John Deere 2.4L and 3.0L Diesel Engine Components Technical Manual (CTM301)

Catalog: 
Make: 
Price: US$ 45.00

John Deere 2.4L and 3.0L Diesel Engine Components Technical Manual (CTM301)

John Deere 2.4L and 3.0L Diesel Engines Components Technical Manual (CTM301).pdf

Complete Components Technical Manual for John Deere 2.4L and 3.0L Diesel Engines, with all the shop information to maintain, diagnostic, repair, service like professional mechanics.

John Deere 2.4L and 3.0L Diesel Engines Component Technical Manual  (CTM301) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 641 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS (Expanded View)
 01 - GENERAL INFORMATION
    00 - Safety
       Avoid Heating Near Pressurized Fluid Lines
       Avoid High-Pressure Fluids
       Avoid Static Electricity Risk When Refueling
       Construct Dealer-Made Tools Safely
       Dispose of Waste Properly
       DO NOT USE Starting Fluids
       Handle Chemical Products Safely
       Handle Fluids Safely—Avoid Fires
       Handle Starting Fluid Safely
       Handling Batteries Safely
       Illuminate Work Area Safely
       Live With Safety
       Practice Safe Maintenance
       Prepare for Emergencies
       Prevent Acid Burns
       Prevent Battery Explosions
       Prevent Bypass Starting
       Remove Paint Before Welding or Heating
       Service Cooling System Safely
       Service Machines Safely
       Understand Signal Words
       Use Proper Lifting Equipment
       Use Proper Tools
       Wear Protective Clothing
       Work in Clean Area
       Work In Ventilated Area
    01 - Engine Identification Information
       Engine Application Chart
       Engine Model Designation
       Engine Serial Number Plate
       OEM Engine Option Code Label
       Record Engine Serial Number
        ™ Medallion
    02 - Fuels, Lubricants, and Coolant
        Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER
        Alternative and Synthetic Lubricants
        Bio-Diesel Fuel
        Diesel Engine Break-In Oil
        Diesel Engine Coolant (engine with wet sleeve cylinder liners)
        Diesel Engine Oil
        Diesel Fuel Additive Products
        Diesel Fuel
        Diesel Fuel Storage
        Disposing of Coolant
        Extended Diesel Engine Oil Service Intervals
        Filling Fuel Tank
        Grease
        Handling And Storing Bio-Diesel Fuel
        Lubricant Storage
        Lubricity of Diesel Fuel
        Minimizing the Effect of Cold Weather on Diesel Engines
        Mixing of Lubricants
        Oil Filters
        OILSCAN ® and COOLSCAN ™
        Operating in Warm Temperature Climates
        Supplemental Coolant Additives
        Testing Diesel Engine Coolant
        Testing Diesel Fuel
 02 - REPAIR & ADJUSTMENTS
    010 - Engine Rebuild
       Clean Engine
       Disconnect Turbocharger Oil Inlet Line
       Engine Assembly Sequence
       Engine Break-In Guidelines
       Engine Disassembly Sequence
       Engine Lifting Procedure
       Engine Overhaul Guidelines
       Engine Repair Stand
       Engine Stand Safety Precautions
       Install Adapters on Engine Repair Stand
       Mount Engine on Repair Stand
       Perform Engine Break-In
    020 - Cylinder Head & Valve Repair & Adjustment
       Check Cylinder Head Flatness
       Clean and Inspect Valve Seats
       Clean Valves
       Cylinder Head - Exploded View
       Cylinder Head — Thickness Measurement
       Disassemble and Inspect Rocker Arm Assembly
       Grind Valve Seats
       Grind Valves
       Head Gasket Inspection and Repair Sequence
       Inspect and Clean Cylinder Head
       Inspect and Clean Exhaust Manifold
       Inspect and Measure Valves
       Inspect and Measure Valve Springs
       Inspect Cylinder Head Cap Screws
       Inspect, Remove, and Install Glow Plugs and Wire Harness
       Install Cylinder Head (4-Cylinder)
       Install Cylinder Head (5-Cylinder)
       Install Rocker Arm Assembly
       Install Valves
       Knurl Valve Guides
       Measure Valve Recess in Cylinder Head
       Preliminary Cylinder Head and Valve Checks
       Remove and Install Rocker Arm Cover
       Remove Cylinder Head
       Remove Valve Assembly
    030 - Cylinder Block, Liners, Pistons, and Connecting Rods
       Assemble Piston and Connecting Rod
       Check Engine Rotation for Excessive Tightness
       Check Piston Ring Groove Wear
       Clean Pistons
       Complete Final Assembly
       Connecting Rods—General Information
       Deglaze Cylinder Bores
       Determine Piston-to-Cylinder Bore Clearance
       Disassemble Piston and Rod Assembly
       Inspect and Clean Cylinder Block
       Inspect and Measure Connecting Rod Bearings (Rod and Crankshaft in Engine)
       Inspect and Measure Connecting Rod Bearings (Rods Removed from Engine)
       Inspect and Measure Cylinder Bore
       Inspect Piston Pins and Bushings
       Inspect Rod and Cap
       Install Piston and Connecting Rod Assembly
       Install Piston Rings
       Measure Camshaft Bushing Bores in Block
       Measure Camshaft Follower Machined Bore
       Measure Cylinder Block Main Bearing Bore
       Measure Cylinder Block Top Deck Flatness
       Measure Piston Height
       Measure Piston Pin Bore
       Measure Piston Protrusion - Locate TDC
       Measure Piston Skirt
       Measure Rod Center-to-Center Bores
       Preliminary Cylinder Block, Pistons, and Rod Checks
       Rebore Cylinder Bores
       Remove, Inspect, and Install Piston Cooling Orifices
       Remove Pistons and Connecting Rod Assembly
       Torque-Turn Connecting Rod Cap Screws
       Visually Inspect Pistons
    040 - Crankshaft, Main Bearings, and Flywheel
       Check Crankshaft End Play
       Check Flywheel Face Flatness
       Check Main Bearing Oil Clearance
       Check Pilot Bearing Bore Concentricity
       Clean and Inspect Crankshaft Flange
       Crankshaft and Main Bearing Failure Analysis
       Crankshaft Grinding Guidelines
       Crankshaft Grinding Specifications
       Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
       Flywheel—Removal
       Inspect Crankshaft
       Inspect Flywheel
       Inspect Pulley and Wear Sleeve
       Inspect Vibration Damper (If Equipped)
       Install Crankshaft Pulley _ Damper
       Install Crankshaft Rear Oil Seal Housing
       Install Crankshaft Rear Oil Seal
       Install Flywheel Housing
       Install Flywheel
       Install Main Bearings, Thrust Washers and Crankshaft
       Measure Assembled ID of Main Bearing Caps
       Measure Crankshaft Journals and Main Bearing ID
       Measure Main Thrust Journal Width and Thrust Washers
       Remove Crankshaft Main Bearings
       Remove Crankshaft
       Remove Crankshaft Pulley _ Damper
       Remove Crankshaft Rear Oil Seal and Housing
       Remove Flywheel Housing
       Replace Flywheel Ring Gear
       Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover)
    050 - Camshaft, Balancing Shaft, and Timing Gear Train Repair & Adjustment
       Clean and Inspect Timing Gear Cover
       Inspect and Measure Balancer Shaft Bushings and Journals
       Inspect and Measure Camshaft Bushing ID and Journal OD
       Inspect Balancer Shaft Gears and Thrust Plates
       Inspect Camshaft Followers
       Inspect Camshaft
       Install Balancer Bushings
       Install Balancer Shafts (If Equipped)
       Install Camshaft
       Install Governor Assembly
       Install Timing Gear Cover
       Measure Camshaft Lobe Height
       Measure Idler Gear Bushing and Shaft
       Remove and Install Camshaft Bushings
       Remove Balancer Bushings
       Remove Balancer Shafts (If Equipped)
       Remove Camshaft
       Remove Governor Assembly and Camshaft Drive Gear
       Remove, Inspect and Install Balancer Idler Gears and Shafts (If Equipped)
       Remove Timing Gear Cover
       Time Camshaft
    060 - Lubrication System Repair & Adjustment
       General Lubrication System Information
       Install Oil Cooler
       Install Oil Pump
       Oil Dipstick Tube  _  Oil Fill — Installation
       Oil Dipstick Tube  _  Oil Fill — Removal
       Remove and Inspect Oil Pump
       Remove and Install Cold Start Advance Valve
       Remove and Install Oil Dipstick Tube with Oil Pan Installed
       Remove and Install Oil Pan
       Remove and Install Oil Pressure Regulating Valve
       Remove, Inspect, and Install Oil Pick-Up Tube Assembly
       Remove Oil Cooler
    070 - Cooling System Repair & Adjustment
       Checking Belt Tensioner Spring Tension and Belt Wear
       Cooling System Deaeration
       Inspect and Clean Coolant Pump Parts
       Inspect and Install Fan Assembly
       Install Coolant Pump
       Install Standard-Duty Fan Bearing
       Remove and Install Automatic (Spring) Belt Tensioner
       Remove and Install Fan Bearing Serial Number (0010609 —)
       Remove and Install Thermostat
       Remove Coolant Pump
       Remove Standard-Duty Fan Bearing
       Replacing Fan and Alternator Belt
    080 - Air Intake & Exhaust System Repair & Adjustment
       Extending Turbocharger Life
       Install Turbocharger
       Prelube Turbocharger
       Remove, Inspect, and Install Exhaust Manifold
       Remove, Inspect, and Install Intake Manifold
       Remove Turbocharger
       Repair Turbocharger
       Turbocharger Failure Analysis
       Turbocharger Inspection
    090 - Electronic Fuel System Repair & Adjustment
       Adjust Electronic Governor Actuator Arm
       Change Low Idle Bumper Spring
       Change Main Governor Spring
       Clean Fuel Injection Nozzle Bore
       Clean Fuel Injection Nozzle
       Drain Injection Nozzle
       Install and Synchronize Injection Pumps
       Install Electronic Governor Coupler
       Install Electronic Governor
       Install Seals on Fuel Injection Nozzle
       Install Speed Sensor
       Measure Fuel Control Rack Travel
       Remeasure Fuel Control Rack Travel
       Remove and Inspect Injection Pump Units
       Remove and Install Aneroid
       Remove and Install Fuel Rail Check Valve
       Remove and Install Fuel Shut-Off Solenoid
       Remove and Install Fuel Supply Pump
       Remove and Install Full Load Stop Screw
       Remove and Install Governor Lever Assembly
       Remove and Install Idle Bias Adjustment Screw
       Remove and Install Injection Nozzles
       Remove and Install Throttle Control Assembly
       Remove, Inspect and Install Fuel Control Rack
       Test Fuel Injection Nozzles
    100 - OEM Starting & Charging Systems Repair & Adjustment
        Remove and Install Alternator
        Remove and Install Starter
 03 - THEORY OF OPERATION
    120 - Base Engine Operation
       Air Cleaner Operation
       Air Intake and Exhaust System Operation
       Coolant System Operation
       General Engine Operation
       Lubrication System Operation
       Turbocharger Lubrication
       Turbocharger Operation
    130 - Electronic Fuel System
        Aneroid Operation
        Cold Start Advance Operation
        Fuel Filter _ Water Separator Operation
        Fuel Supply Pump
        Fuel System Operation
        Glow Plug Operation
        Governor Operation
        Integrated Fuel System (IFS) Operation
        Light Load and Speed Advance Operation
 04 - DIAGNOSTICS
    150 - Base Engine Observable Diagnostics & Tests
       A2 - Glow Plug Check
       About This Group of the Manual
       C1 - Engine Coolant Temperature Above Normal
       C2 - Engine Coolant Temperature Below Normal
       C3 - Coolant in Oil or Oil in Coolant
       Check Air Intake System
       Check and Service Cooling System
       Check Engine Oil Pressure
       Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)
       Check for Exhaust Air Leaks (Turbocharged Engines)
       Check for Head Gasket Failures
       Check for Intake and Exhaust Restrictions
       Check for Turbocharger Oil Seal Leak
       Cylinder Misfire Test
       Dynamometer Test
       Engine Oil Consumption
       Excessive Engine Vibration
       Glow Plug Operation_{1707}
       Guideline for Acceptable Oil Consumption
       Inspect Thermostat and Test Opening Temperature
       L1 - Excessive Oil Consumption
       L2 - Engine Oil Pressure Low
       L3 - Engine Oil Pressure High
       L4 - Soot or Sludge in the Oil
       Measure Intake Manifold Pressure (Turbocharger Boost)
       Pressure Test Cooling System and Radiator Cap
       Test Engine Compression Pressure
       Test Engine Cranking Speed
       Test for Intake Air Leaks
       Test Fuel Shutoff Solenoid
       Test Turbocharger Wastegate
    151 - Fuel System Observable Diagnostics & Tests
       About This Group of the Manual_{1745}
       Adjust Engine Power
       Bench Test Fuel Transfer Pump
       Bleed the Fuel System
       Check and Adjust Fast Idle Speed
       Check and Adjust Slow Idle Speed
       Check Cold Start Advance Operation
       Check Engine Power
       Check for Restricted Fuel Return Line
       Check Fuel Shut-Off Solenoid Operation
       Check Fuel Supply Quality
       Disable Fuel Control Rack Magnet
       E1—Engine Cranks _ Won't Start
       E2—Engine Misfires _ Runs Irregularly
       E3—Engine Does Not Develop Full Power
       E4—Engine Emits Excessive White Exhaust Smoke
       E5—Engine Emits Excessive Black or Gray Exhaust Smoke
       E6—Engine Will Not Crank
       E7—Engine Idles Poorly
       E8—Abnormal Engine Noise
       F1—Fuel Supply System Check
       F2—Excessive Fuel Consumption
       F3—Fuel in Oil
       Fuel Control Rack Magnet Adjustment
       Governor Adjustment
       Measure Fuel Transfer Pump Pressure
       Test Air in Fuel
       Test Cylinder Misfire
       Test for Fuel Drain Back
    160 - Electronic Controller Diagnostics & Tests
        About this Group of the Manual_{2201}
        Connecting Parameter Setup Tool (PST)
        Electrical Circuit Malfunctions
        Electrical Concepts
        Electronically Controlled Governor System Diagnostics
        Electronic Governor Calibration
        Engine Control Unit (ECU) Wiring
        LED Status Indicators
        Parameter Reference
        Reprogramming the ECU
        Troubleshooting Circuit Malfunctions
        Using a Digital Multimeter
        Viewing and Modifying ECU Parameters
 05 - TOOLS & OTHER MATERIALS
    170 - Repair Tools & Other Materials
       Engine Rebuild Essential Tools
       Engine Rebuild Service Equipment and Tools
       Group 020 — Cylinder Head and Valves Essential Tools
       Group 020 — Cylinder Head and Valves Other Materials
       Group 020 — Cylinder Head and Valves Service Equipment and Tools
       Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential Tools
       Group 040 — Crankshaft, Main Bearings and Flywheel Essential Tools
       Group 040 — Crankshaft, Main Bearings and Flywheel Other Materials
       Group 040 — Crankshaft, Main Bearings and Flywheel Service Equipment and Tools
       Group 050 — Camshaft and Timing Gear Train Essential Tools
       Group 060 — Lubrication System Essential Tools
       Group 070 — Cooling System Essential Tools
       Group 090 — Fuel Injection System Essential Tools
    180 - Diagnostic Service Tools
       Base Engine Diagnostic Tools
       Fuel System Observable Diagnostic Tools
    190 - Dealer Fabricated Service Tools
        DFRG7 — Notched Screwdriver Spring Tool
        DFRG9
        How to Make Tools
 06 - SPECIFICATIONS
    200 - Repair & General OEM Specifications
       Air Intake and Exhaust System Specifications
       Camshaft, Balancer Shafts and Timing Gear Train Specifications
       Cooling System Specifications
       Crankshaft, Main Bearings, and Flywheel Specifications
       Cylinder Block, Liners, Pistons, and Rods Specifications
       Cylinder Head and Valves Specifications
       Engine Crankcase Oil Fill Quantities
       Engine Power Rating and Speed Specifications
       Engine Rebuild Specifications
       Fuel System Specifications
       General OEM Engine Specifications—2.4 L Engines
       General OEM Engine Specifications—3.0 L Engines
       Lubrication System Specifications
       Metric Bolt and Screw Torque Values
       Starting and Charging Systems Specifications
       Unified Inch Bolt and Screw Torque Values
    210 - Diagnostic Specifications
        Electronic Governor Specifications
        Glow Plug Specifications
        Intake Manifold Pressure (Turbocharger Boost) Specifications

Logo