John Deere Series 500 & 6101 Engine Components Technical Manual CTM61 - Repair, Diagnostic & Wiring Diagrams PDF - MJODCTM61.zip

John Deere 500 and 6101 Series Engine Components Service Guide (CTM61)

CTM61 - John Deere 500 and 6101 Series 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