John Deere POWERTECH 2.4L & 3.0L Diesel Engines Repair and Operator’s Manuals


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Included 2 Manuals:

POWERTECH 2.4L & 3.0L Diesel Engines Component Technical Manual CTM301.
Updated 22SEP05. Detailed step by step Repair Information. Illustrations, instructions, diagrams.

POWERTECH 2.4L & 3.0L 4024 and 5030 OEM Diesel Engines OPERATOR’S MANUAL OMRG34851
Read This Manual carefully to le arn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage.

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POWERTECH 2.4L & 3.0L Diesel Engines



General Information
—Engine Identification
—Fuels, Lubricants, and Coolant
Repair and Adjustments
—Engine Rebuild
—Cylinder Head and Valves
—Cylinder Block, Pistons, and Rods
—Crankshaft, Main Bearings and Flywheel
—Camshaft, Balancer Shafts and Timing
Gear Train
—Lubrication System
—Cooling System
—Air Intake and Exhaust System
—Fuel System
—Starting and Charging Systems
Theory of Operation
—Base Engine Operation
—Fuel/Governor System Operation
—Base Engine Observable Diagnostics and Tests
—Fuel System Observable Diagnostics and Tests
—Electronic Controller Diagnostics and Tests
Tools and Other Materials
—Repair Tools and Other Materials
—Diagnostic Service Tools
—Dealer Fabricated Service Tools
—Repair and General OEM Specifications
—Diagnostic Specifications

Record Keeping
PowerTech™ Medallion
Engine Serial Number Plate
Record Engine Serial Number
Engine Option Codes
Fuels, Lubricants, and Coolant
Diesel Fuel
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
Dieselscan Fuel Analysis
Bio-Diesel Fuel
Kerosene (Burner) Fuels
Minimizing the Effect of Cold Weather on
Diesel Engines
Diesel Engine Oil
Extended Diesel Engine Oil Service Intervals
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Diesel Engine Coolant
Drain Intervals for Diesel Engine Coolant
Supplemental Coolant Additives
Testing Diesel Engine Coolant
Operating in Warm Temperature Climates
Disposing of Coolant
Engine Operating Guidelines
Instrument Panel
Normal Engine Operation
Break-In Service
Auxiliary Gear Drive Limitations
Starting The Engine
Cold Weather Starting
Warming Engine
Avoid Excessive Engine Idling
Locking Throttle at Preset Speed
Stopping the Engine
Using a Booster Battery or Charger
Lubrication and Maintenance
Observe Service Intervals
Use Correct Fuels, Lubricants, and Coolant
Lubrication and Maintenance Service
Interval Chart—Standard Industrial Engines
Lubrication and Maintenance Service
Interval Chart—Generator (Standby)
Lubrication & Malntenance/Dally
Daily Prestarting Checks
Lubrication & Malntenance/500 Hour/12 Month
Changing Engine Oil and Replacing Filter
Replacing Fuel Filter Element
Cleaning Crankcase Vent Tube
Checking Air Intake System
Check Engine Speeds
Checking Belt Tensioner Spring Tension
and Belt Wear (Automatic Tensioner)
Checking Engine Electrical Ground
Servicing Fire Extinguisher
Checking Engine Mounts
Servicing Battery
Checking Cooling System
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Testing Diesel Engine Coolant
Pressure Testing Cooling System
Lubrication & Malnt/2000 Hour/24 Month
Checking Crankshaft Vibration Damper (If Equipped)
Flushing and Refilling Cooling System
Testing Thermostats Opening Temperature
Service as Required
Additional Service Information
Do Not Modify Fuel System
Adding Coolant
Replacing Single Stage Air Cleaner Element
Replacing Axial Seal Air Cleaner Filter
Replacing Radial Seal Air Cleaner Filter
Replacing Fan and Alternator Belt
Checking Fuses
Checking Air Compressors
Adjusting Speed Gain (Generator Sets)
Bleeding the Fuel System
General Troubleshooting Information
Electrical System Schematic
Engine Troubleshooting
Engine Storage Guidelines
Preparing Engine for Long Term Storage
Removing Engine from Long Term Storage
General OEM Engine Specifications
Engine Power Rating and Speed
Engine Crankcase Oil Capacities
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records
Daily (Prestarting) Service
500 Hour/12 Month Service
2000 Hour/24 Month Service
Service as Required
Emission System Warranty
US EPA Emissions Control Warranty
Emissions Control System Certification Label