John Deere 6135 Diesel Engine Workshop Repair Manual CTM104919 PDF Download - MJODCTM104919.zip
A full workshop and repair guide for John Deere 6135 Diesel Engines, complete with electrical wiring schematics, offering every technical detail needed to service, troubleshoot, fix, and overhaul these engines at a professional mechanic's level.
Inside the John Deere 6135 Diesel Engines workshop service repair manual, you'll find:
* 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.
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PRODUCT DETAILS:
Total Pages: 4,301 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Category: CTM
Language: English Spanish Chinese French German Italian Portuguese Russian
Published on 2018/12/01
TABLE OF CONTENTS
Section 01: General Information...743
Group 000: Safety...68
Understand Signal Words...71
Avoid Heating Near Pressurized Fluid Lines...72
Avoid High-Pressure Fluids...73
Avoid Hot Exhaust...74
Avoid Static Electricity Risk When Refueling...75
Construct Dealer-Made Tools Safely...77
Decommissioning — Proper Recycling and Disposal of Fluids and Components...78
Exhaust Filter Cleaning...79
Follow Safety Instructions...80
Handle Fluids Safely—Avoid Fires...81
Handling Batteries Safely...82
Illuminate Work Area Safely...84
Install All Guards...85
Live With Safety...86
Practice Safe Maintenance...87
Precautions for Welding...89
Prepare for Emergencies...91
Prevent Acid Burns...92
Prevent Battery Explosions...94
Prevent Machine Runaway...95
Protect Against High Pressure Spray...96
Protect Against Noise...97
Recognize Safety Information...98
Remove Paint Before Welding or Heating...99
Replace Safety Signs...100
Service Cooling System Safely...101
Service Machines Safely...102
Stay Clear of Rotating Drivelines...103
Support Machine Properly...104
Use Proper Lifting Equipment...105
Use Proper Tools...106
Wait Before Opening High-Pressure Fuel System...107
Wear Protective Clothing...108
Work in Clean Area...109
Work In Ventilated Area...110
Group 001: Engine Identification and Applications...69
Engine Serial Number Plate Information...113
OEM Engine Option Code Label...115
Information Relative to Emissions Regulations...116
Group 002: Fuels, Lubricants and Coolant...69
Diesel Fuel...119
Supplemental Diesel Fuel Additives...121
Handling and Storing Diesel Fuel...122
Lubricity of Diesel Fuel...123
Testing Diesel Fuel...124
Biodiesel Fuel...125
Fuel Filters...127
Minimizing the Effect of Cold Weather on Diesel Engines...128
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V...130
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V...131
Diesel Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V— OEM Applications...133
Engine Oil and Filter Service Intervals...135
Oil Filters...136
Lubricant Storage...137
Mixing of Lubricants...138
Alternative and Synthetic Lubricants...139
Diesel Engine Coolant (engine with wet sleeve cylinder liners)...140
Water Quality for Mixing with Coolant Concentrate...142
Operating in Warm Temperature Climates...143
Testing Coolant Freeze Point...144
Disposing of Coolant...146
Section 02: Repair and Adjustments...147
Group 010: Engine Rebuild...147
Overhaul Guidelines...160
Check Air Intake System...161
Check and Service Cooling System...162
Check Crankcase Ventilation System...164
Check Electrical System...165
Check Exhaust System...167
Clean Engine...168
Disconnect Turbocharger Oil Supply Lines...169
Engine Assembly Sequence...170
Engine Break-In Guidelines...174
Engine Disassembly Sequence...175
Engine Repair Stand...179
General Tune-Up Recommendations...180
Install Adapter on Repair Stand...181
Install Lifting Straps...182
Lifting Procedure...184
Mount Engine on Repair Stand...185
Perform Engine Break-In...187
Safety Precautions...189
Group 020: Cylinder Head and Valve Repair and Adjustment...147
Cylinder Head — Cleaning and Inspection...192
Cylinder Head — Flatness Check...194
Cylinder Head — Installation...195
Cylinder Head — Removal...199
Cylinder Head Gasket — Inspection...205
Cylinder Head Injector Bore — Cleaning and Inspection...207
Fuel Injector Sleeve — Installation...208
Fuel Injector Sleeve — Removal...212
Rocker Arm Access Panel — Installation...215
Rocker Arm Access Panel — Removal...218
Rocker Arm Cover — Installation...220
Rocker Arm Cover — Removal...223
Rocker Arm Cover Heat Shield — Installation...226
Rocker Arm Cover Heat Shield — Removal...228
Rocker Arm Injector — Inspection...230
Rocker Arm Intake and Exhaust — Inspection...231
Rocker Arm Shaft — Inspection...233
Rocker Arm Shaft — Reassemble...235
Rocker Arm Shaft — Tear Down...237
Rocker Arm Shaft Assembly — Installation...239
Rocker Arm Shaft Assembly — Removal...243
Valve — Cleaning and Inspection...245
Valve — Clearance Adjustment and Injector Preload...246
Valve — Grinding...261
Valve — Measurement...262
Valve — Recess Measurement...264
Valve Assembly — Installation...265
Valve Assembly — Removal...268
Valve Guide — Cleaning...271
Valve Guide — Installation...272
Valve Guide — Knurling...274
Valve Guide — Measurement...275
Valve Guide — Removal...276
Valve Retainer, Valve Bridge, and Valve Retainer Lock — Inspection...277
Valve Seat — Cleaning and Inspection...278
Valve Seat — Grinding...279
Valve Seat Insert — Installation...281
Valve Seat Insert — Removal...282
Valve Spring — Inspection...283
Valve Spring — Measurement...284
Group 030: Cylinder Block, Liners, Pistons, and Rods...148
Connecting Rod and Cap — Inspection...289
Connecting Rod Bearing — Inspection and Measurement...293
Cylinder Block — Inspect and Reclaim...295
Cylinder Block — Measurements...309
Cylinder Block Oil and Coolant Plug — Installation...310
Cylinder Liner — Cleaning...313
Cylinder Liner — Deglazing...314
Cylinder Liner — Inspection...316
Cylinder Liner — Installation and Height Measurement...318
Cylinder Liner — Removal...322
Cylinder Liner Shim — Installation...324
Oil Dipstick Tube Assembly — Inspection...325
Oil Dipstick Tube Assembly — Installation...326
Oil Dipstick Tube Assembly — Removal...328
Oil Filler and Dipstick Assembly — Installation...329
Oil Filler and Dipstick Assembly — Removal...331
Piston — Cleaning...332
Piston — Inspection...333
Piston and Connecting Rod Assembly — Installation...334
Piston and Connecting Rod Assembly — Removal...342
Piston and Connecting Rod Assembly — Tear Down...348
Piston Cooling Orifice — Installation...350
Piston Cooling Orifice — Removal and Inspection...352
Piston Pin and Bore — Inspection...354
Piston Pin and Bushing — Inspection...356
Piston to Liner — Clearance Check...358
Group 040: Crankshaft, Main Bearings, Flywheel Repair, and Adjustment...149
Crankshaft — End Play Check...362
Crankshaft — Inspection...363
Crankshaft — Installation...365
Crankshaft — Removal...372
Crankshaft Gear — Replacement...375
Crankshaft Journals — Assembled Measurements...377
Crankshaft Unitized Front Oil Seal and Hub — Installation...378
Crankshaft Unitized Front Oil Seal and Hub — Removal...381
Crankshaft Unitized Rear Oil Seal — Removal...384
Crankshaft Unitized Rear Oil Seal and Housing — Installation...386
Crankshaft Unitized Rear Oil Seal Housing — Removal...391
Crankshaft Vibration Damper — Inspection...392
Crankshaft Vibration Damper and Hub — Installation...394
Crankshaft Vibration Damper and Hub — Removal...399
Flywheel — Inspection...403
Flywheel — Installation...404
Flywheel — Removal...407
Flywheel Face — Runout Check...409
Flywheel Housing — Installation...410
Flywheel Housing — Removal...413
Flywheel Ring Gear — Installation...414
Flywheel Ring Gear — Removal...416
Main Bearing Cap — Installation...417
Main Bearing Cap — Line Bore Specifications...419
Main Bearing Cap — Removal...423
Open Crankcase Ventilation System — Inspection...427
Open Crankcase Ventilation System — Installation...428
Open Crankcase Ventilation System — Removal...434
Pilot Bearing Bore — Runout Check...438
Thrust Bearing — Inspection...439
Thrust Bearing and Main Bearing Cap— New Part Specification...440
Group 050: Camshaft and Timing Gear Train Repair and Adjustment...150
Air Compressor Assembly — Installation...453
Air Compressor Assembly — Removal...464
Camshaft — Installation...467
Camshaft — Removal...471
Camshaft — Visual Inspection...477
Camshaft Bushing — Service...478
Camshaft Bushing ID and Journal OD — Inspection and Measurement...484
Camshaft End Play and Gear Backlash — Check...485
Camshaft Follower — Inspection...491
Camshaft Gear — Installation...493
Camshaft Gear — Removal...495
Camshaft Journal — Measurement...496
Camshaft Lobe — Lift Measurement...497
Camshaft Position Sensor Lobe — Inspection...498
Camshaft Timing Pin...499
Camshaft to Crankshaft Timing — Check and Adjustment...500
Crankshaft Driven Auxiliary Drive — Installation...504
Crankshaft Driven Auxiliary Drive — Removal and Inspection...506
Coolant Pump Idler Gear — Installation...508
Coolant Pump Idler Gear — Removal...510
High-Pressure Fuel Pump Drive Pin — Replacement...512
Retaining Washer — Thickness Measurement...513
SAE B Rear Auxiliary Drive — Removal and Installation...514
Timing Gear Cover — Installation...516
Timing Gear Cover — Removal...521
Group 060: Lubrication System Repair and Adjustment...151
Oil Cooler — Inspection...525
Oil Cooler Bypass Valve — Installation...526
Oil Cooler Bypass Valve — Removal...527
Oil Filler, Right Hand Side — Installation...528
Oil Filler, Right Hand Side — Removal...529
Oil Filter — Installation...530
Oil Filter — Removal...532
Oil Filter Adapter — Removal and Inspection...533
Oil Filter and Oil Cooler Housing Assembly — Assemble...534
Oil Filter and Oil Cooler Housing Assembly — Installation...537
Oil Filter and Oil Cooler Housing Assembly — Removal...540
Oil Filter Bypass Valve — Installation...542
Oil Filter Bypass Valve — Removal...543
Oil Pan — Installation...544
Oil Pan — Removal...549
Oil Pressure Regulating Valve — Installation...551
Oil Pressure Regulating Valve — Removal...553
Oil Pump — Cleaning and Inspection...554
Oil Pump — Installation...555
Oil Pump — Removal...557
Oil Pump Oil Pickup Tube — Installation...558
Oil Pump Oil Pickup Tube — Removal and Inspection...560
Group 070: Cooling System Repair and Adjustment...152
Accessory Belt — Removal...563
Accessory Belt — Installation...564
Belt Tensioner — Installation...565
Belt Tensioner — Removal...568
Belt Tensioner — Spring Tension and Belt Wear Check...570
Coolant Bypass Tube — Installation...573
Coolant Bypass Tube — Removal...575
Coolant Heater — Servicing...577
Coolant Pump — Visual Inspection...579
Coolant Pump Assembly — Installation...581
Coolant Pump Assembly — Removal...585
Coolant System — Air Bleeding...587
Fan Drive Assembly — Installation...589
Fan Drive Assembly — Removal...592
Rear Top Liner Coolant Return Line — Installation...594
Rear Top Liner Coolant Return Line — Removal...597
Thermostat — Installation...599
Thermostat — Removal...601
Thermostat — Testing...603
Thermostat Cover — Installation...605
Thermostat Cover — Removal...610
Thermostat Housing — Installation...612
Thermostat Housing — Removal...615
Group 080: Air, Intake, and Exhaust System Repair and Adjustment...152
Air System ― Component View...618
Air Throttle and EGR Mixer Housing — Installation...619
Air Throttle and EGR Mixer Housing — Removal...626
EGR Cooler — Installation...628
EGR Cooler — Removal...633
EGR Cooler Coolant Return Line — Installation...636
EGR Cooler Coolant Return Line — Removal...638
EGR Cooler Coolant Supply Line — Installation...639
EGR Cooler Coolant Supply Line — Removal...641
EGR System — Component View...642
Exhaust Manifold — Installation...643
Exhaust Manifold — Removal and Inspection...648
Exhaust Manifold Pressure Sensor— Installation...650
Exhaust Manifold Pressure Sensor— Removal...652
Extending Turbocharger Life...654
Fixed Geometry Turbocharger — Removal...657
Fixed Geometry Turbocharger — Installation...659