PowerTech 6105HF User manual

P OWER T ECH

10.5 L & 12.5 L
Diesel Engines
Base Engine
TECHNICAL MANUAL
P OWER T ECH 10.5 L & 12.5 L Diesel
Engines—Base Engine
CTM100 06APR04 (ENGLISH)
For complete service information also see:
P OWER T ECH

10.5 L & 12.5 L Diesel
Engines—Delphi/Lucas Electronic Fuel
Systems With Delphi/Lucas EUIs
.................................... CTM115
P OWER T ECH

10.5 L & 12.5 L Diesel
Engines—Level 6 Electronic Fuel Systems
With Delphi/Lucas EUIs................. CTM188
OEM Engine Accessories ...... CTM67 (English Only)
Alternators and Starter Motors........... CTM77
John Deere Power Systems
LITHO IN U.S.A.

Introduction
RG,RG34710,1 –19–11OCT00–1/1
Forward
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
This manual (CTM100) covers only the base engine. It
is one of three volumes on 10.5 L and 12.5 L engines.
The following two companion manuals cover electronic
fuel system repair, operation and diagnostics:
•CTM115—Delphi/Lucas Electronic Fuel Systems
With Delphi/Lucas EUIs
•CTM188—Level 6 Electronic Fuel Systems With
Delphi/Lucas EUIs
CTM115 and CTM188 will cover fuel system repair,
formerly included in CTM100, Groups 35 and 36.
Other manuals will be added in the future to provide
added information on new electronic fuel systems.
A complete set of all three manuals covering the 10.5
L and 12.5 L engines can be procured by ordering
CTM650 Binder Set.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
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 OWER T ECH 10.5 L & 12.5 L Diesel Engines
040604
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Introduction
OUO1004,0000BBC –19–11OCT00–1/2
John Deere Dealers
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)
•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)
•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.
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.
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Introduction
OUO1004,0000BBC –19–11OCT00–2/2
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 OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Introduction
RG,RG34710,3 –19–06NOV00–1/1
POWERTECH

6105HF and 6125HF Engines
RG9030 –UN–21MAY98
Right Side View (Early Engine)
RG9031 –UN–21MAY98
Left Side View (Early Engine)
RG9032 –UN–21MAY98
3/4 Right Front View (Early Engine)
RG9033 –UN–21MAY98
3/4 Left Front View (Early Engine)
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Introduction
DPSG,OUO1004,915 –19–16NOV00–1/1
POWERTECH

6105HF and 6125HF Engines—Continued
RG11174 –UN–20NOV00
3/4 Right Rear View (Early Engine)
RG11175 –UN–20NOV00
3/4 Left Rear View (Early Engine)
RG11171A –UN–03NOV00
Right Side View Later Engine S.N. (30000— )
RG11172A –UN–04DEC00
3/4 Right Front View Later Engine S.N. (30000— )
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
040604
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Introduction
RG,RG34710,3A –19–30SEP97–1/1
POWERTECH

6105HRW and 6125HRW Engines
RG8222 –UN–21MAY98
Right Side View
RG8221 –UN–21MAY98
Left Side View
RG8223 –UN–21MAY98
3/4 Right Front View
RG8224 –UN–21MAY98
3/4 Left Front View
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
040604
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Introduction
DPSG,OUO1004,916 –19–30JUN99–1/1
POWERTECH

6105HRW and 6125HRW Engines—Continued
RG8220 –UN–21MAY98
3/4 Right Rear View
RG8219 –UN–21MAY98
3/4 Left Rear View
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Introduction
RG,RG34710,5 –19–30SEP97–1/1
POWERTECH

6105ADW Engine
RG8454 –UN–21MAY98
Right Side View (Early Engine)
RG8448 –UN–21MAY98
3/4 Left Front View (Early Engine)
RG8453 –UN–21MAY98
3/4 Right Rear View (Early Engine)
RG8451 –UN–21MAY98
3/4 Left Rear View (Early Engine)
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
040604
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Introduction
OUO1080,000028D –19–27AUG02–1/1
POWERTECH

6105ADW Engine—Continued
RG11171A –UN–03NOV00
Right Side View Later Engines S.N. (30000—)
RG11172A –UN–04DEC00
Right Front View Later Engines S.N. (30000—)
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
040604
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Introduction
RE38635,0000026 –19–20JUN03–1/1
POWERTECH

6125 Tier II (30000—)
RG11171A –UN–03NOV00
Right Side View (30000—)
RG11172A –UN–04DEC00
Right Front View (30000—)
P OWER T ECH is a registered trademark of Deere & Company.
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
040604
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Introduction
RG,RG34710,8 –19–30SEP97–1/1
6105 and 6125 Engine Cutaway View
RG8435 –UN–12JUL99
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
CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Contents
01
SECTION 01—General Information
Group 000—Safety
Group 001—Engine Identification and Applications
Group 002—Fuels, Lubricants and Coolant
02
SECTION 02—Repair and Adjustments
Group 010—Engine Rebuild Guide, Break-In and
Tune-Up
Group 020—Cylinder Head and Valves
Group 030—Cylinder Block, Liners, Pistons, and
Rods
Group 040—Crankshaft, Main Bearings, and
Flywheel
Group 050—Camshaft and Timing Gear Train
Group 060—Lubrication System
Group 070—Cooling System
03
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
04
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
05
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.
06
COPYRIGHT

2003
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION

Manual
Previous Editions
Copyright

1996, 1997, 1999, 2001
INDX
CTM100 (06APR04) i P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Contents
01
02
03
04
05
06
INDX
CTM100 (06APR04) ii P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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01
Section 01
General Information
Contents
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
CTM100 (06APR04) 01-1 P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Contents
01
CTM100 (06APR04) 01-2 P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Group 000
Safety
01
000
1
DX,FLAME –19–29SEP98–1/1
Handle Fluids Safely—Avoid Fires
TS227 –UN–23AUG88
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.
DX,RCAP –19–04JUN90–1/1
Service Cooling System Safely
TS281 –UN–23AUG88
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.
DX,FIRE2 –19–03MAR93–1/1
Prepare for Emergencies
TS291 –UN–23AUG88
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.
CTM100 (06APR04) 01-000-1 P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Safety
01
000
2
DPSG,OUO1004,2758 –19–11MAY00–1/1
Handling Batteries Safely
TS204 –UN–23AUG88
Explosion
TS203 –UN–23AUG88
Acid
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.
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.
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 P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Safety
01
000
3
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X9811 –UN–23AUG88
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.
DX,WEAR –19–10SEP90–1/1
Wear Protective Clothing
TS206 –UN–23AUG88
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.
CTM100 (06APR04) 01-000-3 P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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Safety
01
000
4
DX,LOOSE –19–04JUN90–1/1
Service Machines Safely
TS228 –UN–23AUG88
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.
DX,AIR –19–17FEB99–1/1
Work In Ventilated Area
TS220 –UN–23AUG88
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
DX,CLEAN –19–04JUN90–1/1
Work in Clean Area
T6642EJ –UN–18OCT88
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.
CTM100 (06APR04) 01-000-4 P OWER T ECH 10.5 L & 12.5 L Diesel Engines
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