このマニュアルは英語または説明に記載されている言語で作成されることにご注意ください
Illustrated Factory Repair Component Technical Manual for PowerTech 6.8L, 6068 Compressed Natural Gas Engine This manual contains high quality images, circuit diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your truck. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation. Language: English Format: PDF, 485 pages Covered models:   6068CNG Contents:    Foreword    About This Manual    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 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 (SCAs) 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