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.

CTM61 - John Deere Series 500, 6101 Engine (500000-) Components Technical Manual.pdf

Total Pages: 792 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
Category: CTM

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

John Deere Engines Series 500, 6101 Components Technical Manual (CTM61)