John Deere Powertech 8.1 L 6081 OEM Diesel Engines Operator's Manual
The Best PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization !
Models Covered :
This manual covers all
POWERTECH 8.1L OEM engines.
Those engines produced starting in
the year 1996 are noted as engines
( —199,999).
CONTENTS :
Record Keeping Using Diagnostic Gauge to Access
Record Engine Serial Number . . . . . . . . . . . . . . 01-1 Engine Information (Electronic Panel) . . . . . . . 15-9
Engine Option Codes . . . . . . . . . . . . . . . . . . . . . 01-2 Using Touch Switches to Display
Record Fuel Injection Pump Model Number . . . . 01-4 Information . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Record PTO Serial Number . . . . . . . . . . . . . . . . 01-4 Changing Units of Measure (English or
Metric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Viewing Engine Configuration Data . . . . . . . . . 15-16
Viewing Active Engine Service
Codes/Diagnostic Trouble Codes (DTCs) . . . 15-18
Fuels, Lubricants, and Coolant
Viewing Stored Service
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Codes/Diagnostic Trouble Codes
Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . . . 10-2
(DTCs) in the Engine ECU . . . . . . . . . . . . . . 15-19
Filling Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . 10-3 Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . 15-20
DIESELSCANä Fuel Analysis . . . . . . . . . . . . . . 10-3 Auxiliary Gear Drive Limitations . . . . . . . . . . . . 15-22
Minimizing the Effect of Cold Weather on Generator Set (Standby) Power Units. . . . . . . . 15-22
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 15-23
Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Normal Engine Operation . . . . . . . . . . . . . . . . . 15-26
Handling And Storing Bio-Diesel Fuel. . . . . . . . . 10-6 Cold Weather Operation. . . . . . . . . . . . . . . . . . 15-27
Aviation (Jet) Fuels. . . . . . . . . . . . . . . . . . . . . . . 10-7 Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . 15-28
Kerosene (Burner) Fuels . . . . . . . . . . . . . . . . . . 10-7 Idling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-8 Changing Engine Speed-Standard
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-9 (Mechanical) Governor . . . . . . . . . . . . . . . . . 15-29
Extended Diesel Engine Oil Service Changing Engine Speed (Engines
Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 w/Electronic Instrument Panels) . . . . . . . . . . 15-30
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . 10-10 Stopping the Engine (Engines With
OILSCANâand COOLSCANä. . . . . . . . . . . . . . 10-10 Standard Instrument Panels). . . . . . . . . . . . . 15-31
Alternative and Synthetic Lubricants. . . . . . . . . 10-11 Stopping the Engine (Engines With
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . 10-11 Electronic Instrument Panel) . . . . . . . . . . . . . 15-32
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Using a Booster Battery or Charger . . . . . . . . . 15-33
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-13
Additional Information About Diesel Lubrication and Maintenance
Engine Coolants and Supplemental Coolant Observe Service Intervals. . . . . . . . . . . . . . . . . . 20-1
Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Use Correct Fuels, Lubricants and Coolants. . . . 20-1
Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-15 Lubrication and Maintenance Service
Supplemental Coolant Additives . . . . . . . . . . . . 10-16 Interval Chart - Prime Power. . . . . . . . . . . . . . 20-2
Operating in Warm Temperature Climates . . . . 10-16 Lubrication and Maintenance Service
Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-17 Interval Chart - Standby Power . . . . . . . . . . . . 20-4
Engine Operating Guidelines Lubrication & Maintenance/Daily
Instrument (Gauge) Panel (Standard). . . . . . . . . 15-1 Daily Prestarting Checks . . . . . . . . . . . . . . . . . . 25-1
Instrument (Gauge) Panel (Electronic) . . . . . . . . 15-4
Instrument (Gauge) Panel (Electronic)- Cont’d . . 15-5
Lubrication & Maintenance/250 Hour/6 Month Troubleshooting
Servicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-1 General Troubleshooting Information . . . . . . . . . 50-1
Lubricating PTO Clutch Shaft Bearings . . . . . . . 30-1 Engine Wiring Layout (Engines w/Electronic
Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-2 Instument Panel) . . . . . . . . . . . . . . . . . . . . . . 50-2
Changing Engine Oil and Replacing Oil Filter . . . 30-4 Engine Wiring Diagram (Engines
Visually Inspecting Coolant Pump . . . . . . . . . . . 30-5 w/Standard Instrument Panels) . . . . . . . . . . . 50-3
Checking Engine Mounts (Generator Sets). . . . . 30-6 Precautions for Welding on Machines
Checking PTO Clutch Adjustment. . . . . . . . . . . . 30-7 Equipped with ECU. . . . . . . . . . . . . . . . . . . . . 50-4
Engine Wiring Diagram (Engines with
Electronic Instrument Panel) . . . . . . . . . . . . . 50-5 Lubrication & Maintenance/500 Hour/12 Month
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . 50-7
Lubricating PTO Clutch Internal Levers and Electrical Troubleshooting. . . . . . . . . . . . . . . . . 50-13
Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Lubrication System Troubleshooting . . . . . . . . . 50-15
Cleaning Crankcase Vent Tube . . . . . . . . . . . . . 35-1 Cooling System Troubleshooting . . . . . . . . . . . 50-17
Checking Air Intake System . . . . . . . . . . . . . . . . 35-2 Air Intake System Troubleshooting . . . . . . . . . . 50-19
Replacing (Rectangular) Final Fuel Filter Diagnostic Trouble Code Procedure
Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3 (Engines w/Standard Instrument Panel) . . . . 50-22
Replacing (Round) Primary Fuel Diagnostic Trouble Code Procedure
Filter/Water Separator . . . . . . . . . . . . . . . . . . 35-4 (Engines w/Electronic Instrument Panel)) . . . 50-24
Checking Belt Tensioner Spring Tension Displaying of Diagnostic Trouble Codes
and Belt Wear. . . . . . . . . . . . . . . . . . . . . . . . . 35-5 (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
Checking Belt Wear . . . . . . . . . . . . . . . . . . . . . . 35-5 Listing of Diagnostic Trouble Codes (DTCs) . . 50-26
Checking Tensioner Spring Tension . . . . . . . . . . 35-6 Intermittent Fault Diagnostics . . . . . . . . . . . . . . 50-29
Checking Cooling System. . . . . . . . . . . . . . . . . . 35-7
Testing Diesel Engine Coolant . . . . . . . . . . . . . . 35-8 Storage
Replenishing Supplemental Coolant Engine Storage Guidelines . . . . . . . . . . . . . . . . . 55-1
Additives (SCAs) Between Coolant Preparing Engine for Long Term Storage . . . . . . 55-1
Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9 Removing Engine from Long Term Storage . . . . 55-2
Pressure Testing Cooling System. . . . . . . . . . . 35-11
Checking and Adjusting Engine Speeds . . . . . . 35-12 Specifications
Checking Crankshaft Vibration Damper . . . . . . 35-13 General OEM Engine Specifications. . . . . . . . . . 60-1
Checking Engine Ground Connection. . . . . . . . 35-14 Engine Power and Speed Ratings
Specifications (OEM Engines). . . . . . . . . . . . . 60-3
Lubrication&Maintenance/2000Hour/24Month Engine Crankcase Oil Fill Quantities . . . . . . . . . 60-6
Unified Inch Bolt and Cap Screw Torque
Flushing Cooling System . . . . . . . . . . . . . . . . . . 40-1
Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7
Checking and Adjusting Engine Valve Metric Bolt and Cap Screw Torque Values . . . . . 60-8
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Lubrication and Maintenance Records
Service As Required Using Lubrication and Maintenance Records . . . 65-1
Additional Service Information . . . . . . . . . . . . . . 45-1 Daily (Prestarting) Service . . . . . . . . . . . . . . . . . 65-1
Do Not Modify Fuel System . . . . . . . . . . . . . . . . 45-1 250 Hour/6 Month Service . . . . . . . . . . . . . . . . . 65-2
Drain Fuel/Water Separator Bowl . . . . . . . . . . . . 45-2 500 Hour/12 Month Service . . . . . . . . . . . . . . . . 65-3
Adding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . 45-3 2000 Hour/24 Month Service . . . . . . . . . . . . . . . 65-4
Replacing Air Cleaner Filter Elements . . . . . . . . 45-4 Service as Required . . . . . . . . . . . . . . . . . . . . . . 65-5
Inspecting Primary Filter Element . . . . . . . . . . . . 45-5
Cleaning Primary Filter Element . . . . . . . . . . . . . 45-5 Emission System Warranty
Element Storage. . . . . . . . . . . . . . . . . . . . . . . . . 45-6 Emissions Control System Certification Label. . . 70-1
Replacing Fan/Alternator Belt . . . . . . . . . . . . . . . 45-7 U.S. Emissions Control Warranty Statement. . . . 70-2
Power Take-Off (PTO) Clutch. . . . . . . . . . . . . . . 45-8
Checking Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 45-9
Bleeding Fuel System . . . . . . . . . . . . . . . . . . . 45-10
Checking Air Compressors . . . . . . . . . . . . . . . . 45-12
