Complete Component Technical Manual for John Deere PowerTech 10.5L & 12.5L Diesel Engines. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This John Deere PowerTech 10.5L & 12.5L Diesel Engines - John Deere Base Engine Technical Manual is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

CTM100 (06APR04) (ENGLISH) - PowerTech™ 10.5L & 12.5L Diesel Engines - John Deere Base Engine Technical Manual.pdf
ctm103 - PowerTech™ 10,5-l- und 12,5-l- Dieselmotoren Grundmotor -: (Weltweite Ausgabe).pdf
ctm102 - Moteurs diesel PowerTech™ 10,5 l et 12,5 l Moteur standard -: (Édition internationale).pdf
ctm141 - Motori diesel PowerTech™ da 10,5 l e 12,5 l Motore base -: (Edizione universale).pdf
ctm197 - Дизельные двигатели PowerTech™ 10,5 л и 12,5 л базовые двигатели -: (Исполнение для всех стран).pdf
ctm269 - PowerTech™ 10.5 升和 12.5 升 柴油发动机 基本发动机 -: (世界通用机型).pdf
ctm101 - Motores diesel PowerTech™ 10,5 l y 12,5 l Motor básico -: (Edición mundial).pdf

Category: CTM
Language: Spanish French German Italian Russian Chinese
Published on 2017/03/22

EXCERPT:
TABLE OF CONTENTS
SECTION 01—General Information
Group 000—Safety
Group 001—Engine Identification and Applications
Group 002—Fuels, Lubricants and Coolant
02 SECTION 02—Repair and Adjustments
Group 010—Engine Rebuild Guide, Break-In and Tune-Up
Group 020—Cylinder Head and Valves
Group 030—Cylinder Block, Liners, Pistons, and Rods
Group 040—Crankshaft, Main Bearings, and Flywheel
Group 050—Camshaft and Timing Gear Train
Group 060—Lubrication System
Group 070—Cooling System
Group 080—Air Intake and Exhaust System
Group 090—Fuel System
Group 100—Starting and Charging Systems
SECTION 03—Theory of Operation
Group 120—Base Engine Operation
SECTION 04—Diagnostics
Group 150—Observable Diagnostics and Tests
SECTION 05—Tools and Other Materials
Group 170—Repair Tools and Other Materials
Group 180—Diagnostic Service Tools
Group 190—Dealer Fabricated Service Tools
SECTION 06—Specifications
Group 200—Repair and General OEM
Specifications
Group 210—Diagnostic Specifications
Index
...
TABLE OF CONTENTS...1
Section 01: General Information...26
  Group 000: Safety...26
    Avoid Heating Near Pressurized Fluid Lines...30
    Avoid High-Pressure Fluids...31
    Avoid Hot Exhaust...32
    Construct Dealer-Made Tools Safely...33
    Decommissioning — Proper Recycling and Disposal of Fluids and Components...34
    Follow Safety Instructions...35
    Handle Agricultural Chemicals Safely...36
    Handle Fluids Safely—Avoid Fires...38
    Handling Batteries Safely...39
    Illuminate Work Area Safely...41
    Install All Guards...42
    Live With Safety...43
    Park Machine Safely...44
    Practice Safe Maintenance...45
    Precautions for Welding...46
    Prepare for Emergencies...48
    Prevent Acid Burns...49
    Prevent Battery Explosions...51
    Prevent Machine Runaway...52
    Protect Against High Pressure Spray...53
    Protect Against Noise...54
    Recognize Safety Information...55
    Remove Paint Before Welding or Heating...56
    Replace Safety Signs...57
    Service Cooling System Safely...58
    Service Machines Safely...59
    Stay Clear of Rotating Drivelines...60
    Support Machine Properly...61
    Understand Signal Words...62
    Use Proper Lifting Equipment...63
    Use Proper Tools...64
    Use Steps and Handholds Correctly...65
    Wait Before Opening High-Pressure Fuel System...509
    Wear Protective Clothing...67
    Work in Clean Area...68
    Work In Ventilated Area...69
  Group 001: Engine Identification and Applications...27
    Engine Model Designation...72
    Engine Serial Number Plate Information...74
    Engine Option Code Label...76
    Engine Application Chart...77
  Group 002: Fuels, Lubricants and Coolant...27
    Diesel Fuel...81
    Diesel Fuel Additive Products...83
    BioDiesel Fuel...84
    Lubricity of Diesel Fuel...86
    Handling and Storing Diesel Fuel...87
    Testing Diesel Fuel...88
    Fuel Filters...89
    Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III...90
    Oil Information for Uncertified or Tier 1 Engines...92
    Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I...93
    Oil Information for Tier 2 Engines...95
    Diesel Engine Oil — Tier 2 and Stage II...96
    Extended Diesel Engine Oil Service Intervals...98
    Alternative and Synthetic Lubricants...99
    Mixing of Lubricants...100
    Oilscan™ and CoolScan™...101
    Grease...102
    Diesel Engine Coolant (engine with wet sleeve cylinder liners)...103
    Supplemental Coolant Additives...105
    Testing Diesel Engine Coolant...106
    Disposing of Coolant...107
    Operating in Warm Temperature Climates...108
Section 02: Repair and Adjustments...109
  Group 010: Engine Rebuild Guide, Break-In and Tune-Up...109
    Engine Overhaul Guidelines...116
    Engine Repair Stand...117
    Safety Precautions...118
    Disconnect Turbocharger Oil Inlet Line...119
    Install Adapter on Repair Stand...120
    Engine Lifting Procedure...121
    Mount Engine on Repair Stand...123
    Clean Engine...124
    6105 and 6125 Engine Disassembly Sequence...125
    Sealant Application Guidelines...129
    6105 and 6125 Engine Assembly Sequence...131
    Engine Break-In Guidelines...135
    Perform Engine Break-In...136
    Check Crankcase Ventilation System...138
    Check Air Intake System...139
    Check Exhaust System...140
    Check and Service Cooling System...141
    Check Electrical System...143
    Preliminary Engine Testing Before Tune-Up...145
    General Tune-Up Recommendations...146
  Group 020: Cylinder Head and Valves...109
    Remove and Install Rocker Arm Cover...149
    Clean and Inspect Crankcase Ventilation Assembly...151
    Replace Rocker Arm Cover Gasket...152
    Check and Adjust Valve Assembly Clearances and Injector Preload...153
    Remove Rocker Arm Assembly...159
    Remove Cylinder Head...161
    Diagnosing Head Gasket Joint Failures...165
    Head Gasket Inspection and Repair Sequence...167
    Disassemble and Inspect Rocker Arms and Shaft Assembly...169
    Preliminary Cylinder Head and Valve Checks...171
    Assemble Rocker Arms and Shaft Assembly...173
    Check Valve Height in Relation to Head Surface (Valve Recess)...174
    Remove Valve Assembly...175
    Inspect and Measure Valve Springs...177
    Inspect Valve Rotators...179
    Clean, Inspect, and Measure Valves...180
    Grind Valves...182
    Clean and Inspect Cylinder Head...183
    Check Cylinder Head Flatness...184
    Measure Cylinder Head Thickness...185
    Resurface Cylinder Head Combustion Face...186
    Measure Valve Guide ID...187
    Replace Valve Guides...188
    Clean and Inspect Valve Seats...190
    Grind Valve Seats...191
    Remove Valve Seat Inserts...193
    Measure Valve Seat Bore in Cylinder Head...194
    Install Valve Seat Inserts...195
    Install Valves...196
    Replace Unit Injector Sleeve in Cylinder Head Using JDG981...198
    Replace Unit Injector Sleeve in Cylinder Head Using JDG1184...203
    Remove Unit Injector Sleeve Using JDG10014...214
    Clean and Inspect Top Deck of Cylinder Block...217
    Measure Cylinder Liner Standout (Height Above Block)...248
    Install Cylinder Head...220
    Torque-Turn Cylinder Head Cap Screws...222
    Install Rocker Arm Assembly...225
    Complete Final Assembly for Cylinder Head Installation...233
  Group 030: Cylinder Block, Liners, Pistons, and Rods...110
    Remove and Install Cylinder Block Front Plate...237
    Preliminary Liner, Piston, and Rod Checks...240
    Connecting Rods—General Information...242
    Remove Pistons and Connecting Rods...244
    Measure Cylinder Liner Standout (Height Above Block)...248
    Remove Cylinder Liners Using D01062AA or D01073AA Cylinder Liner Puller...250
    Remove Cylinder Liners Using JDG1145 Cylinder Liner Service Set...252
    Visually Inspect Cylinder Liners...255
    Deglaze Cylinder Liners...258
    Clean Cylinder Liners...259
    Cylinder Liner Manufacturing Date Code Explanation...260
    Disassemble Piston/Rod Assembly and Clean Piston...262
    Check Piston Compression Ring Groove Wear—6105 Engines...264
    Check Piston Compression Ring Groove Wear—6125 Engines...266
    Check Piston Oil Control Ring Groove Wear—6105 and 6125 Engines...268
    Inspect Piston Pin and Pin Bore in Piston...270
    Determine Piston-to-Liner Clearance...272
    Measure Liner Flange Thickness...274
    Inspect and Measure Connecting Rod Bearings...275
    Inspect Connecting Rod and Cap...277
    Inspect Piston Pins and Rod Bushings...281
    Remove Piston Pin Bushing, Clean, and Inspect Bushing Bore...283
    Install Piston Pin Bushing...284
    Complete Disassembly of Cylinder Block (If Required)...286
    Inspect and Clean Cylinder Block...288
    Measure Cylinder Block...290
    Recheck Cylinder Liner Standout (Height Above Block)...292
    Install Cylinder Liner O-Rings and Packings...294
    Install Cylinder Liners...296
    Assemble Pistons and Connecting Rods...298
    Install Pistons and Connecting Rods...300
    Torque-Turn Connecting Rod Cap Screws...304
    Check Engine Rotation for Excessive Tightness...306
    Measure Piston Protrusion...307
    Remove and Install Piston Spray Jets...308
    Complete Final Assembly...382
  Group 040: Crankshaft, Main Bearings, and Flywheel...111
    Crankshaft Vibration Damper Torque Sequence...312
    Inspect Crankshaft Vibration Damper...313
    Check Crankshaft End Play...315
    Remove Crankshaft Rubber Damper and Pulley...316
    Remove Viscous Damper and Front Crankshaft Oil Seal...318
    Remove Timing Gear Cover...321
    Check Flywheel Housing Face Runout...323
    Check Flywheel Face Flatness...325
    Remove Flywheel...326
    Inspect and Repair Flywheel...327
    Replace Flywheel Ring Gear...328
    Remove and Install Flywheel Housing...329
    Install Flywheel...331
    Remove Rear Crankshaft Oil Seal and Housing Assembly...334
    Crankshaft and Main Bearing Failure Analysis...337
    Remove Crankshaft Main Bearings...338
    Check Main Bearing-to-Journal Oil Clearance...340
    Remove Crankshaft...341
    Inspect Crankshaft...343
    Measure Assembled ID of Bearings and OD of Crankshaft Journals...345
    Measure Assembled ID of Main Bearing Caps (Without Bearings)...346
    Crankshaft Grinding Guidelines...347
    Crankshaft Grinding Specifications...349
    Replace Crankshaft Drive Gear...350
    Inspect Thrust Bearings...352
    Thrust Bearing New Part Specifications...353
    Install Main and Thrust Bearing Inserts in Block...354
    Install Crankshaft...356
    Install Crankshaft Rear Oil Seal Housing...361
    Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly...363
    Install Timing Gear Cover...365
    Install Crankshaft Vibration Rubber Damper and Front Oil Seal...372
    Install Viscous Damper Assembly and Front Oil Seal...376
    Complete Final Assembly...382
  Group 050: Camshaft and Timing Gear Train...113
    Camshaft Gear Access Cover Torque Sequence...384
    Check and Adjust Camshaft-to-Crankshaft Timing...385
    Adjust Front Timing Gear Backlash...388
    Adjust Front Timing Gear Backlash Without Using JDG993...393
    Remove and Install Camshaft...398
    Replace Fuel Supply Pump Drive Pin...406
    Visually Inspect Camshaft and Roller Followers...407
    Inspect and Measure Camshaft Bushing ID and Journal OD...408
    Measure Camshaft Lobe Lift Height...409
    Inspect Camshaft Position Sensor Lobe...410
    Replace Camshaft Bushings...411
    SAE “A” (Front) and SAE “B” (Rear) Auxiliary Drive Assembly...417
    SAE B Rear Auxiliary Drive — Removal and Installation...419
    Align SAE “A” Front Auxiliary Drive Adapter...421
  Group 060: Lubrication System...113
    Oil Filter and Oil Conditioning Housing Assembly...425
    Remove Oil Filter and Valve Housing/Oil Cooler Cover and Valve Housing...427
    Inspect and Replace Oil Filter Adapter...428
    Remove, Inspect, and Install Oil Pressure Regulating Valve...429
    Remove, Inspect, and Install Oil Cooler and Oil Filter Bypass Valves...430
    Remove, Inspect, and Install Oil Pressure Relief Valve (If Equipped)...432
    Remove, Clean, and Inspect Engine Oil Cooler...433
    Install Oil Cooler/Oil Filter Valve Housing Assembly or Oil Cooler Cover/Valve Housing Assembly...436
    Remove Engine Oil Pump...439
    Clean and Inspect Oil Pump and Drive Gear...441
    Install Engine Oil Pump...442
    Remove Engine Oil Pan...444
    Remove and Install Oil Pickup Tube...445
    Install Engine Oil Pan...446
  Group 070: Cooling System...113
    Replace Bearings in Fan Drive Assembly...453
    Inspect and Check Belt Tensioner Spring Tension...457
    Replace Belt Tensioner Assembly...459
    Remove Coolant Pump...461
    Clean and Inspect Coolant Pump Parts...463
    Install Coolant Pump...465
    Remove Thermostats...466
    Install Thermostats...467
    Test Thermostat Opening Temperature...469
    Remove and Install Thermostat Housing...471
    Remove and Install Coolant Heater—if Equipped...473
  Group 080: Air Intake and Exhaust System...114
    Extending Turbocharger Life...478
    Remove Turbocharger...481
    Turbocharger Failure Analysis...482
    Turbocharger Seven-Step Inspection...485
    Perform Radial Bearing Clearance Test...492
    Perform Axial Bearing End Play Test...493
    Turbocharger — Repair...494
    Prelube Turbocharger...495
    Install Turbocharger...496
    Turbocharger Break-In...498
    Recommendations for Turbocharger Use...499
    Remove, Inspect, and Install Exhaust Manifold...500
    Remove, Inspect, and Install Intake Manifold...503
    Remove and Install Aftercooler Assembly (6105A and 6125A Engines)...505
    Inspect and Repair Aftercooler (6105A and 6125A Engines)...507
  Group 090: Fuel System...509
    Fuel System...509
  Group 100: Starting and Charging Systems...114
    Remove and Install Alternator (OEM Engines)...512
    Remove and Install Starter Motor (OEM Engines)...514
Section 03: Theory of Operation...515
  Group 120: Base Engine Operation...515
    General Engine Operation...519
    Lubrication System Operation...522
    Cooling System Operation...525
    Fuel System Theory of Operation...528
    Head Gasket Joint Construction and Operation...529
    Intake and Exhaust System Operation...531
    Turbocharger Operation...532
    How the Turbocharger is Lubricated...534
Section 04: Diagnostics...535
  Group 150: Observable Diagnostics and Tests...535
    About this Section of the Manual...537
    10.5L/12.5L - L1 - Excessive Oil Consumption...538
    10.5L/12.5L - L2 Engine Oil Pressure High...542
    10.5L/12.5L Engines - L3 - Engine Oil Pressure Low...543
    10.5L/12.5L Engines - L4 - Fuel in Oil...544
    10.5L/12.5L Engines - L5 - Soot or Sludge in the Oil...545
    10.5L/12.5L - C1 - Engine Coolant Temperature Above Normal...547
    10.5L/12.5L - C2 - Engine Coolant Temperature Below Normal...548
    10.5L/12.5L Engines - C3 - Coolant in Oil or Oil in Coolant...549
    10.5L/12.5L Engines - C4 - Coolant Leaking from Weep Hole...550
    Dynamometer Test...551
    Check Cylinder Compression...552
    Engine Oil Consumption...555
    Check Engine Oil Pressure...556
    Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)...557
    Check for Turbocharger Oil Seal Leak...568
    Inspect Thermostat and Test Opening Temperature...569
    Pressure Test Cooling System and Radiator Cap...571
    Check for Head Gasket Failures...573
    Check Intake Manifold Pressure (Turbo Boost)...576
    Check for Intake and Exhaust Restrictions...577
    Check for Intake Air Leaks...579
    Check for Exhaust Air Leaks...581
    Check Camshaft-to-Crankshaft Timing...582
    Check Crankshaft Position Sensor Depth...584
    Excessive Engine Vibration...586
Section 05: Tools and Other Materials...590
  Group 170: Repair Tools and Other Materials...590
    Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Other Material...592
    Cylinder Head and Valves (Group 020) Essential Tools...593
    Cylinder Head and Valves (Group 020) Service Equipment and Tools...597
    Cylinder Head and Valves (Group 020) Other Material...598
    Cylinder Block, Liners, Pistons, and Rods (Group 030) Essential Tools...599
    Cylinder Block, Liners, Pistons, and Rods (Group 030) Service Equipment and Tools...603
    Cylinder Block, Liners, Pistons, and Rods (Group 030) Other Material...604
    Crankshaft, Main Bearings and Flywheel (Group 040) Essential Tools...605
    Crankshaft, Main Bearings and Flywheel (Group 040) Service Equipment and Tools...607
    Crankshaft, Main Bearings and Flywheel (Group 040) Other Material...608
    Camshaft and Timing Gear Train (Group 050) Essential Tools...609
    Camshaft and Timing Gear Train (Group 050) Service Equipment and Tools...611
    Camshaft and Timing Gear Train (Group 050) Other Material...612
    Lubrication System (Group 060) Essential Tools...613
    Lubrication System (Group 060) Other Material...614
    Cooling System (Group 070) Essential Tools...615
    Cooling System (Group 070) Other Material...616
    Air Intake and Exhaust System (Group 080) Essential Tools...617
    Air Intake and Exhaust System (Group 080) Other Material...618
    Starting and Charging Systems (Group 100) Essential Tools...619
  Group 180: Diagnostic Service Tools...590
    Observable Diagnostics and Tests Essential Tools...622
  Group 190: Dealer Fabricated Service Tools...590
    How to Make Tools...625
    DFRG4—Camshaft Locking Tool...626
    DFRG3—Cylinder Liner Holding Fixture...627
Section 06: Specifications...629
  Group 200: Repair and General OEM Specifications...629
    General OEM Engine Specifications...631
    Unified Inch Bolt and Screw Torque Values...632
    Metric Bolt and Screw Torque Values...634
    Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Specifications...636
    Cylinder Head and Valves (Group 020) Specifications...637
    Cylinder Block, Liners, Pistons and Rods (Group 030) Specifications...640
    Crankshaft, Main Bearings and Flywheel (Group 040) Specifications...644
    Camshaft and Timing Gear Train (Group 050) Specifications...647
    Lubrication System (Group 060) Specifications...648
    Cooling System (Group 070) Specifications...650
    Air Intake and Exhaust System (Group 080) Specifications...651
    Starting and Charging Systems (Group 100) Specifications...652
  Group 210: Diagnostic Specifications...629
    Observable Diagnostics and Test Specifications...654
    Dynamometer Test Specifications (OEM Engines)...655
    Intake Manifold Pressure (Turbocharger Boost) Specifications...658
    
John Deere PowerTech 10.5L & 12.5L Diesel Engines Component Technical Manual (CTM100)