John Deere PowerTech 6.8L 6068 Compressed Natural Gas Engine Repair Technical Manual CTM146

Details:

1. Foreword
2. Safety
3. Handle Fluids Safely-Avoid Fires
4. Handle Natural Gas Safely
5. Prevent Battery Explosions
6. Prepare for Emergencies
7. Prevent Acid Burns
8. Avoid High-Pressure Fluids
9. Wear Protective Clothing
10. Service Machines Safely
11. Work in Ventilated Area
12. Work in Clean Area
13. Remove Paint Before Welding or Heating
14. Avoid Heating Near Pressurized Fluid Lines
15. Illuminate Work Area Safely
16. Use Proper Lifting Equipment
17. Practice Safe Maintenance
18. Use Proper Tools
19. Dispose of Waste Properly
20. Handle Compressed Natural Gas (CNG) Safely
21. Service Compressed Natural Gas (CNG) Systems Safely
22. Protect Against High Pressure
23. Protect Against Extremely Cold CNG Leakage
24. Live With Safety
25. General Information
26. Unified Inch Bolt and Cap Screw Torque Values
27. Metric Bolt and Cap Screw Torque Values
28. Engine Model Designation
29. Engine Serial Number Plate Information
30. Fuels, Lubricants, and Coolant
31. Natural Gas Recommendations
32. Natural Gas Engine Oil
33. Engine Break-In Oil
34. Alternative and Synthetic Lubricants
35. Mixing of Lubricants
36. OILSCANOILSCAN is a trademark of Deere & Company. and CoolScanCoolScan is a trademark of Deere & Company.
37. Grease
38. Recommended Engine Coolant
39. Engine Coolant Specifications
40. Testing Diesel Engine Coolant
41. Replenishing Supplemental Coolant Additives (SCA’s) Between Coolant Changes
42. Operating in Warm Temperature Climates
43. Flush and Service Cooling System
44. Disposing of Coolant
45. Engine Mounting
46. Engine Repair Stand
47. Safety Precautions
48. Install Adapters on Engine Repair Stand
49. Engine Lifting Procedure
50. Clean Engine
51. Disconnect Turbocharger Oil Inlet Line
52. Mount Engine on Repair Stand
53. Engine Mounted on Repair Stand
54. Engine Rebuild Guide
55. Engine Disassembly Sequence
56. Sealant Application Guidelines
57. Engine Assembly Sequence
58. Cylinder Head and Valves
59. Special or Essential Tools
60. Service Equipment and Tools
61. Other Material
62. Cylinder Head and Valves Specifications
63. Check and Adjust Valve Clearance
64. Measure Valve Lift
65. Remove Cylinder Head
66. Disassemble and Inspect Rocker Arm Shaft Assembly
67. Assemble Rocker Arm Assembly
68. Inspect, Measure, and Assemble Camshaft Followers
69. Measure Valve Recess in Cylinder Head
70. Preliminary Cylinder Head and Valve Checks
71. Remove Valve Assembly
72. Inspect and Measure Valve Springs
73. Inspect Valve Rotators
74. Clean Valves
75. Inspect and Measure Valves
76. Grind Valves
77. Inspect and Clean Cylinder Head
78. Check Cylinder Head Flatness
79. Measure Cylinder Head Thickness
80. Clean Valve Guides
81. Measure Valve Guides
82. Knurl Valve Guides
83. Clean and Inspect Valve Seats
84. Grind Valve Seats
85. Remove Valve Seat Inserts
86. Measure Valve Seat Bore in Cylinder Head
87. Install Valve Seat Inserts
88. Install Valves
89. Inspect and Clean Exhaust Manifold
90. Clean and Inspect Top Deck of Cylinder Block
91. Measure Cylinder Liner Standout (Height Above Block)
92. Install Cylinder Head and Cap Screws
93. Torque-Turn Method for Proper Torque
94. Install Rocker Arm Assembly
95. Inspect and Clean Ventilator Outlet Hose
96. Install Rocker Arm Cover
97. Complete Final Assembly
98. Perform Engine Break-In
99. Cylinder Block, Liners, Pistons, and Rods
100. Special or Essential Tools
101. Service Equipment and Tools
102. Other Material
103. Cylinder Block, Liners, Pistons, and Rods Specifications
104. Connecting Rods-General Information
105. Remove Pistons and Connecting Rods
106. Remove Cylinder Liners
107. Complete Disassembly of Cylinder Block (If Required)
108. Preliminary Liner, Piston and Rod Checks
109. Disassemble Piston and Rod Assembly
110. Clean Pistons
111. Visually Inspect Pistons
112. Clean Cylinder Liners
113. Visually Inspect Cylinder Liners
114. Check Piston Ring Groove Wear
115. Measure Piston Pin Bore
116. Measure Piston Skirt
117. Determine Piston-to-Liner Clearance
118. Deglaze Cylinder Liners
119. Replace Piston and Liner Sets
120. Inspect and Measure Connecting Rod Bearings
121. Inspect Rod and Cap
122. Inspect Piston Pins and Bushings
123. Remove Piston Pin Bushing
124. Clean and Inspect Connecting Rod Pin Bore
125. Install Piston Pin Bushing in Connecting Rod
126. Measure Rod Center-to-Center Bores
127. Inspect and Clean Cylinder Block
128. Clean Cylinder Liner O-Ring Bore
129. Measure Cylinder Block Main Bearing Bore
130. Measure Camshaft Follower Machined Bore in Block
131. Measure Camshaft Bushing Bores in Block
132. Measure Liner Flange Counterbore Depth in Block
133. Measure Liner Flange Thickness
134. Measure Cylinder Block Top Deck Flatness
135. Remove, Inspect, and Install Piston Cooling Orifices
136. Measure Cylinder Liner Standout (Height Above Block)
137. Install Packing on Cylinder Liner and O-Rings in Block
138. Install Cylinder Liner in Block
139. Assemble Connecting Rods onto Piston
140. Install Piston Rings
141. Connecting Rods-General Information
142. Install Piston and Rod Assembly
143. Torque-Turn Connecting Rod Cap Screws
144. Check Engine Rotation for Excessive Tightness
145. Measure Piston Protrusion
146. Complete Final Assembly
147. Crankshaft, Main Bearings, and Flywheel
148. Special or Essential Tools
149. Service Equipment and Tools
150. Other Material
151. Crankshaft, Main Bearings, and Flywheel Specifications
152. Crankshaft Grinding Specifications
153. Crankshaft and Main Bearing Failure Analysis
154. Inspect Vibration Damper
155. Remove Pulley or Vibration Damper and Pulley
156. Install Pulley or Vibration Damper Pulley
157. Checking Vibration Damper or Pulley
158. Replace Front Crankshaft Oil Seal and Wear Sleeve (Without Removing Timing Gear Cover)
159. Check Crankshaft End Play
160. Inspect Flywheel
161. Remove Flywheel
162. Replace Flywheel Ring Gear
163. Install Flywheel
164. Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
165. Remove Unitized (Non-Separable) Crankshaft Rear Oil Seal and Wear Sleeve
166. Install Crankshaft Rear Oil Seal and Wear Sleeve
167. Remove Flywheel Housing
168. Remove Crankshaft Main Bearings
169. Check Main Bearing Oil Clearance
170. Remove and Install Crankshaft Gear (Crankshaft Installed In Engine)
171. Remove Crankshaft
172. Inspect Crankshaft
173. Measure Assembled Main Bearing ID and OD of Crankshaft Main Journal and Rod Journal
174. Measure Main Thrust Journal Width and Thrust Bearing Width
175. Crankshaft Grinding Guidelines
176. Measure Assembled ID of Main Bearing Caps
177. Remove, Inspect, and Install Piston Cooling Orifices
178. Install Main and Thrust Bearing Inserts in Block
179. Install Crankshaft
180. Install Flywheel Housing
181. Complete Final Assembly
182. Camshaft and Timing Gear Train
183. Special or Essential Tools
184. Service Equipment and Tools
185. Other Material
186. Camshaft and Timing Gear Train Specifications
187. Measure Valve Lift
188. Remove Timing Gear Cover
189. Remove and Install Camshaft Bushing With Front Plate Installed
190. Measure Camshaft End Play
191. Measure Idler Gear End Play
192. Measure Timing Gear Backlash
193. Remove Camshaft
194. Visually Inspect Camshaft
195. Measure Camshaft Thrust Plate Clearance
196. Inspect and Measure Camshaft Bushing ID and Journal OD
197. Measure Camshaft Lobe Height
198. Remove and Install Camshaft Gear
199. Inspect Camshaft Followers
200. Remove Cylinder Block Front Plate
201. Measure Idler Gear Bushing and Shaft
202. Remove and Install Idler Gear Bushing
203. Remove Lower and Upper Idler Shafts
204. Clean and Inspect Front Plate
205. Install Idler Shaft Spring Pins
206. Install Upper Idler Shaft in Front Plate
207. Install Lower Idler Shaft in Front Plate
208. Install Engine Front Plate
209. Install and Time Camshaft
210. Clean and Inspect Timing Gear Cover
211. Install Timing Gear Cover
212. Install Crankshaft Front Wear Sleeve and Oil Seal
213. Complete Final Assembly
214. Lubrication System
215. Special or Essential Tools
216. Service Equipment and Tools
217. Other Material
218. Lubrication System Specifications
219. Diagnosing Lubrication System Malfunctions
220. Remove, Inspect, and Install Oil Filter Base
221. Remove, Inspect, and Install Oil Cooler
222. Remove, Inspect, and Install Oil Bypass Valve
223. Remove and Install Oil Pressure Regulating Valve and Seat
224. Remove and Install Oil Fill Tube
225. Remove and Install Dipstick Tube With Oil Pan Installed
226. Replace Oil Pump Pick-Up Tube Assembly
227. Engine Oil Pump Assembly
228. Remove Engine Oil Pump
229. Inspect and Measure Clearances
230. Complete Oil Pump Disassembly
231. Assemble Engine Oil Pump
232. Install Engine Oil Pump
233. Install Oil Pan
234. Cooling System
235. Special or Essential Tools
236. Service Equipment and Tools
237. Other Material
238. Cooling System Specifications
239. Diagnosing Cooling System Malfunctions
240. Remove Water Manifold/Thermostat Cover and Thermostat
241. Test Thermostat
242. Install Water Manifold/Thermostat Cover and Thermostat
243. Remove Water Pump
244. Water Pump Assembly
245. Disassemble Water Pump
246. Inspect, Clean, and Measure Water Pump Parts
247. Assemble Water Pump
248. Install Water Pump
249. Remove and Install Automatic (Spring) Belt Tensioner
250. Checking Belt Tensioner Spring Tension and Belt Wear
251. Remove and Inspect Idler Pulley Assembly
252. Replace Bearing in Idler Pulley Assembly
253. Install Idler Pulley Assembly
254. Remove and Install Coolant Heater
255. Air Intake and Exhaust System
256. Other Material
257. Air Intake and Exhaust System Specifications
258. Extending Turbocharger Life
259. Remove Turbocharger
260. Turbocharger Failure Analysis
261. Turbocharger Seven-Step Inspection
262. Perform Axial Bearing End Play Test
263. Repair Turbocharger
264. Clean and Inspect Turbine and Compressor Housings
265. Adjust Turbocharger Wastegate Actuator
266. Prelube Turbocharger
267. Install Turbocharger
268. Cleaning PCV Orifice
269. Remove, Inspect, and Install Exhaust Manifold
270. Remove, Inspect, and Install Intake Manifold
271. Fuel Supply System
272. Specifications
273. Fuel Pressure Leak-Off Procedure
274. Leak Check Procedure
275. Remove and Install Natural Gas Regulator
276. Repair Natural Gas Regulator
277. Remove and Install Fuel Metering Valve
278. Repair Fuel Metering Valve
279. Remove and Install Fuel Mixer
280. Starting and Charging System
281. Special or Essential Tools
282. Specifications
283. Remove and Install Starter
284. Bench Test Starting Motor
285. Make Solenoid Return Test
286. Make No Load Test
287. Diagnose No Load Test
288. Remove and Install Alternator
289. Charging System Failure
290. Alternator Troubleshooting
291. Alternator Output Test
292. Diode Trio Test
293. Full Field Test
294. Electronic Engine Controls
295. Special or Essential Tools
296. Service Equipment and Tools
297. Other Material
298. Specifications
299. Remove and Install Spark Plugs
300. Removal of Seized Spark Plugs (Tool JDG1193 Not Available or Spark Plug Ceramic Stem Has Broken Off)
301. Remove and Install Ignition Coils
302. Remove and Install Ignition Control Unit (ICU)
303. Remove and Install Cam Sensor
304. Remove and Install Crank Sensor
305. Remove and Install Engine Coolant Temperature (ECT) Sensor
306. Remove and Install Foot Pedal Position Sensor
307. Remove and Install Manifold Absolute Pressure (MAP) Sensor
308. Remove and Install Manifold Air Temperature (MAT) Sensor
309. Remove and Install Natural Gas Tank Temperature (NGTT) Sensor
310. Remove and Install Preturbine Pressure (PTP) Sensor
311. Remove and Install Exhaust Back Pressure (EBP) Sensor
312. Remove and Install Electronic Throttle and Throttle Position Sensor
313. Remove and Install Universal Exhaust Gas Oxygen (UEGO) Sensor
314. Remove and Install Oil Pressure Switch
315. Remove and Install Turbocharger Wastegate Control Valve
316. Natural Gas Engine Wiring Harness
317. Natural Gas Engine Component Location Diagram
318. Connectors
319. Using High-Pressure Washer
320. Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector
321. Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact
322. Remove Connector Body from Blade Terminals
323. Replace (Pull Type) METRI-PACK METRI-PACK is a trademark of Packard Electric. Connectors
324. Replace (Push Type) METRI-PACK METRI-PACK is a trademark of Packard Electric. Connectors
325. Use Electrical Insulating Compound
326. Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors
327. Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact
328. Miscellaneous Accessories
329. Other Material
330. Miscellaneous Accessories Specifications
331. Remove Air Compressor
332. Inspecting Air Compressor
333. Remove Idler Housing
334. Install Idler Housing
335. Install Air Compressor
336. Dealer Fabricated Tools
337. Dealer Fabricated Tools
338. DFRG3 Cylinder Liner Holding Fixture