John Deere Powertech 10.5 L & 12.5 L Diesel Engines Component Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere Powertech 10.5 L & 12.5 L Diesel Engines Component Technical Manual – PDF DOWNLOAD
For complete service information also see:
PowerTech™ 10.5 L and 12.5 L Diesel
Engines—Delphi/Lucas Electronic Fuel
Systems With Delphi/Lucas EUIs
……………………………………………………………………. CTM115
PowerTech™ 10.5 L and 12.5 L Diesel
Engines—Level 6 Electronic Fuel Systems
With Delphi/Lucas EUIs ……………………………….. CTM188
OEM Engine Accessories …………………………….. CTM67
Alternators and Starter Motors …………………….. CTM77
Application List……………………………………………. CTM106819
Foreword :
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. This manual covers only the base engine. It is one of three volumes on 10.5 L and 12.5 L engines. The following two companion manuals cover electronic fuel system repair, operation and diagnostics:
- These CTMs will cover fuel system repair, formerly included in this CTM, Groups 35 and 36. Other manuals will be added in the future to provide added information on new electronic fuel systems.
- A complete set of all three manuals covering the 10.5 L and 12.5 L engines can be procured by ordering the CTM Binder Set. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
TABLE OF CONTENTS:
John Deere Powertech 10.5 L & 12.5 L Diesel Engines Component Technical Manual – PDF DOWNLOAD
Contents 11
General Information 13
Safety 15
Avoid Harmful Asbestos Dust 15
Avoid Heating Near Pressurized Fluid Lines 15
Avoid High-Pressure Fluids 15
Construct Dealer-Made Tools Safely 16
Dispose of Waste Properly 16
Follow Safety Instructions 16
Handle Agricultural Chemicals Safely 17
Handle Fluids Safely—Avoid Fires 17
Handle Starting Fluid Safely 18
Handling Batteries Safely 18
Illuminate Work Area Safely 19
Install All Guards 19
Live With Safety 19
Practice Safe Maintenance 20
Prepare for Emergencies 20
Prevent Acid Burns 21
Prevent Battery Explosions 21
Prevent Machine Runaway 22
Protect Against High Pressure Spray 22
Protect Against Noise 22
Recognize Safety Information 23
Remove Paint Before Welding or Heating 23
Replace Safety Signs 23
Service Cooling System Safely 24
Service Machines Safely 24
Stay Clear of Rotating Drivelines 24
Understand Signal Words 25
Use Proper Lifting Equipment 25
Use Proper Tools 25
Wear Protective Clothing 26
Work in Clean Area 26
Work In Ventilated Area 26
Engine Identification and Applications 27
Engine Model Designation 27
Engine Serial Number Plate Information 27
Engine Option Code Label 28
Fuels, Lubricants and Coolant 29
Diesel Fuel 29
Biodiesel Fuel 30
Lubricity of Diesel Fuel 31
Testing Diesel Fuel 31
Diesel Engine Break-In Oil 31
Oil Information for Uncertified or Tier 1 Engines 32
Diesel Engine Oil 32
Oil Information for Tier 2 Engines 32
Diesel Engine Oil 33
Extended Diesel Engine Oil Service Intervals 33
Alternative and Synthetic Lubricants 34
Mixing of Lubricants 34
OILSCAN OILSCAN is a trademark of Deere & Company™ and COOLSCAN 34
Grease 35
Heavy Duty Diesel Engine Coolant 36
Supplemental Coolant Additives 36
Testing Diesel Engine Coolant 37
Operating in Warm Temperature Climates 37
Repair and Adjustments 41
Engine Rebuild Guide, Break-In and Tune-Up 43
Engine Overhaul Guidelines 43
Engine Repair Stand 43
Safety Precautions 44
Disconnect Turbocharger Oil Inlet Line 44
Install Engine Adapter Onto Repair Stand 45
Engine Lifting Procedure 46
Mount Engine Onto Repair Stand 47
Clean Engine 48
6105 and 6125 Engine Disassembly Sequence 49
Sealant Application Guidelines 51
6105 and 6125 Engine Assembly Sequence 52
Engine Break-In Guidelines 53
Perform Engine Break-In 54
Check Crankcase Ventilation System 55
Check Air Intake System 55
Check Exhaust System 55
Check and Service Cooling System 56
Check Electrical System 57
Preliminary Engine Testing Before Tune-Up 57
General Tune-Up Recommendations 58
Cylinder Head and Valves 59
Remove and Install Rocker Arm Cover 59
Clean and Inspect Crankcase Ventilation Assembly 60
Replace Rocker Arm Cover Gasket 60
Check and Adjust Valve Assembly Clearances and Injector Preload 61
Remove Rocker Arm Assembly 65
Remove Cylinder Head 66
Diagnosing Head Gasket Joint Failures 69
Head Gasket Inspection and Repair Sequence 70
Disassemble and Inspect Rocker Arms and Shaft Assembly 71
Preliminary Cylinder Head and Valve Checks 72
Assemble Rocker Arms and Shaft Assembly 73
Check Valve Height in Relation to Head Surface (Valve Recess) 73
Remove Valve Assembly 74
Inspect and Measure Valve Springs 75
Inspect Valve Rotators 75
Clean, Inspect, and Measure Valves 76
Grind Valves 76
Clean and Inspect Cylinder Head 77
Check Cylinder Head Flatness 77
Measure Cylinder Head Thickness 78
Resurface Cylinder Head Combustion Face 78
Measure Valve Guide ID 79
Replace Valve Guides 79
Clean and Inspect Valve Seats 80
Grind Valve Seats 80
Remove Valve Seat Inserts 81
Measure Valve Seat Bore in Cylinder Head 81
Install Valve Seat Inserts 82
Install Valves 82
Replace Unit Injector Sleeve in Cylinder Head Using JDG981 84
Replace Unit Injector Sleeve in Cylinder Head Using JDG1184 88
Remove Unit Injector Sleeve Using JDG10014 96
Clean and Inspect Top Deck of Cylinder Block 98
Measure Cylinder Liner Standout (Height Above Block) 99
Install Cylinder Head100
Torque-Turn Cylinder Head Cap Screws102
Install Rocker Arm Assembly103
Complete Final Assembly for Cylinder Head Installation109
Cylinder Block, Liners, Pistons, and Rods111
Remove and Install Cylinder Block Front Plate111
Preliminary Liner, Piston, and Rod Checks113
Connecting Rods—General Information114
Remove Pistons and Connecting Rods115
Measure Cylinder Liner Standout (Height Above Block)118
Remove Cylinder Liners Using D01062AA or D01073AA Cylinder Liner119
Remove Cylinder Liners Using JDG1145 Cylinder Liner Service Set121
Visually Inspect Cylinder Liners123
Deglaze Cylinder Liners124
Clean Cylinder Liners125
Cylinder Liner Manufacturing Date Code Explanation126
Disassemble Piston/Rod Assembly and Clean Piston127
Check Piston Compression Ring Groove Wear—6105 Engines128
Check Piston Compression Ring Groove Wear—6125 Engines129
Check Piston Oil Control Ring Groove Wear—6105 and 6125 Engines130
Inspect Piston Pin and Pin Bore in Piston131
Determine Piston-to-Liner Clearance131
Measure Liner Flange Thickness132
Inspect and Measure Connecting Rod Bearings133
Inspect Connecting Rod and Cap134
Inspect Piston Pins and Rod Bushings136
Remove Piston Pin Bushing, Clean, and Inspect Bushing Bore137
Install Piston Pin Bushing138
Complete Disassembly of Cylinder Block (If Required)139
Inspect and Clean Cylinder Block140
Measure Cylinder Block141
Recheck Cylinder Liner Standout (Height Above Block)142
Install Cylinder Liner O-Rings and Packings143
Install Cylinder Liners144
Assemble Pistons and Connecting Rods145
Install Pistons and Connecting Rods146
Torque-Turn Connecting Rod Cap Screws149
Check Engine Rotation for Excessive Tightness149
Measure Piston Protrusion150
Remove and Install Piston Spray Jets150
Complete Final Assembly151
Crankshaft, Main Bearings, and Flywheel153
Crankshaft Vibration Damper Torque Sequence153
Inspect Crankshaft Vibration Damper153
Check Crankshaft End Play154
Remove Crankshaft Rubber Damper and Pulley154
Remove Viscous Damper and Front Crankshaft Oil Seal156
Remove Timing Gear Cover158
Check Flywheel Housing Face Runout159
Check Flywheel Face Flatness159
Remove Flywheel160
Inspect and Repair Flywheel160
Replace Flywheel Ring Gear161
Remove and Install Flywheel Housing162
Install Flywheel163
Remove Rear Crankshaft Oil Seal and Housing Assembly164
Crankshaft and Main Bearing Failure Analysis166
Remove Crankshaft Main Bearings167
Check Main Bearing-to-Journal Oil Clearance168
Remove Crankshaft169
Inspect Crankshaft170
Measure Assembled ID of Bearings and OD of Crankshaft Journals171
Measure Assembled ID of Main Bearing Caps (Without Bearings)171
Crankshaft Grinding Guidelines172
Crankshaft Grinding Specifications173
Replace Crankshaft Drive Gear174
Inspect Thrust Bearings175
Thrust Bearing New Part Specifications175
Install Main and Thrust Bearing Inserts in Block176
Install Crankshaft177
Install Crankshaft Rear Oil Seal Housing180
Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly181
Install Timing Gear Cover182
Install Crankshaft Vibration Rubber Damper and Front Oil Seal186
Install Viscous Damper Assembly and Front Oil Seal190
Complete Final Assembly193
Camshaft and Timing Gear Train195
Camshaft Gear Access Cover Torque Sequence195
Check and Adjust Camshaft-to-Crankshaft Timing196
Adjust Front Timing Gear Backlash198
Adjust Front Timing Gear Backlash Without Using JDG993201
Remove and Install Camshaft204
Replace Fuel Supply Pump Drive Pin211
Visually Inspect Camshaft and Roller Followers211
Inspect and Measure Camshaft Bushing ID and Journal OD212
Measure Camshaft Lobe Lift Height212
Inspect Camshaft Position Sensor Lobe213
Replace Camshaft Bushings214
SAE “A” (Front) and SAE “B” (Rear) Auxiliary Drive Assembly218
SAE B Rear Auxiliary Drive — Removal and Installation219
Align SAE “A” Front Auxiliary Drive Adapter220
Lubrication System221
Oil Filter and Oil Conditioning Housing Assembly221
Remove Oil Filter and Valve Housing/Oil Cooler Cover and Valve H222
Inspect and Replace Oil Filter Adapter222
Remove, Inspect, and Install Oil Pressure Regulating Valve223
Remove, Inspect, and Install Oil Cooler and Oil Filter Bypass Va224
Remove, Inspect, and Install Oil Pressure Relief Valve (If Equip225
Remove, Clean, and Inspect Engine Oil Cooler225
Install Oil Cooler/Oil Filter Valve Housing Assembly or Oil Cool227
Remove Engine Oil Pump228
Clean and Inspect Oil Pump and Drive Gear229
Install Engine Oil Pump230
Remove Engine Oil Pan231
Remove and Install Oil Pickup Tube232
Install Engine Oil Pan232
Cooling System235
Replace Bearings in Fan Drive Assembly235
Inspect and Check Belt Tensioner Spring Tension238
Replace Belt Tensioner Assembly240
Remove Coolant Pump241
Clean and Inspect Coolant Pump Parts242
Install Coolant Pump243
Remove Thermostats244
Install Thermostats245
Test Thermostat Opening Temperature246
Remove and Install Thermostat Housing247
Remove and Install Coolant Heater—if Equipped248
Air Intake and Exhaust System249
Extending Turbocharger Life249
Remove Turbocharger250
Turbocharger Failure Analysis251
Turbocharger Seven-Step Inspection252
Perform Radial Bearing Clearance Test257
Perform Axial Bearing End Play Test257
Turbocharger — Repair257
Prelube Turbocharger258
Install Turbocharger259
Turbocharger Break-In260
Remove, Inspect, and Install Exhaust Manifold260
Remove, Inspect, and Install Intake Manifold263
Remove and Install Aftercooler Assembly (6105A and 6125A Engines264
Inspect and Repair Aftercooler (6105A and 6125A Engines)265
Fuel System267
Fuel System267
Starting and Charging Systems269
Remove and Install Alternator (OEM Engines)269
Remove and Install Starter Motor (OEM Engines)269
Theory of Operation271
Base Engine Operation273
General Engine Operation273
Lubrication System Operation276
Cooling System Operation278
Fuel System Theory of Operation279
Head Gasket Joint Construction and Operation280
Intake and Exhaust System Operation281
Turbocharger Operation282
How the Turbocharger is Lubricated282
Diagnostics283
Observable Diagnostics and Tests285
About this Section of the Manual285
105L/125L – L1 – Excessive Oil Consumption286
105L/125L – L1 – Excessive Oil Consumption286
105L/125L – L2 Engine Oil Pressure High288
105L/125L Engines – L3 – Engine Oil Pressure Low289
105L/125L Engines – L4 – Fuel in Oil290
105L/125L – C1 – Engine Coolant Temperature Above Normal291
105L/125L – C2 – Engine Coolant Temperature Below Normal292
105L/125L Engines – C3 – Coolant in Oil or Oil in Coolant292
Dynamometer Test292
Check Cylinder Compression293
Engine Oil Consumption294
Check Engine Oil Pressure295
Check for Excessive Engine Crankcase Pressure (Blow-By)296
Check for Turbocharger Oil Seal Leak297
Inspect Thermostat and Test Opening Temperature298
Pressure Test Cooling System and Radiator Cap299
Check for Head Gasket Failures300
Check Intake Manifold Pressure (Turbo Boost)301
Check for Intake and Exhaust Restrictions302
Check for Intake Air Leaks303
Check for Exhaust Air Leaks304
Check Camshaft-to-Crankshaft Timing305
Check Crankshaft Position Sensor Depth306
Tools and Other Materials307
Repair Tools and Other Materials309
Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Other Mat309
Cylinder Head and Valves (Group 020) Essential Tools309
Cylinder Head and Valves (Group 020) Service Equipment and Tools312
Cylinder Head and Valves (Group 020) Other Material313
Cylinder Block, Liners, Pistons, and Rods (Group 030) Essential 314
Cylinder Block, Liners, Pistons, and Rods (Group 030) Service Eq318
Cylinder Block, Liners, Pistons, and Rods (Group 030) Other Mate318
Crankshaft, Main Bearings and Flywheel (Group 040) Essential Too319
Crankshaft, Main Bearings and Flywheel (Group 040) Service Equip321
Crankshaft, Main Bearings and Flywheel (Group 040) Other Materia322
Camshaft and Timing Gear Train (Group 050) Essential Tools323
Camshaft and Timing Gear Train (Group 050) Service Equipment and325
Camshaft and Timing Gear Train (Group 050) Other Material325
Lubrication System (Group 060) Essential Tools326
Lubrication System (Group 060) Other Material326
Cooling System (Group 070) Essential Tools327
Cooling System (Group 070) Other Material327
Air Intake and Exhaust System (Group 080) Essential Tools328
Air Intake and Exhaust System (Group 080) Other Material328
Starting and Charging Systems (Group 100) Essential Tools329
Diagnostic Service Tools331
Observable Diagnostics and Tests Essential Tools331
Dealer Fabricated Service Tools333
How to Make Tools333
DFRG4—Camshaft Locking Tool333
DFRG3—Cylinder Liner Holding Fixture334
Specifications335
Repair and General OEM Specifications337
General OEM Engine Specifications337
Unified Inch Bolt and Screw Torque Values338
Metric Bolt and Screw Torque Values339
Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Specifica339
Cylinder Head and Valves (Group 020) Specifications340
Cylinder Block, Liners, Pistons and Rods (Group 030) Specificati343
Crankshaft, Main Bearings and Flywheel (Group 040) Specification346
Camshaft and Timing Gear Train (Group 050) Specifications348
Lubrication System (Group 060) Specifications349
Cooling System (Group 070) Specifications351
Air Intake and Exhaust System (Group 080) Specifications352
Starting and Charging Systems (Group 100) Specifications352
Diagnostic Specifications353
Observable Diagnostics and Test Specifications353
Dynamometer Test Specifications (OEM Engines)354
Intake Manifold Pressure (Turbocharger Boost) Specifications356
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VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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