POWERTECH DCT 2.4L&3.0L 4024and5030 OEMDieselEngines
DCTPOWERTECH 2.4 L & 3.0 L4024 and 5030OEM Diesel EnginesOPERATOR’S MANUAL2.4 L & 3.0 L OEM Diesel EnginesOMRG34851 Issue 13OCT04 (ENGLISH)CALIFORNIAProposition 65 WarningDiesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthdefects, and other reproductive harm.If this product contains a gasoline engine:WARNINGThe State of California requires the above two warnings.John Deere Power SystemsLITHO IN U.S.A.OMRG34851The engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.
IntroductionForwardREAD THIS MANUAL carefully to learn how to operateand service your engine correctly. Failure to do socould result in personal injury or equipment damage.THIS MANUAL SHOULD BE CONSIDERED apermanent part of your engine and should remain withthe engine when you sell it.MEASUREMENTS IN THIS MANUAL are given in bothmetric and customary U.S. unit equivalents. Use onlycorrect replacement parts and fasteners. Metric andinch fasteners may require a specific metric or inchwrench.RIGHT-HAND AND LEFT-HAND sides are determinedby standing at the drive or flywheel end (rear) of theengine and facing toward the front of the engine.WRITE ENGINE SERIAL NUMBERS and option codesin the spaces indicated in the Record Keeping Section.Accurately record all the numbers. Your dealer alsoneeds these numbers when you order parts. File theidentification numbers in a secure place off the engine.SETTING FUEL DELIVERY beyond published factoryspecifications or otherwise overpowering will result inloss of warranty protection for this engine.CERTAIN ENGINE ACCESSORIES such as radiator,air cleaner, and instruments are optional equipment onJohn Deere OEM Engines. These accessories may beprovided by the equipment manufacturer instead ofJohn Deere. This operator’s manual applies only to theengine and those options available through the JohnDeere distribution network.NOTE: This operators manual covers only enginesprovided to OEM (Outside EquipmentManufacturers). For engines in Deeremachines, refer to the machine operatorsmanual.TX,DH2120 –19–11DEC95–1/1031505PN 2
IntroductionEngine OwnerJohn Deere Engine Owner:Don’t wait until you need warranty or other service tomeet your local John Deere Engine Distributor orService Dealer. To register your engine for warrantyvia the Internet, use the following URL:http://www.johndeere.com/enginewarrantyLearn who your dealer is and where he is. At your firstconvenience, go meet him. He’ll want to get to knowyou and to learn what your needs might be.distributore dei motori John Deere o delconcessionario che fornisce l’assistenza tecnica. Perregistrare via Internet la garanzia del suo motore, sicollegi al seguente sito URL:http://www.johndeere.com/enginewarrantyLo identifichi e si informi sulla sua ubicazione. Allaprima occasione utile lo contatti. Egli desidera fare lasua conoscenza e capire quali potrebbero essere lesue necessità.Propietario De Equipo John Deere:Aux Utilisateurs De Moteurs John Deere:N’attendez pas d’être obligé d’avoir recours à votreconcessionnaire John Deere ou au point de service leplus proche pour vous adresser à lui. Pour enregistrervotre moteur pour la garantie via Internet, utilisezl’adresse nseignez-vous dès que possible pour l’identifier etle localiser. A la première occasion, prenez contactavec lui et faites-vous connaı̂tre. Il sera lui aussiheureux de faire votre connaissance et de vousproposer ses services le moment venu.An Den Besitzer Des John Deere Motors:Warten Sie nicht auf einen evt. Reparaturfall, um dennächstgelegenen John Deere Händler kennen zulernen. Zur Registrierung Ihres Motors für die Garantiedient folgende rrantyNo espere hasta necesitar servicio de garantı́a o deotro tipo para conocer a su Distribuidor de MotoresJohn Deere o al Concesionario de Servicio. Registresu motor para la garantı́a en la siguiente dirección deinternet: http://www.johndeere.com/enginewarrantyEntérese de quién es, y dónde está situado. Cuandotenga un momento, vaya a visitarlo. A él le gustaráconocerlo, y saber cuáles podrı́an ser susnecesidades.Till ägare av John Deere motorer:Ta reda på vem din återförsäljare är och besök honomså snart tillfälle ges. Vänta inte tills det är dags förservice eller eventuellt garantiarbete. Din motorgarantiregistrerar Du via Internet påhttp://www.johndeere.com/enginewarrantyDin återförsäljare vill mycket gärna träffa dig för att lärakänna dina behov och hur bäst han kan hjälpa dig.Machen Sie sich bei ihm bekannt und nutzen Sie sein“Service Angebot”.Proprietario del motore John Deere:Non aspetti fino al momento di far valere la garanzia odi chiedere assistenza per fare la conoscenza delOURGP11,0000251 –19–06NOV03–1/1031505PN 3
Introduction2.4 L Right Side WERTECH 2.4 L & 3.0 L Diesel Engines3.0 L Right Side ViewPOWERTECH is a trademark of Deere & 32.4 L Left Side View3.0 L Left Side ViewRG41183,000001D –19–03JUN03–1/1031505PN 4
ContentsPageRecord KeepingPOWERTECH Medallion . . . . . . . . . . . . . . . . . . .Engine Serial Number Plate . . . . . . . . . . . . . . . .Record Engine Serial Number . . . . . . . . . . . . . .Engine Option Codes . . . . . . . . . . . . . . . . . . . . .PageLubrication and MaintenanceObserve Service Intervals. . . . . . . . . . . . . . . . . .Use Correct Fuels, Lubricants, and Coolant . . . .Lubrication and Maintenance ServiceInterval Chart—Standard Industrial Engines . .Lubrication and Maintenance ServiceInterval Chart—Generator (Standby)Applications . . . . . . . . . . . . . . . . . . . . . . . . . .01-101-101-201-3Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1Fuels, Lubricants, and CoolantDiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . . . 10-2Handling and Storing Diesel Fuel . . . . . . . . . . . . 10-2Dieselscan Fuel Analysis . . . . . . . . . . . . . . . . . . 10-3Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Kerosene (Burner) Fuels . . . . . . . . . . . . . . . . . . 10-4Minimizing the Effect of Cold Weather onDiesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-5Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-7Extended Diesel Engine Oil Service Intervals . . . 10-8Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 10-8OILSCAN and COOLSCAN . . . . . . . . . . . . . . 10-9Alternative and Synthetic Lubricants. . . . . . . . . . 10-9Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . 10-10Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-11Drain Intervals for Diesel Engine Coolant . . . . 10-12Supplemental Coolant Additives . . . . . . . . . . . . 10-13Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-13Operating in Warm Temperature Climates . . . . 10-14Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-1420-120-120-220-4Lubrication & Maintenance/DailyDaily Prestarting Checks . . . . . . . . . . . . . . . . . . 25-1Lubrication & Maintenance/500 Hour/12 MonthChanging Engine Oil and Replacing Filter . . . . . 30-1Replacing Fuel Filter Element. . . . . . . . . . . . . . . 30-4Cleaning Crankcase Vent Tube . . . . . . . . . . . . . 30-5Checking Air Intake System . . . . . . . . . . . . . . . . 30-6Check Engine Speeds . . . . . . . . . . . . . . . . . . . . 30-6Checking Belt Tensioner Spring Tensionand Belt Wear (Automatic Tensioner) . . . . . . . 30-7Checking Engine Electrical GroundConnections . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9Servicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-9Checking Engine Mounts . . . . . . . . . . . . . . . . . . 30-9Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . 30-10Checking Cooling System. . . . . . . . . . . . . . . . . 30-12Replenishing Supplemental CoolantAdditives (SCAs) Between CoolantChanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13Testing Diesel Engine Coolant . . . . . . . . . . . . . 30-15Pressure Testing Cooling System. . . . . . . . . . . 30-16Engine Operating GuidelinesInstrument Panel . . . . . . . . . . . . . . . . . . . . . . . . 15-1Normal Engine Operation . . . . . . . . . . . . . . . . . . 15-3Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . . 15-4Auxiliary Gear Drive Limitations . . . . . . . . . . . . . 15-5Starting The Engine . . . . . . . . . . . . . . . . . . . . . . 15-6Cold Weather Starting . . . . . . . . . . . . . . . . . . . . 15-7Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . . 15-9Avoid Excessive Engine Idling . . . . . . . . . . . . . 15-10Locking Throttle at Preset Speed . . . . . . . . . . . 15-10Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 15-11Using a Booster Battery or Charger . . . . . . . . . 15-12Lubrication & Maint./2000 Hour/24 MonthChecking Crankshaft Vibration Damper (IfEquipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1Flushing and Refilling Cooling System . . . . . . . . 35-2Testing Thermostats Opening Temperature . . . . 35-4Service as RequiredAdditional Service Information . . . . . . . . . . . . . . 40-1Do Not Modify Fuel System . . . . . . . . . . . . . . . . 40-1Continued on next pageAll information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.COPYRIGHT 2004DEERE & COMPANYMoline, IllinoisAll rights reservedA John Deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2003i031505PN 1
ContentsPageAdding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Single Stage Air Cleaner Element . . .Replacing Axial Seal Air Cleaner FilterElement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Radial Seal Air Cleaner FilterElement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Fan and Alternator Belt . . . . . . . . . . .Checking Fuses . . . . . . . . . . . . . . . . . . . . . . . . .Checking Air Compressors . . . . . . . . . . . . . . . . .Adjusting Speed Gain (Generator Sets) . . . . . . .Bleeding the Fuel System. . . . . . . . . . . . . . . . . ngGeneral Troubleshooting Information . . . . . . . . . 45-1Electrical System Schematic. . . . . . . . . . . . . . . . 45-2Engine Troubleshooting . . . . . . . . . . . . . . . . . . . 45-3StorageEngine Storage Guidelines . . . . . . . . . . . . . . . . . 50-1Preparing Engine for Long Term Storage . . . . . . 50-1Removing Engine from Long Term Storage . . . . 50-2SpecificationsGeneral OEM Engine Specifications. . . . . . . . . .Engine Power Rating and SpeedSpecifications . . . . . . . . . . . . . . . . . . . . . . . . .Engine Crankcase Oil Capacities . . . . . . . . . . . .Unified Inch Bolt and Screw Torque Values . . . .Metric Bolt and Screw Torque Values. . . . . . . . .55-255-355-455-5Lubrication and Maintenance RecordsUsing Lubrication and Maintenance Records . . .Daily (Prestarting) Service . . . . . . . . . . . . . . . . .500 Hour/12 Month Service . . . . . . . . . . . . . . . .2000 Hour/24 Month Service . . . . . . . . . . . . . . .Service as Required . . . . . . . . . . . . . . . . . . . . . .60-160-160-260-360-455-1Emission System WarrantyU.S. EPA Emissions Control WarrantyStatement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1Emissions Control System Certification Label. . . 65-2ii031505PN 2
Record KeepingPOWERTECH C02A medallion is located on the rocker arm cover whichidentifies each engine as a John Deere POWERTECH engine.POWERTECH is a trademark of Deere & Company.RG41183,0000022 –19–10DEC02–1/1Engine Serial Number Plate–UN–12DEC02Each engine has a 13-digit John Deere engine serialnumber. The first two digits identify the factory thatproduced the engine. “PE” indicates the engine was built in Torreon, MexicoRG12687Your engine’s serial number plate (A) is located on theleft-hand side of cylinder block behind the starter motor.13-Digit Engine Serial Number PlateRG41183,0000025 –19–11DEC02–1/101-1031505PN 7
Record KeepingRecord Engine Serial NumberRecord all of the numbers and letters found on yourengine serial number plate in the spaces provided below.–UN–21MAY04This information is very important for repair parts orwarranty information.RG13539Engine Serial Number (B)Engine Model Number (C)Engine Serial Number PlateOURGP12,0000104 –19–21MAY04–1/101-2031505PN 8
Record KeepingRG12689A–UN–09JUN04Engine Option CodesEngine Option CodesIn addition to the serial number plate, OEM engineshave an engine option code label affixed to the rockerarm cover. These codes indicate which of the engineoptions were installed on your engine at the factory.When in need of parts or service, furnish yourauthorized servicing dealer or engine distributor withthese numbers.The engine option code label includes an engine basecode (A). This base code must also be recorded alongwith the option codes.The first two digits of each code identify a specificgroup, such as alternators. The last two digits of eachcode identify one specific option provided on yourengine, such as a 12-volt, 70-amp alternator.NOTE: These option codes are based on the latestinformation available at the time of publication.The right is reserved to make changes at anytime without notice.If an engine is ordered without a particular component,the last two digits of that functional group option codewill be 99, 00, or XX. The list on the next page showsonly the first two digits of the code numbers. For futurereference such as ordering repair parts, it is importantto have these code numbers available. To ensure thisavailability, enter the third and fourth digits shown onyour engine option code label in the spaces providedon the following page.Continued on next page01-3RG41183,0000027 –19–11DEC02–1/2031505PN 9
Record KeepingNOTE: Your engine option code label may not containall option codes if an option has been addedafter the engine left the producing factory.An additional option code label may also bedelivered with the engine. Place this sticker ortag, for reference, either on this page or in theengine owner’s warranty booklet underOPTION CODES title.If option code label is lost or destroyed,consult your servicing dealer or enginedistributor selling the engine for a replacement.Option 33536373940434445DescriptionRocker Arm CoverOil FillerCrankshaft PulleyFlywheel HousingFlywheelFuel Injection SystemAir InletAir CleanerOil PanCoolant PumpThermostat CoverThermostatFan DriveFan BeltFanEngine Coolant HeaterRadiatorExhaust ManifoldCrankcase Vent SystemStarter MotorAlternatorInstrument PanelTachometerFuel FilterFront PlateFuel Transfer PumpThermostat HousingOil DipstickStarting AidsTiming Gear CoverBalancer ShaftsOption 88687889295979899DescriptionCylinder Block and CamshaftCrankshaft and BearingsConnecting Rods and PistonsValve Actuating MechanismOil PumpCylinder Head With ValvesAuxiliary Gear DriveShipping StandPaint OptionCoolant Pump InletOil CoolerAlternator Fan Drive PulleyAlternator MountingExhaust ElbowTurbochargerCoolant Temperature SwitchSpeed SensorCrankshaft Rear DamperEngine Serial Number PlateAir Conditioning (Freon) CompressorAir Restriction IndicatorOil Pressure SwitchAir CompressorFan PulleyBelt TensionerOil FilterTest CertificateSpecial Equipment (Factory Installed)Special Equipment (Field Installed)Lift Straps for EngineService Only Parts and KitsEngine Base CodeRG41183,0000027 –19–11DEC02–2/201-4031505PN 10
SafetyRecognize Safety Information–UN–07DEC88This is a safety-alert symbol. When you see this symbolon your machine or in this manual, be alert to thepotential for personal injury.T81389Follow recommended precautions and safe operatingpractices.DX,ALERT –19–29SEP98–1/1Understand Signal WordsTS187DANGER or WARNING safety signs are located nearspecific hazards. General precautions are listed onCAUTION safety signs. CAUTION also calls attention tosafety messages in this manual.–19–30SEP88A signal word—DANGER, WARNING, or CAUTION—isused with the safety-alert symbol. DANGER identifies themost serious hazards.DX,SIGNAL –19–03MAR93–1/1Carefully read all safety messages in this manual and onyour machine safety signs. Keep safety signs in goodcondition. Replace missing or damaged safety signs. Besure new equipment components and repair parts includethe current safety signs. Replacement safety signs areavailable from your John Deere dealer.TS201Learn how to operate the machine and how to usecontrols properly. Do not let anyone operate withoutinstruction.–UN–23AUG88Follow Safety InstructionsKeep your machine in proper working condition.Unauthorized modifications to the machine may impair thefunction and/or safety and affect machine life.If you do not understand any part of this manual and needassistance, contact your John Deere dealer.DX,READ –19–03MAR93–1/105-1031505PN 11
SafetyReplace Safety SignsTS201–UN–23AUG88Replace missing or damaged safety signs. See themachine operator’s manual for correct safety signplacement.DX,SIGNS1 –19–04JUN90–1/1Prevent Bypass StartingAvoid possible injury or death from engine runaway.–UN–28FEB89Do not start engine by shorting across starter terminal.Engine will start with PTO engaged if normal circuitry isbypassed.RG5419Start engine only from operator’s station with PTOdisengaged or in neutral.Prevent Bypass StartingRG,RG34710,7508 –19–30JUN97–1/1Handle Fuel Safely—Avoid FiresPrevent fires by keeping machine clean of accumulatedtrash, grease, and debris. Always clean up spilled fuel.TS202Always stop engine before refueling machine. Fill fuel tankoutdoors.–UN–23AUG88Handle fuel with care: it is highly flammable. Do not refuelthe machine while smoking or when near open flame orsparks.DX,FIRE1 –19–03MAR93–1/105-2031505PN 12
SafetyPrepare for EmergenciesBe prepared if a fire starts.TS291Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.–UN–23AUG88Keep a first aid kit and fire extinguisher handy.DX,FIRE2 –19–03MAR93–1/1DO NOT USE Starting FluidsDO NOT USE ether starting fluids with these glow plug equipped engines as it could cause an extreme explosionwith possible personnal injury.RG41183,00000B5 –19–07FEB03–1/1Handle Fluids Safely—Avoid FiresStore flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.Make sure machine is clean of trash, grease, and debris.TS227Do not store oily rags; they can ignite and burnspontaneously.–UN–23AUG88When you work around fuel, do not smoke or work nearheaters or other fire hazards.DX,FLAME –19–29SEP98–1/105-3031505PN 13
SafetyService Machines Safely–UN–23AUG88Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.TS228Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.DX,LOOSE –19–04JUN90–1/1Wear Protective ClothingWear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.TS206Prolonged exposure to loud noise can cause impairmentor loss of hearing.–UN–23AUG88Wear close fitting clothing and safety equipmentappropriate to the job.Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music hea
POWERTECH 2.4L&3.0L 4024and5030 OEMDieselEngines OPERATOR’SMANUAL 2.4L&3.0LOEMDieselEngines OMRG34
John Deere engines and tran MODEL KW/HP TIER II CERTIFIED ENGINE 5215 41/55 3 cylinder turbocharged 2.9 litre PowerTech 5315 48/65 3 cylinder turbocharged 2.9 litre PowerTech 5415 53/72 4 cylinder naturally aspirated 4.5 litre PowerTech 5515 59/80 4 cylinder turb
VGB-Standard Feed Water, Boiler Water and Steam Quality for Power Plants / Industrial Plants VGB-S-010-T-00;2011-12.EN Third edition 2011 (formerly VGB-R 450 Le) Editor: VGB PowerTech e.V. Publisher: VGB PowerTech Service GmbH Verlag technisch -wissenschaftlicher Schriften Klinkestr. 27-31, 45136 Essen Phone: 49 201 8128-200
(vormals VGB-R 450 L) Herausgegeben vom VGB PowerTech e.V. Zu beziehen bei: VGB PowerTech Service GmbH Verlag technisch-wissenschaftlicher Schriften Postfach 10 39 32, 45039 Essen Tel. 49 201 8128-200 Fax 49 201 8128-329 E-Mail: mark@vgb.org ISBN 978-3-86875-371-4 Jegliche Wiedergabe ist nur mit vorheriger Genehmigung des VGB gestattet.
Manufacturer and Model John Deere PowerTech E 6068H John Deere PowerTech Plus 6068H Non-Road Emission Standard EPA Tier 3/EU Stage IIIA and Brazil MAR-I emissions EPA Tier 3/EU Stage IIIA and Brazil MAR-I emissions Cylinders 6 6 Valves per Cylinder 2 4 Displacement 6.8 L (414 cu. in.) 6.8 L (414 cu. in.) Peak Power (ISO 9249)
Manufacturer and Model John Deere PowerTech E 4045HT072 turbocharged John Deere PowerTech Plus 4045HT082 turbo- charged Non-Road Emission Standard EPA Interim Tier 4/EU Stage IIIB EPA Final Tier 4/EU Stage IV Displacement 4.5 L (276 cu. in.) 4.5 L (276 cu. in.) Net Peak Power (ISO 9249) 52 kW (70 hp) at 1,900 rpm /
Engine, John Deere PowerTech PWX 4.5L, certified to IT4 / Stage IIIB emissions For use only in areas where EPA Interim Tier 4/EU Stage IIIB is required. John Deere PowerTech Plus 4045HT PWX 4.5 L. (275 Cu. In.) Certified to EPA Interim Tier 4 emissions 97 Net Rated hp (ISO 9249) Turbocharger
KKS Application Explanations for Hydro Power Plants VGB–B106 D1 Issued by: VGB PowerTech e.V. Obtainable from: VGB PowerTech Service GmbH Verlag technisch-wissenschaftlicher Schriften Postbox 10 39 32, 45039 Essen Phone: 4
Iowa, 348 P. Sharma, O. P. (1986) Textbook of algae. Tata Mcgrawhill Publishing company Ltd. New Delhi. 396. p. UNESCO (1978) Phytoplankton manual. Unesco, Paris. 337 p. Table 1: Relative abundance of dominant phytoplankton species in water sarnples and stomach/gut of bonga from Parrot Island. Sample Water date 15/1/04 LT (4, 360 cells) Diatom 99.2%, Skeletonema costatum-97.3% HT (12, 152 .
