John Deere Powertech 10.5 L & 12.5 L Diesel Engines Technical Manual 429433645 – PDF DOWNLOAD
DESCRIPTION:
John Deere Powertech 10.5 L & 12.5 L Diesel Engines Technical Manual 429433645 – PDF DOWNLOAD
CTM100 (06APR04)
For complete service information also see:
POWERTECHâ 10.5 L & 12.5 L Diesel
Engines—Delphi/Lucas Electronic Fuel
Systems With Delphi/Lucas EUIs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM115
POWERTECHâ 10.5 L & 12.5 L Diesel
Engines—Level 6 Electronic Fuel Systems
With Delphi/Lucas EUIs. . . . . . . . . . . . . . . . . CTM188
OEM Engine Accessories . . . . . . CTM67 (English Only)
Alternators and Starter Motors. . . . . . . . . . . CTM77
Introduction:
Forward :
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 (CTM100) 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:
· CTM115—Delphi/Lucas Electronic Fuel Systems
With Delphi/Lucas EUIs
· CTM188—Level 6 Electronic Fuel Systems With
Delphi/Lucas EUIs
- CTM115 and CTM188 will cover fuel system repair, formerly included in CTM100, 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 CTM650 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 Technical Manual 429433645 – PDF DOWNLOAD
Contents 13
General Information 15
Safety 17
Handle Fluids Safely—Avoid Fires 17
Service Cooling System Safely 17
Prepare for Emergencies 17
Handling Batteries Safely 18
Avoid High-Pressure Fluids 19
Wear Protective Clothing 19
Service Machines Safely 20
Work In Ventilated Area 20
Work in Clean Area 20
Remove Paint Before Welding or Heating 21
Avoid Heating Near Pressurized Fluid Lines 21
Illuminate Work Area Safely 22
Use Proper Lifting Equipment 22
Construct Dealer-Made Tools Safely 22
Practice Safe Maintenance 23
Use Proper Tools 23
Dispose of Waste Properly 24
Live With Safety 24
Engine Identification and Applications 25
Engine Model Designation 25
Engine Serial Number Plate Information 26
Engine Option Code Label 27
Engine Application Chart 28
Fuels, Lubricants and Coolant 31
Diesel Fuel 31
Bio-Diesel Fuel 32
Lubricity of Diesel Fuel 33
Dieselscan Fuel Analysis 33
Diesel Engine Break-In Oil 34
Diesel Engine Oil—Non-Certified and Tier I Certified Engines 35
Diesel Engine Oil—Tier II Engines 36
Extended Diesel Engine Oil Service Intervals 37
Alternative and Synthetic Lubricants 37
Mixing of Lubricants 38
OILSCAN™and COOLSCAN™ 38
Grease 39
Diesel Engine Coolant 40
Supplemental Coolant Additives 41
Testing Diesel Engine Coolant 42
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes 43
Operating in Warm Temperature Climates 44
Flush and Service Cooling System 45
Disposing of Coolant 46
Repair and Adjustments 47
Engine Rebuild Guide, Break-In and Tune-Up 51
Engine Overhaul Guidelines 51
Engine Repair Stand 51
Safety Precautions 52
Disconnect Turbocharger Oil Inlet Line 53
Install Engine Adapter Onto Repair Stand 53
Engine Lifting Procedure 54
Mount Engine Onto Repair Stand 56
Clean Engine 57
6105 and 6125 Engine Disassembly Sequence 58
Sealant Application Guidelines 61
6105 and 6125 Engine Assembly Sequence 63
Engine Break-In Guidelines 65
Perform Engine Break-In 66
Check Crankcase Ventilation System 67
Check Air Intake System 68
Check Exhaust System 68
Check and Service Cooling System 69
Check Electrical System 71
Preliminary Engine Testing Before Tune-Up 72
General Tune-Up Recommendations 73
Cylinder Head and Valves 75
Remove and Install Rocker Arm Cover 75
Clean and Inspect Crankcase Ventilation Assembly 76
Replace Rocker Arm Cover Gasket 77
Check and Adjust Valve Assembly Clearances and Injector Preload 78
Remove Rocker Arm Assembly 84
Remove Cylinder Head 86
Diagnosing Head Gasket Joint Failures 91
Head Gasket Inspection and Repair Sequence 93
Disassemble and Inspect Rocker Arms and Shaft Assembly 95
Preliminary Cylinder Head and Valve Checks 96
Assemble Rocker Arms and Shaft Assembly 97
Check Valve Height in Relation to Head Surface (Valve Recess) 97
Remove Valve Assembly 98
Inspect and Measure Valve Springs 99
Inspect Valve Rotators100
Clean, Inspect, and Measure Valves101
Grind Valves102
Clean and Inspect Cylinder Head103
Check Cylinder Head Flatness104
Measure Cylinder Head Thickness105
Resurface Cylinder Head Combustion Face106
Measure Valve Guide ID107
Replace Valve Guides107
Clean and Inspect Valve Seats108
Grind Valve Seats109
Remove Valve Seat Inserts110
Measure Valve Seat Bore in Cylinder Head111
Install Valve Seat Inserts112
Install Valves112
Replace Unit Injector Sleeve in Cylinder Head Using JDG981114
Replace Unit Injector Sleeve in Cylinder Head Using JDG1184119
Clean and Inspect Top Deck of Cylinder Block129
Measure Cylinder Liner Standout (Height Above Block)130
Install Cylinder Head131
Torque-Turn Cylinder Head Cap Screws133
Install Rocker Arm Assembly135
Complete Final Assembly for Cylinder Head Installation142
Cylinder Block, Liners, Pistons, and Rods143
Remove and Install Cylinder Block Front Plate143
Preliminary Liner, Piston, and Rod Checks147
Connecting Rods—General Information148
Remove Pistons and Connecting Rods149
Measure Cylinder Liner Standout (Height Above Block)153
Remove Cylinder Liners Using D01062AA or D01073AA Cylinder Liner Puller154
Remove Cylinder Liners Using JDG1145 Cylinder Liner Service Set156
Visually Inspect Cylinder Liners158
Deglaze Cylinder Liners159
Clean Cylinder Liners160
Cylinder Liner Manufacturing Date Code Explanation161
Disassemble Piston/Rod Assembly and Clean Piston162
Check Piston Compression Ring Groove Wear—6105 Engines164
Check Piston Compression Ring Groove Wear—6125 Engines165
Check Piston Oil Control Ring Groove Wear—6105 and 6125 Engines166
Inspect Piston Pin and Pin Bore in Piston167
Determine Piston-to-Liner Clearance168
Measure Liner Flange Thickness170
Inspect and Measure Connecting Rod Bearings171
Inspect Connecting Rod and Cap173
Inspect Piston Pins and Rod Bushings176
Remove Piston Pin Bushing, Clean, and Inspect Bushing Bore178
Install Piston Pin Bushing179
Complete Disassembly of Cylinder Block (If Required)180
Inspect and Clean Cylinder Block181
Measure Cylinder Block183
Recheck Cylinder Liner Standout (Height Above Block)185
Install Cylinder Liner O-Rings and Packings186
Install Cylinder Liners187
Assemble Pistons and Connecting Rods189
Install Pistons and Connecting Rods190
Torque-Turn Connecting Rod Cap Screws194
Check Engine Rotation for Excessive Tightness195
Measure Piston Protrusion195
Remove and Install Piston Spray Jets196
Complete Final Assembly197
Crankshaft, Main Bearings, and Flywheel199
Crankshaft Vibration Damper Torque Sequence199
Inspect Crankshaft Vibration Damper200
Check Crankshaft End Play201
Remove Crankshaft Vibration Damper and Pulley202
Remove Crankshaft Front Oil Seal203
Remove Timing Gear Cover204
Check Flywheel Housing Face Runout205
Check Flywheel Face Flatness206
Remove Flywheel206
Inspect and Repair Flywheel207
Replace Flywheel Ring Gear208
Remove and Install Flywheel Housing209
Install Flywheel210
Remove Rear Crankshaft Oil Seal and Housing Assembly211
Crankshaft and Main Bearing Failure Analysis213
Remove Crankshaft Main Bearings214
Check Main Bearing-to-Journal Oil Clearance216
Remove Crankshaft217
Inspect Crankshaft218
Measure Assembled ID of Bearings and OD of Crankshaft Journals220
Measure Assembled ID of Main Bearing Caps (Without Bearings)221
Crankshaft Grinding Guidelines222
Crankshaft Grinding Specifications223
Replace Crankshaft Drive Gear224
Inspect Thrust Bearings225
Thrust Bearing New Part Specifications225
Install Main Bearing Inserts in Block226
Install Crankshaft227
Install Crankshaft Rear Oil Seal Housing230
Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly231
Install Timing Gear Cover232
Install Crankshaft Vibration Damper and Front Oil Seal237
Complete Final Assembly241
Camshaft and Timing Gear Train243
Camshaft Gear Access Cover Torque Sequence243
Check and Adjust Camshaft-to-Crankshaft Timing244
Adjust Front Timing Gear Backlash246
Remove and Install Camshaft251
Replace Fuel Supply Pump Drive Pin260
Visually Inspect Camshaft and Roller Followers260
Inspect and Measure Camshaft Bushing ID and Journal OD261
Measure Camshaft Lobe Lift Height262
Inspect Camshaft Position Sensor Lobe262
Replace Camshaft Bushings263
SAE “A” (Front) and SAE “B” (Rear) Auxiliary Drive Assembly268
SAE “B” Rear Auxiliary Drive269
Align SAE “A” Front Auxiliary Drive Adapter270
Lubrication System271
Oil Filter and Oil Conditioning Housing Assembly271
Remove Oil Filter and Valve Housing/Oil Cooler Cover and Valve Housing272
Inspect and Replace Oil Filter Adapter272
Remove, Inspect, and Install Oil Pressure Regulating Valve273
Remove, Inspect, and Install Oil Cooler and Oil Filter Bypass Valves274
Remove, Inspect, and Install Oil Pressure Relief Valve (If Equipped)275
Remove, Clean, and Inspect Engine Oil Cooler276
Install Oil Cooler/Oil Filter Valve Housing Assembly or Oil Cooler Cover/Valve Housing Assembly278
Remove Engine Oil Pump280
Clean and Inspect Oil Pump and Drive Gear281
Install Engine Oil Pump282
Remove Engine Oil Pan283
Remove and Install Oil Pickup Tube284
Install Engine Oil Pan285
Cooling System287
Replace Bearings in Fan Drive Assembly287
Inspect and Check Belt Tensioner Spring Tension291
Replace Belt Tensioner Assembly293
Remove Coolant Pump294
Clean and Inspect Coolant Pump Parts295
Install Coolant Pump296
Remove Thermostats297
Install Thermostats298
Test Thermostat Opening Temperature299
Remove and Install Thermostat Housing300
Remove and Install Coolant Heater—if Equipped301
Air Intake and Exhaust System303
Extending Turbocharger Life303
Remove Turbocharger305
Turbocharger Failure Analysis306
Turbocharger Seven-Step Inspection308
Perform Radial Bearing Clearance Test315
Perform Axial Bearing End Play Test316
Repair Turbocharger316
Prelube Turbocharger317
Install Turbocharger318
Turbocharger Break-In319
Remove, Inspect, and Install Exhaust Manifold320
Remove, Inspect, and Install Intake Manifold323
Remove and Install Aftercooler Assembly (6105A and 6125A Engines)325
Inspect and Repair Aftercooler (6105A and 6125A Engines)327
Fuel System329
Fuel System329
Starting and Charging Systems331
Remove and Install Alternator (OEM Engines)331
Remove and Install Starter Motor (OEM Engines)332
Theory of Operation333
Base Engine Operation335
General Engine Operation335
Lubrication System Operation338
Cooling System Operation342
Fuel System Theory of Operation344
Head Gasket Joint Construction and Operation345
Intake and Exhaust System Operation346
Turbocharger Operation347
How the Turbocharger is Lubricated347
Diagnostics349
Observable Diagnostics and Tests351
About this Section of the Manual351
105L/125L – L1 – Excessive Oil Consumption352
105L/125L – L1 – Excessive Oil Consumption352
352
353
353
354
105L/125L – L2 Engine Oil Pressure High355
105L/125L Engines – L3 – Engine Oil Pressure Low356
105L/125L – C1 – Engine Coolant Temperature Above Normal357
105L/125L – C2 – Engine Coolant Temperature Below Normal358
105L/125L Engines – C3 – Coolant in Oil or Oil in Coolant358
Dynamometer Test359
Engine Oil Consumption360
Check Engine Oil Pressure361
Check for Excessive Engine Crankcase Pressure (Blow-By)362
Check for Turbocharger Oil Seal Leak363
Inspect Thermostat and Test Opening Temperature364
Pressure Test Cooling System and Radiator Cap365
Check for Head Gasket Failures367
Check Intake Manifold Pressure (Turbo Boost)369
Check for Intake and Exhaust Restrictions370
Check for Intake Air Leaks371
Check for Exhaust Air Leaks372
Check Camshaft-to-Crankshaft Timing373
Check Crankshaft Position Sensor Depth374
Tools and Other Materials375
Repair Tools and Other Materials377
Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Other Material377
Cylinder Head and Valves (Group 020) Essential Tools377
Cylinder Head and Valves (Group 020) Service Equipment and Tools382
Cylinder Head and Valves (Group 020) Other Material384
Cylinder Block, Liners, Pistons, and Rods (Group 030) Essential Tools385
Cylinder Block, Liners, Pistons, and Rods (Group 030) Service Equipment and Tools390
Cylinder Block, Liners, Pistons, and Rods (Group 030) Other Material391
Crankshaft, Main Bearings and Flywheel (Group 040) Essential Tools392
Crankshaft, Main Bearings and Flywheel (Group 040) Service Equipment and Tools394
Crankshaft, Main Bearings and Flywheel (Group 040) Other Material396
Camshaft and Timing Gear Train (Group 050) Essential Tools397
Camshaft and Timing Gear Train (Group 050) Service Equipment and Tools399
Camshaft and Timing Gear Train (Group 050) Other Material400
Lubrication System (Group 060) Essential Tools401
Lubrication System (Group 060) Other Material402
Cooling System (Group 070) Essential Tools403
Cooling System (Group 070) Other Material403
Air Intake and Exhaust System (Group 080) Essential Tools404
Air Intake and Exhaust System (Group 080) Other Material404
Starting and Charging Systems (Group 100) Essential Tools405
Diagnostic Service Tools407
Observable Diagnostics and Tests Essential Tools407
Dealer Fabricated Service Tools409
How to Make Tools409
DFRG4—Camshaft Locking Tool409
DFRG3—Cylinder Liner Holding Fixture410
Specifications411
Repair and General OEM Specifications413
General OEM Engine Specifications413
Unified Inch Bolt and Cap Screw Torque Values414
Metric Bolt and Cap Screw Torque Values415
Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Specifications416
Cylinder Head and Valves (Group 020) Specifications417
Cylinder Block, Liners, Pistons and Rods (Group 030) Specifications421
Crankshaft, Main Bearings and Flywheel (Group 040) Specifications426
Camshaft and Timing Gear Train (Group 050) Specifications429
Lubrication System (Group 060) Specifications431
Cooling System (Group 070) Specifications433
Air Intake and Exhaust System (Group 080) Specifications435
Starting and Charging Systems (Group 100) Specifications436
Diagnostic Specifications437
Observable Diagnostics and Test Specifications437
Dynamometer Test Specifications (OEM Engines)438
Intake Manifold Pressure (Turbocharger Boost) Specifications440
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