John Deere PowerTech 13.5L 6135 6135HF475 6135HF485 Diesel Engine Repair Manual CTM415 PDF - MJODCTM415.zip

This is the full Base Engine Repair manual, complete with Electrical Wiring Diagrams, covering the John Deere PowerTech 13.5L OEM Diesel Engines Base Engine (Worldwide Edition). Inside you'll find every technical detail needed to service, troubleshoot, fix, and overhaul these engines the way trained professional technicians do.

The John Deere PowerTech 13.5L OEM Diesel Engines Base Engine Repair Component Technical manual contains:

* 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.

ctm415 - John Deere PowerTech 13.5L OEM Diesel Engines Base Engine Repair - (Worldwide Edition) Component Technical Manual.pdf

Total Pages: 814 pages

File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

ctm415 - PowerTech™ 13.5L OEM Diesel Engines Base Engine Repair -: (Worldwide Edition)

Component Technical Manual

Table of Contents

Foreword

PowerTech™ Plus 6135HF485 Engines

PowerTech™ E 6135HF475 Engines

6135 PowerTech™ Engine Cutaway View

6135 PowerTech™ Plus Engine Cutaway View

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 and Applications

Engine Model Designation

Engine Serial Number Plate Information

Engine Option Code Label

Group 002: Fuels, Lubricants and Coolant

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

Fuel Filters

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

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

Section 02: Repair and Adjustments

Group 010: Engine Rebuild Guide, Break-In and Tune-Up

Engine Overhaul Guidelines

Engine Repair Stand

Safety Precautions

Disconnect Turbocharger Oil Inlet Line

Install Adapter on Repair Stand

Engine Lifting Procedure

Mount Engine on Repair Stand

Clean Engine

6135 Engine Disassembly Sequence

Sealant Application Guidelines

6135 Engine Assembly Sequence

Engine Break-In Guidelines

Perform Engine Break-In

Check Crankcase Ventilation System

Check Air Intake System

Check Exhaust System

Check and Service Cooling System

Check Electrical System

Group 020: Cylinder Head and Valves

Remove and Install Rocker Arm Cover

Clean and Inspect Crankcase Ventilation Assembly

Replace Rocker Arm Cover Gasket

Check and Adjust Valve Assembly Clearances and Injector Preload

Remove Rocker Arm Assembly

Remove Cylinder Head

Diagnosing Head Gasket Joint Failures

Head Gasket Inspection and Repair Sequence

Disassemble and Inspect Rocker Arms and Shaft Assembly

Preliminary Cylinder Head and Valve Checks

Assemble Rocker Arms and Shaft Assembly

Check Valve Height in Relation to Head Surface (Valve Recess)

Remove Valve Assembly

Inspect and Measure Valve Springs

Inspect Valve Rotators

Clean, Inspect, and Measure Valves

Grind Valves

Clean and Inspect Cylinder Head

Check Cylinder Head Flatness

Measure Cylinder Head Thickness

Measure Valve Guide ID

Replace Valve Guides

Clean and Inspect Valve Seats

Valve Seat — Grinding

Remove Valve Seat Inserts

Measure Valve Seat Bore in Cylinder Head

Install Valve Seat Inserts

Install Valves

Replace Unit Injector Sleeve in Cylinder Head Using JDG981

Replace Unit Injector Sleeve in Cylinder Head Using JDG1184

Remove Unit Injector Sleeve Using JDG10014

Clean and Inspect Top Deck of Cylinder Block

Measure Cylinder Liner Standout (Height Above Block)

Install Cylinder Head

Torque-Turn Cylinder Head Cap Screws

Install Rocker Arm Assembly

Complete Final Assembly for Cylinder Head Installation

Group 030: Cylinder Block, Liners, Pistons, and Rods

Remove and Install Cylinder Block Front Plate

Preliminary Liner, Piston, and Rod Checks

Connecting Rods—General Information

Remove Piston Spray Jets

Remove Pistons and Connecting Rods

Measure Cylinder Liner Standout (Height Above Block)

Remove Cylinder Liners Using D01062AA or D01073AA Cylinder Liner Puller

Remove Cylinder Liners Using JDG1145 Cylinder Liner Service Set

Visually Inspect Cylinder Liners

Deglaze Cylinder Liners

Clean Cylinder Liners

Cylinder Liner Manufacturing Date Code Explanation

Disassemble Piston/Rod Assembly and Clean Piston

Check Piston Oil Control Ring Groove Wear

Inspect Piston Pin and Pin Bore in Piston

Determine Piston-to-Liner Clearance

Measure Liner Flange Thickness

Inspect and Measure Connecting Rod Bearings

Inspect Connecting Rod and Cap

Inspect Piston Pins and Rod Bushings

Complete Disassembly of Cylinder Block (If Required)

Inspect and Clean Cylinder Block

Cylinder Block — Inspect and Reclaim

Cylinder Block — Measurements

Install Cylinder Liner Shim

Install Cylinder Liner O-Rings and Packings

Install Cylinder Liners

Assemble Pistons and Connecting Rods

Install Pistons and Connecting Rods

Torque-Turn Connecting Rod Cap Screws

Check Engine Rotation for Excessive Tightness

Install Piston Spray Jets

Measure Piston Protrusion

Complete Final Assembly

Group 040: Crankshaft, Main Bearings, and Flywheel

Crankshaft Rubber Damper Torque Sequence

Inspect Crankshaft Vibration Damper

Check Crankshaft End Play

Remove Crankshaft Rubber Damper and Pulley

Remove Viscous Damper and Front Crankshaft Oil Seal

Remove Timing Gear Cover

Check Flywheel Housing Face Runout

Check Flywheel Face Flatness

Remove Flywheel

Inspect and Repair Flywheel

Replace Flywheel Ring Gear

Remove and Install Flywheel Housing

Install Flywheel

Remove Rear Crankshaft Oil Seal and Housing Assembly

Crankshaft Unitized Rear Oil Seal — Removal

Crankshaft Unitized Rear Oil Seal and Housing — Installation

Crankshaft and Main Bearing Failure Analysis

Remove Crankshaft Main Bearings

Check Main Bearing-to-Journal Oil Clearance

Remove Crankshaft

Inspect Crankshaft

Measure Assembled ID of Bearings and OD of Crankshaft Journals

Measure Assembled ID of Main Bearing Caps (Without Bearings)

Replace Crankshaft Drive Gear

Inspect Thrust Bearings

Thrust Bearing New Part Specifications

Install Main and Thrust Bearing Inserts in Block

Install Crankshaft

Install Crankshaft Rear Oil Seal Housing

Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly

Install Timing Gear Cover

Install Crankshaft Rubber Damper and Front Oil Seal

Install Viscous Damper Assembly and Front Oil Seal

Complete Final Assembly

Group 050: Camshaft and Timing Gear Train

Camshaft Timing Pin

Check and Adjust Camshaft-to-Crankshaft Timing

Adjust Front Timing Gear Backlash Using JDG993

Adjust Front Timing Gear Backlash Without Using JDG993

Remove and Install Camshaft

Replace Fuel Supply Pump Drive Pin

Visually Inspect Camshaft and Roller Followers

Inspect and Measure Camshaft Bushing ID and Journal OD

Measure Camshaft Lobe Lift Height

Inspect Camshaft Position Sensor Lobe

Replace Camshaft Bushings

SAE “A” (Front) and SAE “B” (Rear) Auxiliary Drive Assembly

SAE B Rear Auxiliary Drive — Removal and Installation

Align SAE “A” Front Auxiliary Drive Adapter

Group 060: Lubrication System

Oil Filter and Oil Conditioning Housing Assembly

Remove Oil Filter and Valve Housing/Oil Cooler Cover and Valve Housing

Inspect and Replace Oil Filter Adapter

Remove, Inspect, and Install Oil Pressure Regulating Valve

Remove, Inspect, and Install Oil Cooler and Oil Filter Bypass Valves

Remove, Inspect, and Install Oil Pressure Relief Valve

Remove, Clean, and Inspect Engine Oil Cooler

Install Oil Cooler/Oil Filter Valve Housing Assembly or Oil Cooler Cover/Valve Housing Assembly

Remove Engine Oil Pump

Clean and Inspect Oil Pump and Drive Gear

Install Engine Oil Pump

Remove Engine Oil Pan

Remove and Install Oil Pickup Tube

Install Engine Oil Pan

Oil Dipstick Tube Assembly — Installation

Oil Dipstick Tube Assembly — Removal

Group 070: Cooling System

Replace Bearings in Fan Drive Assembly

Inspect and Check Belt Tensioner Spring Tension

Replace Belt Tensioner Assembly

Remove Coolant Pump

Clean and Inspect Coolant Pump Parts

Install Coolant Pump

Remove and Install Thermostat Cover and Thermostats

Test Thermostat Opening Temperature

Remove and Install Thermostat Housing and Coolant Tubes

Remove and Install Coolant Heater—if Equipped

Bleed Air from Coolant System

Group 080: Air Intake and Exhaust System

Extending Turbocharger Life

Remove and Install Variable Geometry Turbocharger Actuator

Remove and Install Actuator Linkage

Remove Turbocharger

Turbocharger — Failure Analysis

Turbocharger Seven-Step Inspection

Perform Radial Bearing Clearance Test

Turbocharger — Repair

Prelube Turbocharger

Install Turbocharger

Turbocharger Break-In

Recommendations for Turbocharger Use

Remove, Inspect, and Install EGR Cooler

Exhaust Manifold — Remove

Exhaust Manifold — Install

Remove, Inspect, and Install Intake Manifold

Remove, Inspect, and Install EGR Valve (Tier 3/Stage III A)

Group 081: Air Intake and Exhaust System — PowerTech™ E Engines

Exhaust Manifold — Remove

Exhaust Manifold — Install

Turbocharger — Remove

Turbocharger — Install

Air Intake Manifold — Remove

Air Intake Manifold — Install

Group 082: Air Intake and Exhaust System — Marine Engines

Air Intake Manifold (Marine) — Removal

Air Intake Manifold (Marine) — Installation

Exhaust Manifold (Marine) — Removal

Exhaust Manifold (Marine) — Installation

Turbocharger (Marine) — Removal

Turbocharger (Marine) — Installation

Group 090: Fuel System

Fuel System

Group 100: Starting and Charging Systems

Remove and Install Alternator (OEM Engines)

Remove and Install Starter Motor (OEM Engines)

Section 03: Theory of Operation

Group 120: Base Engine Operation — PowerTech Plus