POWERTECH 4024 2.4 L DIESEL ENGINES CTM301 TECHNICAL SERVICE MANUAL

POWERTECH 2.4L & 3.0L Diesel Engines

TECHNICAL MANUAL 2.4L & 3.0L Diesel Engines Component Technical Manual CTM301 22SEP05 (ENGLISH)

For complete service information also see: Alternators and Starting Motors. . . . . . . . . . CTM77 OEM Engine Accessories . . . . . . CTM67 (English Only)

John Deere Power Systems

LITHO IN U.S.A.

Introduction Foreword This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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Introduction

Engine Owner John Deere Engine Owner: Don’t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer.

Impari a conoscere chi è` e dove si trova. Alla Sua prima occasione cerchi d’incontrarlo. Egli desidera farsi conoscere e conoscere le Sue necessità`.

Propietario De Equipo John Deere:

Learn who he is and where he is. At your first convenience, go meet him. He’ll want to get to know you and to learn what your needs might be.

No espere hasta necesitar servicio de garantı́ ´a o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio.

Aux Utilisateurs De Moteurs John Deere:

Enté´resedequié´nes,ydó´ndeestá´situado.Cuando

N’attendez pas d’êˆtre obligé´ d’avoir recours a votre concessionnaire John Deere ou point de service le plus proche pour vous adresser a lui.

tenga un momento, vaya a visitarlo. A é´l le gustará´ conocerlo, y saber cuá´les podrı́ ´an ser sus necesidades.

John Deere MotorĨ gare:

Renseignez-vous des que possible pour l’identifier et le localiser. A la premiere occasion, prenez contact avec lui et faites-vous connaı̂ ˆtre. Il sera lui aussi heureux de faire votre connaissance et de vous proposer ses services le moment venu.

An Den Besitzer Des John Deere Motors: Warten Sie nicht auf einen evt. Reparaturfall um den nä¨chstgelegenenJohnDeereHä¨ndlerkennenzu lernen.

Vä¨ntaintemedattbesö¨kaDinJohnDeere å˚terfö¨rsä¨ljaretilldessattDubehö¨verserviceeller garanti reparation.

BekantaDigmedvarhanä¨rochvemhanä¨r.Tag fö¨ rsta tillfä¨ lle att besö¨ ka honom. Han vill också˚ trä¨ ffa Digfö¨rattfå˚vetavadDubehö¨verochhurhankan hjä¨lpaDig.

Machen Sie sich bei ihm bekannt und nutzen Sie sein “Service Angebot”.

Proprietario Del Motore John Deere: Non aspetti fino a quando ha bisogno della garanzia o di un altro tipo di assistenza per incontrarsi con il Suo Concessionario che fornisce l’assistenza tecnica.

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Introduction

About This Manual The changes listed below update your CTM. Discard CTM301 dated 28Sep04 and replace with this manual.

Also refer to the following manuals.

• CTM77—Alternators and Starting Motors • CTM67—OEM Engine Accessories (English Only) SECTION 02—Group 090 (Fuel System) • Added fuel control rack measurement procedure • Revised install and synchronize injection pumps procedure SECTION 02—Group 090 (Fuel System) Added check engine power procedure •Added adjust engine power procedure • SECTION 04—Group 160 (Fuel System) Added electronic controller diagnostic test procedures • SECTION 05—Group 170 (Repair Tools) Added tools • SECTION 05—Group 180 (Diagnostic Service Tools) Added electronic controller diagnostic tool •

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Introduction

3.0 L Side Right View

POWERTECH is a trademark of Deere & Company

CTM301 (22SEP05)

3.0 L Left Side View

RG12960 –UN–03JUN03

2.4 L Left Side View

RG12963 –UN–03JUN03

2.4 L Right Side View

RG12961 –UN–03JUN03

2.4 L & 3.0 L Diesel Engines

RG12962 –UN–03JUN03

POWERTECH

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For the full PDF version of this manual, Please click on the above download PDF button.

Contents 01

SECTION 01—General Information Group 000—Safety Group 001—Engine Identification Group 002—Fuels, Lubricants, and Coolant SECTION 02—Repair and Adjustments Group 010—Engine Rebuild Group 020—Cylinder Head and Valves Group 030—Cylinder Block, Pistons, and Rods Group 040—Crankshaft, Main Bearings and Flywheel 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

02

03

04

SECTION 03—Theory of Operation Group 120—Base Engine Operation Group 130—Fuel/Governor System Operation 05

SECTION 04—Diagnostics Group 150—Base Engine Observable Diagnostics and Tests Group 151—Fuel System Observable Diagnostics and Tests Group 160—Electronic Controller Diagnostics and Tests

06

SECTION 05—Tools and Other Materials Group 170—Repair Tools and Other Materials Group 180—Diagnostic Service Tools Group 190—Dealer Fabricated Service Tools

INDX

SECTION 06—Specifications Group 200—Repair and General OEM Specifications Group 210—Diagnostic Specifications

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT  2005 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  2004

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Section 01

General Information Contents Page

Group 000—Safety . . . . . . . . . . . . . . . . . . . .01-000-1 Group 001—Engine Identification Engine Model Designation. . . . . . . . . . . . . . . .01-001-1 POWERTECH Medallion. . . . . . . . . . . . . . . . . .01001-1 Engine Serial Number Plate . . . . . . . . . . . . . .01001-2 Record Engine Serial Number. . . . . . . . . . . . .01001-2 OEM Engine Option Code Label . . . . . . . . . . .01-001-3 Engine Application Chart. . . . . . . . . . . . . . . . .01-001-4 Group 002—Fuels, Lubricants, and Coolant DieselFuel...........................01-002-1 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-2 Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . . .01-002-3 BioDieselFuel........................01-002-4 Handling And Storing Bio-Diesel Fuel . . . . . . .01-002-5 Dieselscan Fuel Analysis. . . . . . . . . . . . . . . . .01-002-5 FillingFuelTank.......................01-002-6 Minimizing the Effect of Cold Weather on DieselEngines.......................01-002-7 Diesel Engine Break-In Oil . . . . . . . . . . . . . . .01-002-8 DieselEngineOil......................01-002-9 Extended Diesel Engine Oil Service Intervals...........................01-002-10 Mixing of Lubricants . . . . . . . . . . . . . . . . . . .01-002-10 OilFilters............................01-002-10 OILSCANand COOLSCAN . . . . . . . . . . . .01-002-11 Alternative and Synthetic Lubricants . . . . . . .01-002-11 Lubricant Storage . . . . . . . . . . . . . . . . . . . . .01-002-12 Grease.............................01-002-12 Diesel Engine Coolant. . . . . . . . . . . . . . . . . .01-002-13 Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives..........................01-002-15 Testing Diesel Engine Coolant . . . . . . . . . . .01-002-16 Supplemental Coolant Additives . . . . . . . . . .01-002-17 Operating in Warm Temperature Climates . .01-002-17 Disposing of Coolant . . . . . . . . . . . . . . . . . . .01-002-18

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01

Group 000

Safety 01 00 01

Handle Fluids Safely—Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

TS227 –UN–23AUG88

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

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Handle Starting Fluid Safely Starting fluid is highly flammable.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

TS1356 –UN–18MAR92

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

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Safety 01 000 2

Prevent Bypass Starting Avoid possible injury or death from engine runaway.

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Do not start engine by shorting across starter terminal.

Engine will start with PTO engaged if normal circuitry is bypassed.

Start engine only from operator’s station with PTO disengaged or in neutral.

Prevent Bypass Starting

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Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281 –UN–23AUG88

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

DO NOT USE Starting Fluids DO NOT USE ether starting fluids with these glow plug equipped engines as it could cause an extreme explosion with possible personal injury.

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Safety 01 00 03

Prepare for Emergencies Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

TS291 –UN–23AUG88

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

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Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

TS204 –UN–23AUG88

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

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For the full PDF version of this manual, Please click on the above download PDF button.