John Deere 6135 13.5L Diesel Engine Level 15 ECU Worldwide Edition Component Technical Manual CTM370 - Repair, Wiring Diagrams PDF - MJODCTM370.zip
Full Component Service Guide with Electrical Schematics for the John Deere 6135 Diesel Engine — Level 15 ECU, containing every technical detail needed to service, troubleshoot, overhaul, and rebuild the engine just like a seasoned professional technician.
The John Deere 6135 Diesel Engine — Level 15 ECU workshop service repair manual covers:
* 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.
ctm370 - John Deere 6135 Diesel Engine — Level 15 ECU - (Worldwide Edition) Component Technical Manual.pdf
ctm370 - John Deere 6135 Diesel Engine — Level 15 ECU - (Worldwide Edition) Component Technical Manual.epub
PRODUCT DETAILS:
Total Pages: 1,959 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English
ctm370 - 6135 Diesel Engine — Level 15 ECU -: (Worldwide Edition) Component Technical Manual
Table of Contents
Foreword
CALIFORNIA PROPOSITION 65 WARNING
Section 01: General Information
Group 000: Safety
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Avoid Hot Exhaust
Avoid Static Electricity Risk When Refueling
Construct Dealer-Made Tools Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Follow Safety Instructions
Handle Agricultural Chemicals Safely
Handle Fluids Safely—Avoid Fires
Handling Batteries Safely
Illuminate Work Area Safely
Install All Guards
Live With Safety
Park Machine Safely
Practice Safe Maintenance
Precautions for Welding
Prepare for Emergencies
Prevent Acid Burns
Prevent Battery Explosions
Prevent Machine Runaway
Protect Against High Pressure Spray
Protect Against Noise
Recognize Safety Information
Remove Paint Before Welding or Heating
Replace Safety Signs
Service Cooling System Safely
Service Machines Safely
Stay Clear of Rotating Drivelines
Support Machine Properly
Understand Signal Words
Use Proper Lifting Equipment
Use Proper Tools
Use Steps and Handholds Correctly
Wait Before Opening High-Pressure Fuel System
Wear Protective Clothing
Work in Clean Area
Work In Ventilated Area
Group 001: Engine Identification
Engine Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
Emissions Control System Certification Label
Group 002: Fuels, Lubricants and Coolants
Diesel Fuel
Diesel Fuel Additive Products
BioDiesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Handling and Storing Diesel Fuel
Lubricity of Diesel Fuel
Testing Diesel Fuel
Engine Oil and Filter Service Intervals
Diesel Engine Oil — Tier 3 and Stage III
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Oil Filters
Oilscan™ and CoolScan™
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER
Diesel Engine Coolant
Testing Diesel Engine Coolant
Drain Intervals for Diesel Engine Coolant
Group 003: Fuel System Identification
13.5L Fuel Supply System Identification
Section 02: Repair and Adjustments
Group 90: Fuel System Repair and Adjustment — Type 1 Fuel Supply System
General Information
Fuel System Components
Install Primary Filter Assembly
Install Secondary (Final) Filter Assembly
Fuel Filter/Water Separator Assembly
Replacing Fuel Filter/Water Separator
Replacing Fuel Filter/Water Separator
Remove and Install Low Pressure Regulating Valve
Remove and Install High Pressure Regulating Valve
Remove and Install 100 Micron Internal Filter Housing Screen Insert
Remove and Install Fuel Filter Check Valve
Remove and Install Primer Pump
Remove and Install High Pressure Fuel Pump
Remove Electronic Unit Injector
Install Electronic Unit Injectors (EUI) - Type 1 Fuel Supply System
Install Injector Wiring Harness
Adjust Electronic Unit Injector Preload
Bleed Fuel System
Clean Electronic Injector Bore
Clean Electronic Injector Orifice
Clean Electronic Injector Body
Inspect Electronic Injector Body
Clean Electronic injectors (In Engine)
Group 91: Fuel System Repair and Adjustment — Type 2 Fuel Supply System
About This Group
General Information
Fuel System Components - Dual Filter, Right Hand Side
Fuel System Components - Dual Filter, Left Hand Side
Dual Fuel Filter Assembly
Install Fittings into Cylinder Head
Assemble and Install Fuel Filter Head Bracket
Install Jumper Harness to Fuel Filter Header Assembly
Install Fuel Filter Assembly and Fuel Lines
Replace Fittings on Fuel Filter Assembly
Remove and Install High Pressure Fuel Regulator Valve
Remove and Install Fuel Return Regulator Valve
Remove and Install Fuel Filter Screen
Remove and Install High Pressure Fuel Pump
Remove Electronic Unit Injector
Install Electronic Unit Injectors (EUI) - Type 2 Fuel Supply System
Install Injector Wiring Harness
Adjust Electronic Unit Injector Preload
Bleed Fuel System
Clean Electronic Injector Bore
Clean Electronic Injector Orifice
Clean Electronic Injector Body
Inspect Electronic Injector Body
Clean Electronic injectors (In Engine)
Group 100: Electronic Air System Repair and Adjustment
Remove, Inspect, and Install EGR Valve (Tier 3/Stage IIIA)
Remove, Inspect, and Install EGR Cooler
Remove and Install Variable Geometry Turbocharger Actuator
Remove and Install Actuator Linkage
Remove Turbocharger
Install Turbocharger
Group 110: Electrical Component Repair and Adjustment-Type 1 Fuel Supply System
Engine Control Unit (ECU) Maintenance
Remove and Install Engine Control Unit (ECU)
Remove and Install Coolant Temperature Sensor
Remove and Install Fuel Temperature Sensor - Type 1 Fuel Supply System
Remove and Install Fuel Pressure Sensor
Remove and Install Water-in-Fuel (WIF) Sensor - Type 1 Fuel Supply System
Remove and Install Oil Pressure Sensor
Remove and Install Manifold Air Temperature (MAT) Sensor
Remove and Install Manifold Absolute Pressure (MAP) Sensor
Remove and Install Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor
Remove and Install Charge Air Cooler Outlet Temperature Sensor
Remove and Install Compressor Inlet Temperature Sensor
Remove and Install Cam Position Sensor
Remove and Install Crank Position Sensor
Remove and Install Turbo Speed Sensor
Welding
Using High-Pressure Washing
Connectors
Connector Repair
Installation of Repair Wire Assembly (RWA)
Repair WEATHERPACK Connector
Repair METRI-PACK Connectors (Push Type)
Repair DT Series DEUTSCH Connectors
Repair HD Series DEUTSCH Connectors
Repair Cinch FlexBox Connector
Group 115: Electrical Component Repair and Adjustment-Type 2 Fuel Supply System
Remove and Install Electric Low Pressure Fuel Pump
Remove and Install Fuel Temperature Sensor - Type 2 Fuel Supply System
Remove and Install High Pressure Fuel Sensor
Remove and Install Low Pressure Fuel Sensor
Remove and Install Water-in-Fuel (WIF) Sensor - Type 2 Fuel Supply System
Section 03: Theory of Operation
Group 130: Electronic Fuel System Operation
About This Group
Type 1 Fuel Supply System Operation
Type 2 Fuel Supply System Operation
Type 2 Fuel Supply System Fuel Filter Header Assembly
Type 2 Fuel Supply System Electric Low Pressure Fuel Pump
Type 2 Fuel Supply System Right Side Option
Type 2 Fuel Supply System Left Side Option
Type 2 Fuel Supply System Fuel Filters and Water Separator
Type 2 Fuel Supply System Fuel Return
Electronic Unit Injector (EUI) Operation
Group 135: Air System Operation
About This Group
Intake and Exhaust System Operation, non-EGR engines
Turbocharger Operation
Turbocharger Actuator Operation
Exhaust Gas Recirculator (EGR) & Variable Geometry Turbocharger (VGT) Operation
Group 140: Electrical Control System Operation
About This Group
Electronic Control System Terminology
Component Location Diagram 1
Component Location Diagram 2
Component Location Diagram 3
Component Location Diagram 4
Component Location Diagram 5
Component Location Diagram 6
Component Location Diagram 7
Component Location Diagram 8
Component Location Diagram 9
Component Location Diagram 10
Engine Control Unit (ECU) System Operation
Controller Area Network (CAN)
Pilot Injection Operation
Monitoring Engine Parameters
Measuring Temperature
Engine Control Unit (ECU) Temperature Sensor
Engine Coolant Temperature (ECT) Sensor
Fuel Temperature Sensor
Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor
Charge Air Cooler Outlet Air Temperature Sensor
Intake Manifold Air Temperature (MAT) Sensor
Turbo Turbine Inlet Temperature
Turbo Compressor Inlet Temperature Sensor
Measuring Pressure
Barometric Air Pressure (BAP) Sensor
High-Pressure Fuel Pressure Sensor
Fuel Transfer Pump Pressure Sensor
Manifold Air Pressure (MAP) Sensor
Oil Pressure Sensor
Measuring Speed
Crank Position Sensor
Cam Position Sensor
Turbo Speed Sensor
Throttle Descriptions
CAN Throttle
Pulse-Width-Modulated (PWM) Throttle
Analog Throttle
Digital Multi-State Throttle
Dual-State Throttle
Tri-State Throttle
Ramp Throttle
Throttle Adjustments
Throttle Offsets
Self-Calibration
Combination Throttle
Marine Throttle
Engine Derate and Shutdown Protection
Electronic Unit Injector (EUI) Wiring Harness Connector
Torque Curve Selection
Governor Droop Mode Selection
Water in Fuel (WIF) Sensor
Engine Coolant Level Switch
Cruise Control Operation
Power Supply #2
Power Supply #3
Power Supply #4
Power Supply #5
Section 04: Diagnostics
Group 150: Observable Diagnostics and Tests With Type 1 Fuel Supply System
About this Group
E1 - Engine Cranks but Won't Start (Type 1 Fuel Supply System)
E2 - Engine Misfires/Runs Irregularly (Type 1 Fuel Supply System)
E3 - Engine Does Not Develop Full Power (Type 1 Fuel Supply System)
E4 - Engine Emits Excessive White Exhaust Smoke (Type 1 Fuel Supply System)
E5 - Engine Emits Excessive Black or Gray Exhaust Smoke (Type 1 Fuel Supply System)
F1 - Type 1 Fuel Supply System Check
F2 - Excessive Fuel Filter Replacement
Check Fuel Supply Quality (Type 1 Fuel Supply System)
Test for Air in Fuel (Type 1 Fuel Supply System)
Check Fuel Supply Pressure
Bleed Fuel System (Type 1 Fuel Supply System)
Restarting Engine That Has Run Out Of Fuel (Type 1 Fuel Supply System)
Excessive Engine Crankcase Pressure (Blow-By)
Exhaust Gas Recirculation (EGR) System Diagnostic
Variable Geometry Turbocharger (VGT) Component Test (Type 1 Fuel Supply System)
Group 155: Observable Diagnostics and Tests With Type 2 Fuel Supply System
About this Group
E1 - Engine Cranks but Won't Start (Type 2 Fuel Supply System)
E2 - Engine Misfires/Runs Irregularly (Type 2 Fuel Supply System)
E3 - Engine Does Not Develop Full Power (Type 2 Fuel Supply System)
E4 - Engine Emits Excessive White Exhaust Smoke (Type 2 Fuel Supply System)
E5 - Engine Emits Excessive Black or Gray Exhaust Smoke (Type 2 Fuel Supply System)
E8 - Primary Analog Throttle Does Not Respond
E9 - Secondary Analog Throttle Does Not Respond
F1 - Type 2 Fuel Supply System Check
Check Fuel Supply Quality (Type 2 Fuel Supply System)
Test for Air in Fuel (Type 2 Fuel Supply System)
Bleed Fuel System (Type 2 Fuel Supply System)
Type 2 Fuel Return To Tank System Check
Restarting Engine That Has Run Out Of Fuel (Type 2 Fuel Supply System)
Charge Air System
Variable Geometry Turbocharger (VGT) Component Test (Type 2 Fuel Supply System)
Group 160: Trouble Code Diagnostics and Tests
About This Group
Communication Error Test Instructions
Connecting to Service ADVISOR
Control Unit Information and Overview Test
Cylinder Cutout Test Instructions
Cylinder Cutout Test Using JDG1250
Cylinder Electronic Compression Test Instructions