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

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Description

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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Models

POWERTECH 2.4L & 3.0L Diesel Engines

Contents

CTM301

  • General Information
    —Safety
    —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
  • Diagnostics
    —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
  • Specifications
    —Repair and General OEM Specifications
    —Diagnostic Specifications

OMRG34851

  • Record Keeping
    PowerTech™ Medallion
    Engine Serial Number Plate
    Record Engine Serial Number
    Engine Option Codes
  • Safety
  • 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
    OILSCAN™and COOLSCAN™
    Alternative and Synthetic Lubricants
    Lubricant Storage
    Grease
    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)
    Applications
  • 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
    Connections
    Servicing Fire Extinguisher
    Checking Engine Mounts
    Servicing Battery
    Checking Cooling System
    Replenishing Supplemental Coolant
    Additives (SCAs) Between Coolant
    Changes
    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
    Element
    Replacing Radial Seal Air Cleaner Filter
    Element
    Replacing Fan and Alternator Belt
    Checking Fuses
    Checking Air Compressors
    Adjusting Speed Gain (Generator Sets)
    Bleeding the Fuel System
  • Troubleshooting
    General Troubleshooting Information
    Electrical System Schematic
    Engine Troubleshooting
  • Storage
    Engine Storage Guidelines
    Preparing Engine for Long Term Storage
    Removing Engine from Long Term Storage
  • Specifications
    General OEM Engine Specifications
    Engine Power Rating and Speed
    Specifications
    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
    Statement
    Emissions Control System Certification Label