John Deere PowerTech 6081AFM75 Marine Engines Operators Manual

OPERATION AND SERVICE MANUAL Deere Power Systems Group OMRG24828 Issue (20DEC00) LITHO IN U.S.A. ENGLISH POWERTECH 6081 OEM Diesel Engines ﬁ 8.1 L

Introduction DPSG,OUOD007,1 –19–22MAY92–1/1 FOREWORD READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage. THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it. MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. RIGHT-HAND AND LEFT-HAND sides are determined by standing at the drive or flywheel end (rear) of the engine and facing toward the front of the engine. WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section. Accurately record all the numbers. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the engine. SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine. CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment on John Deere OEM Engines. These accessories may be provided by the equipment manufacturer instead of John Deere. This operator’s manual applies only to the engine and those options available through the John Deere distribution network. IMPORTANT: This manual covers all POWERTECH  8.1L OEM engines. Those engines produced starting in the year 1996 are noted as engines ( —199,999). Engines produced after January 2001 which are redesigned to meet the 2001 emission standards are noted as engines (200,000— ). These engines also have a suffix “070” in the engine model number, as in “6081HF070”. NOTE: This operators manual covers only engines provided to OEM (Outside Equipment Manufacturers). For engines in Deere machines, refer to the machine operators manual. CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. POWERTECH is a trademark of Deere & Company 122000 PN=2

Introduction DPSG,OUOE003,2736 –19–11JAN99–1/1 ENGINE OWNER John Deere Engine Owner: Don’t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer. Learn who he is and where he is. At your first convenience, go meet him. He’ll want to get to know you and to learn what your needs might be. Utilisateurs De Moteurs John Deere: N’attendez pas d’e ˆ tre oblige ´ d’avoir recours a votre Concessionnaire ou Point de Service le plus proche pour vous adresser a lui. Renseignez-vous des que possible pour l’identifier et le localiser. A la premiere occasion, prenez contact avec lui et faites-vous connaı ˆtre. Il sera lui aussi heureux de faire votre connaissance et de savoir que vous Perez computer Sur lui le moment menu. An Den Besitzer Des John Deere Motors: Warten Sie nicht auf einen evt. Reparaturfall um den na ¨ chstgelegenen John Deere Ha ¨ ndler kennen zu lernen. Machen Sie sich bei ihm bekannt und nutzen Sie sein “Service Angebot”. Proprietario Del Motore John Deere: Non aspetti fino a quando ha bisogno della garanzia o di un altro tipo di assistenza per incontrarsi con il Suo Concessionario che fornisce l’assistenza tecnica. Impari a conoscere chi e ` e dove si trova. Alla Sua prima occasione cerchi d’incontrarlo. Egli desidera farsi conoscere e conoscere le Sue necessita `. Propietario De Equipo John Deere: No espere hasta necesitar servicio de garantı á o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio. Ente ´ rese de quie ń es, y do ´ nde esta ´ situado. Cuando tenga un momento, vaya a visitarlo. A e ´ l le gustara ´ conocerlo, y saber cua ´ les podrı án ser sus necesidades. John Deere MotorA ¨ gare: Va ¨nta inte med att beso ¨ ka Din John Deere a ˚ terfo ¨ rsa ¨ ljare till dess att Du beho ¨ ver service eller garanti reparation. Bekanta Dig med var han a ¨r och vem han a ¨r. Tag fo ¨ rsta tillfa ¨ lle att beso ¨ ka honom. Han vill ocksa ˚ tra ¨ ffa Dig fo ¨r att fa ˚ veta vad Du beho ¨ver och hur han kan hja ¨ lpa Dig. 122000 PN=3

Introduction RG,RG34710,4001 –19–18JUN99–1/2 IDENTIFICATION VIEWS— ENGINE SERIAL NUMBER ( —199,999) RG7362 –UN–05JAN98 8.1 L Diesel Engine Right Front View— Engines ( — 199,999) RG7363 –UN–05JAN98 8.1 L Diesel Engines Left Front View—Engines ( — 199,999) RG7385 –UN–05JAN98 8.1 L Diesel Engines Right Side View—Engines ( — 199,999) RG7387 –UN–05JAN98 8.1 L Diesel Engines Left Side View—Engines ( —199,999) 122000 PN=4

Introduction RG,RG34710,4001 –19–18JUN99–2/2 RG7388 –UN–20JUN00 8.1 L Diesel Engine Right Front View—Engines ( — 199,999) RG7386 –UN–20JUN00 8.1 L Diesel Engine Left Front View—Engines ( —199,999) RG7383 –UN–05JAN98 8.1 L Diesel Engine Front View—Engines ( —199,999) RG7384 –UN–05JAN98 8.1 L Diesel Engine Rear View—Engines ( —199,999) 122000 PN=5

Introduction RG,OUOD007,4002 –19–01NOV00–1/1 IDENTIFICATION VIEWS— ENGINE SERIAL NUMBER (200,000— ) RG11511 –UN–13DEC00 8.1 L Diesel Engine Right Front View—Engines (200,000— ) RG11512 –UN–31OCT00 8.1 L Diesel Engines Left Front View—Engines (200,000— ) RG11513 –UN–31OCT00 8.1 L Diesel Engine Front View—Engines (200,000— ) RG11514 –UN–31OCT00 8.1 L Diesel Engine Rear View—Engines (200,000— ) 122000 PN=6

Contents Page Page Viewing Stored Service Codes (DTC) in Record Keeping Engine ECU ......................... 15-18 Record Engine Serial Number .............. 01-1 Break-In Service ........................ 15-19 Engine Option Codes ..................... 01-2 Auxiliary Gear Drive Limitations ............ 15-21 Record Fuel Injection Pump Model Number .... 01-4 Generator Set (Standby) Power Units........ 15-22 Record PTO Serial Number ................ 01-4 Starting the Engine ...................... 15-22 Restarting Engine That Has Run Out Of Safety ................................ 05-1 Fuel - Engines (200,000- ) .............. 15-26 Normal Engine Operation ................. 15-28 Fuels, Lubricants, and Coolant Cold Weather Operation .................. 15-29 Diesel Fuel ............................. 10-1 Warming Engine ........................ 15-30 Lubricity of Diesel Fuels ................... 10-1 Idling Engine .......................... 15-31 Diesel Fuel Storage ...................... 10-2 Changing Engine Speed-Standard DIESELSCAN Fuel Analysis ................ 10-2 (Mechanical) Governor ................. 15-31 Minimizing the Effect of Cold Weather on Changing Engine Speed (Later Engines Diesel Engines ........................ 10-3 w/Electronic Instrument Panels) .......... 15-32 Diesel Engine Break-In Oil ................. 10-4 Stopping the Engine (Engines With Diesel Engine Oil ........................ 10-5 Standard Instrument Panels) ............. 15-33 Extended Diesel Engine Oil Service Intervals . . . 10-6 Stopping the Engine (Engines With Mixing of Lubricants ...................... 10-6 Electronic Instrument Panel) ............. 15-34 Oilscan and Coolscan..................... 10-7 Using a Booster Battery or Charger ......... 15-35 Alternative and Synthetic Lubricants .......... 10-7 Lubricant Storage ........................ 10-8 Lubrication and Maintenance Grease ................................ 10-8 Observe Service Intervals.................. 20-1 Diesel Engine Coolant .................... 10-9 Use Correct Fuels, Lubricants and Coolants.... 20-1 Diesel Engine Coolants And Supplemental Lubrication and Maintenance Service Additive Information ................... 10-10 Interval Chart - Prime Power .............. 20-2 Testing Diesel Engine Coolant ............. 10-11 Lubrication and Maintenance Service Suppemental Coolant Additives ............ 10-12 Interval Chart - Standby Power ............ 20-4 Operating in Warm Temperature Climates .... 10-12 Disposing of Coolant .................... 10-13 Lubrication & Maintenance/Daily Daily Prestarting Checks .................. 25-1 Engine Operating Guidelines Instrument (Gauge) Panels (Standard) ........ 15-1 Instrument (Gauge) Panel (Electronic) ........ 15-3 Lubrication & Maintenance/250 Hour/6 Month Using Diagnostic Gauge to Access Servicing Fire Extinguisher ................. 30-1 Engine Information (Electronic Panel) ....... 15-8 Lubricating PTO Clutch Shaft Bearings ....... 30-1 Using Touch Switches to Display Servicing Battery ........................ 30-2 Information .......................... 15-11 Handling Batteries Safely .................. 30-3 Changing Units of Measure (English or Changing Engine Oil and Replacing Oil Filter. . . 30-4 Metric).............................. 15-13 Checking PTO Clutch Adjustment............ 30-6 Viewing Engine Configuration Data ......... 15-15 Continued on next page Viewing Active Engine Service Codes (DTC) . . 15-17 All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT  2001 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION  Manual Previous Editions Copyright  1996, 2000 i 122000 PN=1

Contents Page Page Visually Inspecting Coolant Pump ........... 30-7 Troubleshooting General Troubleshooting Information ......... 50-1 Checking Engine Mounts (Generator Sets) ..... 30-8 Engine Wiring Diagram (Engines w/Earlier Standard Instrument Panel - Engines ( Lubrication & Maintenance/600 Hour/12 Month -199,999) ............................ 50-3 Lubricating PTO Clutch Internal Levers and Engine Wiring Diagram (Engines w/Later Linkage .............................. 35-1 Standard Instrument Panels) ............. 50-5 Cleaning Crankcase Vent Tube ............. 35-1 Precautions for Welding on Machines Checking Air Intake System ................ 35-2 Equipped with ECU..................... 50-6 Replacing (Rectangular) Final Fuel Filter Engine Wiring Diagram (Engines with Element - Engines ( -199,999) ............ 35-3 Electronic Instrument Panel) - Engines ( Replacing (Round) Primary Fuel -199,999) ............................ 50-7 Filter/Water Separator - Engines ( Engine Wiring Diagram (Engines with -199,999) ............................ 35-4 Electronic Instrument Panel) - Engines Clean Fuel Strainer - Engines (200,000- ) ..... 35-5 (200,000- ) ........................... 50-9 Replacing Main Fuel Filter - Engines Engine Wiring Layout (Engines (200,000- ) ........................... 35-6 w/Electronic Instument Panel) - Engines ( Checking Belt Tensioner Spring Tension -199,999) ........................... 50-11 and Belt Wear ......................... 35-7 Engine Wiring Layout (Engines Checking Belt Wear ...................... 35-7 w/Electronic Instument Panel) - Engines (200,000-) Checking Tensioner Spring Tension .......... 35-7 ................................... 50-12 Checking Cooling System.................. 35-8 Engine Troubleshooting .................. 50-13 Testing Diesel Engine Coolant .............. 35-9 Electrical Troubleshooting................. 50-20 Replenishing Supplemental Coolant Lubrication System Troubleshooting ......... 50-22 Additives (SCAs) Between Coolant Cooling System Troubleshooting ........... 50-24 Changes ............................ 35-10 Air Intake System Troubleshooting .......... 50-26 Pressure Testing Cooling System........... 35-12 Diagnostic Trouble Code Procedure (Earlier Checking and Adjusting Engine Speeds ...... 35-13 Engines) ............................ 50-29 Checking Crankshaft Vibration Damper ...... 35-13 Diagnostic Trouble Code Procedure (Later Checking Engine Ground Connection ........ 35-14 Engines) ............................ 50-31 Displaying of Diagnostic Trouble Codes Lubrication&Maintenance/2000Hour/24Month (DTCs) ............................. 50-32 Flushing Cooling System .................. 40-1 Listing of Diagnostic Trouble Codes Checking and Adjusting Engine Valve (DTCs) - Engines ( -199,999) ............ 50-33 Clearance - Engines ( -199,999) ........... 40-3 Listing of Diagnostic Trouble Codes (DTCs) - Engines (200,000- ) ............ 50-35 Check Valve Clearance - Engines (200,000- ) . . 40-5 Adjust Valve Clearance - Engines (200,000- ) . . 40-8 Storage Engine Storage Guidelines ................. 55-1 Service As Required Use AR41785 Engine Storage Kit............ 55-1 Additional Service Information .............. 45-1 Preparing Engine for Long Term Storage ...... 55-2 Do Not Modify Fuel System ................ 45-1 Removing Engine from Long Term Storage .... 55-3 Drain Fuel/Water Separator Bowl ............ 45-2 Adding Coolant .......................... 45-3 Replacing Air Cleaner Filter Elements ........ 45-4 Specifications Inspecting Primary Filter Element ............ 45-5 General OEM Engine Specifications .......... 60-1 Cleaning Primary Filter Element ............. 45-6 General OEM Engine Element Storage......................... 45-7 Specifications--Continued ................ 60-3 Replacing Fan/Alternator Belt ............... 45-8 Fuel Injection Pump Specifications (OEM Power Take-Off (PTO) Clutch............... 45-9 Engines) ............................. 60-5 Checking Fuses ........................ 45-10 Engine Crankcase Oil Fill Quantities ......... 60-8 Bleeding Fuel System - Engines ( -199,999) . . 45-11 Continued on next page Bleeding Fuel System - Engines (200,000- ) . . 45-13 ii 122000 PN=2

Contents Page Unified Inch Bolt and Cap Screw Torque Values............................... 60-9 Metric Bolt and Cap Screw Torque Values .... 60-10 Lubrication and Maintenance Records Using Lubrication and Maintenance Records . . . 65-1 Daily (Prestarting) Service ................. 65-1 250 Hour/6 Month Service ................. 65-2 600 Hour/12 Month Service ................ 65-3 2000 Hour/24 Month Service ............... 65-4 Service as Required ...................... 65-5 Emission System Warranty Emissions Control System Certification Label. . . 70-1 U.S. Emissions Control Warranty Statement.... 70-2 iii 122000 PN=3

Contents iv 122000 PN=4

John Deere PowerTech 6081AFM75 Marine Engines Operators Manual

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