John Deere 8.1 L OEM Diesel Engines Operator’s Manual PDF

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John Deere 8.1 L OEM Diesel Engines (PowerTech™) Operator’s Manual – PDF DOWNLOAD

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John Deere 8.1 L OEM Diesel Engines (PowerTech™) Operator’s Manual – PDF DOWNLOAD

• P/N: OMRG24828_71
• Language: English
• Division: Construction
• Product Lines: Engines
• Publication Type: Operator’s Manuals
• Associated Models: 8.1L, 6081HF001, 6081TF001
• Series: POWERTECH
• Serial: 010001–199999
• Additional Information: This manual covers POWERTECH® 8.1 L OEM engines meeting Tier 1 emission standards. These engines, produced starting in the year 1996, include all engines up through engine serial number 199,999. Tier 2 engines were also produced after January 2001, and are redesigned to meet the 2001 emission standards. These newer engines, beginning with serial number 200,000, are covered in a separate operator’s manual, OMRG34944.

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TABLE OF CONTENTS:

John Deere 8.1 L OEM Diesel Engines (PowerTech™) Operator’s Manual – PDF DOWNLOAD

Contents 7
Record Keeping 11
Record Engine Serial Number 11
Engine Option Codes 12
Record Fuel Injection Pump Model Number 14
Record PTO Serial Number (If Equipped) 14
Safety 15
Recognize Safety Information 15
Understand Signal Words 15
Follow Safety Instructions 15
Replace Safety Signs 16
Prevent Bypass Starting 16
Handle Fuel Safely—Avoid Fires 16
Prepare for Emergencies 17
Handle Starting Fluid Safely 17
Handle Fluids Safely—Avoid Fires 17
Service Machines Safely 18
Wear Protective Clothing 18
Protect Against Noise 18
Handle Chemical Products Safely 19
Stay Clear of Rotating Drivelines 19
Practice Safe Maintenance 20
Work In Ventilated Area 20
Avoid High-Pressure Fluids 21
Avoid Heating Near Pressurized Fluid Lines 21
Remove Paint Before Welding or Heating 21
Service Cooling System Safely 22
Install Fan Guards 22
Avoid Hot Parts 22
Avoid Harmful Asbestos Dust 23
Prevent Battery Explosions 23
Handling Batteries Safely 23
Protect Against High Pressure Spray 24
Use Proper Lifting Equipment 25
Use Proper Tools 25
Decommissioning — Proper Recycling and Disposal of Fluids and Components 26
Fuels, Lubricants, and Coolant 27
Diesel Fuel 27
Lubricity of Diesel Fuel 28
Handling and Storing Diesel Fuel 28
Testing Diesel Fuel 28
Biodiesel Fuel 29
Aviation (Jet) Fuels 30
Burner Fuels 30
Minimizing the Effect of Cold Weather on Diesel Engines 31
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III 32
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I 33
Extended Diesel Engine Oil Service Intervals 33
Mixing of Lubricants 33
Oilscan™ and CoolScan™ 34
Alternative and Synthetic Lubricants 34
Lubricant Storage 34
Oil Filters 35
Multipurpose Extreme Pressure (EP) Grease 35
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 36
Drain Intervals for Diesel Engine Coolant 37
Supplemental Coolant Additives 37
Testing Diesel Engine Coolant 38
Operating in Warm Temperature Climates 38
Disposing of Coolant 39
Engine Operating Guidelines 40
Instrument (Gauge) Panel (Engines With Standard Instrument Panel) 40
Instrument (Gauge) Panel (Engines With Electronic Instrument Panel) 42
Instrument (Gauge) Panel (Engines With Electronic Instrument Panel)— Continued 43
Instrument (Gauge) Panel (Engines With Electronic Instrument Panel)— Continued 44
Instrument (Gauge) Panel (Engines With Electronic Instrument Panel)— Continued 45
Using Diagnostic Gauge To Access Engine Information 46
Using Touch Switches to Display Information 48
Changing Units of Measure (English or Metric) 49
Viewing Engine Configuration Data 50
Viewing Active Engine Service Codes/Diagnostic Trouble Codes (DTCs) 52
Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) in the Engine ECU 53
Break-In Service 54
Auxiliary Gear Drive Limitations 56
Generator Set (Standby) Applications 56
Starting the Engine 56
Normal Engine Operation 59
Cold Weather Operation 59
Warming Engine 60
Idling Engine 60
Changing Engine Speed—Standard (Mechanical) Governor 61
Changing Engine Speed (Engines With Electronic Instrument Panel) 61
Stopping the Engine (Engines With Standard Instrument Panel) 62
Stopping the Engine (Engines With Electronic Instrument Panel) 63
Using a Booster Battery or Charger 64
Lubrication and Maintenance 65
Required Emission-Related Information 65
Observe Service Intervals 65
Use Correct Fuels, Lubricants, and Coolant 65
Lubrication and Maintenance Service Interval Chart—Industrial and Generator (Prime Power) 66
Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications 67
Lubrication & Maintenance/Daily 69
Daily Prestarting Checks 69
Lubrication & Maintenance/250 Hour/6 Month 72
Servicing Fire Extinguisher 72
Lubricating PTO Clutch Shaft Bearings (If Equipped) 72
Servicing Battery 73
Changing Engine Oil and Replacing Oil Filter 75
Visually Inspecting Coolant Pump 76
Checking Engine Mounts (Generator Sets) 77
Checking PTO Clutch Adjustment (If Equipped) 77
Lubrication & Maintenance/500 Hour/12 Month 78
Lubricating PTO Clutch Internal Levers and Linkage (If Equipped) 78
Cleaning Crankcase Vent Tube 78
Checking Air Intake System 79
Replacing (Rectangular) Final Fuel Filter Element 80
Replacing (Round) Primary Fuel Filter/Water Separator 81
Checking Belt Tensioner Spring Tension and Belt Wear 82
Checking Belt Wear 82
Checking Tensioner Spring Tension 82
Checking Cooling System 83
Testing Diesel Engine Coolant 84
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes 85
Pressure Testing Cooling System 86
Checking and Adjusting Engine Speeds 87
Checking Crankcase Vibration Damper 87
Checking Engine Ground Connection 88
Lubrication&Maintenance/2000Hour/24Month 89
Flushing And Refilling Cooling System 89
Checking and Adjusting Engine Valve Clearance 90
Service As Required 92
Additional Service Information 92
Do Not Modify Fuel System 92
Draining Fuel/Water Separator Bowl 92
Adding Coolant 93
Replacing Air Cleaner Filter Elements 94
Inspecting Primary Filter Element 95
Cleaning Primary Filter Element 95
Element Storage 95
Replacing Fan/Alternator Belt 96
Power Take-Off (PTO) Clutch (If Equipped) 97
Checking Air Conditioning Compressor (If Equipped) 97
Checking Fuses 98
Checking Electrical Wiring And Connections 98
Bleeding Fuel System 99
Checking Air Compressors (If Equipped) 100
Troubleshooting 101
General Troubleshooting Information 101
Engine Wiring Layout (Engines With Electronic Instrument Panel) 102
Engine Wiring Diagram—(Engines With Standard Instrument Panel) 104
Precautions for Welding on Vehicles Equipped with Electronic Engine Control Unit (ECU) 105
Engine Wiring Diagram—(Engines With Electronic Instrument Panel) 106
Engine Wiring Diagram (Engines With Electronic Instrument Panel)—Continued 107
Engine Troubleshooting 108
Electrical Troubleshooting 113
Lubrication System Troubleshooting 115
Cooling System Troubleshooting 117
Air Intake System Troubleshooting 119
Diagnostic Trouble Code Procedure (Engines With Standard Instrument Panel) 122
Diagnostic Trouble Code Procedure (Engines With Electronic Instrument Panel) 123
Displaying of Diagnostic Trouble Codes (DTCs) 123
Listing of Diagnostic Trouble Codes (DTCs) 124
Intermittent Fault Diagnostics 127
Storage 128
Engine Storage Guidelines 128
Preparing Engine for Long-Term Storage 128
Removing Engine from Long-Term Storage 128
Specifications 129
General OEM Engine Specifications 129
램Ƈ (OEM Engines) 131
Engine Crankcase Oil Fill Quantities 134
Unified Inch Bolt and Screw Torque Values 135
Metric Bolt and Screw Torque Values 136
Lubrication and Maintenance Records 137
Using Lubrication and Maintenance Records 137
Daily (Prestarting) Service 137
250 Hour/6 Month Service 137
500 Hour/12 Month Service 138
2000 Hour/24 Month Service 138
Service as Required 139
Emissions System Warranty 140
Emissions Control System Certification Label 140
U S EPA Emissions Control Warranty Statement 140
John Deere Service Literature Available 141
Technical Information 141
Publications for This Engine 142
John Deere Service Keeps You On The Job 147
John Deere Parts 147
The Right Tools 147
Well-Trained Technicians 147
Prompt Service 147
Page Number 7
Section 01 11
Section 05 15
Section 10 27
Section 15 40
Section 20 65
Section 25 69
Section 30 72
Section 35 78
Section 40 89
Section 45 92
Section 50 101
Section 55 128
Section 60 129
Section 65 137
Section 70 140
Section 75 141

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