POWERTECH 2.4L & 3.0L Diesel Engines

1 POWERTECH & EnginesTECHNICAL & Diesel EnginesComponent Technical ManualCTM301 22 SEP05 (ENGLISH)For complete service information also see:Alternators and Starting Engine (English Only) john deere Power SystemsLITHO IN ,TMIFC 19 29 SEP98 1/1 ForewordThis manual is written for an experienced tools required in performing certain servicework are identified in this manual and arerecommended for with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal manuals are divided in two parts: repair andoperation and tests.

2 Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable essential tools, service equipment and tools,other materials needed to do the job, service parts kits,specifications, wear tolerances, and torque Manuals are concise guides for specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their (22 SEP05) POWERTECH & Diesel Engines092605PN=2 IntroductionDPSG,OUOE003,2736 19 11 JAN99 1/1 Engine OwnerJohn deere Engine Owner:Don t wait until you need warranty or other service tomeet your local john deere Engine Distributor orService who he is and where he is.

3 At your firstconvenience, go meet him. He ll want to get to knowyou and to learn what your needs might Utilisateurs De Moteurs john deere :N attendez pas d e tre oblige d avoir recours a votreconcessionnaire john deere ou point de service leplus proche pour vous adresser a des que possible pour l identifier etle localiser. A la premiere occasion, prenez contactavec lui et faites-vous conna tre. Il sera lui aussiheureux de faire votre connaissance et de vousproposer ses services le moment Den Besitzer Des john deere Motors:Warten Sie nicht auf einen evt. Reparaturfall um denna chstgelegenen john deere Ha ndler kennen Sie sich bei ihm bekannt und nutzen Sie sein Service Angebot.

4 Proprietario Del Motore john deere :Non aspetti fino a quando ha bisogno della garanzia odi un altro tipo di assistenza per incontrarsi con il SuoConcessionario che fornisce l assistenza a conoscere chi e` e dove si trova. Alla Suaprima occasione cerchi d incontrarlo. Egli desidera farsiconoscere e conoscere le Sue necessita` .Propietario De Equipo john deere :No espere hasta necesitar servicio de garant aodeotro tipo para conocer a su Distribuidor de MotoresJohn deere o al Concesionario de rese de quie nes,ydo nde esta situado. Cuandotenga un momento, vaya a visitarlo. A e l le gustara conocerlo, y saber cua les podr an ser deere MotorA gare:Va nta inte med att beso ka Din john Deerea terfo rsa ljare till dess att Du beho ver service ellergaranti Dig med var han a r och vem han a r.

5 Tagfo rsta tillfa lle att beso ka honom. Han vill ocksa tra ffaDig fo r att fa veta vad Du beho ver och hur han kanhja lpa (22 SEP05) POWERTECH & Diesel Engines092605PN=3 IntroductionRG19661,0000028 19 22 SEP05 1/1 About This ManualThe changes listed below update your dated 28 Sep04 and replace with this 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 pumpsprocedureSECTION 02 Group 090 (Fuel System) Added check engine power procedure Added adjust engine power procedureSECTION 04 Group 160 (Fuel System) Added electronic controller diagnostic test proceduresSECTION 05 Group 170 (Repair Tools) Added toolsSECTION 05 Group 180 (Diagnostic Service Tools) Added electronic controller diagnostic toolCTM301 (22 SEP05)

6 POWERTECH & Diesel Engines092605PN=4 IntroductionRG41183,000001D 19 03 JUN03 1/1 POWERTECH L & L Diesel EnginesRG12961 UN L Right Side ViewRG12960 UN L Left Side ViewRG12962 UN L Side Right ViewRG12963 UN L Left Side ViewPOWERTECH is a trademark of deere & CompanyCTM301 (22 SEP05) POWERTECH & Diesel Engines092605PN=5 IntroductionCTM301 (22 SEP05) POWERTECH & Diesel Engines092605PN=6 Contents01 SECTION 01 General InformationGroup 000 SafetyGroup 001 Engine IdentificationGroup 002 Fuels, Lubricants, and Coolant02 SECTION 02 Repair and AdjustmentsGroup 010 Engine RebuildGroup 020 Cylinder Head and ValvesGroup 030 Cylinder Block, Pistons, and RodsGroup 040 Crankshaft, Main Bearings andFlywheelGroup 050 Camshaft.

7 Balancer Shafts and TimingGear TrainGroup 060 Lubrication SystemGroup 070 Cooling SystemGroup 080 Air Intake and Exhaust System03 Group 090 Fuel SystemGroup 100 Starting and Charging SystemsSECTION 03 Theory of OperationGroup 120 Base Engine OperationGroup 130 Fuel/Governor System OperationSECTION 04 DiagnosticsGroup 150 Base Engine Observable Diagnosticsand TestsGroup 151 Fuel System Observable Diagnostics04and TestsGroup 160 Electronic Controller Diagnostics andTestsSECTION 05 Tools and Other MaterialsGroup 170 Repair Tools and Other MaterialsGroup 180 Diagnostic Service ToolsGroup 190 Dealer Fabricated Service ToolsSECTION 06 SpecificationsGroup 200 Repair and General OEM05 SpecificationsGroup 210 Diagnostic SpecificationsAll information, illustrations and specifications in this manual are based onthe latest information available at the time of publication.

8 The right isreserved to make changes at any time without 2005 deere & COMPANYM oline, IllinoisAll rights reservedA john deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2004 INDXCTM301 (22 SEP05)iPowerTech & Diesel Engines092605PN=1 Contents010203040506 INDXCTM301 (22 SEP05)iiPowerTech & Diesel Engines092605PN=201 Section 01 General InformationContentsPageGroup 000 001 Engine IdentificationEngine Model Serial Number Engine Serial Engine Option Code Application 002 Fuels, Lubricants, and CoolantDiesel of Diesel Fuel And Storing Bio- Diesel Fuel Fuel the Effect of Cold Weather onDiesel Engine Break-In Engine Diesel Engine Oil of and COOLSCAN.

9 01-002-11 Alternative and Synthetic Engine Information About DieselEngine Coolants and Supplemental Diesel Engine Coolant in Warm Temperature Climates ..01-002-17 Disposing of (22 SEP05)01-1 POWERTECH & Diesel Engines092605PN=1 Contents01 CTM301 (22 SEP05)01-2 POWERTECH & Diesel Engines092605PN=2 Group 000 Safety010001DX,FLAME 19 29 SEP98 1/1 Handle Fluids Safely Avoid FiresTS227 UN 23 AUG88 When you work around fuel, do not smoke or work nearheaters or other fire flammable fluids away from fire hazards. Do notincinerate or puncture pressurized sure machine is clean of trash, grease, and not store oily rags; they can ignite and ,FIRE3 19 16 APR92 1/1 Handle Starting Fluid SafelyTS1356 UN 18 MAR92 Starting fluid is highly all sparks and flame away when using it.

10 Keepstarting fluid away from batteries and prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected not incinerate or puncture a starting fluid (22 SEP05)01-000-1 POWERTECH & Diesel Engines092605PN=11 Safety010002RG,RG34710,7508 19 30 JUN97 1/1 Prevent Bypass StartingRG5419 UN 28 FEB89 Prevent Bypass StartingAvoid possible injury or death from engine not start engine by shorting across starter will start with PTO engaged if normal circuitry engine only from operator s station with PTOdisengaged or in ,RCAP 19 04 JUN90 1/1 Service Cooling System SafelyTS281 UN 23 AUG88 Explosive release of fluids from pressurized coolingsystem can cause serious off engine.