection Pump Overflow Valve (Bosch and Nippondenso)...83
    Service Injection Pump Overflow Valve (Bosch and Nippondenso)...83
    Remove and Install Fuel Shut-off Solenoid (Bosch and Nippondenso)—If Equipped...85
    Remove and Install Fuel Shut-off Solenoid (Motorpal)—If Equipped...87
    Identification of In-Line Fuel Injection Pumps...88
    Service of Fuel Injection Pumps...91
    Replace Motorpal Fuel Injection Pump Delivery Valve O-Rings...92
    Remove Fuel Injection Pump (Bosch and Nippondenso)...94
    Remove Fuel Injection Pump (Motorpal)...97
    Install Fuel Injection Pump (Bosch and Nippondenso)...100
    Install Fuel Injection Pump (Motorpal)...105
    Remove Fuel Injection Nozzles...110
    Diagnose Injection Nozzle Malfunction...113
    Test Fuel Injection Nozzles...115
    Perform Opening Pressure Test...116
    Injection Nozzle Opening Pressure Specifications...117
    Perform Nozzle Leakage Test...118
    Perform Chatter and Spray Pattern Test...120
    Disassemble Fuel Injection Nozzle...121
    Clean and Inspect Fuel Injection Nozzle Assembly...124
    Perform Nozzle Slide Test...125
    Clean Spray Orifices...126
    Inspect Nozzle Holder...127
    Inspect Gland Nut...130
    Assemble Fuel Injection Nozzle...132
    Test and Adjust Injection Nozzle Opening Pressure...135
    Inspect and Clean Cylinder Head Nozzle Bore...136
    Inspect and Clean Nozzle Seating Surface...137
    Install Fuel Injection Nozzles...138
Section 03: Theory of Operation...144
  Group 130: Mechanical Fuel Systems Operation...144
    Fuel Injection Pump - General Information...146
    Fuel System Overview...147
    Fuel Supply Pump Operation...149
    Rectangular Final Fuel Filter Operation...152
    Round Primary Fuel Filter/Water Separator Operation...153
    Fuel Injection Pump Operation...155
    Fuel Injection Nozzle Operation...157
    Mechanical Governor Operation...159
    Speed Droop...167
    Fuel Shut-off Solenoid...168
    Aneroid Operation...169
    Hydraulic Aneroid Activator Operation...171
Section 04: Diagnostics...173
  Group 150: Observable Diagnostics and Tests...173
    About This Section of the Manual...175
    E1 - Engine Cranks/Won't Start...173
    E2 - Engine Misfires/Runs Irregularly...173
    E3 - Engine Does Not Develop Full Power...173
    E4 - Engine Emits Excessive White Exhaust Smoke...173
    E5 - Engine Emits Excessive Black or Gray Exhaust Smoke...173
    E6 - Engine Will Not Crank...173
    E7 - Engine Idles Poorly...173
    E8 - Abnormal Engine Noise...173
    F1 - Fuel Supply System Check...173
    F2 - Excessive Fuel Consumption...173
    F3 - Fuel in Oil...173
    F4 - Excessive Fuel Filter Replacement...204
    Check Fuel Supply Quality...207
    Measure Fuel Supply Pump Pressure...209
    Check Fuel Supply Pump Operation...210
    Bleed the Fuel System...212
    Cylinder Misfire Test (Engine Running)...216
    Test for Fuel Drain Back...217
    Test for Air in Fuel...218
    Check for Restricted Fuel Return Line...219
    Check and Adjust Injection Pump Static Timing...221
    Check Fuel Shut-Off Solenoid Operation...223
    Test Fuel Shut-Off Solenoid Resistance...225
    Fuel Shut-Off Solenoid Linkage Adjustment...226
    Check and Adjust Slow Idle Speed...227
    Check Fast Idle Speed...230
    Adjust Injection Pump Timing (Genset Applications)...231
Section 05: Tools...233
  Group 170: Repair Tools...233
    Mechanical Fuel System Repair Tools...237
    Service Equipment and Tools...240
    Other Material...241
  Group 180: Diagnostic Service Tools...233
    Base Engine Diagnostic Tools...244
Section 6: Specifications...246
  Group 200: Repair and General OEM Specifications...246
    General Engine Specifications (OEM Applications)...249
    General Engine Specifications (OEM Applications)—Continued...251
    Unified Inch Bolt and Screw Torque Values...252
    Metric Bolt and Screw Torque Values...254
    Fuel System Specifications...256
    
John Deere PowerTech 8.1 L Diesel Engines Mechanical Fuel Systems Component Technical Manual (CTM243)