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

John Deere PowerTech 6068 6.8L Compressed Natural Gas Engine Repair Technical Manual CTM146
Language: English
Format: PDF
Document: Repair Technical Manual
Machine: Compressed Natural Gas Engine
Machine Model: 6068CNG
Pages: 485 Pages
Part Number: CTM146

Contents:
Foreword
  Safety
     Handle Fluids Safely-Avoid Fires
     Handle Natural Gas Safely
     Prevent Battery Explosions
     Prepare for Emergencies
     Prevent Acid Burns
     Avoid High-Pressure Fluids
     Wear Protective Clothing
     Service Machines Safely
     Work in Ventilated Area
     Work in Clean Area
     Remove Paint Before Welding or Heating
     Avoid Heating Near Pressurized Fluid Lines
     Illuminate Work Area Safely
     Use Proper Lifting Equipment
     Practice Safe Maintenance
     Use Proper Tools
     Dispose of Waste Properly
     Handle Compressed Natural Gas (CNG) Safely
     Service Compressed Natural Gas (CNG) Systems Safely
     Protect Against High Pressure
     Protect Against Extremely Cold CNG Leakage
     Live With Safety
  General Information
     Unified Inch Bolt and Cap Screw Torque Values
     Metric Bolt and Cap Screw Torque Values
     Engine Machine Model Designation
     Engine Serial Number Plate Information
  Fuels, Lubricants, and Coolant
     Natural Gas Recommendations
     Natural Gas Engine Oil
     Engine Break-In Oil
     Alternative and Synthetic Lubricants
     Mixing of Lubricants
     OILSCANOILSCAN is a trademark of Deere & Company. and CoolScanCoolScan is a trademark of Deere & Company.
     Grease
     Recommended Engine Coolant
     Engine Coolant Specifications
     Testing Diesel Engine Coolant
     Replenishing Supplemental Coolant Additives (SCA’s) Between Coolant Changes
     Operating in Warm Temperature Climates
     Flush and Service Cooling System
     Disposing of Coolant
  Engine Mounting
     Engine Repair Stand
     Safety Precautions
     Install Adapters on Engine Repair Stand
     Engine Lifting Procedure
     Clean Engine
     Disconnect Turbocharger Oil Inlet Line
     Mount Engine on Repair Stand
     Engine Mounted on Repair Stand
  Engine Rebuild Guide
     Engine Disassembly Sequence
     Sealant Application Guidelines
     Engine Assembly Sequence
  Cylinder Head and Valves
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Cylinder Head and Valves Specifications
     Check and Adjust Valve Clearance
     Measure Valve Lift
     Remove Cylinder Head
     Disassemble and Inspect Rocker Arm Shaft Assembly
     Assemble Rocker Arm Assembly
     Inspect, Measure, and Assemble Camshaft Followers
     Measure Valve Recess in Cylinder Head
     Preliminary Cylinder Head and Valve Checks
     Remove Valve Assembly
     Inspect and Measure Valve Springs
     Inspect Valve Rotators
     Clean Valves
     Inspect and Measure Valves
     Grind Valves
     Inspect and Clean Cylinder Head
     Check Cylinder Head Flatness
     Measure Cylinder Head Thickness
     Clean Valve Guides
     Measure Valve Guides
     Knurl Valve Guides
     Clean and Inspect Valve Seats
     Grind Valve Seats
     Remove Valve Seat Inserts
     Measure Valve Seat Bore in Cylinder Head
     Install Valve Seat Inserts
     Install Valves
     Inspect and Clean Exhaust Manifold
     Clean and Inspect Top Deck of Cylinder Block
     Measure Cylinder Liner Standout (Height Above Block)
     Install Cylinder Head and Cap Screws
     Torque-Turn Method for Proper Torque
     Install Rocker Arm Assembly
     Inspect and Clean Ventilator Outlet Hose
     Install Rocker Arm Cover
     Complete Final Assembly
     Perform Engine Break-In
  Cylinder Block, Liners, Pistons, and Rods
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Cylinder Block, Liners, Pistons, and Rods Specifications
     Connecting Rods-General Information
     Remove Pistons and Connecting Rods
     Remove Cylinder Liners
     Complete Disassembly of Cylinder Block (If Required)
     Preliminary Liner, Piston and Rod Checks
     Disassemble Piston and Rod Assembly
     Clean Pistons
     Visually Inspect Pistons
     Clean Cylinder Liners
     Visually Inspect Cylinder Liners
     Check Piston Ring Groove Wear
     Measure Piston Pin Bore
     Measure Piston Skirt
     Determine Piston-to-Liner Clearance
     Deglaze Cylinder Liners
     Replace Piston and Liner Sets
     Inspect and Measure Connecting Rod Bearings
     Inspect Rod and Cap
     Inspect Piston Pins and Bushings
     Remove Piston Pin Bushing
     Clean and Inspect Connecting Rod Pin Bore
     Install Piston Pin Bushing in Connecting Rod
     Measure Rod Center-to-Center Bores
     Inspect and Clean Cylinder Block
     Clean Cylinder Liner O-Ring Bore
     Measure Cylinder Block Main Bearing Bore
     Measure Camshaft Follower Machined Bore in Block
     Measure Camshaft Bushing Bores in Block
     Measure Liner Flange Counterbore Depth in Block
     Measure Liner Flange Thickness
     Measure Cylinder Block Top Deck Flatness
     Remove, Inspect, and Install Piston Cooling Orifices
     Measure Cylinder Liner Standout (Height Above Block)
     Install Packing on Cylinder Liner and O-Rings in Block
     Install Cylinder Liner in Block
     Assemble Connecting Rods onto Piston
     Install Piston Rings
     Connecting Rods-General Information
     Install Piston and Rod Assembly
     Torque-Turn Connecting Rod Cap Screws
     Check Engine Rotation for Excessive Tightness
     Measure Piston Protrusion
     Complete Final Assembly
  Crankshaft, Main Bearings, and Flywheel
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Crankshaft, Main Bearings, and Flywheel Specifications
     Crankshaft Grinding Specifications
     Crankshaft and Main Bearing Failure Analysis
     Inspect Vibration Damper
     Remove Pulley or Vibration Damper and Pulley
     Install Pulley or Vibration Damper Pulley
     Checking Vibration Damper or Pulley
     Replace Front Crankshaft Oil Seal and Wear Sleeve (Without Removing Timing Gear Cover)
     Check Crankshaft End Play
     Inspect Flywheel
     Remove Flywheel
     Replace Flywheel Ring Gear
     Install Flywheel
     Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
     Remove Unitized (Non-Separable) Crankshaft Rear Oil Seal and Wear Sleeve
     Install Crankshaft Rear Oil Seal and Wear Sleeve
     Remove Flywheel Housing
     Remove Crankshaft Main Bearings
     Check Main Bearing Oil Clearance
     Remove and Install Crankshaft Gear (Crankshaft Installed In Engine)
     Remove Crankshaft
     Inspect Crankshaft
     Measure Assembled Main Bearing ID and OD of Crankshaft Main Journal and Rod Journal
     Measure Main Thrust Journal Width and Thrust Bearing Width
     Crankshaft Grinding Guidelines
     Measure Assembled ID of Main Bearing Caps
     Remove, Inspect, and Install Piston Cooling Orifices
     Install Main and Thrust Bearing Inserts in Block
     Install Crankshaft
     Install Flywheel Housing
     Complete Final Assembly
  Camshaft and Timing Gear Train
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Camshaft and Timing Gear Train Specifications
     Measure Valve Lift
     Remove Timing Gear Cover
     Remove and Install Camshaft Bushing With Front Plate Installed
     Measure Camshaft End Play
     Measure Idler Gear End Play
     Measure Timing Gear Backlash
     Remove Camshaft
     Visually Inspect Camshaft
     Measure Camshaft Thrust Plate Clearance
     Inspect and Measure Camshaft Bushing ID and Journal OD
     Measure Camshaft Lobe Height
     Remove and Install Camshaft Gear
     Inspect Camshaft Followers
     Remove Cylinder Block Front Plate
     Measure Idler Gear Bushing and Shaft
     Remove and Install Idler Gear Bushing
     Remove Lower and Upper Idler Shafts
     Clean and Inspect Front Plate
     Install Idler Shaft Spring Pins
     Install Upper Idler Shaft in Front Plate
     Install Lower Idler Shaft in Front Plate
     Install Engine Front Plate
     Install and Time Camshaft
     Clean and Inspect Timing Gear Cover
     Install Timing Gear Cover
     Install Crankshaft Front Wear Sleeve and Oil Seal
     Complete Final Assembly
  Lubrication System
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Lubrication System Specifications
     Diagnosing Lubrication System Malfunctions
     Remove, Inspect, and Install Oil Filter Base
     Remove, Inspect, and Install Oil Cooler
     Remove, Inspect, and Install Oil Bypass Valve
     Remove and Install Oil Pressure Regulating Valve and Seat
     Remove and Install Oil Fill Tube
     Remove and Install Dipstick Tube With Oil Pan Installed
     Replace Oil Pump Pick-Up Tube Assembly
     Engine Oil Pump Assembly
     Remove Engine Oil Pump
     Inspect and Measure Clearances
     Complete Oil Pump Disassembly
     Assemble Engine Oil Pump
     Install Engine Oil Pump
     Install Oil Pan
  Cooling System
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Cooling System Specifications
     Diagnosing Cooling System Malfunctions
     Remove Water Manifold/Thermostat Cover and Thermostat
     Test Thermostat
     Install Water Manifold/Thermostat Cover and Thermostat
     Remove Water Pump
     Water Pump Assembly
     Disassemble Water Pump
     Inspect, Clean, and Measure Water Pump Parts
     Assemble Water Pump
     Install Water Pump
     Remove and Install Automatic (Spring) Belt Tensioner
     Checking Belt Tensioner Spring Tension and Belt Wear
     Remove and Inspect Idler Pulley Assembly
     Replace Bearing in Idler Pulley Assembly
     Install Idler Pulley Assembly
     Remove and Install Coolant Heater
  Air Intake and Exhaust System
     Other Material
     Air Intake and Exhaust System Specifications
     Extending Turbocharger Life
     Remove Turbocharger
     Turbocharger Failure Analysis
     Turbocharger Seven-Step Inspection
     Perform Axial Bearing End Play Test
     Repair Turbocharger
     Clean and Inspect Turbine and Compressor Housings
     Adjust Turbocharger Wastegate Actuator
     Prelube Turbocharger
     Install Turbocharger
     Cleaning PCV Orifice
     Remove, Inspect, and Install Exhaust Manifold
     Remove, Inspect, and Install Intake Manifold
  Fuel Supply System
     Specifications
     Fuel Pressure Leak-Off Procedure
     Leak Check Procedure
     Remove and Install Natural Gas Regulator
     Repair Natural Gas Regulator
     Remove and Install Fuel Metering Valve
     Repair Fuel Metering Valve
     Remove and Install Fuel Mixer
  Starting and Charging System
     Special or Essential Tools
     Specifications
     Remove and Install Starter
     Bench Test Starting Motor
     Make Solenoid Return Test
     Make No Load Test
     Diagnose No Load Test
     Remove and Install Alternator
     Charging System Failure
     Alternator Troubleshooting
     Alternator Output Test
     Diode Trio Test
     Full Field Test
  Electronic Engine Controls
     Special or Essential Tools
     Service Equipment and Tools
     Other Material
     Specifications
     Remove and Install Spark Plugs
     Removal of Seized Spark Plugs (Tool JDG1193 Not Available or Spark Plug Ceramic Stem Has Broken Off)
     Remove and Install Ignition Coils
     Remove and Install Ignition Control Unit (ICU)
     Remove and Install Cam Sensor
     Remove and Install Crank Sensor
     Remove and Install Engine Coolant Temperature (ECT) Sensor
     Remove and Install Foot Pedal Position Sensor
     Remove and Install Manifold Absolute Pressure (MAP) Sensor
     Remove and Install Manifold Air Temperature (MAT) Sensor
     Remove and Install Natural Gas Tank Temperature (NGTT) Sensor
     Remove and Install Preturbine Pressure (PTP) Sensor
     Remove and Install Exhaust Back Pressure (EBP) Sensor
     Remove and Install Electronic Throttle and Throttle Position Sensor
     Remove and Install Universal Exhaust Gas Oxygen (UEGO) Sensor
     Remove and Install Oil Pressure Switch
     Remove and Install Turbocharger Wastegate Control Valve
     Natural Gas Engine Wiring Harness
     Natural Gas Engine Component Location Diagram
     Connectors
     Using High-Pressure Washer
     Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector
     Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact
     Remove Connector Body from Blade Terminals
     Replace (Pull Type) METRI-PACK METRI-PACK is a trademark of Packard Electric. Connectors
     Replace (Push Type) METRI-PACK METRI-PACK is a trademark of Packard Electric. Connectors
     Use Electrical Insulating Compound
     Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors
     Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact
  Miscellaneous Accessories
     Other Material
     Miscellaneous Accessories Specifications
     Remove Air Compressor
     Inspecting Air Compressor
     Remove Idler Housing
     Install Idler Housing
     Install Air Compressor
  Dealer Fabricated Tools
     Dealer Fabricated Tools
     DFRG3 Cylinder Liner Holding Fixture