Description
Details:
- 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 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
