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John Deere John Deere 6068 Diesel Engine Maintenance, Operation and Troubleshooting Technical Data for 4.5 L and 6.8 L


Detailed Description:

John Deere John Deere 6068 Diesel Engine Maintenance, Operation and Troubleshooting Technical Data for 4.5 L and 6.8 L

SECTION 01—General Information

Group 000—Safety

Group 001—Engine Identification and Application

Charts

Group 002—Fuels, Lubricants and Coolants

02

SECTION 02—Repair and Adjustments

Group 010—Engine Rebuild

Group 020—Cylinder Head and Valves (Two-Valve

Head Engines)

Group 021—Cylinder Head and Valves (Four-Valve

Head Engines)

Group 030--Cylinder Block, Liners, Pistons and

Rods

Group 040--Crankshaft, Main Bearings and

Flywheel

03

Group 050--Camshaft, Balancer Shafts and Timing

Gear Train

Group 060—Lubrication System

Group 070—Cooling System

Group 080—Air Intake and Exhaust System

Group 090—Fuel System

Group 100—Starting and Charging Systems

SECTION 03—Theory of Operation

Group 120—Base Engine Operation

04

SECTION 04—Diagnostics

Group 150—Observable Diagnostics and Tests

SECTION 05—Tools and Other Materials

Group 170—Repair Tools and Other Materials

Group 180—Diagnostic Service Tools

Group 190—Dealer Fabricated Service Tools

SECTION 06—Specifications

Group 200—Repair and General OEM

Specifications

05

Group 210—Diagnostic Specifications

Group 000-Safety............

Group 001—Engine Identification and Application

Charts

Engine Model Designation.........

Engine Serial Number Plate Information....

OEM Engine Option Code Label......

Information Relative to Emissions

Regulations ...............

Engine Application Charts.........

Group 002—Fuels, Lubricants and Coolants

Diesel Fuel................

Bio-Diesel Fuel ................

Lubricity of Diesel Fuel..........

Dieselscan Fuel Analysis.........

Diesel Engine Break-In Oil.........

Diesel Engine Oil—Non-Certified and Tier I

Certified Engines.............

Diesel Engine Oil--Tier II Engines.....

OILSCANâ, OILSCAN Plusâ,

COOLSCANä and COOLSCAN PLUSä... 01-002-7

Grease.................... E...

Diesel Engine Coolant............

Diesel Engine Coolants, Supplemental

Additive Information.........

Testing Diesel Engine Coolant......

Supplemental Coolant Additives.....

Operating in Warm Temperature Climates. .01-002-12

Flush and Service Cooling System.....

Disposing of Coolant.........

4045TF275 diesel engine

4 ............. Number of cylinders

4.5 Liter displacement

T .................. Aspiration code

F ............ User code

275 ............... POWERTECHâ application codeAspiration Code

D .................. Naturally aspirated

T .................. Turbocharged, no aftercooling

A ............ Turbocharged and air-to-coolant aftercooled

H ............ Turbocharged and air-to-air aftercooledUser Factory Code

AT ............... Agritalia srl (Vittoria, Sicily, Italy)

CQ ............... John Deere Brazil (Horizontina, Brazil)

DW ......... John Deere Davenport Works (Davenport, Iowa)

E ............ John Deere Ottumwa Works (Ottumwa, Iowa)

F ............ OEM (Outside Equipment Manufacturers)

FF ................. Deere-Hitachi (Kernersville, North Carolina)

FG ............... Goldoni SPA (Modena, Italy)

FM ............... Marine Engines

H ............ John Deere Harvester Works (East Moline, Illinois)

KV ............... John Deere Commercial Worksite Products (Knoxville, Tennessee / Dubuque, Iowa)

L ............. John Deere Werke Mannheim (Germany)

LA ............... John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)

LV ............... John Deere Commercial Products (Augusta, Georgia)

N ............ John Deere Des Moines Works (Des Moines, Iowa)

P ............ Industrias John Deere Mexico SA de CV (Saltillo / Monterrey, Mexico)

PY ............... Larson & Toubro Ltd. (Pune, India)

RW ......... John Deere Waterloo Tractor Works (Waterloo, Iowa)

T ............ John Deere Dubuque Works (Dubuque, Iowa)

T8 ........... Cameco Industries (Thibodaux, Louisiana)

TJ ................. Timberjack (Deere) (Sweden / Finland / Canada)

YC ............... John Deere Jialian Harvester Co. Limited (China)

Z .................. John Deere WERKE Zweibrucken (Germany) Application Code

001, etc. ....... See Engine Application Charts, later in thisGroup

4045TF275 Diesel Engine Repair and Adjustment

John Deere John Deere 4045TF275 Diesel Engine Repair and Adjustment

Group 010-Engine Rebuild Knurl Valve Guides.............

Engine Overhaul Guidelines.......... Clean and Inspect Valve Seats...

Engine Repair Stand.............. ............................................................................. . .02-020-32

Engine Stand Safety Precautions ...... 02-010-2 Remove Valve Seat Inserts...........

Install Adapters on Engine Repair Stand.... 02-010-3 Measure Valve Seat Bore in Cylinder

Engine Lifting Procedure... .. 02-010-4 Head ............ .... 02-020-37

Clean Engine.................... ....... ..02-020-38

Disconnect Turbocharger Oil Inlet Line... 02-010-6 Install Valves..........

Mount Engine on Repair Stand...... 02-010-7 Clean and Inspect Cylinder Head Cap

Engine Mounted on Repair Stand ... .. 02-010-8 Screws......... -020-39

Engine Disassembly Sequence...... 02-010-8 Inspect and Clean Exhaust Manifold... 02-020-39

Sealant Application Guidelines..... 02-010-12 Clean and Inspect Top Deck of Cylinder

Engine Assembly Sequence... .. 02-010-13 Block........... .02-020-40

Engine Break-In Guidelines........

Perform Engine Break-In........ 02-010-18 Above Block.......... . .02-020-41

Install Cylinder Head............

Group 020—Cylinder Head and Valves (Two-Valve Torque-Turn Method for Proper Torque.....

Head Engines) Install Rocker Arm Assembly.......

General Information........... 02-020-1 Inspect and Clean Ventilator Outlet Hose.. 02-020-45

Check and Adjust Valve Clearance..... 02-020-2 Install Rocker Arm Cover.......

Measure Valve Lift........... Complete Final Assembly........... -47

Remove Cylinder Head............

Disassemble and Inspect Rocker Arm Shaft Group 021—Cylinder Head and Valves (Four-Valve

Assembly.......... Head Engines)

Assemble Rocker Arm Assembly ... .. 02-020-15 General Information...........

Inspect, Measure, and Install Fuel Supply Check and Adjust Valve Clearance......

Pump Push Rod (If Applicable) ... .. 02-020-15 Measure Valve Lift.........

Inspect, Measure, and Assemble Camshaft Remove Cylinder Head.............

Followers............... Measure Valve Bridges ...

Measure Valve Recess in Cylinder Head... 02-020-19 Disassemble and Inspect Rocker Arm Shaft

Preliminary Cylinder Head and Valve Assembly..............

Checks............. 18

Remove Valve Assembly......... 02-020-21 Inspect, Measure, and Install Fuel Supply

Inspect and Measure Valve Springs ... .. 02-020-21 Pump Push Rod................

Inspect Valve Rotators........ 02-020-22 Inspect, Measure, and Assemble Camshaft

Clean Valves..................... .....

Inspect and Measure Valves....... Measure Valve Recess in Cylinder Head.. 02-021-22

Grind Valves.............

Head Gasket Inspection and Repair Checks....................

Sequence.......... Remove Valve Assembly.......... 02-021-24

Inspect and Clean Cylinder Head..... 02-020-26 Inspect and Measure Valve Springs...

Check Cylinder Head Flatness... .. 02-020-27 Clean Valves.......... -25

Measure Cylinder Head Thickness... .. 02-020-28 Inspect and Measure Valves.......

Clean Injection Nozzle Bores... .. 02-020-29 Grind Valves ...... 021-27

Clean Valve Guides..........

Measure Valve Guides .......... 02-020-30 Continued on next page

Head Gasket Inspection and Repair Deglaze Cylinder Liners...........

Sequence........... Replace Piston and Liner Sets... 02-021-28 -20

Inspect and Clean Cylinder Head...... 02-021-30 Inspect and Measure Connecting Rod

Check Cylinder Head Flatness...... 02-021-30 Bearings (Rods Removed from Engine)..

Measure Cylinder Head Thickness..... 02-021-31 Inspect and Measure Connecting Rod

Remove Fuel Injector Sleeves...... 02-021-32 Bearings (Rod and Crankshaft in Engine)

02

Clean Fuel Injector Bores... .. 02-021-32 ............. ....

Install Fuel Injector Sleeves ...... 02-021-33 Inspect Rod and Cap........

Clean Glow Plug Bores...... 02-021-34 Inspect Piston Pins and Bushings...

Clean Valve Guides....... 02-021-34 Remove Piston Pin Bushing....

Measure Valve Guides....... 02-021-35 Clean and Inspect Connecting Rod Pin

Knurl Valve Guides ............... 02-021-36 Bore.......... .....

Clean and Inspect Valve Seats...... 02-021-36 Install Piston Pin Bushing in Connecting

Grind Valve Seats ...... ... 02-021-37 Rod ......... .....

Remove Valve Seat Inserts...... 02-021-37 Measure Rod Center-to-Center Bores... 02-030-30

Measure Valve Seat Bore in Cylinder Inspect and Clean Cylinder Block.......

Head................. ................................................................................. .02-030-34

Install Valve Seat Inserts....... 02-021-42 Measure Cylinder Block Main Bearing

Install Valves............. ......

Clean and Inspect Cylinder Head Cap Measure Camshaft Follower Machined Bore

Screws.............. ......

Inspect and Clean Exhaust Manifold.... 02-021-44 Measure Camshaft Bushing Bores in

Clean and Inspect Top Deck of Cylinder Block................

Block.............. Measure Balancer Shaft Bushing ID in Block

Measure Cylinder Liner Standout (Height (4-Cylinder Engines)...........

Above Block).......... Measure Cylinder Liners and Block Bores.. 02-030-38

Install Cylinder Head......... 02-021-47 Measure Liner Flange Counterbore Depth

Torque-Turn Method for Proper Torque ... 02-021-49 in Block ............. 39

Install Fuel Injectors............. Measure Liner Flange Thickness... .. 02-030-39

Install Carrier Assemly.........

Measure Cylinder Block Top Deck

Install Rocker Arm Assembly.......

Inspect and Clean Ventilator Outlet Hose .. 02-021-54 Flatness.................

Install Rocker Arm Cover...... 02-021-54 Remove, Inspect, and Install Piston

Complete Final Assembly...... 02-021-56 Cooling Orifices......... 41

Measure Fuel Supply Pump Push Rod

Group 030-Cylinder Block, Liners, Pistons and Bore and Push Rod OD...........

Rods Measure Cylinder Liner Standout (Height

Connecting Rods-General Information... 02-030-1 Above Block).......

Remove Pistons and Connecting Rods.... 02-030-2 Install Packing on Cylinder Liner and O-Rings

Remove Cylinder Liners ... ..... 02-030-5 in Block ........ ... 02-030-44

Complete Disassembly of Cylinder Block (If Install Cylinder Liner in Block........

Required)........... Assemble Piston and Connecting Rod... 02-030-48

Preliminary Liner, Piston and Rod Checks .. 02-030-8 Install Piston Rings...............

Disassemble Piston and Rod Assembly.... 02-030-9 Install Piston and Connecting Rod

Clean Pistons................. .....

Visually Inspect Pistons...........

Clean Cylinder Liners ...... .. 02-030-12 Screws ........ .... 02-030-54

Visually Inspect Cylinder Liners...... 02-030-13 Check Engine Rotation for Excessive

Check Piston Ring Groove Wear ... .. 02-030-15 Tightness............ -55

Measure Piston Pin Bore.......... Measure Piston Protrusion......

Measure Piston Skirt........ 02-030-17 Complete Final Assembly.......

Measure Piston Height...........

Determine Piston-to-Liner Clearance ...... 02-030-18 Continued on next page

Page Page

Group 040--Crankshaft, Main Bearings and Group 050--Camshaft, Balancer Shafts and Timing

Flywheel Gear Train

Crankshaft and Main Bearing Failure Measure Valve Lift..............

Analysis ... .. .. 04-040-1 Remove Timing Gear Cover... ..02-050-3

Inspect Vibration Damper (6.8 L Engines)... 02-040-2 Remove and Install Camshaft Bushing

Remove Pulley or Vibration Damper and with Front Plate Installed........

Pulley ................

Install Pulley or Vibration Damper and Auxiliary Drive..............

Pulley ..................... ................................................................................. ..02-050-11

Replace Front Crankshaft Oil Seal and Wear Measure Balancer Shaft End Play (If

Sleeve................ .02-050-11

Check Crankshaft End Play........ Measure Idler Gear End Play.......

Inspect Flywheel........... Measure Timing Gear Backlash...

Check Flywheel Face Flatness... .. 02-040-19 Remove Camshaft..........

Visually Inspect Camshaft.........

Check Pilot Bearing Bore Concentricity....

Measure Camshaft Thrust Plate Clearance

Remove Flywheel................. .02-050-17

Replace Flywheel Ring Gear....... 02-040-21 Inspect and Measure Camshaft Bushing

Replace Pilot Bearing in Flywheel (If ID and Journal OD...........

02-040-22 Measure Camshaft Lobe Height ..... 02-050- 19

Install Flywheel................. 02-050-19

Crankshaft Rear Oil Seal and Wear Sleeve Inspect Camshaft Followers........

Handling Precautions......... 02-040-24 Inspect, Measure, and Install Fuel Supply

Remove Crankshaft Rear Oil Seal and Wear Pump Push Rod............

Sleeve.................

Clean and Inspect Crankshaft Flange... 02-040-29 4-Cylinder Engines)...........

Install Crankshaft Rear Oil Seal and Wear Inspect and Measure Balancer Shaft

Sleeve...................... ... 02-050-23

Remove Flywheel Housing.......... Remove and Install Balancer Shaft

Remove and Install Crankshaft Timing Wheel Bushings...............

(Two-Valve Head Engines with VP44 or Inspect Balancer Shaft Gears and Thrust

DE10 Fuel Injection Pumps and All Plates................

Four-Valve Head Engines) ...... 02-040-34 Remove and Install Balancer Shaft Gears.. 02-050-26

Remove Crankshaft Main Bearings ... .. 02-040-35 Remove Cylinder Block Front Plate.....

Check Main Bearing Oil Clearance.... 02-040-36 Measure Idler Gear Bushing and Shaft... 02-050-30

Remove and Install Crankshaft Gear Remove Idler Gear Bushings........

(Crankshaft Installed in Engine)... 02-040-37 Install Idler Gear Bushings.........

Remove Crankshaft............ Remove Lower and Upper Idler Shafts... 02-050-33

Inspect Crankshaft...............

Transfer Fuel Injection Pump Timing Mark

Measure Crankshaft Journals and Main

onto Replacement Front Plate

Bearing ID........... 02-040-41 (Two-Valve Head Engine with Mechanical Fuel

Measure Main Thrust Journal Width and Injection)..................

Thrust Bearing Width........ 02-040-42 Install Idler Shaft Spring Pins (If

Crankshaft Grinding Guidelines ......... 02-040-43 Equipped).......... 35

Crankshaft Grinding Specifications...... 02-040-44 Install Upper Idler Shaft in Front Plate...

Measure Assembled ID of Main Bearing Install Lower Idler Shaft in Front Plate..... 02-050-36

Caps....................... C 02-050-36

Install Main and Thrust Bearing Inserts in Install and Time Balancer Shafts (If

Block............... ................................................................... .02-050-38

Install Crankshaft...................... ..02-050-42

Install Flywheel Housing.........

Complete Final Assembly....... 02-040-54 Continued on next page

Page Page

Clean and Inspect Timing Gear Cover ... .. 02-050-47 Install Coolant Pump..............

Install Timing Gear Cover ... ..... 02-050-48 Cooling System Deaeration......

Remove and Install Magnetic Pick-Up Remove and Install Automatic (Spring) Belt

Sensor..................... ............. .....

Complete Final Assembly...... 02-050-52 Checking Belt Tensioner Spring Tension and

Belt Wear ...................

02

Group 060—Lubrication System Manual Belt Tensioner Adjustment Using Belt

General Lubrication System Information... 02-060-1 Tension Gauge.............

Remove, Inspect, and Install Oil Filter Manual Belt Tensioner Adjustment Using Belt

Base..............

Remove, Inspect, and Install Oil Cooler... 02-060-5 Engines without Auxiliary Drive.).....

Remove, Inspect, and Install Oil Bypass Inspect and Install Fan Assembly......

Valve................ Remove and Inspect Fan Drive Assembly.. 02-070-25

Remove and Install Oil Filter Bypass Valve Replace Bearings in Adjustable Fan Drive

(Extended-Life Filter)........ 02-060-12 Assembly.......... ....

Remove and Install Oil Pressure Replace Bearings in Heavy-Duty,

Regulating Valve............

Remove and Install Oil Fill Adapter... .. 02-060-17 Install Fan Drive Assembly.........

Remove and Install Dipstick Tube with Oil Remove and Install Fan Drive Assembly

Pan Installed............... .... 02-070-34

Remove and Install Dipstick Tube with Remove and Install Coolant Heater (If

Fitting................. ......

Remove, Inspect, and Install Oil Pump Remove and Install Cold Start Advance

Pick-Up Tube Assembly.......... 070-36

Engine Oil Pump Assembly........

Remove Engine Oil Pump........ 02-060-23 Group 080—Air Intake and Exhaust System

Inspect and Measure Clearances ... .. 02-060-24 Extending Turbocharger Life.....

Complete Oil Pump Disassembly... .. 02-060-26 Remove Turbocharger............

Assemble Engine Oil Pump.........

Install Engine Oil Pump............. Turbocharger Inspection.........

Install Oil Pan..............

Adjust Turbocharger Wastegate Actuator (If

Group 070-Cooling System Equipped)...............

Remove Coolant Manifold / Thermostat Cover Repair Turbocharger.............

and Thermostat......... Prelube Turbocharger...... -080-16

Install Coolant Manifold / Thermostat Cover Install Turbocharger............

and Thermostat........... 02-080-18

Remove and Install Coolant Recommendations for Turbocharger Use..

Manifold / Thermostat Cover and Remove, Inspect, and Install Exhaust

Thermostat (High Flow Single Manifold.......................

Thermostat)............ Remove and Install Air-to-Air Aftercooler... 02-080-21

Remove and Install Coolant Manifold and Remove and Install Air Intake Pipe.....

Thermostats (Dual Thermostats)..... 02-070-7 Remove, Inspect, and Install Intake Manifold

Remove and Install Coolant Manifold, (Four-Valve Head)............

Thermostats and Side Port (Four-Valve Remove and Install Air Heater (If

Head) ................... ......

Test Thermostat (s)........... Remove and Install Starting Aid (If

Remove Coolant Pump ... ................ .. 02-080-25

Coolant Pump Assembly.........

Disassemble Coolant Pump...... 02-070-12 Group 090-Fuel System

Inspect, Clean, and Measure Coolant Fuel System...............

Pump Parts..............

Assemble Coolant Pump.............

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