John Deere 6101 Generator Set

⚠ Disconnect negative battery terminal before valve adjustment

Tools: JDE81-1 Flywheel Turning Tool, JDE81-4 Timing Pin, Feeler gauge

1. Remove rocker arm cover from cylinder head.
2. Remove timing hole plugs; install JDE81-1 turning tool and JDE81-4 timing pin.
3. Rotate engine until timing pin engages flywheel at No. 1 TDC compression.
4. Check intake 0.33-0.43 mm and exhaust 0.58-0.68 mm with engine cold.
5. Adjust Nos. 1, 3, 5 exhaust and Nos. 1, 2, 4 intake valves.
6. Loosen locknut; turn adjusting screw until feeler gauge slips with slight drag.
7. Tighten locknut to 27 N·m (20 lb-ft); recheck clearance.
8. Rotate flywheel 360 degrees and adjust remaining valves.

⚠ Replace center housing and rotating assembly if not within specification

Tools: Magnetic base plunger-type dial indicator, 51 mm (2.0 in.) indicator extension rod

1. Fasten magnetic base dial indicator to turbocharger mounting base.
2. Assemble extension adapter and 51 mm indicator extension rod onto dial indicator.
3. Position indicator tip through center housing oil return onto center of shaft.
4. Preload indicator tip and zero the dial.
5. Grasp shaft at both ends and move shaft toward then away from indicator.
6. Observe and record total dial indicator reading.

⚠ Do not use pneumatic wrench to tighten main bearing cap screws

⚠ Crankshaft is heavy; plan proper lifting procedure

Tools: Hoist and lift sling, Pry bar, Torque wrench

1. Position crankshaft onto main bearings using a hoist and lift sling.
2. Dip main bearing cap screws in clean engine oil; oil the bearing inserts.
3. Install bearing caps with recesses and tabs aligned in matching order.
4. Pry crankshaft rearward then forward to align thrust bearing flanges.
5. Tighten No. 1, 2, 3, 4, 6, 7 cap screws to 68 N·m; hand tighten No. 5.
6. Gently pry crankshaft to align thrust washers on No. 5 main bearing.
7. Tighten all main bearing cap screws to 285 N·m (210 lb-ft); turn crankshaft by hand.

⚠ Do not use screwdrivers or pry bars between block and head

Tools: Torque wrench, JDE141 Torque Wrench Adapter

1. Place a new head gasket on cylinder block; do not use sealant.
2. Position cylinder head over dowels using appropriate lifting equipment.
3. Clean cap screws; dip entire cap screws and washers in clean engine oil.
4. Install cap screws in proper locations (197, 171, 248 mm lengths).
5. Tighten cap screw No. 17 to 200 N·m (150 lb-ft) first.
6. Tighten remaining cap screws to 200 N·m in numerical sequence.
7. Torque-turn all cap screws 90-100 degrees in same sequence.

⚠ Always approach timing mark by rotating crankshaft in direction of engine rotation

Tools: JDE81-1 Flywheel Turning Tool, JDE81-4 Timing Pin, Torque wrench

1. Rotate flywheel until timing pin engages flywheel with No. 1 cylinder at TDC compression.
2. Rotate pump drive hub until marks on hub and pointer align.
3. Install a new O-ring on bearing plate; lubricate with clean engine oil.
4. Install pump with moderate forward pressure and slight rocking motion.
5. Install four mounting stud nuts and finger tighten.
6. Install drive gear on pump hub; install drive hub nut and tighten to 100-110 N·m.
7. Tighten four mounting stud nuts to 47 N·m (35 lb-ft).
8. Recheck pump timing alignment and install gear cover with new gasket.

⚠ Never use connecting rod cap screws more than once for final assembly

Tools: JDE94 or JDE135 Piston Ring Expander, JDE97 Piston Ring Compressor, Torque Angle Gauge JT05993

1. Lubricate piston pin and bushing with clean engine oil.
2. Install pin through piston and rod; be sure front of rod aligns with front of piston.
3. Insert new snap rings; install expander and piston rings.
4. Stagger ring gaps; coat pistons and liners with clean engine oil.
5. Install ring compressor over liner; push piston into liner.
6. Install connecting rod caps; dip new cap screws in engine oil.
7. Tighten blind-hole screws 27 N·m, all screws 75 N·m, then torque-turn 90-100 degrees.

⚠ Air must be expelled from cooling system when refilling

Tools: Hoist or assistant, Guide studs

1. Install water pump onto cylinder block with a new gasket.
2. Tighten four mounting cap screws to 68 N·m (50 lb-ft).
3. Install oil cooler-to-water pump hose and tighten clamp securely.
4. Install bypass hose on pump elbow and tighten clamp.
5. Install aftercooler inlet hose and tighten clamp.
6. Connect coolant filter conditioner line using new packing.
7. Install fan and fan belts; adjust belt tension.
8. Install washer and cap screw on pump shaft; tighten to 115 N·m (85 lb-ft).

Tools: Dynamometer (preferred load control)

1. Run engine at slow idle, no load, for 1 minute; check for leaks.
2. Increase to fast idle, then load to 50 rpm above rated speed for 10 minutes.
3. Recheck valve clearance after engine cools; adjust as necessary.
4. Install rocker arm cover; tighten cap screws to 11 N·m (8 lb-ft).
5. Follow all recommended hourly service intervals in Operator's Manual.

⚠ Pump seal should not touch impeller

Tools: D01045AA Bushing, Bearing and Seal Driver Set, JDG743 Water Pump Bearing Driver, R78350 Driver, D01047AA Puller Set

1. Install inner grease seal into housing bore until it bottoms against shoulder.
2. Pack bearings with TY6341 grease; install bearings on shaft with JDG743 driver.
3. Fill cavity between bearings about half full with grease.
4. Install shaft and bearing assembly into housing using JDG743 driver.
5. Install correct thickness snap ring to obtain proper end play.
6. Install outer grease seal with spring loaded lip facing bearings.
7. Drive new pump seal until it bottoms on housing lip using R78350 Driver.
8. Press impeller onto shaft to 0.039-0.89 mm clearance; press pulley onto shaft.

⚠ Never steam clean or pour cold water on an injection pump while warm

⚠ Keep delivery valve fittings stationary while loosening line nuts

Tools: JDE81-1 and JDE81-4 Engine Rotation Tool Set, JDG886 Injection Pump Timing Pin, JDE90 Serrated Wrench, JDF22 Crowsfoot Wrench

1. Clean injection lines and area around the injection pump.
2. Remove timing hole plug.
3. Rotate crankshaft until No. 1 piston is at TDC compression stroke.
4. Verify timing marks on pump drive hub and pointer align and timing pin enters flywheel.
5. Install JDG886 Timing Pin through drive gear and thread into pump hub.
6. Remove injection pump drive gear cap screws; remove fuel filter.
7. Disconnect fuel inlet, outlet, leak-off and aneroid lines.
8. Remove four mounting stud nuts; remove pump from block bore.

⚠ Do not rotate crankshaft with head removed unless liners are bolted down

Tools: Ridge reamer, Compressed air

1. Drain coolant and oil; disconnect turbocharger oil inlet line.
2. Remove cylinder head, oil pan and oil pump.
3. Bolt cylinder liners down in seven locations; tighten to 68 N·m (50 lb-ft).
4. Remove carbon from liner bore with scraper or ridge reamer.
5. Remove connecting rod cap screws and rod caps with bearings.
6. Mark piston and liner as a set; keep matched parts together.
7. Tap piston through top of cylinder block from the bottom.

⚠ Whenever rear oil seal is replaced, wear sleeve MUST be replaced also

⚠ Do not separate seal and wear sleeve assembly

Tools: JDG22 Seal Remover, JDG790 Rear Wear Sleeve Puller, JDG309 Pilot, JDG310 Installer

1. Remove flywheel.
2. Drill two small holes about 20 degrees apart in bottom of seal casing.
3. Install sheet metal screws with JDG22 Seal Remover; cock seal and pull from housing.
4. Assemble JDG790 Rear Wear Sleeve Puller onto crankshaft flange with sleeve in jaws.
5. Tighten band clamp and forcing screw until wear sleeve is removed.
6. Clean OD of crankshaft flange with solvent that removes sealant.
7. Install new seal and wear sleeve assembly as a unit using JDG300 installer.