John Deere 6135 Diesel Engines Repair Service Manual (CTM104919)
Complete service repair manual with Electrical Wiring Diagrams for John Deere 6135 Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere 6135 Diesel Engines workshop service repair manual includes:
* 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.
CTM104919 - John Deere 6135 Diesel Engine — Level 22 ECU - (Worldwide Edition) Component Technical Manual.pdf
ctm104963 - John Deere Motor diésel 6135 — ECU Nivel 22 -: (Edición mundial).pdf
ctm104914 - John Deere 6135 柴油发动机 — 22 级 ECU -: (世界通用机型).pdf
ctm104928 - John Deere Moteur diesel 6135—Contrôleur ECU niveau 22 -: (Édition mondiale).pdf
ctm104929 - John Deere Dieselmotor 6135 — ECU (Level 22) -: (Weltweite Ausgabe).pdf
ctm104939 - John Deere Motore diesel 6135 – ECU livello 22 -: (Edizione universale).pdf
ctm104954 - John Deere 6135 Motor a Diesel — Nível 22 ECU -: (Edição Mundial).pdf
ctm104959 - John Deere Дизельный двигатель 6135 — БУД уровня 22 -: (Исполнение для всех стран).pdf
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
Fixed Geometry Turbocharger Oil Return Line — Installation...664
Fixed Geometry Turbocharger Oil Return Line — Removal...665
Fixed Geometry Turbocharger Oil Supply Line — Installation...666
Fixed Geometry Turbocharger Oil Supply Line — Removal...668
Intake Air — Installation...670
Intake Air — Removal...672
Intake Manifold — Installation...674
Intake Manifold — Removal and Inspection...676
Turbocharger — Break-In...677
Turbocharger — Failure Analysis...678
Turbocharger — Prelube...681
Turbocharger — Repair...682
Turbocharger Compressor — Inspection...683
Turbocharger Compressor Housing — Orientation...689
Turbocharger Compressor Interstage — Installation...690
Turbocharger Compressor Interstage — Removal...695
Turbocharger Turbine Interstage — Installation...697
Turbocharger Turbine Interstage — Removal...701
Venturi — Installation...703
Venturi — Removal...706
Venturi Coolant Return Line — Installation...708
Venturi Coolant Return Line — Removal...709
Venturi Coolant Supply Line — Installation...710
Venturi Coolant Supply Line — Removal...713
VGT — Installation...715
VGT — Removal...718
VGT Actuator Coolant Return Line — Installation...721
VGT Actuator Coolant Return Line — Removal...722
VGT Actuator Coolant Supply Line — Installation...723
VGT Actuator Coolant Supply Line — Removal...724
VGT Actuator Linkage — Installation...725
VGT Actuator Linkage — Removal...729
VGT Oil Return Line — Installation...731
VGT Oil Return Line — Removal...735
VGT Oil Supply Line — Installation...737
VGT Oil Supply Line — Removal...740
Group 090: Electronic Fuel System Repair and Adjustment...154
General Information...743
Electronic Unit Injector — Installation...744
Electronic Unit Injector — Removal...746
Electronic Unit Injector Body — Cleaning...747
Electronic Unit Injector Body — Inspection...748
Electronic Unit Injector Bore — Cleaning...749
Electronic Unit Injector Orifice — Cleaning...750
Fuel Filter — Installation...751
Fuel Filter — Removal...753
Fuel Filter Header — Assembly...755
Fuel Filter Header and Fuel Lines — Installation...757
Fuel Filter Header and Fuel Lines — Removal...764
Fuel Filter Header Fitting — Replacement...768
Fuel Filter Header Sensor Manifold — Installation...770
Fuel Filter Header Sensor Manifold — Removal...771
Fuel System — Bleeding...772
High-Pressure Fuel Pump — Installation...774
High-Pressure Fuel Pump — Removal...776
Injector Wiring Harness — Installation...867
Injector Wiring Harness — Removal...888
Low-Pressure Fuel Pump — Installation...782
Low-Pressure Fuel Pump — Removal...784
Low-Pressure Fuel System Jumper Harness — Installation...785
Low-Pressure Fuel System Jumper Harness — Removal...786
Group 100: OEM Starting and Charging Systems Repair and Adjustment...155
Alternator — Installation...789
Alternator — Removal...791
Starter Motor — Installation...793
Starter Motor — Removal...795
Group 110: Electrical Engine Control Repair and Adjustment...155
Component Location Diagram 1...1071
Component Location Diagram 2...1072
Component Location Diagram 3...800
Component Location Diagram 4...801
Component Location Diagram 5...803
Component Location Diagram 6...804
Camshaft Position Sensor — Installation...805
Camshaft Position Sensor — Removal...806
Charge Air Cooler Outlet Air Temperature Sensor — Installation...807
Charge Air Cooler Outlet Air Temperature Sensor — Removal...808
Crankshaft Position Sensor — Installation...809
Crankshaft Position Sensor — Removal...811
DPF Differential Pressure Sensor Assembly — Installation...812
DPF Differential Pressure Sensor — Removal...815
ECU and Mounting Bracket— Installation...816
ECU and Mounting Bracket — Removal...819
EGR Flow Sensor — Installation...821
EGR Flow Sensor — Removal...823
EGR Temperature Sensor — Installation...825
EGR Temperature Sensor — Removal...826
EGR Valve Actuator — Installation...827
EGR Valve Actuator — Removal...830
Engine Coolant Pressure Sensor — Installation...832
Engine Coolant Pressure Sensor — Removal...833
Engine Coolant Temperature Sensor — Installation...834
Engine Coolant Temperature Sensor — Removal...835
Engine Oil Pressure Sensor — Installation...836
Engine Oil Pressure Sensor — Removal...837
Exhaust Filter Temperature Module — Installation...838
Exhaust Filter Temperature Module — Removal...840
Exhaust Manifold Pressure Sensor — Installation...841
Exhaust Manifold Pressure Sensor — Removal...843
Fixed Turbocharger Compressor Outlet Temperature Sensor — Installation...845
Fixed Turbocharger Compressor Outlet Temperature Sensor — Removal...846
Fuel Temperature Sensor — Installation...847
Fuel Temperature Sensor — Removal...848
High-Pressure Fuel Pressure Sensor — Installation...849
High-Pressure Fuel Pressure Sensor — Removal...850
Intake Air Sensor — Installation...851
Intake Air Sensor — Removal...852
Low-Pressure Fuel Pressure Sensor — Installation...853
Low-Pressure Fuel Pressure Sensor — Removal...854
Manifold Air Pressure (MAP) Sensor — Installation...855
Manifold Air Pressure (MAP) Sensor — Removal...856
Manifold Air Temperature (MAT) Sensor — Installation...857
Manifold Air Temperature (MAT) Sensor — Removal...858
VGT Actuator — Installation...859
VGT Actuator — Removal...861
VGT Speed Sensor — Installation...863
VGT Speed Sensor — Removal...864
Water-In-Fuel Sensor (WIF) — Installation...865
Water-In-Fuel Sensor (WIF) — Removal...866
Wiring Harness — Installation...867
Wiring Harness — Removal...888
Wiring Harness — Routing...906
Group 112: Connector Repair and Adjustment...908
Connector Repair and Adjustment...908
Installation of Repair Wire Assembly (RWA)...909
Repair AMP® Seal 16 - Type “A” Connectors...918
Repair AMP® Seal 16 - Type “B” Connectors...923
Repair AMP® Seal 16 - Type “C” Connectors...929
Repair Bosch Connectors...931
Repair DEUTSCH Connectors...934
Repair Metri-Pack™ Connectors...939
Repair WEATHER PACK® Connectors...942
Using High-Pressure Washing...944
Group 115: Aftertreatment Devices Repair and Adjustment...157
Diesel Oxidation Catalyst (DOC) — Cleaning...948
Diesel Particulate Filter Maintenance and Service...951
Exhaust Filter — Assemble...952
Exhaust Filter — Cleaning...954
Exhaust Filter — Diesel Particulate Filter Ash Handling and Disposal...955
Exhaust Filter — Disposal...956
Exhaust Filter — Handling...957
Exhaust Filter — Tear Down and Inspection...959
Exhaust Filter, Brackets, and Piping — Assembly and Installation...965
Exhaust Filter, Brackets and Piping — Removal...966
Exhaust Filter Inlet Piping — Installation...967
Exhaust Filter Inlet Piping — Removal...970
Fuel Dosing Injector — Installation...972
Fuel Dosing Injector — Removal...975
Fuel Dosing Pump Assembly — Assemble...978
Fuel Dosing Pump Assembly — Installation...981
Fuel Dosing Pump Assembly — Removal...984
Fuel Dosing Pump Assembly — Tear Down...986
Fuel Dosing Pump — Installation...989
Fuel Dosing Pump — Removal...991
Fuel Dosing System Fuel Lines — Installation...993
Fuel Dosing Unit — Installation...1001
Fuel Dosing Unit — Removal...1004
Section 03: Theory of Operation...1007
Group 120: Base Engine Operation...1007
Engine Sectional View Component Location Diagrams...1027
General Engine Operation...1015
Head Gasket Joint Construction and Operation...1017
Group 123: Cooling System...1007
Component Location Diagrams...1027
Cooling System Operation...1023
Group 126: Lubrication System...1007
Component Location Diagrams...1027
Lubrication System Operation...1029
Group 130: Electronic Fuel System...1007
Component Location Diagram...1032
Electronic Unit Injector (EUI) Operation...1033
Fuel System Operation...1038
High-Pressure Fuel Pump Operation...1045
High-Pressure Fuel System Operation...1046
Low-Pressure Fuel Pump Operation...1049
Low-Pressure Fuel System Operation...1050
Primary and Secondary Fuel Filter Operation...1054
Group 135: Air Intake and Exhaust System...1007
Component Locations Diagram 1...1057
Component Locations Diagram 2...1058
Component Locations Diagram 3...1059
Component Locations Diagram 4...1060
Air Intake and Exhaust System Operation...1061
Air Throttle Actuator Operation...1063
Ether Start Aid Operation...1064
EGR Cooler Operation...1066
EGR Valve Operation...1067
Fixed Turbocharger Operation...1068
VGT Operation...1069
Group 137: After Treatment System...1008
Component Location Diagram 1...1071
Component Location Diagram 2...1072
Aftertreatment System Operation...1074
Exhaust Filter Operation...1075
Fuel Dosing Pump Operation...1078
Fuel Dosing Unit Operation...1080
Fuel Dosing Injector Operation...1082
Group 140: Electronic Control System...1008
Analog Throttle...1084
A5501 — ECU Connector #1...1085
A5502 — ECU Connector #2...1087
A5503 — ECU Connector #3...1089
B5000 — Fuel Dosing Inlet Sensor...1091
B5101 — Engine Oil Pressure Sensor...1094
B5102 — Exhaust Manifold Pressure Sensor...1096
B5103 — EGR Flow Sensor...1098
B5104 — Manifold Air Pressure (MAP) Sensor...1100
B5106 — Fuel Dosing Outlet Pressure Sensor...1102
B5107 — Low-Pressure Fuel Pressure Sensor...1104
B5108 — Engine Coolant Pressure Sensor...1106
B5109 — DPF Differential Pressure Sensor...1108
B5110 — High-Pressure Fuel Pressure Sensor...1109
B5200 — Fixed Turbocharger Compressor Outlet Temperature Sensor...1111
B5204 — Exhaust Filter Temperature Module...1114
B5205 — Charge Air Cooler Outlet Temperature Sensor...1116
B5206 — Manifold Air Temperature (MAT) Sensor...1119
B5207 — EGR Temperature Sensor...1122
B5208 — Engine Coolant Temperature Sensor...1125
B5209 — Fuel Temperature Sensor...1128
B5300 — VGT Speed Sensor...1130
B5301 — Crankshaft Position Sensor...1132
B5302 — Camshaft Position Sensor...1135
B5500 — Intake Air Sensor...1137
B5600 — Water-In-Fuel Sensor...1139
Barometric Air Pressure Sensor...1141
CAN Throttle...1142
Combination Throttle...1143
Controller Area Network (CAN)...1145
Cruise Control Operation...1146
Determining Engine Speed and Piston Position...1147
Digital Throttle...1148
Engine Control Unit (ECU) System Operation...1150
Engine Control Unit (ECU) Temperature Sensor...1153
Engine Derate and Shutdown Protection...1154
Governor Droop Mode Selection...1156
Measuring Pressure...1157
Measuring Speed...1158
Measuring Temperature...1159
Pilot Injection Operation...1160
Pulse-Width-Modulated (PWM) Throttle...1161
S5001 — Engine Coolant Level Alarm Switch...1162
S5002 — Engine Coolant Level Information Switch...1164
Sensor Supply #1...1166
Sensor Supply #2...1167
Sensor Supply #3...1168
Sensor Supply #4...1169
Sensor Supply #5...1170
Sensor Supply #6...1171
Sensor Supply #7...1172
Sensor Supply #8...1173
Sensor Supply #9...1174
Throttle Adjustments...1175
Throttle Offset...1176
Throttle Self-Calibration...1177
X5023 — Fuel Injector Harness (6-Pin)...1178
X5024 — Fuel Injector Harness (8-Pin)...1180
Y5000 — Fuel Dosing Shutoff Valve...1182
Y5001 — Fuel Dosing Control Valve...1184
Y5005 — Variable Speed Fan...1186
Y5400 — EGR Valve...1188
Y5401 — Air Throttle Actuator...1190
Y5500 — VGT Actuator...1192
Y5501 — Low-Pressure Fuel Pump...1194
Y5502 — Fuel Dosing Pump...1196
Section 04: Diagnostics...1198
Group 150: Observable Diagnostics and Tests...1198
Abnormal Engine Noise...1198
Coolant in Oil or Oil in Coolant...1198
Coolant Leaking from Weep Hole...1198
Coolant System Loses Pressure...1198
ECU Does Not Communicate with Powerview...1198
ECU Does Not Communicate with Service ADVISOR...1198
ECU Does Not Program with Service ADVISOR...1198
EGR Cooler Leaking...1198
Engine Coolant Temperature Below Normal...1198
Engine Cranks and will Not Start...1198
Engine Does Not Develop Full Power...1198
Engine Emits Excessive Black or Gray Exhaust Smoke...1198
Engine Emits Excessive Blue Exhaust Smoke...1198
Engine Emits Excessive White Exhaust Smoke...1198
Engine Misfires or Runs Irregularly...1198
Engine Will Not Crank...1198
Excessive Crankcase Separator Carryover...1198
Excessive Fuel Consumption...1198
Excessive Oil Consumption...1321
Frequent Regenerations...1198
Fuel in Coolant...1198
Fuel in Oil...1198
JDLink Does Not Communicate with ECU...1336
Throttle Not Responding...1198
Group 155: Checks, Tests and Procedures...1198
Aftertreatment Verification Procedure...1441
Air in Fuel Check...1342
CAN Message Not Received...1345
CAN Message Received Error...1347
CAN Message Received Is Incorrect...1349
Carbon Removal Procedure...1352
Charge Air Cooler Test...1353
Cooling System Pressure Test...1355
Crankcase Pressure (Blow-By) Test...1358
EGR Cooler Test...1366
Engine CAN Diagnostic Procedure...1367
Engine Cranking Speed Check...1375
Engine Oil Pressure Check...1376
Exhaust Condition Check...1378
Fuel Dosing System Air Purge Procedure...1389
Fuel Dosing System Air Purge Instructions...1392
Fuel Return Line Restriction Check...1393
Fuel Supply Quality Check...1394
Fuel System Bleeding...1396
Fuel System Leakage Test...1400
High-Pressure Fuel System Check...1404
Low-Pressure Fuel System Check...1414
Mechanical Compression Check...1427
Problem Not Found Procedure...1430
Short to Voltage Procedure...1432
Terminal Test...1434
Turbocharger Oil Seal Leak Check...1438
Venturi — Cleaning...1439
Verification Procedure...1441
Wiggle Test...1443
Group 160: Diagnostic Instructions and Information...1199
Air Throttle Actuator Learn Value Reset Instructions...1445
Clear Aftertreatment Latched DTC — Test Instructions...1446
Communication Error Test Instructions...1447
Connecting to Service ADVISOR...1448
Control Unit Information and Overview Test...1450
Cylinder Cutout Test Instructions...1452
Cylinder Electronic Compression Test Instructions...1455
Cylinder Misfire Test Instructions...1460
Data Points Used in Service ADVISOR...1462
Diagnostic Gauge — Active DTC Viewing Instructions...1473
Diagnostic Gauge — Data Parameters Viewing Instructions...1475
Diagnostic Gauge — Exhaust Filter Service Recovery Instructions...1478
Diagnostic Gauge — Stored DTC Clearing Instructions...1488
Diagnostic Gauge — Stored DTC Viewing Instructions...1490
Diagnostic Test Box — Using...1492
Diagnostic Trouble Code (DTC) Group Locator...1501
Diagnostic Trouble Code (DTC) Group Locator Continued...1524
Diagnostic Trouble Code Designations...1533
Digital Multimeter — Using...1537
DOC Calibration — Instructions...1539
DPF Calibration — Instructions...1540
EGR Valve — Clean Test Instructions...1541
EGR Valve — Learn Value Reset Instructions...1543
Electrical Circuit Concepts...1544
Electrical Noise — Possible Causes...1550
Electronic Injector — Calibration Information...1551
Enable Low-Pressure Fuel Pump...1553
Engine Control Unit (ECU) — Level Identification...1554
Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere...1555
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU...1559
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU...1561
Engine Control Unit (ECU) — Reprogramming Current ECU...1563
Engine Control Unit (ECU) — Reprogramming Instructions...1564
Engine Hours — Updating Instructions...1566
Engine Overspeed Verification Test...1568
ESM Operator Action Information Decoder — Instructions...1569
Exhaust Temperature Management Test Instructions...1570
Fuel Dosing Pump Diagnostic Test...1571
Harness Diagnostic Mode Test...1572
Interactive Tests and Calibration Results — Printing, Exporting, or Saving Instructions...1574
Internal Data Monitor — Instructions...1575
Keep Electronic Control Unit Connectors Clean...1580
Load Profile Information Test — Instructions...1581
Lost ECU Data Reset...1585
Regeneration Abort Source Identification Test — Instructions...1586
Regeneration Failure — Possible Causes...1587
Service Regeneration Instructions...1591
Servicing Electronic Control Units...1593
Snapshot Instructions...1594
Software and Hardware Verification...1595
Trim Options Information...1598
VGT — Learn Value Reset Instructions...1600
View Non-Clearable DTCs — Test Instructions...1601
Welding Near Electronic Control Units...1602
Group 161: DTC SPN - 000001—000199...1201
000027.03 - EGR Valve Position Signal Out of Range High...1201
000027.04 - EGR Valve Position Signal Out of Range Low...1201
000027.07 - EGR Valve Desired and Actual Position Mismatch...1201
000028.03 - Digital Throttle Signal Out of Range High...1201
000028.04 - Digital Throttle Signal Out of Range Low...1201
000028.14 - Digital Throttle Inhibited...1201
000029.03 - Secondary Analog Throttle Signal Out of Range High...1201
000029.04 - Secondary Analog Throttle Signal Out of Range Low...1201
000029.14 - Secondary Analog Throttle Inhibited...1201
000051.03 - Air Throttle Actuator Position Signal Out of Range High...1201
000051.04 - Air Throttle Actuator Position Signal Out of Range Low...1201
000051.07 - Air Throttle Actuator Desired and Actual Position Mismatch...1201
000051.14 - Air Throttle Actuator and EGR Valve Connectors Swapped...1201
000091.03 - Primary Analog Throttle Signal Out of Range High...1201
000091.04 - Primary Analog Throttle Signal Out of Range Low...1201
000091.09 - Primary Analog Throttle Signal Erratic...1201
000091.14 - Primary Analog Throttle Inhibited...1201
000094.03 - Low-Pressure Fuel Signal Out of Range High...1201
000094.04 - Low-Pressure Fuel Signal Out of Range Low...1202
000094.16 - Low-Pressure Fuel Signal Moderately High...1202
000094.17 - Low-Pressure Fuel Signal Slightly Low...1202
000094.18 - Low-Pressure Fuel Signal Moderately Low...1202
000097.00 - Water-In-Fuel Level Extremely High...1202
000097.03 - Water-In-Fuel Signal Out Of Range High...1202
000097.04 - Water-In-Fuel Signal Out Of Range Low...1202
000097.16 - Water-In-Fuel Level Moderately High...1202
000100.01 - Engine Oil Pressure Signal Extremely Low...1202
000100.02 - Engine Oil Pressure is not Zero with Engine Stopped...1202
000100.03 - Engine Oil Pressure Signal Out of Range High...1202
000100.04 - Engine Oil Pressure Signal Out of Range Low...1202
000100.18 - Engine Oil Pressure Signal Moderately Low...1202
000102.03 - Manifold Air Pressure Signal Out of Range High...1202
000102.04 - Manifold Air Pressure Signal Out of Range Low...1202
000102.07 - Manifold Air Pressure Signal In Range Invalid...1202
000103.00 - VGT Speed Signal Extremely High...1202
000103.02 - VGT Speed Signal Invalid...1202
000103.05 - VGT Speed Circuit Has High Resistance...1202
000105.00 - Manifold Air Temperature Signal Extremely High...1202
000105.03 - Manifold Air Temperature Signal Out of Range High...1202
000105.04 - Manifold Air Temperature Signal Out of Range Low...1202
000105.15 - Manifold Air Temperature Signal Slightly High...1202
000105.16 - Manifold Air Temperature Signal Moderately High...1202
000107.00 - Air Filter Pressure Differential Extremely High...1202
000107.15 - Air Filter Pressure Differential Slightly High...1202
000107.16 - Air Filter Pressure Differential Moderately High...1202
000108.02 - Barometric Pressure Signal Invalid...1202
000108.07 - Barometric Pressure Signal Mismatch...1202
000109.01 - Engine Coolant Pressure Signal Extremely Low...1202
000109.03 - Engine Coolant Pressure Signal Out of Range High...1202
000109.04 - Engine Coolant Pressure Signal Out of Range Low...1202
000109.17 - Engine Coolant Pressure Signal Slightly Low...1202
000109.18 - Engine Coolant Pressure Signal Moderately Low...1203
000109.31 - Engine Coolant Pressure Signal Fault...1203
000110.00 - Engine Coolant Temperature Signal Extremely High...1203
000110.03 - Engine Coolant Temperature Signal Out of Range High...1203
000110.04 - Engine Coolant Temperature Signal Out of Range Low...1203
000110.15 - Engine Coolant Temperature Signal Slightly High...1203
000110.16 - Engine Coolant Temperature Signal Moderately High...1203
000110.17 - Engine Coolant Temperature Signal Slightly Low...1203
000111.01 - Engine Coolant Level Alarm Switch Activated at High Coolant Temperature...1203
000111.07 - Engine Coolant Level Switch Mismatch...1203
000111.17 - Engine Coolant Level Information Switch Activated...1203
000111.18 - Engine Coolant Level Alarm Switch Activated at Moderate Coolant Temperature...1203
000137.00 - Auxiliary Gauge Pressure Reading Extremely High...1203
000137.01 - Auxiliary Gauge Pressure Reading Extremely Low...1203
000157.01 - High-Pressure Fuel Signal Extremely Low...1203
000157.03 - High-Pressure Fuel Signal Out of Range High...1203
000157.04 - High-Pressure Fuel Signal Out of Range Low...1203
000157.18 - High-Pressure Fuel Signal Moderately Low...1203
000158.01 — Battery Voltage Extremely Low...1944
000158.12 - ECU Power Down Error...1203
000160.02 - Primary Shaft Speed Invalid...1203
000168.01 - Unswitched Battery Voltage Extremely Low...1203
000168.16 - Unswitched Battery Voltage Moderately High...1203
000168.18 - Unswitched Battery Voltage Moderately Low...1203
000174.00 - Fuel Temperature Signal Extremely High...1203
000174.03 - Fuel Temperature Signal Out Of Range High...1203
000174.04 - Fuel Temperature Signal Out Of Range Low...1203
Section 05: Tools and Other Materials...4247
Group 180: Special Tools...4110
75240...4115
313793...4116
D01062AA...4117
D01168AA...4118
D01300AA...4119
D05012ST-A...4120
D05104ST...4121
D05223ST...4122
D17006BR...4123
D17015BR...4124
D17024BR...4125
D17030BR...4126
D17525CI...4127
D17526CI...4128
D17527CI...4129
DFRG3...4130
DFRG4...4132
DFRG11...4133
DFRG12...4135
DFRG13...4137
J-35616-20...4138
JDE41296...4139
JDG164A...4140
JDG360...4141
JDG361...4142
JDG362...4143
JDG363...4144
JDG364...4145
JDG451...4146
JDG777...4147
JDG782A...4148
JDG783...4149
JDG820...4150
JDG839...4151
JDG865...4152
JDG967...4153
JDG968-1...4154
JDG968-2...4155
JDG968-3...4156
JDG968-4...4157
JDG968-5...4158
JDG969A...4159
JDG972...4160
JDG978...4161
JDG982A...4162
JDG982AP2...4163
JDG982AP3...4164
JDG996...4165
JDG998...4166
JDG1069...4167
JDG1144...4168
JDG1145...4169
JDG1167...4170
JDG1333...4171
JDG1334...4172
JDG1449...4173
JDG8092...4174
JDG10057...4175
JDG10205...4176
JDG10233...4177
JDG10243...4178
JDG10246A...4179
JDG10249...4180
JDG10254...4181
JDG10273...4182
JDG10273P1...4183
JDG10273P2...4184
JDG10357B...4185
JDG10456...4186
JDG10458...4187
JDG10459...4188
JDG10460...4189
JDG10461...4190
JDG10462...4191
JDG10463...4192
JDG10464...4193
JDG10465...4194
JDG10466...4195
JDG10467...4196
JDG10519...4197
JDG10539A...4198
JDG10543...4199
JDG10854...4200
JDG10996...4201
JDG10997...4202
JDG11005...4203
JDG11016...4204
JDG11017...4205
JDG11019...4206
JDG11056...4207
JDG11072...4208
JDG11074...4209
JDG11077...4210
JDG11084...4211
JDG11100A...4212
JDG11101...4213
JDG11186...4214
JDG11202...4215
JDG11233...4216
JDG11263...4217
JDG11311...4219
JDG11311P2...4220
JDG11315A...4221
JDG11324...4222
JDG11325...4223
JDG11325P1...4224
JDG11325P2...4225
JDG11334P3...4226
JDG11373...4227
JDG11374...4228
JDG11375...4229
JDG11409...4230
JDG11544...4231
JDG11831...4232
JDG11860...4233
JDG11864...4234
JT01674A...4235
JT03513C...4236
JT05470...4237
JT05697A...4240
JT05719...4241
JT07253...4242
JT07306...4243
JT07336...4244
Group 190: Lubricants, Sealants, and Other Materials...4247
Other Materials...4247
Section 06: Specifications...4249
Group 200: Repair and General OEM Specifications...4249
General OEM Engine Specifications...4251
Unified Inch Bolt and Screw Torque Values...4252
Metric Bolt and Screw Torque Values...4254
Group 210: Diagnostic Specifications...4249
13.5L Wiring Diagram 1...4258
13.5L Wiring Diagram 2...4260
13.5L Wiring Diagram 3...4262
13.5L Wiring Diagram 4...4264
13.5L Wiring Diagram 5...4266
13.5L Wiring Diagram 6...4268
13.5L Wiring Diagram 7...4270
13.5L Wiring Diagram 8...4273
13.5L Wiring Diagram 9...4275
13.5L Wiring Diagram 10...4277
13.5L Wiring Diagram 11...4279
13.5L Wiring Diagram 12...4281
Connector Repair Information Table...4283
EGR Temperature Sensor Characteristics...4287
Engine Schematic 1...4288
Engine Schematic 2...4291
Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics...4294
OEM Engines - Derate Specifications...4295
OEM Instrument Panel Schematic...4299
Wire Splice Location Diagrams...4302
John Deere 6135 Diesel Engines Repair Service Manual (CTM104919)
