PowerTech 6105HF, 6105ADW, 6125 Tier II, 6125HF, 6105HRW Technical Manual

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OWERTECH

10.5 L & 12.5 L Diesel Engines

Base Engine

TECHNICAL MANUAL



OWERTECH

Engines—Base Engine

10.5 L & 12.5 L Diesel

CTM100 06APR04 (ENGLISH)

For complete service information also see:

OWERTECH

Engines—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs

.................................... CTM115

OWERTECH

Engines—Level 6 Electronic Fuel Systems

With Delphi/Lucas EUIs................. CTM188

OEM Engine Accessories ......CTM67 (English Only)

Alternators and Starter Motors........... CTM77



10.5 L & 12.5 L Diesel



10.5 L & 12.5 L Diesel

John Deere Power Systems

LITHO IN U.S.A.

Forward

Introduction

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.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Use this component technical manual in conjunction with the machine technical manual. An application

listing in Section 01, Group 001 identifies product-model/component type-model relationship.

Information is organized in sections and groups for the various components requiring service instruction. At the end of this manual are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Before beginning repair on an engine, clean the engine and mount on a repair stand. (See Section 2, Group

010.) This manual contains SI Metric units of measure

followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric.

Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on this and for engine removal and installation procedures.

Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the 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.

CTM100 (06APR04) P

OWERTECH

RG,RG34710,1 –19–11OCT00–1/1

10.5 L & 12.5 L Diesel Engines

040604

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John Deere Dealers

Introduction

The changes listed below make your CTM obsolete. Repair, operation and diagnostics on 10.5 L and 12.5 L diesel engines is now covered in three manuals. Fuel system repair has been removed from CTM100 and incorporated into its two companion manuals.

Discard CTM100 dated 20MAR01 and replace with the following new manuals.

• CTM100—10.5 L and 12.5 L Diesel Engines—Base Engine

• CTM115—10.5 L and 12.5 L Diesel Engines— Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs

• CTM188—10.5 L and 12.5 L Diesel Engines—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs

Also, copy these pages listing changes and route through your Service Department.

SECTION 01, GROUP 000 (Safety)

• Updated safety information.

SECTION 01, GROUP 001 (Engine Identification and Applications)

• Revised procedure for adjusting valves and injector preload.

• Revised procedure for repair of crankcase ventilation assembly.

• Revised valve guide specifications.

• Revised procedure for installation of rocker arm

assembly.

SECTION 02, GROUP 030 (Cylinder Block, Liners, Pistons and Rods)

• Revised procedure for connecting rod inspection.

SECTION 02, GROUP 040 (Crankshaft, Main Bearings and Flywheel)

• Revised procedure for installing timing gear cover.

• Revised procedure for checking flywheel housing

face runout.

SECTION 02, GROUP 050 (Camshaft and Timing Gear Train)

• Revised procedure for adjusting front timing gear backlash.

• Updated engine model designation chart.

• Updated engine application charts.

SECTION 01, GROUP 002 (Fuels, Lubricants and Coolants)

• Revised diesel/bio-diesel fuel guidelines and specifications.

• Revised diesel engine oil guidelines.

• Revised oilscan and coolscan guidelines.

• Revised diesel engine coolant guidelines.

SECTION 02, GROUP 010 (Engine Rebuild)

• Added new engine front lift strap.

• Revised engine disassembly sequence.

• Revised engine assembly sequence.

SECTION 02, GROUP 020 (Cylinder Head and Valves)

SECTION 02, GROUP 060 (Lubrication System)

• Added torque specifications for remote filter lines.

• Revised procedure for installation of oil pump.

• Revised specifications for oil pan cap screw torque.

SECTION 02, GROUP 070 (Cooling System)

• Revised procedure for replacement of fan drive bearings.

• Revised procedure for replacement of belt tensioners.

• Revised procedures for removal and installation of thermostats.

SECTION 02, GROUP 080 (Air Intake and Exhaust System)

• Added new information for extending turbocharger life.

CTM100 (06APR04) P

OWERTECH

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10.5 L & 12.5 L Diesel Engines

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Introduction

SECTION 02—GROUP 090 and 091(Fuel System)

NOTE: Repair procedures for fuel systems has been

moved to the following manuals:

• CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs, Section 02, Group 090

• CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs, Section 02, Group 090 (Dual Rail System) and Group 091 (Single Rail System)

Later Tier II 12.5 L engines with dual- or single-rail fuel systems are covered in CTM188.

SECTION 02—GROUP 100 (Starting and Charging Systems)

• Updated torque specifications for alternator mounting hardware.

SECTION 02—GROUP 110 (Electrical Engine Control)

NOTE: Repair procedures for electrical engine control

components has been moved to section 02, group 110 of the following manuals:

• CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs

• CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs

SECTION 03—GROUP 120 (Base Engine Operation)

• Base engine theory of operation is covered in this section/group.

NOTE: Fuel system theory of operation has been

moved to Section 03, Group 130 of the following manuals:

•

CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs

•

CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs

SECTION 04—GROUP 150 (Observable Diagnostics and Tests)

• Base engine observable tests and diagnostics are covered in this section/group.

NOTE: Fuel system testing and diagnostics has been

moved to Section 04, Group 150 in two other technical manuals: CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs and CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs.

SECTION 5 (Tools and Other Materials)

• All essential tools, service tools, dealer fabricated tools and other materials listed throughout this manual are consolidated in this section for ease of reference.

SECTION 6 (Specifications)

• All repair, test and diagnostic specifications listed throughout this manual are consolidated in this section for ease of reference.

• Updated dynamometer test specifications.

• Updated intake manifold pressure specifications.

CTM100 (06APR04) P

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10.5 L & 12.5 L Diesel Engines

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POWERTECH6105HF and 6125HF Engines

Introduction

Right Side View (Early Engine)

3/4 Right Front View (Early Engine)

RG9030 –UN–21MAY98

RG9032 –UN–21MAY98

Left Side View (Early Engine)

RG9031 –UN–21MAY98

RG9033 –UN–21MAY98

3/4 Left Front View (Early Engine)

OWERTECH

is a registered trademark of Deere & Company.

CTM100 (06APR04) P

OWERTECH

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10.5 L & 12.5 L Diesel Engines

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Introduction

POWERTECH6105HF and 6125HF Engines—Continued

3/4 Right Rear View (Early Engine)

Right Side View Later Engine S.N. (30000— )

RG11174 –UN–20NOV00

RG11171A –UN–03NOV00

3/4 Left Rear View (Early Engine)

RG11175 –UN–20NOV00

RG11172A –UN–04DEC00

3/4 Right Front View Later Engine S.N. (30000— )

OWERTECH

is a registered trademark of Deere & Company.

CTM100 (06APR04) P

OWERTECH

DPSG,OUO1004,915 –19–16NOV00–1/1

10.5 L & 12.5 L Diesel Engines

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Introduction

POWERTECH6105HRW and 6125HRW Engines

Right Side View

3/4 Right Front View

RG8222 –UN–21MAY98

RG8223 –UN–21MAY98

Left Side View

RG8221 –UN–21MAY98

RG8224 –UN–21MAY98

3/4 Left Front View

OWERTECH

is a registered trademark of Deere & Company.

CTM100 (06APR04) P

OWERTECH

RG,RG34710,3A –19–30SEP97–1/1

10.5 L & 12.5 L Diesel Engines

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Introduction

POWERTECH6105HRW and 6125HRW Engines—Continued

OWERTECH

3/4 Right Rear View

RG8220 –UN–21MAY98

is a registered trademark of Deere & Company.

3/4 Left Rear View

RG8219 –UN–21MAY98

DPSG,OUO1004,916 –19–30JUN99–1/1

CTM100 (06APR04) P

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10.5 L & 12.5 L Diesel Engines

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POWERTECH6105ADW Engine

Introduction

Right Side View (Early Engine)

3/4 Right Rear View (Early Engine)

RG8454 –UN–21MAY98

RG8453 –UN–21MAY98

3/4 Left Front View (Early Engine)

RG8448 –UN–21MAY98

RG8451 –UN–21MAY98

3/4 Left Rear View (Early Engine)

OWERTECH

is a registered trademark of Deere & Company.

CTM100 (06APR04) P

OWERTECH

RG,RG34710,5 –19–30SEP97–1/1

10.5 L & 12.5 L Diesel Engines

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Introduction

POWERTECH6105ADW Engine—Continued

OWERTECH

Right Side View Later Engines S.N. (30000—)

is a registered trademark of Deere & Company.

RG11171A –UN–03NOV00

Right Front View Later Engines S.N. (30000—)

RG11172A –UN–04DEC00

OUO1080,000028D –19–27AUG02–1/1

CTM100 (06APR04) P

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POWERTECH6125 Tier II (30000—)

Introduction

Right Side View (30000—)

Right Front View (30000—)

RG11171A –UN–03NOV00

RG11172A –UN–04DEC00

OWERTECH

is a registered trademark of Deere & Company.

CTM100 (06APR04) P

OWERTECH

RE38635,0000026 –19–20JUN03–1/1

10.5 L & 12.5 L Diesel Engines

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6105 and 6125 Engine Cutaway View

Introduction

Engine Cutaway View

A—Oil Cooler E—Crankshaft I—Piston Rings M—Valves B—Oil Pump Drive Gear F—Cylinder Liner J—Connecting Rod N—Electronic Unit Injector C—Idler Gear G—Cylinder Liner O-Rings K—Oil Spray Jet O—Two-Piece Rocker Arm D—Camshaft Gear H—Piston L—Camshaft Shaft

RG,RG34710,8 –19–30SEP97–1/1

CTM100 (06APR04) P

OWERTECH

10.5 L & 12.5 L Diesel Engines

RG8435 –UN–12JUL99

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SECTION 01—General Information

Group 000—Safety Group 001—Engine Identification and Applications Group 002—Fuels, Lubricants and Coolant

Contents

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

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.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

Previous Editions

INDX

CTM100 (06APR04)

OWERTECH

10.5 L & 12.5 L Diesel Engines

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Contents

INDX

CTM100 (06APR04)

OWERTECH

10.5 L & 12.5 L Diesel Engines

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Page

Group 000—Safety ....................01-000-1

Group 001—Engine Identification and Applications

Engine Model Designation................01-001-1

Engine Serial Number Plate Information .....01-001-2

Engine Option Code Label ...............01-001-3

Engine Application Chart.................01-001-4

Group 002—Fuels, Lubricants and Coolant

Diesel Fuel ...........................01-002-1

Bio-Diesel Fuel ........................01-002-2

Lubricity of Diesel Fuel ..................01-002-3

Dieselscan Fuel Analysis.................01-002-3

Diesel Engine Break-In Oil ...............01-002-4

Diesel Engine Oil—Non-Certified and Tier I

Certified Engines .....................01-002-5

Diesel Engine Oil—Tier II Engines .........01-002-6

Extended Diesel Engine Oil Service

Intervals............................01-002-7

Alternative and Synthetic Lubricants ........01-002-7

Mixing of Lubricants ....................01-002-8

OILSCANand COOLSCAN ............01-002-8

Grease ..............................01-002-9

Diesel Engine Coolant..................01-002-10

Supplemental Coolant Additives ..........01-002-11

Testing Diesel Engine Coolant ...........01-002-12

Replenishing Supplemental Coolant

Additives (SCAs) Between Coolant

Changes ..........................01-002-13

Operating in Warm Temperature Climates . .01-002-14

Flush and Service Cooling System ........01-002-15

Disposing of Coolant...................01-002-16

Section 01

General Information

Contents

CTM100 (06APR04)

01-1

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10.5 L & 12.5 L Diesel Engines

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Contents

CTM100 (06APR04)

01-2

OWERTECH

10.5 L & 12.5 L Diesel Engines

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Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn

spontaneously.

Group 000

Safety

01 000 1

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Prepare for Emergencies

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

DX,RCAP –19–04JUN90–1/1

TS281 –UN–23AUG88

CTM100 (06APR04)

01-000-1

OWERTECH

DX,FIRE2 –19–03MAR93–1/1

10.5 L & 12.5 L Diesel Engines

TS291 –UN–23AUG88

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000

Handling Batteries Safely

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Safety

Always remove grounded (-) battery clamp first and replace it last.

CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

Explosion

TS204 –UN–23AUG88

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed2L(2quarts).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

CTM100 (06APR04)

01-000-2

OWERTECH

Acid

DPSG,OUO1004,2758 –19–11MAY00–1/1

10.5 L & 12.5 L Diesel Engines

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TS203 –UN–23AUG88

Safety

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

01 000 3

X9811 –UN–23AUG88

Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,FLUID –19–03MAR93–1/1

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

CTM100 (06APR04)

01-000-3

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10.5 L & 12.5 L Diesel Engines

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000

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Safety

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

Work in Clean Area

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt

shortcuts.

DX,LOOSE –19–04JUN90–1/1

TS228 –UN–23AUG88

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

CTM100 (06APR04)

01-000-4

OWERTECH

DX,CLEAN –19–04JUN90–1/1

10.5 L & 12.5 L Diesel Engines

T6642EJ –UN–18OCT88

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Safety

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch. Remove paint before heating:

• Remove paint a minimum of 101 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

01 000 5

TS220 –UN–23AUG88

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

DX,PAINT –19–24JUL02–1/1

TS953 –UN–15MAY90

DX,TORCH –19–03MAR93–1/1

CTM100 (06APR04)

01-000-5

OWERTECH

10.5 L & 12.5 L Diesel Engines

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000

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Safety

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

DX,LIGHT –19–04JUN90–1/1

TS223 –UN–23AUG88

TS226 –UN–23AUG88

DX,LIFT –19–04JUN90–1/1

CTM100 (06APR04)

01-000-6

Construct Dealer-Made Tools Safely

DPSG,OUO1004,899 –19–19MAY99–1/1

OWERTECH

10.5 L & 12.5 L Diesel Engines

LX1016749 –UN–01JUL97

040604

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Safety

Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

01 000 7

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS779 –UN–08NOV89

Use only service parts meeting John Deere specifications.

CTM100 (06APR04)

01-000-7

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DX,REPAIR –19–17FEB99–1/1

10.5 L & 12.5 L Diesel Engines

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000

Dispose of Waste Properly

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Safety

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

CTM100 (06APR04)

01-000-8

OWERTECH

DX,LIVE –19–25SEP92–1/1

10.5 L & 12.5 L Diesel Engines

TS231 –19–07OCT88

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Engine Identification and Applications

Engine Model Designation

Example: John Deere Engine Model—6105HRW01 John Deere engine model designation includes number of

cylinders, displacement in liters, aspiration, user code, and application code. For example:

6105HRW01 Engine

6 ............................................................................ Number of cylinders

10.5 ............................................................................. Liter designation

H ............................................................................................. Aspiration

RW ........................................................................................ User code

01 ............................................................................... Application Code

Aspiration Code

A ...................................... Turbocharged and air-to-coolant aftercooled

H ............................................. Turbocharged and air-to-air aftercooled

User Code

DW .................................. Davenport (Construction Equipment) Works

F ......................................... OEM (Outside Equipment Manufacturers)

RW ................................................................ Waterloo (Tractor) Works

T ........................................ Dubuque (Construction Equipment) Works

T8 ............................................................................................. Cameco

Z ............................................. Zweibrucken (Forage Harvester) Works

OEM users are non-Deere users of John Deere engines.

Group 001

01 001 1

RG8427 –UN–21MAY98

Engine Serial Number Plate

Application Code

01, 02, etc., .............................................. Code for specific application

RG,RG34710,23 –19–05SEP02–1/1

CTM100 (06APR04)

01-001-1

OWERTECH

10.5 L & 12.5 L Diesel Engines

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Engine Identification and Applications

001

Engine Serial Number Plate Information

IMPORTANT: The engine serial number plate can be

easily destroyed. Remove the plate or record the information elsewhere, before “hot tank” cleaning the block.

1. Example Engine Serial Number (A) Each engine has a 13-digit John Deere engine serial

number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example:

RG6105H000000

RG ........................................................ Factory code producing engine

6105H ........................................................... Engine model designation

000000 .................................................................... Sequential number

Factory Code Producing Engine

RG ................................................................... Waterloo Engine Works

Engine Model Designation

6105H ..................... See Engine Model Designation on previous page

Example Engine Serial Number Plate

RG8427A –UN–09DEC97

Sequential Number

000000 .......................................................... 6-digit sequential number

2. Engine Application Data (B) The second line of information on the engine serial

number plate identifies the engine/Deere machine or OEM relationship. See ENGINE APPLICATION CHART later in this group.

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Engine Option Code Label

Engine Identification and Applications

01 001 3

Option Code Label

In addition to the serial number plate, OEM engines have an engine option code label affixed to the rocker arm cover. These codes indicate which of the engine options were installed on your engine at the factory.

RG8740 –UN–12JUL99

When in need of parts or service, furnish your authorized servicing dealer or engine distributor with these numbers.

DPSG,OUO1004,917 –19–30JUN99–1/1

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Engine Identification and Applications

001

Engine Application Chart

John Deere Agricultural Equipment Applications

Machine Model No. Engine Model WATERLOO TRACTORS—4-WHEEL DRIVE

9200 .............................................................................................................................................................. 6105HRW01, 6105HRW02,

9220 .............................................................................................................................................................. 6125HRW10, 6125HRW13,

9300 .............................................................................................................................................................. 6125HRW01, 6125HRW11,

9320 .............................................................................................................................................................. 6125HRW13, 6125HRW16

9400 .............................................................................................................................................................. 6125HRW02, 6125HRW12,

9420 .............................................................................................................................................................. 6125HRW15, 6125HRW17

9520 .............................................................................................................................................................. 6125HRW15, 6125HRW17

9620 .............................................................................................................................................................. 6125HRW18

WATERLOO TRACTORS—TRACK TYPE

9300T ............................................................................................................................................................ 6125HRW03, 6125HRW06

9320T ............................................................................................................................................................ 6125HRW13, 6125HRW16

9400T ............................................................................................................................................................ 6125HRW04, 6125HRW08

9420T ............................................................................................................................................................ 6125HRW15, 6125HRW17

9520T ............................................................................................................................................................ 6125HRW15, 6125HRW17

9620T ............................................................................................................................................................ 6125HRW18

HARVESTER—COMBINES

9860 .............................................................................................................................................................. 6125HH003

ZWEIBRUCKEN—COMBINES/FORAGE HARVESTERS

6750 .............................................................................................................................................................. 6125HZ002, 6125HZ006

6850 .............................................................................................................................................................. 6125HZ001, 6125HZ005

7300 (Europe) ............................................................................................................................................... 6125HZ007

7400 (Europe) ............................................................................................................................................... 6125HZ008

7500 (Europe) ............................................................................................................................................... 6125HZ009

7700 (Europe) ............................................................................................................................................... 6125HZ009

7300 (North America) .................................................................................................................................... 6125HZ011

7400 (North America) .................................................................................................................................... 6125HZ012

7500 (North America) .................................................................................................................................... 6125HZ013

7700 (North America) .................................................................................................................................... 6125HZ013

9880 STS Combine (Europe) ....................................................................................................................... 6125HZ004

CANE HARVESTER (CAMECO—THIBODAUX, LA)

CH2500 ......................................................................................................................................................... 6125AT801

6125HRW05 (30000— )

6125HRW16

6125HRW07 (30000— )

6125HRW09 (30000— )

(30000— )

John Deere Construction and Forestry Equipment Applications

Machine Model No. Engine Model

744H/HMH Loader ......................................................................................................................................... 6125ADW01, 6125HDW01

LX230 Loader (Hitachi Construction Machinery) .......................................................................................... 6125ADW70

450C LC Excavator ....................................................................................................................................... 6125HT001 (30000— )

824J Loader ................................................................................................................................................... 6125HDW01

844J Loader (production summer 2005) ....................................................................................................... 6125HT003

744J Loader ................................................................................................................................................... 6125HDW01

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040604

PN=28

Engine Identification and Applications

Original Equipment Manufacturers (OEM) Applications

Machine Model No. Engine Model

OEM .............................................................................................................................................................. 6105AF001

6105HF001 6125AF001 6125HF001 (30000— ) 6125HF070 (30000— ) Tier II

Marine ........................................................................................................................................................... 6125AFM01, 6125AFM75-Tier II

RG,RG34710,25 –19–05SEP02–2/2

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001

Engine Identification and Applications

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Diesel Fuel

Consult your local fuel distributor for properties of the diesel fuel available in your area.

Group 002

Fuels, Lubricants and Coolant

01 002 1

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test.

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

In all cases, the fuel shall meet the following properties:

Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C(9°F) below the expected low temperature.

Sulfur content:

• Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred.

• If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%.

• DO NOT use diesel fuel with sulfur content greater than 1.0%.

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification.

DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

OURGP11,000018C –19–12FEB04–1/1

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002

Bio-Diesel Fuel

Consult your local fuel distributor for properties of the bio-diesel fuel available in your area.

Fuels, Lubricants and Coolant

handling of bio-diesel fuel especially important. Areas of concern include:

Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM D6751, EN 14214, or equivalent specification.

It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend (also known as B5) in petroleum diesel fuel.

When using a blend of bio-diesel fuel, the engine oil level must be checked daily when the air temperature is –10°C (14°F) or lower. If oil becomes diluted with fuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use as fuel in any concentration in John Deere engines.

These oils do not burn completely, and will cause engine failure by leaving deposits on injectors and in the combustion chamber.

A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and

• Quality of new fuel

• Water content of the fuel

• Problems due to aging of the fuel

Potential problems resulting from deficiencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms:

• Power loss and deterioration of performance

• Fuel leakage

• Corrosion of fuel injection equipment

• Coked and/or blocked injector nozzles, resulting in

engine misfire

• Filter plugging

• Lacquering and/or seizure of internal components

• Sludge and sediments

• Reduced service life of engine components

Consult your fuel supplier for additives to improve storage and performance of bio-diesel fuels.

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Fuels, Lubricants and Coolant

Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components.

ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.

Sulfur content of diesel fuel for highway use is less than 0.05% (500 ppm) in the United States and Canada, and less than 0.035% (350 ppm) in the European Union.

Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in

01 002 3

these fuels also adversely affects injection pump seals and may result in leaks.

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke.

Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

Dieselscan Fuel Analysis

DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL5 –19–19DEC03–1/1

DX,FUEL6 –19–06DEC00–1/1

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Fuels, Lubricants and Coolant

002

Diesel Engine Break-In Oil

New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.

If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation:

• API Service Category CE

• API Service Category CD

• API Service Category CC

• ACEA Oil Sequence E2

• ACEA Oil Sequence E1

After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in this manual.

IMPORTANT: Do not use PLUS-50 oil or engine oils

meeting any of the following during the first 100 hours of operation of a new or rebuilt engine:

API CI-4 ACEA E5 API CH-4 ACEA E4 API CG-4 ACEA E3 API CF-4 API CF-2 API CF

These oils will not allow the engine to break-in properly.

PLUS-50 is a trademark of Deere & Company

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Fuels, Lubricants and Coolant

Diesel Engine Oil—Non-Certified and Tier I Certified Engines

Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oil is preferred:

01 002 5

• John Deere PLUS-50



The following oil is also recommended:

• John Deere TORQ-GARD SUPREME



Other oils may be used if they meet one or more of the following:

• API Service Classification CI-4

• API Service Classification CH-4

• API Service Classification CG-4

• API Service Classification CF-4

• ACEA Specification E5

• ACEA Specification E4

• ACEA Specification E3

• ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% (5000 ppm) is used, reduce the service interval by 50%.

Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere dealer for more information.

TS1661 –UN–10OCT97

PLUS-50 is a registered trademark of Deere & Company. TORQ-GARD SUPREME is a registered trademark of Deere & Company

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Fuels, Lubricants and Coolant

002

Diesel Engine Oil—Tier II Engines

Use oil viscosity based on the expected air temperature range during the period between oil changes.

50˚C 122˚F

The following oil is preferred:

• John Deere PLUS-50



The following oils are also recommended:

• John Deere TORQ-GARD SUPREME



• Oils meeting ACEA Specification E5

Other oils may be used if they meet one or more of the following:

• API Service Classification CI-4

• API Service Classification CH-4

• ACEA Specification E3

• ACEA Specification E4

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

If diesel fuel with sulfur content greater than 0.05% (500 ppm) is used, reduce the service interval by 100 hours.

SAE 15W-40

SAE 10W-40

SAE 0W-40

SAE 5W-30

Diesel Engine Oil

40˚C 104˚F

30˚C 86˚F

20˚C 68˚F

10˚C 50˚F

0˚C 32˚F

-10˚C 14˚F

-20˚C -4˚F

-30˚C -22˚F

-40˚C -40˚F

TS1668A –UN–14DEC01

If diesel fuel with sulfur content greater than 0.5% (5000 ppm) is used, reduce the service interval by 50%.

Diesel fuel with sulfur content greater than 1.0% (10,000 ppm) is not recommended.

When John Deere PLUS-50is used along with the specified John Deere filter, the oil change interval may be extended from every 250 hours to every 375 hours of operation.

PLUS-50 is a registered trademark of Deere & Company. TORQ-GARD SUPREME is a trademark of Deere & Company

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Fuels, Lubricants and Coolant

Extended Diesel Engine Oil Service Intervals

When John Deere PLUS-50, ACEA E5, or ACEA E4 oils are used with the specified John Deere filter, the service interval for engine oil and filter changes may be increased by 50% but not to exceed a maximum of 500 hours.

If John Deere PLUS-50, ACEA E5, or ACEA E4 oils are used with other than the specified John Deere filter, change the engine oil and filter at the normal service interval.

If John Deere TORQ-GARD SUPREME, API CI-4, API CH-4, or ACEA E3 oils are used, change the engine oil and filter at the normal service interval.

Alternative and Synthetic Lubricants

01 002 7

DX,ENOIL8 –19–03NOV03–1/1

Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

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Fuels, Lubricants and Coolant

002

Mixing of Lubricants

In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

OILSCANand COOLSCAN

OILSCANand COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage.

Oil and coolant samples should be taken from each system prior to its recommended change interval.

Consult your John Deere dealer to obtain specific information and recommendations.

DX,LUBMIX –19–18MAR96–1/1

Check with your John Deere dealer for the availability of OILSCAN and COOLSCAN kits.

OILSCAN is a registered trademark of Deere & Company. COOLSCAN is a trademark of Deere & Company.

T6828AB –UN–15JUN89T6829AB –UN–18OCT88

DX,OILSCAN –19–02DEC02–1/1

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Fuels, Lubricants and Coolant

Grease

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

The following greases are preferred:

• John Deere SD POLYUREA GREASE The following greases are also recommended:

• John Deere HD MOLY GREASE

• John Deere HD LITHIUM COMPLEX GREASE

• John Deere HD WATER RESISTANT GREASE

• John Deere GREASE-GARD

Other greases may be used if they meet the following:

• NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickener are not

compatible with others. Consult your grease supplier before mixing different types of grease.

01 002 9

TS1667 –UN–30JUN99

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Fuels, Lubricants and Coolant

002

Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

John Deere COOL-GARD Prediluted Coolant is preferred for service.

John Deere COOL-GARD Prediluted Coolant is available in either a concentration of 50% ethylene glycol or a 55% propylene glycol.

Additional recommended coolants

The following engine coolant is also recommended:

Other low silicate ethylene glycol base coolants for heavy-duty engines may also be used if they meet one of the following specifications:

• ASTM D4985 ethylene glycol base prediluted (50%) coolant

• ASTM D4985 ethylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives, formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting. They also require periodic replenishment of additives during the drain interval.

• John Deere COOL-GARD Coolant Concentrate in a 40% to 60% mixture of concentrate with quality water.

John Deere COOL-GARD coolants do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Other fully formulated coolants

Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications:

• ASTM D6210 prediluted (50%) coolant

• ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Coolants requiring supplemental coolant additives

Other coolants

If a coolant known to meet the requirements of coolant specifications shown in this manual is not available, use either:

• ethylene glycol or propylene glycol base prediluted (40% to 60%) coolant

• ethylene glycol or propylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

The coolant concentrate or prediluted coolant shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system.

Water quality

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.

COOL-GARD is a trademark of Deere & Company

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Fuels, Lubricants and Coolant

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.

Supplemental Coolant Additives

IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.

DX,COOL3 –19–19DEC03–2/2

01 002 11

The concentration of coolant additives is gradually depleted during engine operation. For all recommended coolants, replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing.

John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

IMPORTANT: Do not add a supplemental coolant

additive when the cooling system is drained and refilled with John DeereCOOL-GARD.

COOL-GARD is a trademark of Deere & Company

If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

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002

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating.

Fuels, Lubricants and Coolant

method to check the freeze point and additive levels of your engine coolant.

Compare the results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added.

COOLSCAN and COOLSCAN PLUS

Coolant test strips

Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company

For a more thorough evaluation of your coolant, perform a COOLSCAN or COOLSCAN PLUS analysis, where available. See your John Deere dealer for information.

DX,COOL9 –19–19DEC03–1/1

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Fuels, Lubricants and Coolant

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

01 002 13

Radiator Coolant Check

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is drained and refilled with John Deere ANTIFREEZE/SUMMER COOLANT or John Deere COOL-GARD.

NOTE: If a system is to be filled with coolant that does

not contain SCAs, the coolant must be precharged. Determine the total system capacity and premix with 3% John Deere Coolant Conditioner.

Through time and use, the concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere ANTIFREEZE/SUMMER COOLANT is used. The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner.

RG6261 –UN–08DEC97

JT07298 Refractometer

Maintaining the correct coolant conditioner concentration (SCAs) and freeze point is essential in your cooling system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution.

John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

DO NOT mix one brand of SCA with a different brand.

Test the coolant solution at 600 hours or 12 months of operation using either John Deere coolant test strips or a COOLSCANanalysis. If a COOLSCANanalysis is not available, recharge system per instructions printed on label of John Deere Liquid Coolant Conditioner.

RG6262 –UN–05DEC97

COOL-GARD is a registered trademark of Deere & Company COOLSCAN is a registered trademark of Deere & Company.

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Fuels, Lubricants and Coolant

002

IMPORTANT: ALWAYS maintain coolant at correct

level and concentration. DO NOT operate engine without coolant for even a few minutes.

If frequent coolant makeup is required, the glycol concentration should be checked with JT07298 Coolant/Battery Tester to ensure that the desired freeze point is maintained. Follow manufacturer’s instructions provided with refractometer.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

See DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION earlier in this group for proper mixing of coolant ingredients before adding to the cooling system.

Operating in Warm Temperature Climates

John Deere engines are designed to operate using glycol base engine coolants.

Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

IMPORTANT: Water may be used as coolant

emergency situations only.

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

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Fuels, Lubricants and Coolant

Flush and Service Cooling System

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing cap completely.

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Follow procedure given in your operator’s manual.

The ethylene glycol base (antifreeze) can become depleted of SCAs allowing various acids to form that will damage engine components. In addition, heavy metals, such as lead, copper and zinc, accumulate in the ethylene glycol base. The heavy metals come from corrosion that occurs to some degree with in a cooling system. When a coolant is saturated to the point where it can no longer hold heavy metals and other dissolved solids, they settle out and act as abrasives on engine parts.

01 002 15

TS281 –UN–23AUG88

NOTE: Refer to your operator’s manual for a specific

service interval.

Flush cooling system as described in your operator’s manual. Clean cooling system with clean water and TY15979 John Deere Heavy-Duty Cooling System Cleaner or an equivalent cleaner such as FLEETGUARD RESTOREor RESTORE PLUS. Follow the instructions provided with the cleaner. Refill cooling system with the appropriate coolant solution. See ENGINE COOLANT SPECIFICATIONS, earlier in this group.

FLEETGUARD is a registered trademark of the Cummins Engine Company. RESTORE is a trademark of FLEETGUARD. RESTORE PLUS is a trademark of FLEETGUARD.



Continued on next page

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Fuels, Lubricants and Coolant

002

IMPORTANT: NEVER overfill the system. A

pressurized system needs space for heat expansion without overflowing at the top of the radiator. Coolant level should be at bottom of radiator filler neck.

Air must be expelled from cooling system when system is refilled. Loosen plug in side of thermostat housing to allow air to escape when filling system. Retighten plug when all the air has been expelled.

After adding new coolant solution, run engine until it reaches operating temperature. This mixes the coolant solution uniformly and circulates it through the entire system. After running engine, check coolant level and entire cooling system for leaks.

Contact your engine servicing dealer, if there are further questions.

Disposing of Coolant

Improperly disposing of engine coolant can threaten the environment and ecology.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your engine servicing dealer.

RG,01,DT7033 –19–29OCT97–2/2

TS1133 –UN–26NOV90

RG,01,DT7032 –19–29OCT97–1/1

CTM100 (06APR04)

01-002-16

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=46

Section 02

Repair and Adjustments

Contents

Page Page

Group 010—Engine Rebuild Guide, Break-In and

Tune-Up

Engine Overhaul Guidelines ..............02-010-1

Engine Repair Stand....................02-010-1

Safety Precautions .....................02-010-2

Disconnect Turbocharger Oil Inlet Line ......02-010-3

Install Engine Adapter Onto Repair Stand....02-010-3

Engine Lifting Procedure.................02-010-4

Mount Engine Onto Repair Stand ..........02-010-6

Clean Engine .........................02-010-7

6105 and 6125 Engine Disassembly

Sequence ..........................02-010-8

Sealant Application Guidelines ...........02-010-11

6105 and 6125 Engine Assembly

Sequence .........................02-010-13

Engine Break-In Guidelines..............02-010-15

Perform Engine Break-In................02-010-16

Check Crankcase Ventilation System ......02-010-17

Check Air Intake System................02-010-18

Check Exhaust System.................02-010-18

Check and Service Cooling System .......02-010-19

Check Electrical System ................02-010-21

Preliminary Engine Testing Before

Tune-Up ..........................02-010-22

General Tune-Up Recommendations ......02-010-23

Group 020—Cylinder Head and Valves

Remove and Install Rocker Arm Cover ......02-020-1

Clean and Inspect Crankcase Ventilation

Assembly...........................02-020-2

Replace Rocker Arm Cover Gasket.........02-020-3

Check and Adjust Valve Assembly

Clearances and Injector Preload .........02-020-4

Remove Rocker Arm Assembly...........02-020-10 Group 030—Cylinder Block, Liners, Pistons, and

Diagnosing Head Gasket Joint Failures.....02-020-17 Remove and Install Cylinder Block Front

Sequence .........................02-020-19 Preliminary Liner, Piston, and Rod Checks . . .02-030-5

Shaft Assembly .....................02-020-21 Remove Pistons and Connecting Rods ......02-030-7

Checks ...........................02-020-22 Above Block) .......................02-030-11

Assembly..........................02-020-23 or D01073AA Cylinder Liner Puller ......02-030-12

Check Valve Height in Relation to Head

Surface (Valve Recess)...............02-020-23

Remove Valve Assembly................02-020-24

Inspect and Measure Valve Springs .......02-020-25

Inspect Valve Rotators .................02-020-26

Clean, Inspect, and Measure Valves.......02-020-27

Grind Valves .........................02-020-28

Clean and Inspect Cylinder Head .........02-020-29

Check Cylinder Head Flatness ...........02-020-30

Measure Cylinder Head Thickness ........02-020-31

Resurface Cylinder Head Combustion

Face .............................02-020-32

Measure Valve Guide ID................02-020-33

Replace Valve Guides..................02-020-33

Clean and Inspect Valve Seats ...........02-020-34

Grind Valve Seats.....................02-020-35

Remove Valve Seat Inserts..............02-020-36

Measure Valve Seat Bore in Cylinder

Head .............................02-020-37

Install Valve Seat Inserts................02-020-38

Install Valves.........................02-020-38

Replace Unit Injector Sleeve in Cylinder

Head Using JDG981 .................02-020-40

Replace Unit Injector Sleeve in Cylinder

Head Using JDG1184 ................02-020-45

Clean and Inspect Top Deck of Cylinder

Block .............................02-020-55

Measure Cylinder Liner Standout (Height

Above Block) .......................02-020-56

Install Cylinder Head...................02-020-57

Torque-Turn Cylinder Head Cap Screws....02-020-59

Install Rocker Arm Assembly.............02-020-61

Complete Final Assembly for Cylinder Head

Installation .........................02-020-68

RodsRemove Cylinder Head.................02-020-12

Plate ..............................02-030-1Head Gasket Inspection and Repair

Connecting Rods—General Information .....02-030-6Disassemble and Inspect Rocker Arms and

Measure Cylinder Liner Standout (HeightPreliminary Cylinder Head and Valve Remove Cylinder Liners Using D01062AAAssemble Rocker Arms and Shaft

Continued on next page

CTM100 (06APR04)

02-1

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=1

Contents

Page Page

Remove Cylinder Liners Using JDG1145 Remove Timing Gear Cover ..............02-040-6

Check Flywheel Housing Face Runout ......02-040-7Cylinder Liner Service Set .............02-030-14

Visually Inspect Cylinder Liners...........02-030-16 Check Flywheel Face Flatness ............02-040-8

Remove Flywheel ......................02-040-8Deglaze Cylinder Liners ................02-030-17

Clean Cylinder Liners ..................02-030-18 Inspect and Repair Flywheel ..............02-040-9

Replace Flywheel Ring Gear.............02-040-10Cylinder Liner Manufacturing Date Code

Explanation ........................02-030-19 Remove and Install Flywheel Housing......02-040-11

Install Flywheel .......................02-040-12Disassemble Piston/Rod Assembly and Clean

Piston ............................02-030-20 Remove Rear Crankshaft Oil Seal and

Housing Assembly...................02-040-13Check Piston Compression Ring Groove

Wear—6105 Engines.................02-030-22 Crankshaft and Main Bearing Failure

Analysis...........................02-040-15Check Piston Compression Ring Groove

Wear—6125 Engines.................02-030-23 Remove Crankshaft Main Bearings........02-040-16

Check Main Bearing-to-Journal OilCheck Piston Oil Control Ring Groove

Wear—6105 and 6125 Engines.........02-030-24 Clearance .........................02-040-18

Remove Crankshaft....................02-040-19Inspect Piston Pin and Pin Bore in Piston . . .02-030-25

Determine Piston-to-Liner Clearance.......02-030-26 Inspect Crankshaft ....................02-040-20

Measure Assembled ID of Bearings andMeasure Liner Flange Thickness..........02-030-28

Inspect and Measure Connecting Rod OD of Crankshaft Journals.............02-040-22

Measure Assembled ID of Main BearingBearings ..........................02-030-29

Inspect Connecting Rod and Cap .........02-030-31 Caps (Without Bearings) ..............02-040-23

Crankshaft Grinding Guidelines...........02-040-24Inspect Piston Pins and Rod Bushings .....02-030-34

Remove Piston Pin Bushing, Clean, and Crankshaft Grinding Specifications ........02-040-25

Replace Crankshaft Drive Gear...........02-040-26Inspect Bushing Bore.................02-030-36

Install Piston Pin Bushing ...............02-030-37 Inspect Thrust Bearings ................02-040-27

Thrust Bearing New Part Specifications ....02-040-27Complete Disassembly of Cylinder Block (If

Required)..........................02-030-38 Install Main Bearing Inserts in Block .......02-040-28

Install Crankshaft .....................02-040-29Inspect and Clean Cylinder Block .........02-030-39

Measure Cylinder Block ................02-030-41 Install Crankshaft Rear Oil Seal Housing....02-040-32

Install Crankshaft Rear Oil Seal and WearRecheck Cylinder Liner Standout (Height

Above Block) .......................02-030-43 Sleeve Assembly....................02-040-33

Install Timing Gear Cover ...............02-040-34Install Cylinder Liner O-Rings and

Packings ..........................02-030-44 Install Crankshaft Vibration Damper and

Front Oil Seal ......................02-040-39Install Cylinder Liners ..................02-030-45

Assemble Pistons and Connecting Rods....02-030-47 Complete Final Assembly ...............02-040-43

Install Pistons and Connecting Rods.......02-030-48

Torque-Turn Connecting Rod Cap Group 050—Camshaft and Timing Gear Train

Camshaft Gear Access Cover TorqueScrews............................02-030-52

Check Engine Rotation for Excessive Sequence ..........................02-050-1

Check and Adjust Camshaft-to-CrankshaftTightness..........................02-030-53

Measure Piston Protrusion ..............02-030-53 Timing .............................02-050-2

Adjust Front Timing Gear Backlash.........02-050-4Remove and Install Piston Spray Jets......02-030-54

Complete Final Assembly ...............02-030-55 Remove and Install Camshaft .............02-050-9

Replace Fuel Supply Pump Drive Pin ......02-050-18

Visually Inspect Camshaft and RollerGroup 040—Crankshaft, Main Bearings, and

Flywheel Followers..........................02-050-18

Inspect and Measure Camshaft BushingCrankshaft Vibration Damper Torque

Sequence ..........................02-040-1 ID and Journal OD...................02-050-19

Measure Camshaft Lobe Lift Height .......02-050-20Inspect Crankshaft Vibration Damper .......02-040-2

Check Crankshaft End Play ..............02-040-3 Inspect Camshaft Position Sensor Lobe ....02-050-20

Replace Camshaft Bushings .............02-050-21Remove Crankshaft Vibration Damper and

Pulley .............................02-040-4

Remove Crankshaft Front Oil Seal .........02-040-5

Continued on next page

CTM100 (06APR04)

02-2

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

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Contents

Page Page

SAE “A” (Front) and SAE “B” (Rear) Auxiliary Repair Turbocharger ...................02-080-14

Prelube Turbocharger ..................02-080-15Drive Assembly .....................02-050-26

SAE “B” Rear Auxiliary Drive.............02-050-27 Install Turbocharger ...................02-080-16

Align SAE “A” Front Auxiliary Drive Turbocharger Break-In .................02-080-17

Remove, Inspect, and Install ExhaustAdapter ...........................02-050-28

Manifold...........................02-080-18

Remove, Inspect, and Install IntakeGroup 060—Lubrication System

Oil Filter and Oil Conditioning Housing Manifold...........................02-080-21

Remove and Install Aftercooler AssemblyAssembly...........................02-060-1

Remove Oil Filter and Valve Housing/Oil (6105A and 6125A Engines) ...........02-080-23

Inspect and Repair Aftercooler (6105A andCooler Cover and Valve Housing.........02-060-2

Inspect and Replace Oil Filter Adapter ......02-060-2 6125A Engines).....................02-080-25

Remove, Inspect, and Install Oil Pressure

Regulating Valve .....................02-060-3 Group 090—Fuel System

Fuel System ..........................02-090-1Remove, Inspect, and Install Oil Cooler

and Oil Filter Bypass Valves ............02-060-4

Remove, Inspect, and Install Oil Pressure Group 100—Starting and Charging Systems

Remove and Install Alternator (OEMRelief Valve (If Equipped) ..............02-060-5

Remove, Clean, and Inspect Engine Oil Engines) ...........................02-100-1

Remove and Install Starter Motor (OEMCooler .............................02-060-6

Install Oil Cooler/Oil Filter Valve Housing Engines) ...........................02-100-2

Assembly or Oil Cooler Cover/Valve Housing

Assembly...........................02-060-8

Remove Engine Oil Pump...............02-060-10

Clean and Inspect Oil Pump and Drive

Gear .............................02-060-11

Install Engine Oil Pump.................02-060-12

Remove Engine Oil Pan ................02-060-13

Remove and Install Oil Pickup Tube .......02-060-14

Install Engine Oil Pan ..................02-060-15

Group 070—Cooling System

Replace Bearings in Fan Drive Assembly ....02-070-1

Inspect and Check Belt Tensioner Spring

Tension ............................02-070-5

Replace Belt Tensioner Assembly..........02-070-7

Remove Coolant Pump..................02-070-8

Clean and Inspect Coolant Pump Parts......02-070-9

Install Coolant Pump...................02-070-10

Remove Thermostats ..................02-070-11

Install Thermostats ....................02-070-12

Test Thermostat Opening Temperature.....02-070-13

Remove and Install Thermostat Housing....02-070-14

Remove and Install Coolant Heater—if

Equipped ..........................02-070-15

Group 080—Air Intake and Exhaust System

Extending Turbocharger Life ..............02-080-1

Remove Turbocharger...................02-080-3

Turbocharger Failure Analysis.............02-080-4

Turbocharger Seven-Step Inspection .......02-080-6

Perform Radial Bearing Clearance Test ....02-080-13

Perform Axial Bearing End Play Test ......02-080-14

CTM100 (06APR04)

02-3

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

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Contents

CTM100 (06APR04)

02-4

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=4

Engine Rebuild Guide, Break-In and Tune-Up

Engine Overhaul Guidelines

Engine life and performance will vary depending on operating conditions and the level of regular engine maintenance. Engines can be brought back to original performance standards through proper overhaul procedure and replacement of parts with genuine John Deere service parts. Overhauling the engine prior to failure can avoid costly repairs and downtime.

Consider installing a John Deere overhaul kit when:

• The engine begins to experience power loss and there

are no known engine component failures.

• The engine is hard to start due to low cranking

compression.

• The engine begins to smoke and there are no known

engine component failures.

• The engine begins to use oil. Refer to Section 04 for

acceptable oil consumption.

• The engine has high usage hours and the owner wants

to take preventive measure to avoid high-cost repairs

and costly downtime.

Group 010

02 010 1

John Deere overhaul kits have a 1500-hour or 12-month warranty, whichever comes first. Installation labor is covered by warranty if an authorized John Deere dealer installed the overhaul kit and the replacement parts.

Engine Repair Stand

NOTE: Only the 2722 kg (6000 lb) heavy-duty engine

repair stand (A) No. D05223ST manufactured by Owatonna Tool Co., Owatonna, Minnesota is referenced in this manual. When any other repair stand is used, consult the manufacturer’s instructions for mounting the engine.

Refer to machine technical manual for steps to remove engine from machine before installing it on repair stand.

A—Engine Repair Stand

DPSG,OUO1032,3410 –19–15JUN00–1/1

CTM100 (06APR04)

02-010-1

Engine Repair Stand

OWERTECH

RG4929 –UN–05DEC97

RG,RG34710,1043 –19–23OCT97–1/1

10.5 L & 12.5 L Diesel Engines

040604

PN=49

Safety Precautions

Engine Rebuild Guide, Break-In and Tune-Up

The engine repair stand should be used only by qualified service technicians familiar with this equipment.

010

To maintain shear strength specifications, alloy steel

Class 12.9 or SAE Grade 8 or higher cap screws must be used to mount adapters and engine to repair stand. Use LOCTITE242 Thread Lock and Sealer on cap screws when installing lifting straps on engine. Tighten cap screws to specifications given.

For full thread engagement, be certain that tapped holes in adapters and engine blocks are clean and not damaged. A thread length engagement equal to 1-1/2 screw diameters minimum is required to maintain strength requirements.

To avoid structural or personal injury, do not exceed the maximum capacity rating of 2722 kg (6000 lb). Maximum capacity is determined with the center of the engine located not more than 330 mm (13 in.) from the mounting hub surface of the engine stand.

The center of balance of an engine must be located within 51 mm (2 in.) of the engine stand rotating shaft.

Engine center of balance is generally located a few millimeters above the crankshaft.

To prevent possible personal injury due to engine slippage, recheck to make sure engine is solidly mounted before releasing support from engine lifting device.

Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury.

The lifting jack is to be used when it is necessary to lift the engine for rotation. When working on the engine, the jack should be at its lowest position to keep the center of gravity and the possibility of tipping low.

To prevent possible personal injury due to sudden engine movement, lower the engine by operating jack release valve slowly. Do not unscrew release valve knob more than two turns from its closed position.

LOCTITE is a registered trademark of Loctite Corp.

CTM100 (06APR04)

02-010-2

OWERTECH

RG,RG34710,45 –19–30SEP97–1/1

10.5 L & 12.5 L Diesel Engines

040604

PN=50

Engine Rebuild Guide, Break-In and Tune-Up

Disconnect Turbocharger Oil Inlet Line

1. Drain all engine oil and coolant, if not previously done.

IMPORTANT: When servicing turbocharged engines

on a rollover stand, disconnect turbocharger oil inlet line (A) from oil filter housing or turbocharger before rolling engine over. Failure to do so may cause a hydraulic lock upon starting engine. Hydraulic lock may cause possible engine failure.

Hydraulic lock occurs when trapped oil in the oil filter housing drains through the turbocharger, the exhaust and intake manifolds, and then into the cylinder head.

After starting the engine, the trapped oil in the manifold and head is released into the cylinder(s) filling them with oil causing hydraulic lock and possible engine failure.

2. Disconnect turbocharger oil inlet line at turbocharger or

oil filter base.

02 010 3

RG10241 –UN–09JUL99

Turbocharger Oil Inlet Line

A—Turbocharger Oil Inlet Line

Install Engine Adapter Onto Repair Stand

Attach the No. 205466 Adapter Assembly to engine repair stand using four 5/8-11 x 2 in. SAE Grade 8 (or higher grade) cap screws. Tighten cap screws to specification.

Specification

Engine Adapter-to-Repair Stand

Cap Screws—Torque 135 N•m (100 lb-ft)..................................................

CTM100 (06APR04)

02-010-3

DPSG,OUO1004,918 –19–30JUN99–1/1

D05223ST Repair Stand with 205466 Adapter

RG,RG34710,46 –19–21AUG02–1/1

OWERTECH

10.5 L & 12.5 L Diesel Engines

RG8183 –UN–08DEC97

040604

PN=51

Engine Rebuild Guide, Break-In and Tune-Up

Engine Lifting Procedure

1. Install R503481 (OEM & AT801 Applications Only) or R128001 Front Lift Strap and R128000 Rear Lift Strap

010

(or attach sling to front plate lift eye) and tighten cap screws to specification.

Specification

Engine Lift Strap Cap Screws—

Torque 90 N•m (66 lb-ft).............................................................................

NOTE: Lift spacing on sling is adjustable. Position each

lifting point so that engine hangs level when lifted.

2. Attach the JDG23 Engine Lifting Sling (D) to lift straps and overhead hoist or floor crane of adequate lifting capacity.

3. Carefully lift engine to desired location.

A—Alternator B—Front Plate Lift Eye C—Exhaust Shield D—JDG23 Lift Sling E—R128000 Rear Lift Strap F—R503481 (OEM & AT801 Applications Only) or

R128001 Front Lift Strap

Can be ordered from parts catalog.

Continued on next page

Engine Lift Points

RG10349 –UN–13OCT99

RG10350 –UN–13OCT99

Engine Lifting

RG,RG34710,47 –19–20AUG02–1/2

CTM100 (06APR04)

02-010-4

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=52

Engine Rebuild Guide, Break-In and Tune-Up

IMPORTANT: Lifting straps are designed to lift the

engine and small accessories such as hydraulic pumps and air compressors mounted to the engine auxiliary gear drive, or belt-driven components, such as air conditioning compressors and alternators. If larger components, such as PTO’s, transmissions, generators or air compressors, are attached to other locations on the engine, the lift straps provided with the engine are not intended for this purpose. Technician is responsible for providing adequate lifting devices under these situations. See machine technical manual for additional information on removing engine from machine.

CAUTION: The only approved method for lifting the 6105 and 6125 Engine is with the use of JDG23 Lifting Sling (D), R128000 Rear Lift Strap (E) and R503481 (OEM & AT801 Applications Only) or R128001 Front Lift Strap (F). The front plate lift eye (B) can be used as a lifting point instead of R503481 (OEM & AT801 Applications Only) or R128001 Front Lift Strap. Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended.

02 010 5

Lift engine with longitudinal loading on lift sling and lifting brackets only. Angular loading greatly reduces lifting capacity of sling and brackets.

IMPORTANT: Ensure that engine lifting straps are

secured with Class 12.9 (or higher class) cap screws. Apply TY9370 LOCTITE242 Thread Lock and Sealer to lift strap cap screws.

NOTE: If lift eye in front plate (B) is used instead of

R503481 (OEM & AT801 Applications Only) or R128001 Front Lift Strap, remove alternator (A).

If front lift strap (F) is being used, remove exhaust shield (C) and install lift strap using shield mounting cap screw holes.

LOCTITE is a registered trademark of Loctite Corp.

CTM100 (06APR04)

02-010-5

OWERTECH

RG,RG34710,47 –19–20AUG02–2/2

10.5 L & 12.5 L Diesel Engines

040604

PN=53

Mount Engine Onto Repair Stand

CAUTION: NEVER remove the overhead lifting equipment until the engine is securely mounted

010

1. Remove starter motor (A).

onto the repair stand and all mounting hardware is tightened to specified torque. Always release the overhead lifting equipment slowly.

Engine Rebuild Guide, Break-In and Tune-Up

2. On engines with primary fuel filter/water separator (B) on left side of engine, remove primary fuel filter/water separator.

On later engines with large single fuel filter mounted on left side of engine, remove fuel filter assembly.

IMPORTANT: DO NOT use shorter cap screws than

recommended since mounting threads in block bore may be stripped when tightening to specified torque. USE ONLY JDG980 METRIC BOLT KIT for mounting engine to repair stand.

Component Removal for Repair Stand Mounting

RG8184A –UN–05DEC97

A—Starter Motor B—Primary Fuel Filter

RG,RG34710,48 –19–13SEP02–1/3

3. Mount engine to front engine adapter using two1M16 x

2.0 x 65 mm (Class 12.9) cap screws (A). Tighten cap screws to specification.

Engine-to-Stand Adapter Cap

Screws—Torque 400 N•m (300 lb-ft)..........................................................

From JDG980 Metric Bolt Kit.

Specification

CTM100 (06APR04)

Continued on next page

02-010-6

Front Repair Stand Cap Screws

A—Cap Screws

OWERTECH

RG8185 –UN–05DEC97

RG,RG34710,48 –19–13SEP02–2/3

10.5 L & 12.5 L Diesel Engines

040604

PN=54

Engine Rebuild Guide, Break-In and Tune-Up

4. Mount engine to rear engine adapter using two1M16 x

2.0 x 65 mm (Class 12.9) cap screws (B). Tighten cap screws to specification.

Engine-to-Stand Adapter Cap

Screws—Torque 400 N•m (300 lb-ft)..........................................................

B—Cap Screws

From JDG980 Metric Bolt Kit.

Specification

Clean Engine

1. Cap or plug all openings (air intake, exhaust, fuel, coolant, etc.).

2. Remove electrical components (starter, alternator, etc.). Cover electrical components that are not removed with plastic and tape securely to prevent moisture damage.

02 010 7

RG8186 –UN–05DEC97

Rear Repair Stand Cap Screws

RG,RG34710,48 –19–13SEP02–3/3

3. Thoroughly steam clean engine.

IMPORTANT: Never steam clean or pour cold water

on an engine while it is still hot. To do so may cause seizure of precision parts.

6125HRW Engine on Repair Stand

RG8188 –UN–21MAY98

RG,RG34710,49 –19–21DEC00–1/1

CTM100 (06APR04)

02-010-7

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=55

Engine Rebuild Guide, Break-In and Tune-Up

6105 and 6125 Engine Disassembly Sequence

The following sequence is suggested when complete engine disassembly for overhaul is required. Refer to the appropriate repair group when removing individual

components.

010

Procedure Reference

Drain all coolant, fuel and engine oil. See DISPOSING OF COOLANT in Section 01, Group 002. Perform John Deere COOLSCAN and OILSCANanalysis. Dispose See OILSCAN AND COOLSCAN in Section 01, Group 002.

of remaining fluids properly. See TESTING DIESEL ENGINE COOLANT in Section 01, Group

Remove starter motor. See REMOVE AND INSTALL STARTER MOTOR in Group 100. Remove fuel filter assemblies with mounting bases as required See REPLACING PRIMARY FUEL FILTER/WATER SEPARATOR in

(Delphi/Lucas ECU controlled fuel system). CTM115, Section 02, Group 090.

Remove fuel filter assemblies with mounting bases as required (John See REPLACING PRIMARY FUEL FILTER/WATER SEPARATOR in Deere Level 6 ECU controlled fuel system). CTM188, Section 02, Group 090 (dual rail fuel systems).

Mount engine onto recommended safety approved repair stand. See MOUNT ENGINE ONTO REPAIR STAND in this group. Remove fan, drive belts, and fan drive assembly. See Group 070. Remove alternator. See REMOVE AND INSTALL ALTERNATOR in Group 100. Remove compressor. See CTM67, OEM Engine Accessories. Remove vibration damper and pulley assembly from crankshaft. See REMOVE CRANKSHAFT VIBRATION DAMPER AND PULLEY

Disconnect all air intake/exhaust piping and turbocharger oil See REMOVE TURBOCHARGER in Group 080. inlet/drain lines. Remove turbocharger.

Remove exhaust manifold and gaskets. See REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD in

Remove oil filter and oil filter housing. See REMOVE OIL FILTER AND VALVE HOUSING/OIL COOLER

Remove oil cooler assembly. See REMOVE, CLEAN AND INSPECT ENGINE OIL COOLER in

Remove coolant pump assembly. See REMOVE COOLANT PUMP in Group 070. Remove water manifold/thermostat housing assembly. See REMOVE AND INSTALL THERMOSTAT HOUSING in Group

Remove all six piston spray jets. See REMOVE AND INSTALL PISTON SPRAY JETS in Group 030.

ENGINE DISASSEMBLY SEQUENCE

(Continued on next page)

NOTE: Remove starter motor and primary fuel

filter/water separator before mounting engine onto repair stand.

002.

See REPLACE FINAL (SECONDARY) FUEL FILTER ELEMENT in CTM115, Section 02, Group 090.

See REPLACE FINAL (SECONDARY) FUEL FILTER ELEMENT in CTM188, Section 02, Group 090 (dual rail fuel systems). See FUEL FILTER/WATER SEPARATOR ASSEMBLY in CTM188, Section 02, Group 091 (single rail fuel systems).

in Group 040.

Group 080.

COVER AND VALVE HOUSING in Group 060.

Group 060.

070.

COOLSCAN is a trademark of Deere & Company.

OILSCAN is a registered trademark of Deere & Company.

CTM100 (06APR04)

Continued on next page

02-010-8

OWERTECH

RG,RG34710,50 –19–21AUG02–1/3

10.5 L & 12.5 L Diesel Engines

040604

PN=56

Engine Rebuild Guide, Break-In and Tune-Up

ENGINE DISASSEMBLY SEQUENCE—CONTINUED

Procedure Reference

On 6105H and 6125H engines, remove air intake manifold. See REMOVE, INSPECT AND INSTALL INTAKE MANIFOLD in

On 6105A and 6125A engines, remove aftercooler assembly. See REMOVE AND INSTALL AFTERCOOLER ASSEMBLY in Group

Remove fuel supply pump (Delphi/Lucas ECU controlled fuel system). See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM115,

Remove fuel supply pump (John Deere ECU controlled fuel system). See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188,

Remove fuel manifold assembly on Delphi/Lucas ECU controlled fuel See REMOVE AND INSTALL FUEL MANIFOLD in CTM 115, Section systems. 02, Group 090.

Remove fuel manifold assembly on John Deere ECU controlled fuel See REMOVE AND INSTALL FUEL MANIFOLD in CTM 188, Section systems. 02, Group 090 (dual rail fuel systems).

Remove all remaining fuel lines, identify for reassembly in correct See CTM115, Section 02, Group 090. location. See CTM188, Section 02, Group 090 or 091.

Remove engine oil pan. See REMOVE ENGINE OIL PAN in Group 060. Remove oil pickup tube. See REMOVE AND INSTALL OIL PICKUP TUBE in Group 060. Remove front gear train access cover and timing gear cover. See REMOVE TIMING GEAR COVER in Group 040. Remove rocker arm cover. See REMOVE AND INSTALL ROCKER ARM COVER in Group 020.

NOTE: Identify valve train components and electronic unit injectors for reassembly in same location as removed.

Remove front and rear rocker arm and shaft assembly and EUI wiring harness.

Group 080.

080.

Section 02, Group 090.

Section 02, Group 090 (dual rail fuel systems). See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188, Section 02, Group 091 (single rail fuel systems).

See REMOVE ROCKER ARM ASSEMBLY in Group 020.

02 010 9

Remove electronic unit injectors on Delphi/Lucas ECU controlled fuel See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in systems. CTM115, Section 02, Group 090.

Remove electronic unit injectors on John Deere ECU controlled fuel See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in systems. CTM188, Section 02, Group 090 (dual rail fuel systems).

Remove camshaft gear and idler gear assembly. Remove camshaft See REMOVE AND INSTALL CAMSHAFT in Group 050. position sensor and remove camshaft.

Remove oil pump drive gear and remove oil pump assembly. See REMOVE ENGINE OIL PUMP in Group 060. Remove cylinder head and gasket. See REMOVE CYLINDER HEAD in Group 020. Remove flywheel. See REMOVE FLYWHEEL in Group 040. Remove flywheel housing. See REMOVE AND INSTALL FLYWHEEL HOUSING in Group 040. Remove rear crankshaft seal and seal housing. See REMOVE REAR CRANKSHAFT OIL SEAL AND HOUSING

(Continued on next page)

See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188, Section 02, Group 091 (single rail fuel systems).

ASSEMBLY in Group 040.

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ENGINE DISASSEMBLY SEQUENCE—CONTINUED

Procedure Reference

Remove cylinder block front plate. See REMOVE AND INSTALL CYLINDER BLOCK FRONT PLATE in

Perform wear checks on connecting rod bearing surfaces using See REMOVE PISTONS AND CONNECTING RODS in Group 030.

PLASTIGAGE. Remove piston and connecting rod assemblies.

010

Check crankshaft end play. See CHECK CRANKSHAFT END PLAY in Group 040. Remove main bearing caps with bearings. Perform wear checks on See REMOVE CRANKSHAFT MAIN BEARINGS in Group 040.

main bearing surfaces with PLASTIGAGE. See CHECK MAIN BEARING-TO-JOURNAL OIL CLEARANCE in

Remove crankshaft. See REMOVE CRANKSHAFT in Group 040. Remove cylinder block plugs and serial number plate if block is to be See COMPLETE DISASSEMBLY OF CYLINDER BLOCK in Group

put in a hot tank. 030. Inspect and repair individual components. See appropriate repair groups.

Group 030.

Group 040.

PLASTIGAGE is a registered trademark of the DANA Corp.

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Sealant Application Guidelines

Listed below are sealants which have been tested and are used by the John Deere factory to control leakage and ensure hardware retention. ALWAYS use the following recommended sealants when assembling your John Deere Diesel Engine to ensure quality performance.

LOCTITEthread sealants are designed to perform to sealing standards with machine oil residue present. If excessive machine oil or poor cleanliness quality exist, clean with solvent. Refer to John Deere Merchandise and Parts Sales Manual for ordering information.

IMPORTANT: LOCTITEgasket materials are NOT

designed to work with oil residue present. Oil residues must be cleaned from surfaces before applying gasket material.

LOCTITE242 Thread Lock & Sealer (Medium

Strength) (blue):

TY9370 6 mL (0.2 oz) tube

• Threaded plugs and fittings: cylinder block (oil

galley).

• Cap screws: coolant pump, timing gear cover,

camshaft gear access cover, oil pump.

• Oil pressure sending unit.

• Turbocharger oil inlet fitting.

• Fuel filter check valve or elbow (filter header end)

dual rail fuel system.

• Piston spray jets.

• Timing gear cover gasket and camshaft gear access

cover gasket on earlier engines using Fel-Pro gaskets.

• Idler gear carrier cap screws, camshaft gear retainer

cap screws and fuel supply pump drive coupler cap screws.

• EUI hold-down clamp cap screws.

TY9371 6 mL (0.2 oz) tube

• Oil filter adapter-to-base. LOCTITE277 Thread Lock & Sealer (High

Strength) (red):

T43514 50 mL (1.7 oz) bottle

• Expansion plugs in cylinder head and block. LOCTITE515 Flexible Sealant (General Purpose)

(purple):

TY6304 50 mL (1.7 oz) bottle

• Timing gear cover and camshaft gear access cover gasket on earlier engines using Fel-Pro gasket.

LOCTITE592 Pipe Sealant with TEFLON(white): TY9374 6 mL (0.2 oz) tube

• Pipe plugs: cylinder block (water manifold), thermostat housing, air intake manifold, and coolant pump.

• Temperature sending unit.

• Coolant heater.

• Oil pan drain valve/hose.

LOCTITE680 Maximum Strength Retaining

Compound (green):

TY15969 6 mL (0.2 oz) tube

• Crankshaft flange and ID of front wear sleeve for front and rear oil seal/wear sleeve installation.

• Steel cup plugs on cylinder head and block.

02 010 11

LOCTITE271 Thread Lock & Sealer (High

Strength) (clear):

LOCTITE is a registered trademark of Loctite Corp.

TEFLON is a registered trademark of Du Pont Company

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PT569 NEVER-SEEZCompound PT569 227 g (8 oz) Brush PT506 453 g (16 oz) Spray

010

• Cap Screws: exhaust manifold, intake manifold,

aftercooler, turbocharger oil return line, and turbocharger cap screws/nut.

LOCTITE222 Small Screw Threadlocker

(Removable) (Purple)

TY24311 0.5 mL (0.02 oz) tube

LOCTITE is a registered trademark of Loctite Corp.

NEVER-SEEZ is a registered trademark of Emhart Chemical Group

• EUI solenoid terminal nuts. LOCTITE17430 High Flex Form-in-Place Gasket T43514 50 mL (1.7 oz) bottle

• Oil pan-to-cylinder block (timing gear cover and rear seal housing T-joints).

LOCTITE7649, TY16285 Clean-and-Cure Primer

• Clean mating gasket surfaces on timing gear cover, camshaft gear access cover, oil pan, and block sealing surfaces.

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6105 and 6125 Engine Assembly Sequence

The following assembly sequence is suggested when engine has been completely disassembled. Be sure to check runout, clearance, and all critical physical part

IMPORTANT: ALWAYS replace vibration damper

whenever crankshaft is replaced or after a major engine overhaul.

specifications prior to assembling engine. Replace parts as necessary and tighten retaining hardware to specifications given. Refer to the appropriate repair group when assembling engine.

ENGINE ASSEMBLY SEQUENCE

Procedure Reference

Install all plugs in cylinder block that were removed to service See COMPLETE DISASSEMBLY OF CYLINDER BLOCK in Group cylinder block. 030.

IMPORTANT: If new piston and liner kits are being installed, See INSTALL CYLINDER LINERS in Group 030.

Install cylinder liners without O-rings and measure liner stand-out. Install liners with packing.

Install crankshaft. See INSTALL CRANKSHAFT in Group 040. Install main bearings. See INSTALL MAIN BEARING INSERTS IN BLOCK in Group 040. Rotate crankshaft by hand to ensure correct assembly. Check See CHECK CRANKSHAFT END PLAY in Group 040.

crankshaft end play. Install pistons and connecting rods. Rotate crankshaft by hand to See in INSTALL PISTONS AND CONNECTING RODS in Group 030.

ensure correct assembly. Install crankshaft rear oil seal housing. See INSTALL CRANKSHAFT REAR OIL SEAL HOUSING in Group

Install rear oil seal and wear sleeve assembly. See INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE

Install flywheel. See INSTALL FLYWHEEL in Group 040. Install flywheel housing. See REMOVE AND INSTALL FLYWHEEL HOUSING in Group 040. Install cylinder block front plate. See REMOVE AND INSTALL CYLINDER BLOCK FRONT PLATE in

Install engine oil pump and drive gear. See INSTALL ENGINE OIL PUMP in Group 060. Install cylinder head using a new gasket. See INSTALL CYLINDER HEAD in Group 020. Install camshaft and camshaft drive gear. See REMOVE AND INSTALL CAMSHAFT in Group 050. Install timing gear cover. See INSTALL TIMING GEAR COVER in Group 040. Install oil pickup tube. See REMOVE AND INSTALL OIL PICKUP TUBE in Group 060. Install engine oil pan. See INSTALL ENGINE OIL PAN in Group 060. Install idler gear. Pin camshaft and crankshaft. Adjust idler See ADJUST FRONT TIMING GEAR BACKLASH in Group 050.

gear-to-camshaft gear and idler gear-to-oil pump gear backlash. Install new crankshaft vibration damper and pulley assembly (with oil See INSTALL CRANKSHAFT VIBRATION DAMPER AND FRONT

seal). OIL SEAL in Group 040.

install them as an assembly after crankshaft has been installed.

040.

ASSEMBLY in Group 040.

Group 030.

(Continued on next page)

02 010 13

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ENGINE ASSEMBLY SEQUENCE—CONTINUED

Procedure Reference

Install electronic unit injectors on Delphi/Lucas ECU controlled fuel See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in systems. CTM115, Section 02, Group 090.

Install electronic unit injectors on John Deere ECU controlled fuel See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in

systems. CTM188, Section 02, Group 090 (dual rail fuel systems).

010

Install valve bridges and push tubes. Install front and rear rocker arm See INSTALL ROCKER ARM ASSEMBLY in Group 020. shaft assemblies. Install EUI wiring harness.

Preload unit injectors and adjust valve clearance. See CHECK AND ADJUST VALVE ASSEMBLY CLEARANCES AND

Install front camshaft gear access cover. See INSTALL TIMING GEAR COVER in Group 040. Install fuel supply pump (Delphi/Lucas ECU controlled fuel system). See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM115,

Install fuel supply pump (John Deere ECU controlled fuel system). See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188,

Install fuel manifold assembly on Delphi/Lucas ECU controlled fuel See REMOVE AND INSTALL FUEL MANIFOLD in CTM 115, Section systems. 02, Group 090.

Install fuel manifold assembly on John Deere ECU controlled fuel See REMOVE AND INSTALL FUEL MANIFOLD in CTM 188, Section systems. 02, Group 090 (dual rail fuel systems).

Install all remaining fuel lines, identify for reassembly in correct See CTM115, Section 02, Group 090. location. See CTM188, Section 02, Group 090 or 091.

On 6105H and 6125H engines, install air intake manifold. See REMOVE, INSPECT AND INSTALL INTAKE MANIFOLD in

On 6105A engines, install aftercooler assembly. See REMOVE AND INSTALL AFTERCOOLER ASSEMBLY in Group

Install fuel filter assemblies with mounting bases as required See REPLACING PRIMARY FUEL FILTER/WATER SEPARATOR in (Delphi/Lucas ECU controlled fuel system). CTM115, Section 02, Group 090.

Install fuel filter assemblies with mounting bases as required (John See REPLACING PRIMARY FUEL FILTER/WATER SEPARATOR in Deere Level 6 ECU controlled fuel system). CTM188, Section 02, Group 090 (dual rail fuel systems).

Install all six piston spray jets. See REMOVE AND INSTALL PISTON SPRAY JETS in Group 030. Install coolant pump assembly. See INSTALL COOLANT PUMP in Group 070.

(Continued on next page)

See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188, Section 02, Group 091 (single rail fuel systems).

INJECTOR PRELOAD in Group 020.

Section 02, Group 090.

Section 02, Group 090 (dual rail fuel systems). See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188, Section 02, Group 091 (single rail fuel systems).

Group 080.

080.

See REPLACE FINAL (SECONDARY) FUEL FILTER ELEMENT in CTM115, Section 02, Group 090.

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ENGINE ASSEMBLY SEQUENCE—CONTINUED

Procedure Reference

Install water manifold/thermostat housing assembly. See REMOVE AND INSTALL THERMOSTAT HOUSING in Group

070.

Install oil filter housing/oil cooler assembly. See INSTALL OIL COOLER/OIL FILTER VALVE HOUSING

ASSEMBLY OR OIL COOLER COVER/VALVE HOUSING ASSEMBLY in Group 060.

Install exhaust manifold assembly. See REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD in

Group 080.

Install turbocharger. Connect all turbocharger oil lines and See INSTALL TURBOCHARGER in Group 080. intake/exhaust piping.

Install alternator. See REMOVE AND INSTALL ALTERNATOR in Group 100. Install compressor. See CTM67, OEM Engine Accessories. Install fan drive, fan and fan belt. See Group 070. Mount engine into vehicle. See vehicle repair manual. Flush cooling system. Fill engine systems with recommended fuel, See FLUSH AND SERVICE COOLING SYSTEM in Section 01,

lubricant, and coolant. Group 002. Perform engine break-in and normal standard performance checks. See PERFORM ENGINE BREAK-IN in this group.

02 010 15

Engine Break-In Guidelines

Engine break-in should be performed after overhaul or when the following repairs have been made:

Main bearings, rod bearings, crankshaft, or any combination of these parts have been replaced.

Pistons, rings, or liners have been replaced. Rear crankshaft oil seal and wear sleeve have been

replaced. (Primary objective is to see if oil seal still leaks). Cylinder head has been removed. Electronic unit injectors have been removed or critical

adjustments have been made while they are on the engine. (Primary objective of break-in is to check power).

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Perform Engine Break-In

Engine Rebuild Guide, Break-In and Tune-Up

IMPORTANT: If engine has a PTO, break-in can be

performed at the PTO if it is done as

010

specified below. To prevent possible damage to the PTO gear box, DO NOT apply full load through the PTO for any longer than the specified 10 minutes below.

Use a dynamometer to perform the following preliminary break-in procedure. If necessary, preliminary engine break-in can be performed without a dynamometer if under controlled operating conditions.

IMPORTANT: DO NOT use John Deere PLUS-50 oil

or engine oils meeting API CG4, API CF4, ACEA E3 or ACEA E2, performance levels during break-in period of an engine that has had a major overhaul. These oils will not allow an overhauled engine to properly wear during the break-in period.

Do not add makeup oil until the oil level is BELOW the add mark. John Deere Break-In Oil should be used to make up any oil consumed during break-in period.

DO NOT fill above the crosshatch pattern or FULL mark. Oil levels anywhere within the crosshatch are acceptable.

1. Fill engine crankcase to proper level with John Deere ENGINE BREAK-IN OIL during break-in operation. Use break-in oil regardless of ambient temperature. This oil is specifically formulated to enhance break-in of John Deere diesel engines. Under normal conditions, do not exceed 100 hours with break-in oil.

If John Deere Engine Break-In Oil is not available, use diesel engine oil meeting API Service Classification CE or ACEA Specification E1.

IMPORTANT: During preliminary break-in,

periodically check engine oil pressure and coolant temperature. Also check for signs of fuel, oil, or coolant leaks.

2. Start engine, run at loads and speeds shown in following chart for time limits given.

PRELIMINARY ENGINE BREAK-IN AFTER MAJOR OVERHAUL Time Load Engine Speed

1 minute No load 850 rpm 2 minutes No load Fast Idle 10 minutes 1/2—3/4 load 2000 rpm to rated

speed

10 Minutes Full load Rated speed

3. After preliminary break-in, run engine 1—2 minutes at 1500 rpm, with no load before shut-down.

4. Check and readjust valve clearance as necessary. Cylinder head retorque is not required.

NOTE: During the first 20 hours, avoid prolonged

periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine.

5. Operate the engine at heavy loads with minimal idling during the break-in period.

If the engine has significant operating time at idle, constant speeds, and/or light load usage, an additional 100 hour break-in period is recommended using a new change of John Deere ENGINE BREAK-IN OIL and new John Deere oil filter.

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Check engine oil level more frequently during engine break-in period. As a general rule, makeup oil should not need to be added during 100-hour break-in period. However, if makeup oil is required in the first 100-hour break-in, an additional 100-hour break-in period is required. Use a new change of John Deere ENGINE BREAK-IN OIL and a new John Deere oil filter.

After 100 hours maximum, drain break-in oil and change oil filter. Fill crankcase with John Deere TORQ-GARD SUPREMEOR PLUS-50or other

TORQ-GARD SUPREME is a registered trademark of Deere & Company. PLUS-50 is a registered trademark of Deere & Company.

Check Crankcase Ventilation System

1. Inspect crankcase ventilation system for restrictions. Lack of ventilation causes sludge to form in crankcase. This can lead to clogging of oil passages, filters, and screens, resulting in serious engine damage.

heavy-duty diesel engine oil within the same service classification as recommended in this manual. See DIESEL ENGINE OIL in Group 002, Fuels, Lubricants, and Coolant.

NOTE: Some increase in oil consumption may be

expected when low viscosity oils are used. Check oil levels more frequently.

If air temperature is below -10°C (14°F), use an engine block heater.

RG,100,JW7645 –19–05NOV99–2/2

02 010 17

2. Clean crankcase vent tube (A) with solvent and compressed air if restricted. Install and tighten hose clamps securely.

A—Crankcase Vent Tube

Crankcase Vent Tube

RG10239 –UN–09JUL99

DPSG,OUO1004,919 –19–30JUN99–1/1

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Check Air Intake System

1. Replace air cleaner primary filter element. Replace secondary element if primary element has holes in it.

010

(See REPLACING AIR CLEANER FILTER ELEMENTS in operator’s manual.)

2. Check condition of air intake hose(s). Replace hoses that are cracked, split, or otherwise in poor condition.

3. Check hose clamps for tightness. Replace clamps that cannot be properly tightened. This will help prevent dust from entering the air intake system which could cause serious engine damage.

4. If air cleaner has an automatic dust unloader valve (A), inspect valve for dust buildup or restrictions.

5. Check air intake restriction indicator gauge (B) (if equipped) to determine if air cleaner needs to be serviced.

Unloader Valve

RG8717A –UN–12JUL99

A—Unloader Valve B—Restriction Indicator Gauge

Check Exhaust System

1. Inspect exhaust system for leaks or restrictions. Check manifold for cracks. Repair or replace as necessary.

2. Check that turbocharger-to-exhaust elbow adapter clamps are securely tightened and do not leak.

3. Check exhaust stack for evidence of oil leakage past valve stem seals.

Restriction Indicator Gauge

RG8719A –UN–12JUL99

DPSG,OUO1004,920 –19–09JUL99–1/1

Oil in exhaust stack may be caused by excessive valve stem-to-guide clearance or excessive light load engine idling.

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Check and Service Cooling System

1. Remove trash that has accumulated on or near radiator.

2. Visually inspect entire cooling system and all components for leaks or damage. Repair or replace as necessary.

3. Remove the foam filter from weep hole (A, shown removed) located on the side of timing gear cover and discard filter. Inspect the weep hole for any restrictions.

4. Insert a heavy gauge wire deep into weep hole to make sure hole is open.

5. Install new foam filter flush with bore opening.

Weep Hole with Foam Filter

A—Weep Hole

Continued on next page

02 010 19

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CAUTION: Do not drain coolant until the coolant temperature is below operating temperature. Always loosen coolant drain valve (A) slowly to relieve any excess pressure.

010

6. Remove and check thermostat(s). (See REMOVE AND

TEST THERMOSTATS in Group 025.)

7. Drain and flush cooling system. (See FLUSH AND SERVICE COOLING SYSTEM in Group 002.)

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen temperature sending unit fitting at rear of cylinder head, bleed plug at top front of cylinder head, or plug in thermostat housing to allow air to escape when filling system. Retighten fitting or plug when all the air has been expelled.

8. Fill cooling system with coolant. Follow recommendations in Group 002. (See DIESEL ENGINE COOLANT RECOMMENDATIONS in Group

002.)

9. Run engine until it reaches operating temperature. Check entire cooling system for leaks.

10. After engine cools, check coolant level.

NOTE: Coolant level should be even with bottom of

radiator filler neck.

11. Check system for holding pressure. (See PRESSURE

TEST COOLING SYSTEM AND RADIATOR CAP in Section 04, Group 150.)

Service Cooling System Safely

TS281 –UN–23AUG88

RG8246 –UN–06DEC97

Coolant Drain Valve

A—Coolant Drain Valve

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Check Electrical System

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Engine Rebuild Guide, Break-In and Tune-Up

02 010 21

Always remove grounded (-) battery clamp first and replace it last.

1. Clean batteries and cables with damp cloth. If corrosion is present, remove it and wash terminals with a solution of ammonia or baking soda in water. Then flush area with clean water.

2. Coat battery terminals and connectors with petroleum jelly mixed with baking soda to retard corrosion.

3. Test batteries. If batteries are not near full charge, try to find out why.

4. On low-maintenance batteries, check level of electrolyte in each cell of each battery. Level should be to bottom of filler neck. If water is needed, use clean, mineral-free water.

If water must be added to batteries more often than every 250 hours, alternator may be overcharging.

NOTE: Water cannot be added to maintenance-free

batteries.

Prevent Battery Explosions

TS204 –UN–23AUG88

5. If batteries appear to be either undercharged or overcharged, check alternator and charging circuit.

6. Check tension of drive belts. See operator’s manual.

7. Check operation of starter motor and gauges.

NOTE: For test and repair of alternators and starter

motors, see CTM77, Alternators and Starter Motors.

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Preliminary Engine Testing Before Tune-Up

Before tuning-up an engine, determine if a tune-up will restore operating efficiency. If in doubt, the following preliminary tests will help determine if the engine can be

tuned-up. Choose from the following procedures only

010

those necessary to restore the unit.

1. After engine has stopped for several hours, loosen crankcase drain plug and watch for any water to seep out. A few drops could be due to condensation, but any more than this would indicate problems which require engine repairs rather than just a tune-up.

2. With engine stopped, inspect engine coolant for oil film. With engine running, inspect coolant for air bubbles. Either condition would indicate problems which require engine repairs rather than just a tune-up.

3. Perform a dynamometer test and record power output. (See DYNAMOMETER TEST in Section 04, Group

150.) Repeat dynamometer test after tune-up. Compare power output before and after tune-up.

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General Tune-Up Recommendations

As a general rule, an engine tune-up is not necessary if ALL recommended operator’s manual hourly service procedures are performed on schedule. If your engine performance is not within the rated application guidelines, the following service procedures are recommended to help restore engine to normal operating efficiency.

IMPORTANT: These engines are equipped with

electronically-controlled governors which have a diagnostic feature that will display detailed codes to alert operator of specific performance problems. Refer to CTM115 for Delphi/Lucas ECU controls, and refer to CTM188 for later John Deere ECU controls.

Operation Detailed Reference

Check for and correct any diagnostic trouble codes. ........................................................... CTM115 or CTM188

Change engine oil and filters. ............................................................................................... Operator’s Manual

Lubricate PTO clutch internal levers and linkage, if equipped. ............................................ Operator’s Manual

Replace fuel filter. ................................................................................................................. CTM115 or CTM188, Operator’s Manual

Clean crankcase vent tube. .................................................................................................. This Group/Operator’s Manual

Check air intake system. Replace air cleaner elements. ..................................................... This Group/Operator’s Manual

Check exhaust system. ......................................................................................................... This Group

Check and service engine cooling system. .......................................................................... This Group/Operator’s Manual

Check and adjust fan and alternator belts. ........................................................................... Operator’s Manual

Check electrical system. ....................................................................................................... This Group

Check crankshaft vibration damper. ..................................................................................... Group 040/Operator’s Manual

Inspect turbocharger and check turbocharger boost pressure. ............................................ Section 04, Group 150 of CTM115 or CTM188

Check fuel injection system: Check electronic unit injectors. ............................................... Section 04, Group 150 of CTM115 or CTM188

Check engine valve clearance and EUI preload. Adjust if necessary. ................................. Section 02, Group 020 of CTM115 or CTM188

Check engine oil pressure. Correct as necessary. ............................................................... Section 04, Group 150

Check engine speeds. Correct as necessary. ...................................................................... Authorized Servicing Dealer

Check engine performance on dynamometer. ...................................................................... Section 04, Group 150

02 010 23

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PN=71

010

Engine Rebuild Guide, Break-In and Tune-Up

CTM100 (06APR04)

02-010-24

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=72

Remove and Install Rocker Arm Cover

Remove Rocker Arm Cover

Group 020

Cylinder Head and Valves

1. Remove air intake cross-over tube (shown removed).

NOTE: Turbocharger is removed for photographic

purposes only. It is not necessary to remove turbocharger for rocker arm cover removal.

2. Remove center hold-down cap screw with isolator.

3. Remove two outside cap screws with isolators (A), and thread cap screws into rocker arm cover as shown.

NOTE: Rocker arm cover gasket is reusable if no visible

damage is detected. Do not store cover resting on gasket surface.

4. Lift rocker arm cover off engine.

Install Rocker Arm Cover

IMPORTANT: Always check routing of unit injector

wiring (B) before installing rocker arm cover. Wiring should be positioned so that rocker arms never contact wire.

1. Inspect rocker arm cover gasket to ensure that gasket is properly seated in groove and that contact face is clean.

02 020 1

RG8173 –UN–05DEC97

Isolators

RG8818 –UN–11DEC97

Unit Injector Wiring

A—Isolators B—Unit Injector Wiring

2. Position rocker arm cover onto two locating dowels in cylinder head.

3. Install center hold-down cap screw with isolator. Tighten to specifications.

Rocker Arm Cover Hold-Down

Cap Screws1—Torque 30 N•m (22 lb-ft).....................................................

Specification

4. Install two outside hold-down cap screws with isolators. Tighten to specifications.

Tighten center cap screw first, then tighten sides.

CTM100 (06APR04)

Continued on next page

02-020-1

OWERTECH

RG,RG34710,60 –19–03NOV99–1/2

10.5 L & 12.5 L Diesel Engines

040604

PN=73

Cylinder Head and Valves

Rocker Arm Cover Hold-Down

Cap Screws1—Torque 30 N•m (22 lb-ft).....................................................

Specification

5. Install air intake cross-over tube and tighten

020

connections securely.

Tighten center cap screw first, then tighten sides.

Clean and Inspect Crankcase Ventilation Assembly

1. Remove ventilation outlet tube from rocker arm cover (shown removed).

NOTE: Ventilator assembly-to-rocker cover self-tapping

cap screws have been replaced by flange head cap screws with pre-applied sealant. Discard old self-tapping cap screws and replace with new cap screws.

2. Remove two cap screws securing ventilator assembly (B) to cover and remove.

3. Clean ventilator assembly in solvent and dry with compressed air.

RG,RG34710,60 –19–03NOV99–2/2

RG10242 –UN–20JUL99

Crankcase Ventilation Assembly

A—O-Rings B—Ventilator Assembly

4. Install ventilator assembly in reverse order of removal. Replace O-rings (A) as necessary.

5. Tighten ventilator assembly-to-rocker arm cover cap screws to specifications.

Specification

Crankcase Vent Baffle-to-Rocker

Arm Cover Cap Screws—Torque 15 N•m (11 lb-ft) (133 lb-in.).................

6. Install ventilator outlet tube onto elbow attached to rocker arm cover.

CTM100 (06APR04)

02-020-2

OWERTECH

RG,RG34710,61 –19–03SEP02–1/1

10.5 L & 12.5 L Diesel Engines

040604

PN=74

Cylinder Head and Valves

Replace Rocker Arm Cover Gasket

1. Remove rocker arm cover. (See REMOVE AND INSTALL ROCKER ARM COVER earlier in this group.)

2. Remove existing gasket from cover and discard. Clean gasket groove as needed.

3. Position new gasket at two front corners of cover with double lips (A) of gasket facing up.

IMPORTANT: DO NOT stretch gasket while seating in

groove of cover.

4. Seat gasket on front side of cover and proceed around entire cover gasket groove using a deep-well socket.

5. Re-seat gasket again (especially in corners) after entire gasket is installed in groove.

A—Gasket Double Lips

02 020 3

RG8784 –UN–10DEC97

Replacing Rocker Arm Cover Gasket

RG,RG34710,62 –19–30SEP97–1/1

CTM100 (06APR04)

02-020-3

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=75

Cylinder Head and Valves

Check and Adjust Valve Assembly Clearances and Injector Preload

Rocker arm assembly adjustments consist of intake and exhaust valve clearance (lash) and electronic unit injector

preload adjustment.

020

CAUTION: To prevent accidental starting of engine while performing rocker arm adjustment, ALWAYS disconnect NEGATIVE (–) battery terminal.

IMPORTANT: All rocker arm assembly adjustments

MUST BE performed with engine COLD.

1. Remove rocker arm cover. (See REMOVE AND INSTALL ROCKER ARM COVER earlier in this group.)

2. Remove plug from cylinder block and install JDG820 Flywheel Turning Tool (B).

3. Remove threaded plug from timing hole below oil cooler and filter housing assembly.

IMPORTANT: Timing pin MUST BE installed in slot of

camshaft first, then install second timing pin in crankshaft slot by carefully rocking flywheel back and forth.

4. Rotate engine flywheel in running direction (counterclockwise as viewed from rear) until JDG971 Timing Pin (A) engages single timing slot (D) in camshaft. The proper timing slot can be found by viewing camshaft timing lobe through camshaft timing pin bore while rotating engine. The double timing slot (E) will be at approximately 11 o’clock (viewed from rear of engine) when pin is installed in slot (D).This ensures that engine is locked at TDC of No. 1 cylinder’s compression stroke. Intake and exhaust rocker arms on No. 1 cylinder should be loose.

A—JDG971 Timing Pin B—JDG820 Flywheel Turning Tool C—JDG971 Timing Pin D—Single Timing Slot E—Double Timing Slot

JDG971 Timing Pin in Camshaft

RG8228A –UN–05DEC97

RG8227D –UN–05DEC97

JDG971 Timing Pin in Crankshaft

CTM100 (06APR04)

Continued on next page

02-020-4

Camshaft Timing Slot

OWERTECH

RG11165 –UN–30OCT00

RG,RG34710,63 –19–16OCT00–1/6

10.5 L & 12.5 L Diesel Engines

040604

PN=76

Cylinder Head and Valves

IMPORTANT: DO NOT insert timing pin full depth into

cylinder block crankshaft timing hole when rotating engine flywheel until double slot on camshaft timing lobe is at approximately 11 o’clock (viewed from rear of engine) to avoid crankshaft counterweight bending timing pin.

5. Slightly move engine flywheel back and forth with turning tool until a second JDG971 Timing Pin (C) can be installed in slot in crankshaft. This ensures that camshaft and crankshaft are in sync (properly timed).

If timing pin does not enter crankshaft timing slot, crankshaft is not properly timed with camshaft. Crankshaft MUST BE timed to camshaft. (See CHECK AND ADJUST CAMSHAFT-TO-CRANKSHAFT TIMING in Group 050.)

02 020 5

Continued on next page

RG,RG34710,63 –19–16OCT00–2/6

CTM100 (06APR04)

02-020-5

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=77

020

Cylinder Head and Valves

Rocker Arm Assembly Identification

6. Check and adjust (as needed) valve stem-to-bridge clearance (lash) on intake valves Nos. 1, 2, and 4, and exhaust valves Nos. 1, 3, and 5 (shaded locations). Adjust preload on electronic unit injectors Nos. 3, 5, and 6 (shaded locations).

Valve clearance is adjusted using JDG1333 Feeler Gauge Set or equivalent 1/4 inch (6.0 mm) wide automotive ignition point-type feeler gauge installed at the joint between the valve bridge and valve stem tip (B) that is near the exhaust (right) side of engine. Loosen lock nuts, set clearance with adjusting screw and tighten lock nut to specified torque while holding adjusting screw stationary.

Valve Stem-to-Bridge Clearance (Engine Cold)—Specification

Intake Valve—Clearance 0.58 ± 0.05 mm (0.023 ± 0.002

Exhaust Valve—Clearance 1.08 ± 0.05 mm (0.043 ± 0.002

..........................

in.)

.......................

in.)

7. Tighten intake and exhaust valve adjusting screw lock nuts to specifications.

RG8773 –UN–19MAY98

RG8232 –UN–05DEC97

Adjusting Valve Lash/Clearance

B—Valve Stem Tip

Intake and Exhaust Valve

Specification

Adjusting Screw Lock Nuts—

Torque 50 N•m (37 lb-ft).............................................................................

CTM100 (06APR04)

Continued on next page

02-020-6

OWERTECH

RG,RG34710,63 –19–16OCT00–3/6

10.5 L & 12.5 L Diesel Engines

040604

PN=78

Cylinder Head and Valves

8. Set electronic unit injector preload by turning the EUI rocker arm adjusting screw in until there is zero clearance between the rocker arm roller and camshaft lobe. Next, turn the adjusting screw in an additional one-half turn (180°). Hold adjusting screw stationary while tightening lock nut to specified torque. Tighten EUI adjusting screw lock nuts to specifications.

02 020 7

Electronic Unit Injector—Preload 0.00 mm (in.) clearance plus 1/2

Electronic Unit Injector Adjusting

Screw Lock Nuts—Torque 65 N•m (48 lb-ft)..............................................

Specification

...........

turn in (180°)

Continued on next page

RG,RG34710,63 –19–16OCT00–4/6

CTM100 (06APR04)

02-020-7

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=79

020

Cylinder Head and Valves

Rocker Arm Assembly Identification

9. Reference mark flywheel (A) as shown with engine locked at No.1 TDC compression stroke.

IMPORTANT: DO NOT insert timing pin full depth into

cylinder block when rotating engine flywheel until reference mark is within a few degrees of a full crankshaft revolution to eliminate possibility of crankshaft counterweight bending timing pin.

10. Remove both timing pins and rotate engine flywheel

one full revolution (360°) until timing pin (B) enters slot in crankshaft again. Engine will now be locked at No. 6 TDC compression stroke.

11. Check and adjust, as needed, valve clearance (lash)

on intake valves Nos. 3, 5, and 6 and exhaust valves Nos. 2, 4, and 6 (shaded locations). Adjust preload on injectors Nos. 1, 2, and 4 (shaded locations).

12. Tighten intake and exhaust valve adjusting screw lock

nuts to specifications.

RG8774 –UN–19MAY98

RG8229 –UN–05DEC97

Locking Engine at No.6 TDC

A—Flywheel Reference Mark B—Timing Pin

Intake and Exhaust Valve

Specification

Adjusting Screw Lock Nuts—

Torque 50 N•m (37 lb-ft).............................................................................

Tighten EUI adjusting screw lock nuts to specifications.

Specification

Electronic Unit Injector Adjusting

Screw Lock Nuts—Torque 65 N•m (48 lb-ft)..............................................

CTM100 (06APR04)

Continued on next page

02-020-8

OWERTECH

RG,RG34710,63 –19–16OCT00–5/6

10.5 L & 12.5 L Diesel Engines

040604

PN=80

Cylinder Head and Valves

IMPORTANT: Thoroughly inspect ALL intake and

exhaust valve bridges (A) for proper seating on valve stems (B) from both sides of engine. Also, be sure that push tubes (C) are properly seated in top of valve bridge.

Use a flashlight and carefully check each bridge (for proper seating on valve stems) from both sides of the engine, by lifting up on each bridge to verify proper seating. VALVE BRIDGES THAT ARE NOT PROPERLY SEATED ON VALVE STEMS WILL RESULT IN MAJOR ENGINE VALVE TRAIN FAILURE.

02 020 9

13. Check that all intake rocker arm adjusting screws (D) have approximately the same number of threads visible above lock nut. Normally flush to maximum of two threads.

If the number of threads above lock nut at any location is visually different, verify bridge seating and readjust valve clearance to ensure everything is within specification at this location.

14. Install plug in timing pin hole below oil cooler and tighten to specifications.

Specification

Timing Pin Plug (Below Oil

Cooler)—Torque 33 N•m (24 lb-ft)..............................................................

Inspect Valves

RG9743 –UN–04DEC98

RG9626A –UN–04DEC98

Adjusting Screws

A—Valve Bridges B—Valve Stems C—Push Tubes D—Adjusting Screws

RG,RG34710,63 –19–16OCT00–6/6

CTM100 (06APR04)

02-020-9

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=81

Remove Rocker Arm Assembly

CAUTION: After operating engine, allow exhaust system to cool before servicing engine.

020

1. Remove rocker arm cover.

2. Lock camshaft and crankshaft at TDC of No.1 cylinder’s compression stroke.

Cylinder Head and Valves

3. Remove electronic unit injector wiring harness from rocker arm shaft clamps.

IMPORTANT: ALWAYS loosen all intake, exhaust and

EUI rocker arm adjusting screws before removal or installation of rocker arm assembly to relieve pressure. This allows for a more uniform rocker arm cap screw clamp load and reduces the possibility of damage to valve train components.

Remove push tubes and valve bridges immediately after relieving rocker arm pressure. Push tubes can fall into oil drain opening of cylinder head causing oil pan removal to retrieve tubes.

4. Loosen EUI, intake, and exhaust valve rocker arm adjusting screw lock nut and relieve pressure at all locations.

5. Remove push tubes (C) and valve bridges (D) from all valve stems.

Removing Valve Bridge and Push Tubes

RG8262B –UN–06DEC97

RG8459A –UN–21JUL99

Removing Rocker Arm Assembly with JDG970A

A—Rocker Arm Shaft Oil Tubes (Dual Rail Fuel

System Only) B—Rocker Arm Lifting Fixture C—Push Tubes D—Valve Bridges

6. Remove two rocker arm shaft oil tubes (A) (dual rail system only). Remove rocker arm shaft hold-down clamps.

IMPORTANT: Rocker arm shaft hold-down clamp cap

screws can not be reused. Use new cap screws for reassembly.

7. Install shaft clamp cap screw in end hole of each rocker arm shaft so that rocker arms do not slide off shaft when lifted.

CTM100 (06APR04)

Continued on next page

02-020-10

OWERTECH

RG,RG34710,64 –19–21DEC00–1/2

10.5 L & 12.5 L Diesel Engines

040604

PN=82

Cylinder Head and Valves

CAUTION: A second set of pins has been added to JDG970A tool. With 6125 Tier II engines (engine serial no. 030000—), the holes for the pins in the rocker arm shaft are smaller. The new pins have a smaller diameter shaft and are marked “JDG1847”. To safely handle the rocker arm shaft assembly, BE CERTAIN to verify the engine serial number, then use the correct pins for that engine.

8. Depress actuator (ball) pins and install JDG970A Rocker Arm Lifting Fixture (B) into rocker arm shaft cap screw holes as shown. Replace pins to seat ball locks.

9. Remove both front and rear rocker arm and shaft assemblies using JDG970A Rocker Arm Lifting Fixture.

10. Discard rocker arm shaft hold-down clamp cap

screws.

02 020 11

RG,RG34710,64 –19–21DEC00–2/2

CTM100 (06APR04)

02-020-11

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=83

Remove Cylinder Head

On some applications, it may be necessary to remove engine from machine to service cylinder head. Refer to your Machine Technical Manual for engine removal

procedure.

020

CAUTION: After operating engine, allow exhaust system to cool before servicing engine.

Cylinder Head and Valves

DO NOT drain coolant until the coolant is below operating temperature. Only remove radiator filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

1. Drain all oil and coolant.

2. Remove intake manifold (6105H and 6125H engines). (See REMOVE, INSPECT AND INSTALL INTAKE MANIFOLD in Group 080.)

3. Remove turbocharger (A). (See REMOVE TURBOCHARGER in Group 080.)

4. Remove exhaust manifold (B). (See REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD in Group 080.)

5. On 6105A and 6125A engines, remove aftercooler assembly. (See REMOVE AND INSTALL AFTERCOOLER ASSEMBLY in Group 080.)

6. Remove thermostat housing/water manifold (C). (See REMOVE AND INSTALL THERMOSTAT HOUSING in Group 070.)

Removing Turbocharger and Exhaust Manifold

RG8187A –UN–05DEC97

A—Turbocharger B—Exhaust Manifold C—Thermostat Housing/Water Manifold

7. Remove rocker arm assembly. (See REMOVE AND INSTALL ROCKER ARM ASSEMBLY, earlier in this group).

8. Remove electronic unit injectors and wiring harness. Refer to the appropriate fuel system repair manual.

Delphi/Lucas ECU controlled fuel systems:

CTM100 (06APR04)

Continued on next page

02-020-12

OWERTECH

RG,RG34710,65 –19–13AUG99–1/5

10.5 L & 12.5 L Diesel Engines

040604

PN=84

Cylinder Head and Valves

• See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM115, Section 02, Group 090.

John Deere Level 6 ECU controlled fuel systems:

• See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188, Section 02, Group 090 (dual rail fuel systems).

• See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188, Section 02, Group 091 (single rail fuel systems).

9. Remove fan drive hub and camshaft gear access cover.

Continued on next page

02 020 13

RG,RG34710,65 –19–13AUG99–2/5

CTM100 (06APR04)

02-020-13

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=85

Cylinder Head and Valves

10. Remove six cap screws securing camshaft gear retaining washer (A) and remove camshaft gear (B).

NOTE: Later engines: 10.5 L S.N. (003764— ) and 12.5 L

020

S.N. (010967— ) with single rail fuel systems do not have a fuel manifold. Return fuel line is connected to port of single rail in back of cylinder head. Inlet line and port are on left side of head up by No.1 cylinder.

11. Remove fuel manifold block (C) on engines with dual rail systems, or disconnect fuel inlet and return lines on single rail systems. Refer to the appropriate fuel system repair manual.

Delphi/Lucas ECU controlled fuel systems:

• See REMOVE AND INSTALL FUEL MANIFOLD in

CTM115, Section 02, Group 090.

John Deere Level 6 ECU controlled fuel systems:

Removing Camshaft Gear

RG8251A –UN–06DEC97

• See REMOVE AND INSTALL FUEL MANIFOLD in

CTM188, Section 02, Group 090.

12. Remove fuel supply pump. Refer to the appropriate fuel system repair manual.

Delphi/Lucas ECU controlled fuel systems:

• See REMOVE AND INSTALL FUEL SUPPLY

PUMP in CTM115, Section 02, Group 090.

John Deere Level 6 ECU controlled fuel systems:

• See REMOVE AND INSTALL FUEL SUPPLY

PUMP in CTM188, Section 02, Group 090 (dual rail fuel systems).

• See REMOVE AND INSTALL FUEL SUPPLY

PUMP in CTM188, Section 02, Group 091 (single rail fuel systems).

Removing Supply Pump and Fuel Manifold (Early Engine

RG8264B –UN–06DEC97

Shown)

RG8544B –UN–10DEC97

DFRG4 Camshaft Locking Tool

A—Gear Retaining Washer B—Camshaft Gear C—Fuel Manifold D—Fuel Supply Pump E—DFRG4 Camshaft Locking Tool

CTM100 (06APR04)

Continued on next page

02-020-14

OWERTECH

RG,RG34710,65 –19–13AUG99–3/5

10.5 L & 12.5 L Diesel Engines

040604

PN=86

Cylinder Head and Valves

NOTE: Cylinder head can be removed without removing

camshaft.

IMPORTANT: If cylinder head is removed with

camshaft installed, secure camshaft in bushings with DFRG4 Camshaft Locking Tool (E) so that camshaft journals and bushings are not damaged by camshaft sliding out of bushings. (See DFRG4-CAMSHAFT LOCKING TOOL in Section 05, Group 190 for details on this dealer fabricated tool.)

Camshaft position sensor MUST BE removed from air intake side of cylinder head when removing or installing camshaft to prevent camshaft binding on sensor.

13. Remove camshaft front thrust ring. Remove camshaft position sensor and remove camshaft if desired (see REMOVE AND INSTALL CAMSHAFT in Group 050).

02 020 15

Continued on next page

RG,RG34710,65 –19–13AUG99–4/5

CTM100 (06APR04)

02-020-15

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=87

Cylinder Head and Valves

NOTE: If removing head with camshaft installed,

camshaft will have to be rotated to remove two of the cylinder head cap screws.

14. Remove 26 cylinder head cap screws with washers

020

and discard.

IMPORTANT: DO NOT use screwdrivers or prybars

between cylinder block and head to loosen gasket seal. Screwdrivers and prybars can damage head and block gasket surfaces.

15. Carefully lift cylinder head from block using an overhead hoist or floor crane. Place head on a clean, flat surface.

16. Remove cylinder head gasket. Inspect gasket for any manufacturing imperfections. Inspect head, gasket, and check for possible oil, coolant, or combustion chamber leakage.

Removing Cylinder Head

RG8285 –UN–21MAY98

NOTE: DO NOT rotate engine crankshaft with cylinder

head removed unless all cylinder liners are secured with cap screws and large, flat washers. (See REMOVE PISTONS AND CONNECTING RODS in Group 030.)

RG,RG34710,65 –19–13AUG99–5/5

CTM100 (06APR04)

02-020-16

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=88

Cylinder Head and Valves

Diagnosing Head Gasket Joint Failures

Head gasket failures generally fall into three categories:

• Combustion seal leakage.

• Coolant seal leakage.

• Oil seal leakage.

Combustion seal leakage failures occur when combustion gases escape between cylinder head and head gasket combustion flange, or between combustion flange and cylinder liner. Leaking combustion gases may vent to an adjacent cylinder, to a coolant or oil passage, or externally.

Coolant or oil seal failures occur when oil or coolant escapes between cylinder head and gasket body, or between cylinder block and gasket body. The oil or coolant may leak to an adjacent coolant or oil passage, or externally.

Follow these diagnostic procedures when a head gasket joint failure occurs or is suspected:

1. Before starting or disassembling engine, conduct a visual inspection of machine, and note any of the following:

• Oil or coolant in head gasket seam, or on adjacent

surfaces, especially right rear corner of gasket joint.

• Displacement of gasket from normal position.

• Discoloration or soot from combustion gas leakage.

• Leaking radiator, overflow tank, or hoses.

• Leaking coolant from coolant pump weep hole.

• Damaged or incorrect radiator, fan, or shroud.

• Obstructed air flow or coolant flow.

• Worn or slipping belts.

• Damaged or incorrect pressure cap.

• Presence of oil in coolant.

• Low coolant levels or improper coolant.

• Unusually high or low oil levels.

• Oil degradation, dilution, or contamination.

• Correctly specified electronic unit injectors.

• Indications of fuel delivery or gear train not properly

timed.

• Unburned fuel or coolant in exhaust system.

Cylinder Head Gasket Sealing Area

A—Combustion Sealing Areas B—Coolant Sealing Areas C—Cylinder Head Cap Screws

02 020 17

RG8430 –UN–22MAY98

CTM100 (06APR04)

Continued on next page

02-020-17

OWERTECH

RG,RG34710,69 –19–01NOV00–1/2

10.5 L & 12.5 L Diesel Engines

040604

PN=89

Cylinder Head and Valves

2. Obtain coolant and oil samples for further analysis.

3. Start and warm up engine if it can be safely operated. Examine all potential leakage areas again as outlined

020

previously. Using appropriate test and measurement equipment, check for the following:

• White smoke, excessive raw fuel, or moisture in

exhaust system.

• Rough, irregular exhaust sound, or misfiring.

• Air bubbles, gas entrainment in radiator or overflow

tank.

• Loss of coolant from overflow.

• Excessive cooling system pressure.

• Coolant overheating.

• Low coolant flow.

• Loss of cab heating (air lock).

4. Shut engine down. Recheck crankcase, radiator, and overflow tank for any significant differences in fluid levels, viscosity, or appearance.

5. Compare your observations from above steps with the appropriate diagnostic procedures in Section 04, Group

150. If diagnostic evaluations and observations provide conclusive evidence of combustion gas, coolant, or oil leakage from head gasket joint, the cylinder head must be removed for inspection and repair of gasket joint components.

RG,RG34710,69 –19–01NOV00–2/2

CTM100 (06APR04)

02-020-18

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=90

Cylinder Head and Valves

Head Gasket Inspection and Repair Sequence

02 020 19

Cylinder Head Gasket Inspection

A—Combustion Seals B—Gasket Body C—Front of Engine

(Flanges)

The following inspection procedures are recommended whenever a head gasket joint failure occurs or when joint disassembly takes place.

1. Review historical data relating to machine operation, maintenance and repair, along with diagnostic observations. Note all areas requiring further inspection and analysis.

2. Remove rocker arm cover and check for presence of coolant in the oil.

3. Record head cap screw torques prior to removal. Upon removal, check cap screw length differences.

4. Remove cylinder head using appropriate lifting devices to prevent handling damage to head gasket. (See REMOVE CYLINDER HEAD in this group.)

RG8429 –UN–19MAY98

Examine gasket body (B) for the following:

• Combustion gas erosion paths or soot deposits originating at combustion seals.

• Extreme discoloration/hardening/embrittlement in localized areas.

• Oil or coolant paths from port areas.

• Localized areas of low compression.

6. Before cleaning components, inspect head, block, and liners for evidence of combustion gas and fluid leakage. Inspect cylinders and valve ports for unusual deposits.

7. Clean cylinder block. (See INSPECT AND CLEAN CYLINDER BLOCK in Group 030.) Clean cylinder head. (See CLEAN AND INSPECT CYLINDER HEAD in this group.) Clean liners. (See CLEAN CYLINDER LINERS in Group 030.)

5. Observe surfaces of removed head gasket. Examine combustion seals (A) for the following:

• Flange severed/expanded/cracked/deformed.

• Adjacent body area burned/eroded.

• Fire ring severed/displaced/missing.

• Flange sealing pattern eccentric/contains voids.

• Discoloration of flange and adjacent body areas.

• Flange surfaces rough/abraided/channelled.

CTM100 (06APR04)

8. Proceed with the following dimensional checks and

Continued on next page

02-020-19

visual inspections:

• Cylinder Head (this group) – Check surface flatness/finish. – Inspect for surface damage. – Check cylinder head thickness, if resurfacing.

• Cylinder Block and Liners (assembled and clamped) (Group 030)

RG,RG34710,70 –19–30SEP97–1/2

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=91

Cylinder Head and Valves

020

– Check liner standout at four places on each

liner.

– Check liner standout difference between

cylinders.

• Cylinder Block (Group 030) – Check surface flatness/finish. – Inspect for surface damage. – Check liner counterbore depth (if liner is

removed).

– Check top deck to crankshaft centerline

dimension.

– Inspect cap screw bosses; must be

clean/intact.

• Cylinder Liner (Group 030) – Check liner flange flatness/finish.

– Check liner flange thickness (if liner is

removed).

– Inspect flange for damage.

• Cylinder Head Cap Screws (this group) – Inspect condition of threads. – Check length.

9. When inspections and measurements have been completed, determine most probable causes of joint failure. Make all necessary repairs to joint components, cooling system, and fuel injection system.

10. Reassemble the engine according to procedures

and specifications in the appropriate repair groups of this manual.

RG,RG34710,70 –19–30SEP97–2/2

CTM100 (06APR04)

02-020-20

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=92

Cylinder Head and Valves

Disassemble and Inspect Rocker Arms and Shaft Assembly

1. Remove rocker arms from shaft and identify for installation in same position as removed.

2. Inspect rocker arm shaft for scoring and excess wear at rocker arm contact points. Roll on a flat surface and check for bends or distortion.

02 020 21

3. Check rocker arm adjusting screws and lock nuts for thread damage.

4. Check valve bridges and push tubes for contact wear.

5. Clean all parts with clean solvent. Dry with compressed air.

6. Measure rocker arm shaft OD and rocker arm bushing ID. Compare measurements with specifications below.

7. Inspect rocker arm roller for uneven wear. Measure roller OD and compare with specifications below.

Rocker Arm Bushing—ID 38.064 ± 0.013 mm (1.4986 ±

Rocker Arm Shaft—OD 38.000 ± 0.013 mm (1.4961 ±

Rocker Arm Shaft-to-Bushing— Oil Clearance 0.064 ± 0.026 mm (0.0025 ±

Rocker Arm Shaft Intake and Exhaust Roller—OD 39.995—40.045 mm

Rocker Arm Shaft Unit Injector Roller—OD 37.995—38.045 mm

................................................

..................................................

................................................................

Specification

...........................

0.0005 in.)

..............................

0.0005 in.)

0.0010 in.)

(1.5746—1.5766 in.)

(1.4959—1.4978 in.)

Measure Rocker Arm Shaft

RG8395 –UN–21MAY98

RG8392 –UN–21MAY98

Measure Rocker Arm Bushing

Replace parts as necessary.

CTM100 (06APR04)

02-020-21

Measure Rocker Arm Roller

RG,RG34710,71 –19–30SEP97–1/1

OWERTECH

10.5 L & 12.5 L Diesel Engines

RG8390 –UN–21MAY98

040604

PN=93

Cylinder Head and Valves

Preliminary Cylinder Head and Valve Checks

Make preliminary inspection of cylinder head and valve assembly during disassembly.

Look for the following conditions:

020

Sticking Valves:

• Carbon deposits on valve stem.

• Worn valve guides.

• Scored valve stems.

• Warped valve stems.

• Misaligned or broken valve springs.

• Worn or distorted valve seats.

• Insufficient lubrication.

Warped, Worn, or Distorted Valve Guides:

• Lack of lubrication.

• Cylinder head distortion.

• Excessive heat.

• Unevenly tightened cylinder head cap screws.

Distorted Cylinder Head and Gasket Leakage:

• Loss of cylinder head cap screw torque.

• Broken cylinder head cap screw.

• Overheating from low coolant level operation.

• Insufficient liner standout.

• Coolant leakage into cylinder causing hydraulic

failure of gasket.

• Leaking aftercooler.

• Cracked cylinder head.

• Cracked cylinder liner.

• Damaged or incorrect gasket.

• Overpowering or overfueling.

• Damaged cylinder head or block surfaces.

• Improper surface finish on cylinder head.

• Improperly tightened cylinder head cap screws or

faulty gasket installation (misaligned).

Worn or Broken Valve Seats:

• Distorted cylinder head.

• Carbon deposits on seats due to incomplete

combustion.

• Valve spring tension too weak.

• Excessive heat.

• Improper valve clearance.

• Improper valve timing.

• Incorrect valve or seat installed.

Burned, Pitted, Worn, or Broken Valves:

• Worn or distorted valve seats.

• Loose valve seats.

• Worn valve guides.

• Insufficient cooling.

• Cocked or broken valve springs.

• Improper engine operation.

• Improper valve train timing.

• Faulty valve rotators.

• Warped or distorted valve stems.

• “Stretched” valves due to excessive spring tension.

• Warped cylinder head.

• Carbon build-up on valve seats.

• Rocker arm failure.

• Incorrect valve or seat installed.

• Incorrect piston-to-valve clearance.

Improper Valve Clearance:

• Inefficient use of fuel.

• Engine starts harder.

• Maximum engine power will not be achieved.

• Shorter service life of valve train.

• Greater chance for engine to overheat.

Excessive Valve Recession:

• Worn valve seats.

• Bent valves.

• Debris passed through valve train.

• Misaligned valves.

CTM100 (06APR04)

02-020-22

OWERTECH

RG,RG34710,72 –19–30SEP97–1/1

10.5 L & 12.5 L Diesel Engines

040604

PN=94

Cylinder Head and Valves

Assemble Rocker Arms and Shaft Assembly

1. Make sure that rocker arm shaft end plugs are firmly seated in each shaft end bore.

2. Assemble parts on rocker arm shaft in reverse sequence as removed.

3. Install cap screws (B) and (C) in holes at each end of rocker arm shaft to keep rocker arms from sliding off shaft during installation.

4. Install JDG970A Rocker Arm Lifting Fixture (A) onto rocker arm and shaft assembly.

A—JDG970A Rocker Arm Assembly Lifting Fixture B—Cap Screw C—Cap Screw

Check Valve Height in Relation to Head Surface (Valve Recess)

Rocker Arm and Shaft Assembly

Lifting Rocker Arm Assembly

RG,RG34710,73 –19–13AUG99–1/1

02 020 23

RG8460 –UN–21MAY98

RG8304 –UN–06DEC97

1. Thoroughly clean all gasket material from cylinder head combustion face.

2. Measure and record valve recess using JDG451 (English) or KJD10123 (Metric) Height Gauge (A) along with D17526CI (English, in.) or D17527CI Dial Indicator (Metric) (B). Measurements must be made a maximum of 3.0 mm (0.12 in.) in from edge of valve head.

Specification

Intake and Exhaust Valves—

Recess 1.85—2.35 mm (0.073—0.093 in.).................................................

Install new valves, inserts, or grind existing valves and inserts (as necessary) to obtain specified valve recess.

CTM100 (06APR04)

02-020-23

Measure Valve Recess

A—Height Gauge B—Dial Indicator

OWERTECH

RG8330A –UN–09DEC97

RG,RG34710,74 –19–03NOV99–1/1

10.5 L & 12.5 L Diesel Engines

040604

PN=95

Cylinder Head and Valves

Remove Valve Assembly

NOTE: A small magnet may be used to aid removal of

valve retainer locks (D).

1. Place cylinder head on a clean flat surface with

020

combustion face down.

2. Using JDG982 Valve Spring Compressor (A), compress valve spring far enough to remove retainer locks as shown.

3. Release spring tension, remove valve rotator (C) and valve spring (B).

4. Remove valve stem seals (E) from valve guide tower.

5. Lay cylinder head on air intake side using a 1016 x 51 x 102 mm (40 x 2.0 x 4.0 in.) block of wood.

6. Remove valves and identify for assembly in same location.

Removing Valve Springs

RG8305 –UN–06DEC97

A—JDG982 Valve Spring Compressor B—Valve Springs C—Valve Rotators D—Valve Retainer Locks E—Valve Stem Seals

Removing Valve Stem Seals

RG8306B –UN–06DEC97

RG,RG34710,75 –19–30SEP97–1/1

CTM100 (06APR04)

02-020-24

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=96

Cylinder Head and Valves

Inspect and Measure Valve Springs

IMPORTANT: Replacement valve springs (R133891)

have higher working loads than older springs (R116585). Newer valve springs (R133891) have two green paint stripes for identification. Valve springs must be replaced in sets of two with new rotators. DO NOT intermix springs across valve bridges.

02 020 25

1. Inspect valve springs for alignment, wear, and damage.

2. Using D01168AA Spring Compression Tester, check valve spring tension. Compressed height must be within specification given below.

Specification

Intake and Exhaust Valve Springs (All)1—Height at 0 N (0 lb-force)

Free Length 67.9—72.1 mm (2.67—2.84 in.).............................................

Intake and Exhaust Valve Springs (R116585)—Height at 352—396 N (79—89 lb-force) (Valve

Closed) 59.4 mm (2.34 in.).........................................................................

Intake and Exhaust Valve Springs (R116585)—Height at 845—935 N (190-210 lb-force) (Valve

Open) 45.5 mm (1.79 in.)............................................................................

Intake and Exhaust Valve Springs (R133891)—Height at 527—593 N (118—133 lb-force) (Valve

Closed) 59.4 mm (2.34 in.).........................................................................

Intake and Exhaust Valve Springs (R133891)—Height at 1187— 1313 N (267—295 lb-force)

(Valve Open) 46.4 mm (1.83 in.)................................................................

Valve Spring

RG2732 –UN–04DEC97

RG7427 –UN–21MAY98

Measuring Valve Spring Compression

Free length of springs may vary slightly between springs.

CTM100 (06APR04)

02-020-25

OWERTECH

RG,RG34710,76 –19–13AUG99–1/1

10.5 L & 12.5 L Diesel Engines

040604

PN=97

Cylinder Head and Valves

Inspect Valve Rotators

Valve rotators cannot be repaired. Replace valve rotators when valves are replaced or reground.

Ensure that valve rotators turn freely in both directions.

020

Replace if defective.

Inspecting Valve Rotator

RG8323 –UN–21MAY98

RG,RG34710,77 –19–30SEP97–1/1

CTM100 (06APR04)

02-020-26

OWERTECH

10.5 L & 12.5 L Diesel Engines

040604

PN=98

PowerTech 6105HF, 6105ADW, 6125 Tier II, 6125HF, 6105HRW Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual