John Deere 6135 Diesel Engine Level 32 ECU Worldwide Workshop Repair Service Manual CTM119919 PDF - MJODCTM119919.zip
A full-service repair guide, complete with electrical wiring diagrams, covering the John Deere 6135 Diesel Engine — packed with every technical detail needed to service, troubleshoot, fix, and rebuild the engine the way professional technicians do.
Contained within the John Deere 6135 Diesel Engine workshop service and repair manual:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
ctm119914 - 6135 柴油发动机 — 32 级 ECU - (世界通用机型) Component Technical Manual.pdf
ctm119919 - 6135 Diesel Engine — Level 32 ECU (Worldwide Edition) Component Technical Manual.pdf
ctm119928 - Moteur diesel 6135—Contrôleur ECU niveau 32 - (Édition mondiale) Component Technical Manual.pdf
ctm119939 - Motore diesel 6135 – ECU livello 32 - (Edizione universale) Component Technical Manual.pdf
ctm119954 - 6135 Motor a Diesel — Nível 32 ECU -: (Edição Mundial) Manual Técnico de Componentes.pdf
ctm119959 - Дизельный двигатель 6135 — БУД уровня 32 - (Исполнение для всех стран) Техническое руководство по компонентам.pdf
ctm119963 - Motor diésel 6135 — ECU Nivel 32 -: (Ediciónmundial) Manual técnico de componentes.pdf
PRODUCT DETAILS:
Total Pages: 4,433 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English etc.
Category: CTM
ctm119963 - Motor diésel 6135 — ECU Nivel 32 -: (Edición mundial) Spanish
ctm119914 - 6135 柴油发动机 — 32 级 ECU -: (世界通用机型) Chinese
ctm119919 - John Deere 6135 Diesel Engine — Level 32 ECU -: (Worldwide Edition) English
ctm119928 - Moteur diesel 6135—Contrôleur ECU niveau 32 -: (Édition mondiale) French
ctm119929 - Dieselmotor 6135 — ECU (Level 32) -: (Weltweite Ausgabe) German
ctm119939 - Motore diesel 6135 – ECU livello 32 -: (Edizione universale) Italian
ctm119954 - 6135 Motor a Diesel — Nível 32 ECU -: (Edição Mundial) Portuguese
ctm119959 - Дизельный двигатель 6135 — БУД уровня 32 -: (Исполнение для всех стран) Russian
TABLE OF CONTENTS
Section 01: General Information...62
Group 000: Safety...62
Understand Signal Words...66
Recognize Safety Information...67
Replace Safety Signs...68
Follow Safety Instructions...69
California Proposition 65 Warning...70
Exhaust Filter Cleaning...71
Avoid Hot Exhaust...72
Work In Ventilated Area...73
Decommissioning — Proper Recycling and Disposal of Fluids and Components...74
Prevent Machine Runaway...75
Practice Safe Maintenance...76
Work in Clean Area...78
Wear Protective Clothing...79
Service Machines Safely...80
Use Proper Tools...81
Construct Dealer-Made Tools Safely...82
Support Machine Properly...83
Use Proper Lifting Equipment...84
Protect Against Noise...85
Illuminate Work Area Safely...86
Install All Guards...87
Stay Clear of Rotating Drivelines...88
Protect Against High Pressure Spray...89
Service Cooling System Safely...90
Remove Paint Before Welding or Heating...91
Precautions for Welding...92
Wait Before Opening High-Pressure Fuel System...94
Avoid High-Pressure Fluids...95
Avoid Heating Near Pressurized Fluid Lines...96
Avoid Static Electricity Risk When Refueling...97
Handle Fluids Safely—Avoid Fires...99
Prepare for Emergencies...100
Handling Batteries Safely...101
Prevent Acid Burns...103
Prevent Battery Explosions...105
Live With Safety...106
Group 001: Engine Identification...63
Engine Serial Number Plate Information...109
OEM Engine Option Code Label...111
Information Relative to Emissions Regulations...112
Emissions Control System Certification Label...113
Group 002: Fuels, Lubricants, and Coolant...63
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines...115
Storing Diesel Exhaust Fluid (DEF)...116
Refilling Diesel Exhaust Fluid (DEF) Tank...117
Testing Diesel Exhaust Fluid (DEF)...119
Disposal of Diesel Exhaust Fluid (DEF)...120
Diesel Fuel...121
Supplemental Diesel Fuel Additives...123
Lubricity of Diesel Fuel...124
Handling and Storing Diesel Fuel...125
Biodiesel Fuel...126
Testing Diesel Fuel...128
Fuel Filters...129
Minimizing the Effect of Cold Weather on Diesel Engines...130
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V...132
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V...133
Diesel Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V— OEM Applications...135
Diesel Engine Oil and Filter Service Intervals...137
Mixing of Lubricants...138
Alternative and Synthetic Lubricants...139
Lubricant Storage...140
Oil Filters...141
Diesel Engine Coolant (engine with wet sleeve cylinder liners)...142
Water Quality for Mixing with Coolant Concentrate...144
Operating in Warm Temperature Climates...145
Testing Coolant Freeze Point...146
Disposing of Coolant...148
Section 02: Repair and Adjustments...149
Group 010: Engine Rebuild...149
Overhaul Guidelines...165
Check Air Intake System...166
Check and Service Cooling System...167
Check Crankcase Ventilation System...169
Check Electrical System...170
Check Exhaust System...172
Clean Engine...173
Disconnect Turbocharger Oil Supply Lines...174
Engine Assembly Sequence...175
Engine Break-In Guidelines...179
Engine Disassembly Sequence...180
General Tune-Up Recommendations...184
Install Adapter on Repair Stand...185
Lift Strap — Installation...186
Lift Strap — Removal...188
Lifting Procedure...190
Mount Engine on Repair Stand...191
Engine Break-In...193
Engine Repair Stand - Adapter Safety Precautions...195
Sealant Application Guidelines...196
Group 020: Cylinder Head and Valve Repair and Adjustment...149
Cylinder Head — Cleaning and Inspection...200
Cylinder Head — Flatness Check...202
Cylinder Head — Installation...203
Cylinder Head — Removal...207
Cylinder Head Gasket — Inspection...212
Cylinder Head Injector Bore — Cleaning and Inspection...214
Fuel Injector Sleeves — Installation...215
Fuel Injector Sleeve — Removal...219
Rocker Arm Access Panel — Installation...222
Rocker Arm Access Panel — Removal...225
Rocker Arm Cover — Installation...227
Rocker Arm Cover — Removal...230
Rocker Arm Cover Heat Shield — Installation...233
Rocker Arm Cover Heat Shield — Removal...235
Rocker Arm Injector — Inspection...236
Rocker Arm Intake and Exhaust — Inspection...237
Rocker Arm Shaft — Inspection...239
Rocker Arm Shaft Assembly— Assemble...241
Rocker Arm Shaft Assembly — Installation...243
Rocker Arm Shaft Assembly — Removal...247
Rocker Arm Shaft Assembly — Tear Down...249
Valve — Cleaning and Inspection...251
Valve — Clearance Adjustment and Injector Preload...252
Valve — Grinding...266
Valve — Measurement...267
Valve — Recess Measurement...268
Valve Assembly — Installation...269
Valve Assembly — Removal...272
Valve Bridge, Valve Rotator, and Valve Retainer — Inspection...275
Valve Guide — Cleaning and Measurement...276
Valve Guide — Installation...278
Valve Guide — Measurement...280
Valve Guide — Removal...281
Valve Seat — Cleaning and Inspection...282
Valve Seat — Grinding...283
Valve Seat Insert — Installation...285
Valve Seat Insert — Removal...286
Valve Spring — Inspection and Measurement...287
Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment...150
Connecting Rod and Cap — Inspection...293
Connecting Rod Bearing — Inspection and Measurement...297
Connecting Rod Bushing — Inspection...299
Cylinder Block — Inspect and Reclaim...301
Cylinder Block — Measurements...315
Cylinder Block Oil and Coolant Plug — Installation...316
Cylinder Liner — Cleaning...319
Cylinder Liner — Inspection...320
Cylinder Liner — Installation and Height Measurement...322
Cylinder Liner — Removal...326
Cylinder Liner Shim — Installation...329
Oil Dipstick Tube Assembly — Inspection...330
Oil Dipstick Tube Assembly — Installation...331
Oil Dipstick Tube Assembly — Removal...333
Oil Filler and Dipstick Assembly — Installation...548
Oil Filler and Dipstick Assembly — Removal...550
Piston — Cleaning...337
Piston — Inspection...338
Piston and Connecting Rod Assembly — Installation...339
Piston and Connecting Rod Assembly — Removal...347
Piston and Connecting Rod Assembly — Tear Down...352
Piston Cooling Orifice — Installation...354
Piston Cooling Orifice — Removal and Inspection...356
Piston Pin and Bore — Inspection...358
Piston Pin Bushing — Inspection...360
Piston to Liner — Clearance Check...361
Group 040: Crankshaft, Main Bearings, Flywheel Repair, and Adjustment...151
Crankshaft — End Play Check...364
Crankshaft — Inspection...365
Crankshaft — Installation...367
Crankshaft — Removal...373
Crankshaft Front Oil Seal Hub — Installation...376
Crankshaft Front Oil Seal Hub — Removal...379
Crankshaft Gear — Replacement...381
Crankshaft Grinding — Guidelines...383
Crankshaft Main Bearing — Oil Clearance Check...385
Crankshaft Journals — Assembled Measurements...386
Crankshaft Pulley — Installation...387
Crankshaft Pulley — Removal...389
Crankshaft Unitized Front Oil Seal — Installation...391
Crankshaft Unitized Front Oil Seal — Removal...395
Crankshaft Unitized Rear Oil Seal — Installation...397
Crankshaft Unitized Rear Oil Seal — Removal...400
Crankshaft Unitized Rear Oil Seal Housing — Installation...402
Crankshaft Unitized Rear Oil Seal Housing — Removal...404
Crankshaft Vibration Damper — Inspection...405
Crankshaft Vibration Damper and Hub — Installation...407
Crankshaft Vibration Damper and Hub — Removal...411
Flywheel — Inspection...415
Flywheel — Installation...416
Flywheel — Removal...419
Flywheel Face — Runout Check...421
Flywheel Housing — Installation...422
Flywheel Housing — Removal...425
Flywheel Pilot Bearing Bore — Concentricity Runout Check...427
Flywheel Ring Gear — Installation...428
Flywheel Ring Gear — Removal...430
Main Bearing Cap — Installation...431
Main Bearing Cap — Line Bore Specifications...433
Main Bearing Cap — Removal...437
Thrust Bearing — Inspection...440
Thrust Bearing and Main Bearing Cap — New Part Specification...441
Group 050: Camshaft and Timing Gear Train Repair and Adjustment...152
Air Compressor Assembly — Installation...453
Air Compressor Assembly — Removal...464
Auxiliary Gear Drive Front Cover — Installation...467
Auxiliary Gear Drive Front Cover — Removal...468
Auxiliary Gear Drive Rear Cover — Installation...469
Auxiliary Gear Drive Rear Cover — Removal...471
Auxiliary Drive Crankshaft Driven Front Mounted SAE A — Installation...473
Auxiliary Drive Crankshaft Driven Front Mounted SAE A — Removal...475
Auxiliary Drive Crankshaft Driven Front Mounted SAE B — Installation...476
Auxiliary Drive Crankshaft Driven Front Mounted SAE B — Removal...478
Auxiliary Drive Crankshaft Driven Rear Mounted SAE B — Installation...479
Auxiliary Drive Crankshaft Driven Rear Mounted SAE B — Removal...481
Auxiliary Drive Crankshaft Driven Idler Gear — Installation...483
Auxiliary Drive Crankshaft Driven Idler Gear — Removal...484
Camshaft — Check End Play...485
Camshaft — Inspection...486
Camshaft — Removal...487
Camshaft and Gear — Installation...491
Camshaft Bushing — Measurement...495
Camshaft Bushing — Replacement...496
Camshaft Gear — Inspection...502
Camshaft Gear — Removal...503
Camshaft Gear Access Cover — Installation...504
Camshaft Gear Access Cover — Removal...506
Camshaft Follower — Inspection...508
Camshaft Journal — Measurement...510
Camshaft Lobe — Lift Measurement...511
Camshaft Position Sensor Lobe — Inspection...512
Camshaft Retaining Ring — Installation...513
Camshaft Retaining Ring — Removal...515
Camshaft Retaining Ring — Thickness Measurement...517
Camshaft Timing Pin...518
Camshaft to Crankshaft Timing — Check and Adjustment...519
Coolant Pump Idler Gear — Installation...523
Coolant Pump Idler Gear — Removal...525
Front Seal Housing — Installation...527
Front Seal Housing — Removal...529
High-Pressure Fuel Pump Drive Pin — Replacement...530
Timing Gear Cover — Installation...531
Timing Gear Cover — Removal...534
Timing Gears — Check Backlash...537
Upper Idler Gear — Installation...543
Upper Idler Gear — Removal...545
Group 060: Lubrication System Repair and Adjustment...154
Dipstick Assembly — Installation...548
Dipstick Assembly — Removal...550
Oil Cooler — Inspection...552
Oil Cooler— Installation...553
Oil Cooler— Removal...555
Oil Cooler Bypass Valve — Installation...557
Oil Cooler Bypass Valve — Removal...558
Oil Filler— Installation...559
Oil Filler — Removal...560
Oil Filter — Installation...561
Oil Filter — Removal...562
Oil Filter and Oil Cooler Housing Assembly — Installation...563
Oil Filter and Oil Cooler Housing Assembly — Removal...568
Oil Filter Bypass Valve — Installation...570
Oil Filter Bypass Valve — Removal...571
Oil Pan — Installation...572
Oil Pan — Removal...576
Oil Pan Drain Valve — Installation...578
Oil Pan Drain Valve — Removal...579
Oil Pickup Tube — Installation...580
Oil Pickup Tube — Removal and Inspection...582
Oil Pressure Regulating Valve — Installation...584
Oil Pressure Regulating Valve — Removal...586
Oil Pump — Assemble...587
Oil Pump — Installation...589
Oil Pump — Removal...591
Oil Pump — Tear Down and Inspect...592
Open Crankcase Ventilation System — Inspection...594
Open Crankcase Ventilation System — Installation...596
Open Crankcase Ventilation System — Removal...600