JCB 444 Engine Mechanical Service Manual

Open front screen General Information Service Manual - JCB 444 Mechanical Engine Section 4 - General Information Section 2- Care and Safety ‘Section 3 - Routine Maintenance ‘Section 4 - Systems Deseription ‘Section 5 - Fault Finding Section 6 - Test Procedures ‘Section 7 - Fuel System Section 8 - Cooling System ‘Section 9 - Lubrication Systom ‘Section 10 - Electrical System ‘Section 11 - Induction and Exhaust Sy ‘Section 12 - Base Engine Section 1 Publication No. '9806/3000-04 teat Boh aNotes: Section 1 - General Information '9606'3000-04 1-0Section 1 - General Information Contents Contents Page No. Introduction ‘About this Manual 1-41 Using the Service Manual 1-1 Section Numbering .....sneesennenen nnn Vat Left Side, Right Side 1-1 1-1 1-2 1-3 Units of Measurement Machine Related Data ‘Acronyms and Abbreviations Identifying the Engine Engine Identification Plate 1-4 Engine Labels 1-4 Component Labels 1.4 1-5 1-6 Engine Identification Number Explanation . Engine Component Identification Technical Data Basic Engine Data Engine Specifications Engine Block & Bedplate Data Cylinder Head Data Inlet and Exhaust Valve Data ono : Rocker Levers, Rocker Shait and Tappets Data Pistons and Connecting Rods Data Crankshaft Data Camshaft Data Fuel System Data = ‘Acceptable and Unacceptable Fuels Fuel Types ... : Usage and Effects of Fuels Sulphur Content Effects of Fuel Contaminates Lubrication System Data ..... Cooling System Data Electrical Equipment Data Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-32 Introduction ..... 1-32 Bolts and Screws 1-32 Hydraulic Connections 1-36 'O' Ring Face Seal System Pee spcanatal=98 “Torque Stop’ Hose System 1-39 Torque + Angle Explanation 1-40 Torque + Angle Tightening Procedure .. rian Mm a Engine Torque Figures 1-42 Lubricants and Capacities Engine Lubricating Oil 1-57 Recommended Oils 1-57 Engine Oil Capacity 1-57 Coolant Mixtures 1-58 Service Aids Sealing, Retaining and Care Compounds 1-59Section 1 - General Information Contents Service Tools General Engine Tools Specialist Engine Tools Service Tool Drawings ..... 892/01146 - Core Plug Fitting Too! 892/01147 - Crankshaft Turing Too! 892/01148 - Timing Pin 892/01149 - Sump Sealant Template 892/01150 - Oil Sump Location Dowel 892/01151 - Injector Sleeve Removal Tool 882/01152 - Valve Stem Seal Fitting Tool... 892/01184 - FIP Cover Removal Tool 892/01155 - FIP Gear Removal Tool 892/01157 - Crankshaft Front Seal Fitting Tool ..... 892/01186 - Crankshaft Rear Seal Fitting Tool 892/01158 - Crankshaft Rear Seal Alignment Tool 882/01159 - Injector Seal Fitting Tool 892/01168 - Dummy Injector 892/01169 - Top Dead Centre (TDC) Setting Too! Engine Mounting Frame ‘Service Parts and Repair Kits Engine Repair Parts and Kits Identification Engine Lifting Lifting Information Operating Procedures Starting the Engine ... Pre-Start Notes Start Procedure Engine Checks After Start-up Engine Running-in Procedure... Stopping the Engine Page No. 1-80 1-62 1-67 1-87 1-68 1-69 1-70 1-74 1-72 1-73 1-74 41-75 1-76 1-7 1-78 1-78 1-79 1-80 1-81 1-99 1-99 4-100 4-101 1-102 1-103 Contents 1-ii 1-iiw Section 1 - General Information Introduction About this Manual Using the Service Manual This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. ‘These personnel should have @ sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of engines, Renewal of oil seals, gaskets, etc, and any component ‘showing obvious signs of wear or damage is expected as. 2 matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fuid, engine oil and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! ‘The manufacturers policy is one of continuous improvement. The right to change the specification of the engine without notice is reserved, No responsibilty will be accepted for discrepancies which may occur between the ‘specifications ofthe engine and the descriptions contained in this publication Section Numbering ‘The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information includes torque settings and service too's, 2 Care & Safety includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Routine Maintenanceincludes service schedules and recommended lubricants. ‘The remaining sections desl with Descriptions, Fault Finding, Dismantling, Overhaul etc. of specific components, for example: 4 Systems Descriptions 5 Fault Finding ..cte Left Side, Right Side References to the ‘lef’ side and the ‘right’ side of the engine are when viewed from the flywheel end of the ‘engine, as shown at 1A, Fig. Units of Measurement In this manual, the Si. system of units is used. For ‘example, liquid capacities are given in ites. The imperial Unis followin parenthesis () €.9, 26 litres (6 UK gal). 14 39062000-04 74wy Section 1 - General Information Introduction Machine Related Data The JCB 444 Engine can be fitted to a variety of constructions and agricultural machines. The scope of this Publication is limited to the engine, but references to a typical machine installaton will be made. Tasks and information specific to a machine installation wil be listed in the relevant machine Service Manual, for example engine removal and replacement procedures. ‘About this Manual 42 '9606'3000-04 1-2Ww Section 1 - General Information Introduction ‘Acronyms and Abbreviations Acronyms and Abbreviations Some of the following acronyms and abbreviations are Nim Newton Metre Used in this service manual, The remainder are usedin the automotive industry and are repeated for reference only. NSP. Non Serviced Part om Outside Diameter “c Celsius OEM Original Equipment Manufacturer ag Fehrenhelt PPM Parts per Milion AR As Required Psi Pounds per square Inch API ‘American Petroleum Institute PTO. Power Take Off BBDC —_Before Bottom Dead Centre RH Right Hand BoC Bottom Dead Centre RME Rapeseed Methyl Ester BSFC Brake Specific Fuel Consumption REM Revolutions per Minute BTDC —_—_—Before Top Dead Centre SAE Society of Automotive Engineers cov Crankcase Vent SME ‘Sunflower Methyl Ester cp Cubic inch Displacement SOME Soyabean Methyl Ester CsA Cold Start Advance sTD ‘Standard CSAS Cold Start Advance Solenoid TBA To be Advised cst Centistokes Te Turbocharged Eom Electronic Control Module TcA Turbocharged Attercooled Eos Emission Control System Toc Top Dead Centre EPA Environmental Protection Agency 1 Technical Information ESOS —_Ellectric Shut-Off Solenoid or Engine Shut- VOME —_Vegstable Oil Methyl Esters Off Solenoid FAME Fatty Acid Methyl Esters FEAD Front End Accessory Drive FIE Fuel Injection Equipment FIP Fuel injection Pump Hg Mereury HP Horse Power uD Inside Diameter kg Kilogram KPH Kilometres per hour kw Kilowatt LH Left Hand ltr Litre mm Milimetre MPH Miles per Hour NA Naturally Aspirated NA Not Applicable/Not Available 13 seosano008 73Ww Section 1 - General Information Identifying the Engine Engine Identification Plate Engine Labels Each JCB 444 Engine has @ unique identification number ‘stamped onto the main engine block, as shown at 2A. Refer to Engine identification Number Explanation ([}7-5) for a ful detailed description of the umber. In addition to the identifeation number, there is an emisssions legislation label 2B, Component Labels In addition to the engine labels, some of the machine engine components will also have a label attached, or 2 part number etched into the casting, these include: = the starter motor the alternator the fuel injection pump engine bedplate — engine block ~ oylinder head = ~ Turbo charger vara int In some instances, it may be necessary to quote the information on these labels, for instance if there is @ parts query, or @ warranty claim. Make a note of these numbers. 70880 1-4 '9606'3000-04 1-4wD Section 1 - General Information Identifying the Engine Engine Identification Plate Engine Identification Number Explanation SA320/40000U0000104 The full engine number is stamped on the emissions label and the serial number is stamped on the engine block. 2 Fig 2.(1)1-4) ‘An explanation ofthe full engine number is detailed below. 2 Fig 4. (11-5) If you need parts or service information for your engine, you must quote the complete engine number SA 320/40001 U 00001 04 44 Litre Engine Family: SA= Naturally Aspirated SB = Turbocharged SC = Turbocharged and Intercooled SD = Turbocharged ‘SF = Turbocharged and Intercooled Engine Part Number Country of manufacture: U= United Kingdom Engine Serial Number Year of manufacture Fig 4. 18 39062000-04 15Section 1 - General Information Identifying the Engine Engine Component Identification Engine Component Identification Table 4. Engine - As viewed on the left hand side. Fig 5.((\1-7) 42. Fuel fter 1 Rocker cover 43 Lubrication oil filer cap 2 Fuel injectors and high pressure fuel pipes 44 Lubrication oll fiter 3 Lubrication ol filer cap 18 Lubrication ol cooler housing 4 Timing gear case 16 Lubrication oil dip stick 5 Flywheel housing 47 Low duty PTO (blanking cover if no device is fitted) 6 Bed plate 18 Water temperature sender (cold statt) 7 Lubrication oll pan (sump) 19 Low pressure fuel line (to tank) & Engine iting eye 20. Oildrain plug (sump) 8 Airlnlet manifole 21 Oil pressure switch 10 Fuel injection pump 22 Inlet manifold induction heater (if fited) 11 Fuellit pump 16 '9606'3000-04 1-6wD Section 1 - General Information Identifying the Engine Engine Component Identification Fig 5. SB Type engine shown 17 3906000-04 17wy Section 1 - General Information Identifying the Engine Engine Component Identification Table 2. Engine -As viewed on the right hand side Fig 6. (111-8) 1 Rocker cover 41 Exhaust manifold 2 Breather chamber inspection cover 12. Alternator and drive pulley assembly (belt not fited) 3 Cylinder block 13 Coolant pump drive pulley (belt not ited) 4 Timing gear case 14 Coolant pump housing (cylinder block) 5 Flywheel housing 15 Coolant inlevradiator hose connector 6 Bed plate 16 Heavy duty PTO (blanking cover if no device is fited) 7 Lubrication oll pan (sump) 17 Starter motor assembly 8 Liing eye 18 Turbocharger oll drain line (turbocharged engine only) 8 Turbocharger (turbocharged engine only) 19 Turbocharger oll feed line (turbocharged engine only) 10 Turbocharger waste gate actuator assembly 20 Oil drain plug (sump) 18 '9606'3000-04 18Section 1 - General Information Identifying the Engine Engine Component Identification 20 Fig 6. SB Type engine shown 1-9 '9606'3000-04 19Ww Section 1 - General Information Identifying the Engine Engine Component Identification Fig 7. SB Type engine shown ‘Table 3, Engine - As viewed on the crankshaft pulley (front) end 2 Fig 7.(D11-10) 1 Rocker cover 9 Drive bett tensioner and pulley 2 Oylinder head 10 Coolant pump and drive pulley assembly 3 Oyflinder block 11 Idler pulley 4 Bed plate 12 Alternator and dive pulley assembly 5 Lubrication oil pan (sump) 13. Cab heater water hose connector 6 Crankshaft pulley 14 Coolant temperature sender 7 Front end accessory drive belt 15 Coolant thermostat housing/radiator hose connector 8 Idler pulley 110 ‘980602000-04 1-10Ww Section 1 - General Information Identifying the Engine Engine Component Identification Fig 8. SB Type engine shown Table 4, Engine - As viewed on the flywheel (rear) end 2 Fi 1) 1 Rocker cover 4 Fuel injection pump drive gear cover 2 Cylinder head 5 Flywheel housing 3. Flywheel m1 ‘980602000-04 1-11w Section 1 - General Information Technical Data Basic Engine Data Technical Data Basic Engine Data Engine Specifications Engine Type: TSA Naturally Aspirated 738 Turbocharged 73 Turbocharged with Intercooler =3D Turbocharged TSF Turbocharged with Intercooler Rated speed 2200 (em [Weight (Diy) =SA ‘472 kg (1040 16) = 88, SC, 8D, SF 477 kg (1082 16) ‘Number of oyinders a Nominal bore size 108 mim (4,086 in) ‘Soke 132 mm (6.16 in) Cylinder arrangement Taline Combustion Gyale astroke Firing order Taa2 Displacement 440 tres ‘Compression ratio, ~SA 767 738 7a3:7 7s 75:4 780, SF 724 Engine Compression ee Note Direction of rotation (viewed from front (crankshaft pulley} end) _| Clockwise Vanes per oyinder Valve tip clearances (measured cold) = SA 8B, SC Inlet: 0.18 t0 0.27 mm (0.007 to 0.011 in) Exhaust: 0.56 to 0.64 mim (0.022 to 0.026 in) "80, SF Thiet 035 mm (0.074 in) Exhaust 0.56 to 0.64 mim (0.022 to 0.025 in) Lubricating oll pressure ® 4.0 t0 48 bar (68 to 70 Ibin*) ‘Combustion system Direct injection 4-12 '9606'3000-04 1-12wD Section 1 - General Information Technical Data Basic Engine Data Fuel injection pump Rotary Mechanical (1) Compression variance between each cylinder should be no greater than 3.5 bar (60 ib in2) (2) Engine at normal operating temperature and maximum revs. 1413 ‘#80602000-04 1-13,w Section 1 - General Information Technical Data Engine Block & Bedplate Data Engine Block & Bedplate Data [Cylinder bore 103.000 to 103.020 mm (4.055 to 4.046 in) Main bearing balls torque ™ ~ first stage 50 Nm (37 Io) second stage 415 Nm (85 tot f) “final stage ‘turn a further 180° ‘Surface finish for cylinder head joint Rz < ium, Rmax<20um Diameter of frst oversize bore 103.500 to 103.520 mm (4.074 to 4.076 in) Diameter of second oversize bore 104.00 to 104.020 mm (4.094 to 4 S52 in) Main bearing bore (without bearings) Thumbers To 4 {92.000 to 82.020 mm (3.622 to 36231n) Tnumber S 105.000 t6 105.020 mm (4.134 to 4.135 in) Main bearing bore (with bearings) ~humbers 1 4 186.047 to 68.080 mim (3.406 to 3.468 in) ~ number 5 100.047 to 100.080 mm (3.938 to 3.947 in) [Camshaft bore ~ numbers 11 4 100,040 to 60.070 mm (2.364 to 2,365in) = number 6 (bush) ® {60.280 to 60.32 mm (2.374 to 2.875 in) Permissible wave profile wi=i0m (25 distance) (1) Nominal diameter fo be measured 63mm below head face, (2) Torque information MUST be used in conjunction with recommended procedures contained in this manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures may result in an engine failure in service, Refer also fo the procedures for the correct boll tightening sequence, (3) Bush no longer fited from January 2008. 1-14 '9606'3000-04 1-14w Section 1 - General Information Technical Data Cylinder Head Data Cylinder Head Data (Cylinder head distortion (maximum permissible) Tendto end (105 mm (0.002 in} Taide to side (103 mm (0.0072 in} Valve recess depth “Talat (0.85 mm (0.033in) ~ Exhaust (0.85 mm (0.033in) Valve seat angle “inlet 420° (inclusive) ~ exhaust {90° (inclusive) (Cylinder head bolts torque “first stage 40 Nm (GO IbF Tsecond stage 75 Nm (56 Ibf Third stage tepeat 75 Nm fourth stage torque angle * 60" final stage torque angle + 780° ‘Surface finish for eylinder head joint Riz < f5um, Rmax< 200m Permissible wave profile w= 10um 2.5 detance (1) Torque information MUST be used in conjunction with recommenced procedures contained in this manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures may result in an engine Iailure in service, Refer also to the procedures for the correct bolt tightening sequence, 1-15 '9606'3000-04 1-15w Section 1 - General Information Technical Data Inlet and Exhaust Valve Data Inlet and Exhaust Valve Data Max it niet = SA $B, SC ‘837 mm @ 107 atdo ~S80, SF ‘364mm @ 107 atde Max it exhaust ~SA aaa mm @ 10 Bide 7 SB SC ‘9.42 mm @ 116" bide 780, SF ‘9.84 mm @ 116" bide Inlet opens (top of ramp) = SA, 88, SC 10" bide ~80, SF 6 bdo Inlet closes = SA, 88, SC 3 abde 780, SF 2B abde Exhaust opens SA 0" bide 788, SC 0" bide = 80, SF ai bbde Exhaust closes 7 SA 98, SC 10 aide 780, SF [watae Valve stem diameter = SA $8, SC Inlet: 6.885 +/-0.007 mm (0.273 +/0.0003 in) Exhaust 6.975 +-0.0075 mm (0.275 +10.0003 inp "80, SF Inlet: 6.926 to 6.843 mm (0.2727 to 0.2783 in) Exhaust 6 918 to 6.933 mm (0.2724 to 0.2729 in) ‘Valve spring free length 0.18 mm (1.581 in) "Valve guide bore diameter = min {6.858 mm (0.2739 in) =max 6,968 mm (0.2743 in) ‘Valve face angle inlet 605" Texhaust aT ‘Valve length 131.9 t0 132.4 mm (5.19310 5.213 in) ‘Valve sealing “em Seal with sealing washer ‘Valve head depth (below cylinder head surface) Tinlet (0189 t6 7.39 mm (0.035 to 0.0551n) 1-16 '9606'3000-04 1-16wD Section 1 - General Information Technical Data Inlet and Exhaust Valve Data “exhaust (0,95 to 1.45 mm (0.037 to 0.087 in) Valve firm thickness 2.98 to 3.36 mm (0.117 to 0.133in) 147 ‘#80602000-04 147Ww Section 1 - General Information Technical Data Rocker Levers, Rocker Shaft and Tappets Data Rocker Levers, Rocker Shaft and Tappets Data \Valve tip clearances (measured cold) ~ SA, SB, SC Inlet: 0.79 to 0.27 mm (0.007 to 0.07% inp Exhaust 0156 t0 0.64 mim (0.022 to 0.025 in) "8D, SF Tniet 0.35 mm (0.074 inp Exhaust 0:56 to 0.64 mm (0,022 to 0.025 in) Rooker lever bore dameter Trin "26.048 mm (1.025 in} max 26.128 mm (1.029 in) Rooker shat diameter min 26.00 mm (1.0236 in} max 26.024 mm (1.0244 in) Tappets stem diameter Tain 49.987 mm (0.787 in) Tmax 419.975 mm (0.786 in) Tappet bore Giameter Tin 20.00 mam (0.7874 in} max 20.027 mm (0.7882 in) Tappet height (maximum) 55.25 mm (0.0218 in) 78 39062000-04 118Ww Section 1 - General Information Technical Data Pistons and Connecting Rods Data Pistons and Connecting Rods Data ‘Gudgeon pin bore diameter ~min 40.008 mm (0.075751 in) Tmax 40.073 mm (0.078753 in) Piston ring clearance = top ring Keystone ring ~middle ting {0.11 to 0.07 mm (0.0043 to 0.0027 inp bottom (oil) ring {0108 to 0.05 mm (0.0035 to 0.0019 in) Piston ring gap =Top ring 0.31005 mm (0.118 t0 0.010 in) = middle fing (0.55 to 0.8 mm (0.026 to 0.0314 in) ~ bottom (cil) ring (0.25 to 0.50 mm (0.0098 to 0.0196 in) Piston height above cylinder block (cold) (0.0375 to 0.3385 mm (0.0044 to 0.013 in) Piston groove width =top ring ‘3.108 fo 5.133 mm (0.122 to 0.123 in) middle ting 2.47 to 2.67 mm (0.97210 0.105 in) Bottom (oll) ring 04 to 4.06 mm (0.71580 to 0.1588 in) [Connecting rod type ‘Split fracture (Connecting rod bore diameter 77.00 %0 77.01 mm (8.0314 to 3.0318in) (Connecting rod side clearance Tain (0.05 mm (0.0019 in) max (0:40 mm (0.0187 in) Big end bearings: ~ with 32.5 to 33.00 mm (7.279 t0 1.288 in) ~ thickness (at centre) 1.990 to 1.981 mm (0.0783 to 0.0779 in) ‘Small end bearings: ~ inside diameter 40,034 to 40.020 mm (1.5781 to 1.8755 in) (1). Spit tracture type connecting rods MUST NOT be det punched, or etched in any way during disassembly - refer to relevant service procedures. 1-19 '9606'3000-04Ww Section 1 - General Information Technical Data Crankshaft Data Crankshaft Data ain bearing joumal ameter (x4) in 87.98 mm (3.460 inh ~max £86 00 mm (3.464 in) Main rear beating journal diameter 1) =i 99.98 mm (3.836: Tmax 100.00 mm (3.937 in) ‘Connecting rod bearing journal diamoter =min 72.98 mmm (2.873 in) = max 73.00 mm (0.2755 in) Maximum wear end ovalty on journals TBA mim (Crankshaft induction hardness "55 HR min on surface Thrustwasher with =n 2.44 mm (0.086 in} Tmax 2.50 mm (0.787 in) (Crankshaft end float in 0.05 mmm (0.002 in) = max (0.28 mm (0.011 in) 720 39062000-04 1-20Ww Section 1 - General Information Technical Data Camshaft Data Camshaft Data [Camshaft journal diameter ~4 off 159.99 to 59.97 mm (2.362 to 2.361 in) “Toff {50.25 to 60.22 mm (2.372 to 2370 in) (Camshaft lobe wear imits SA $8, SC Inlet 728 +1-0.025 mm (0.285 +/0.001 in) Exhaust: 7250 +1-0/025 mm (0.286 +F0.007 in) 80, SF Inlet: 7-385 to 7 435 mm (0-291 to 0.293 in) Exhaust: 7645 to 7 505 mm (0.207 to 02091n) [Camshaft bush diameter 60-32 to 60.29 mim (2.376 to 2374 in) (Camehatt Gear 104 teeth (1) Bush no longer fted from January 2008. (2) The camshat gear is not available as a separate service item. The gear must be heated onto the camshaft in the correct timed position. Specialist fixtures are used during the production process to achieve the correct timing. 1-21 ‘#80602000-04 1-24w Section 1 - General Information Technical Data Fuel System Data Acceptable and Unacceptable Fuels Important: No warranty liabilty whatsoever will be accepted for failure of fuel injection equipment where the failure is ettnbuted to the quality and grade of the fuel used. Fuel System Data Fuel Specification Applicable Engines [Service Requirements ENS00 Diesel fuel types - AutorO0G 1027 3c ‘All Dieselmax engines, S260 Class AZ ASTM DO75-01 Class 2, US DFT, US OF2, US DFA, IS K2204 (1892) Grades 1, 2, Sand Special Grade 3 ‘Obey the usual routine maintenence schedules and procedures ASTM 0975.91 Class 1A ML 138216 KES NATO F63 French ENS80 (RMES) with 6% maximum ‘All Dieselmax engines. Engines ‘operated with these fuels may have ‘a reduced service life Obey the usual routine maintenence schedules and procedures. Fuel additives ar recommended for use with low sulphur fuels, > Adaitives (1) 1-23) AVCAT FSI, NATO F4@, JPS, MIL T5624, DERD 2452, AVTOR NATO F35, JET Al, DEF STAN 01-07, DERD 2494, JP7 /AVCAT, NATO FA3 (obsolete), JPS without additives JET A (ASTM D1655) ASTM 03699 Kerosene ‘All Dieseimax engines. Engines operated with these fuels will have a reduced service life (Obey the usual routine maintenence schedules and procedures. Fuel additives MUST be used > Additives ([% 1-23) 20 Biodiesel - RME content blended with mineral derived diesel (20% maximum) ~ /ASTM 06751, DIN 51606, ISO 14214 Dieseimax engines manufactured {from 2007 on ONLY" YOU MUST obey special routine maintenance schedules and procedures. > Service [Requirements for use of B20 Biodiesel (1) 1-23) AVTAG (obsolete) 'AVTAG FSII (obsolete), NATO FA0, JPA, DERD 2454 JET 8 (ASTM D1655) BS MAI00 JIS K2203 No.2 Unmodified vegetable ois "These fuels are NOT ACCEPTABLE ‘with or without additives. Engines. MUST NOT be operated with these fuels. (1) The year of manufacture is part of the engine serial number. Refer to identifying the Engine. 1-22 '9606'3000-04 1-22w Section 1 - General Information Technical Data Additives, ‘The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosenefow sulphur fuels up to those of diesel fuels. They must be used as specified by your fuel supplier who will understand the concentration level necessary = EIf 2S 1750, Dosage 1000-1500 ppm (0.1 - 0.15%), ‘specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels. = Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm. = Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%), ‘Note: These products are given as examples only The Information is derived from the manufacturers deta, The products are not recommended or endorsed by JCB, Service Requirements for use of B20 Biodiesel = The engine oil must be a grade CH4 as minimum speetfication. — Do notleave unused 820 biodiesel in the fuel tank for extended periods (top up each day) = Make sure that 1 in fuel tank ils use standard diasel to ENS90 specification, this will help to prevent ‘gumming = Make sure regular ol sampling is completed (look for excessive unburnt fuel content, water or wear patticles, = Change the engine ol and fiter more frequently (as a minimum haif the recommended intervals), or 28 indicated by oil sampling — Change the fuel fiters more frequently (a8 a minimum half the recommended intervals), or if there are engine performance related issues. = Make sure the fuel is stored correctly, care must be taken to make sure no water enters the machine fuel tank (or the storage tank). Water will encourage mico- bacterial growth. — Make sure that the fuel pre-fiteris drained DAILY (not every week as currently advised), = Only JCB ENGINES buit after Jan. 2007 are applicable (Ie. engines with O7 on the end of their Fuel System Data serial number and factory filed with CH4 cil) - this is not approved with other manufacturers. — Use heater kits in low ambient temperature territories, — The biodiesel must meet the following standards: ASTM D6751, DIN 51608, ISO 14214, Note: if necessary use a test kit 10 confirm the fuel specification. Testing kits are available (not from JCB currently), use the internet as @ source for the kits Note: if performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, then the fuel system must be filed with standard diese! (et least 2x tank fils) to EN590 specification and relevant stall speeds recorded prior fo making the report. Warranty JCB have shown a commitment to support the enviroment by approving the use of biodiesel blended fuels. Using 2 820 blend of biodiesel requires caution and additional servicing of the engine is required. = Service Roquiromonts for uso of B20 Biodiosol Failure to follow the additional recommended service requirements may lead to a warranty claim being declined. Failures resulting by the incorrect use of biodiesels or ‘ther fuel additives are not dafects of the JCB Dieselmax engine workmanship and therefore will not be supported by JCB Warranty. 1-23 '9606'3000-04 1-23wD Section 1 - General Information Technical Data Fuel System Data Fuel Types Note: The information that follows does not indicate types of us! that are acceptable or unacceptable. => Acceptable and Una fe Fuels (11-22) ‘Any fuel purchased for operation of the JCB Dieselmax. engine must be purchased from reputable oll producers! outlets and stored in accordance with the manufacturers recommendations, Defects of Fuel Contaminatos (1)1-27) 1. Diesel - mineral derived, hydrocarbon fuels to European standard EN590 or equivalent. 2 Low Sulphur Diesel - mineral derived, hydrocarbon fuels to ENS90 or equivalent. This fuel has totaly replaced automotive (road use) diesel in the European Union since October 1996 and has sulphur limited to @ maximum of 0.05% by weight. 3° Ultra Low Sulphur Diesel - Reformulated mineral detived, hydrocarbon fuels to ENS90 or equivalent. Now widely available in the UK, mainiand Europe and, ‘some parts of he USA, Sulphur limited to 2 maximum of 0.005% by weight or lower, =>Sulphur Content (1) 1-26) 4 Vegetable Oil -unmodified Certain pure vegetable oils (sunflower oil, rapeseed ol ete.) 8 Biodiesel - chemically modified vegetable oll. By chemically modifying vegetable oils, methy| esters of, that oll are produced. These are collectively known as “Fatty Acid Methyl Esters” (FAME) or "Vegetable Oil Methyl Esters" (VOME) Note: Refer also to additional information. => Usage and Effects of Fuels (1) 1-25) 124 39062000-04 1-24wy Section 1 - General Information Technical Data Usage and Effects of Fuels Note: The information that follows does not indicate types offue! that are acceptable or unacceptable. > Acceptable and Una Fucls (11-22) 1. Low Sulphur Diesel In its basic form because of the process of reducing ‘sulphur by removal of sulphur containing compounds (which contribute to mechanical lubrication) an increase in the wear rate of the fuel injection equipment could occur. In view of this, the major fuel producers add suitable lubricity improvers to enable the FIE to run satisfactorily, with no acceleration in wear rate. They must ensure that the lubricity improvers do not themselves create residual deposits that could block the fuel system e.9,fiter, injectors eto In adaition to the lubrication effect there can also be a further reduction in the aromatic content of the fuel which can lead to shrinkinglcracking of traditionally ritile rubber seals throughout the fuel injection equipment that has previously been exposed to higher sulphur level fuels. The major fuel producers. tend to maintain the total aromatic content to an acceptable level (15% by volume). 2 Ultra Low Sulphur Diesel ‘A’so known as “city diese. Available throughout the UK and some parts of Europe since March 1999. This, fue! has @ maximum sulphur content of 0.005% by weight and @ further reduction in the natural lubricity ‘and aromatic content than experienced with low ‘sulphur diesel. Major oil producers will add lubrication improves and also maintain the total aromatic, content to an acceptable level 3 Unmodified Vegetable Oils Burned n diesel engines neat or used as an extender to mineral derived fuel, When these are subjected to heat in the fuel injection system they form sticky deposits that can be found inside the fuel pump and a hard lacquer in the injectors where exposure to even higher temperatures takes place, 4 Chemically Modified Vegetable Oils (FAMEMOME} These fuels have been derived from a wide range of vegetable ols and animal fats, resulting in better Fuel System Data stabiliy, viscosity and cetane number than those produced from unmodified vegetable ils, but it is recognised that there are potential problems associated with the finished fuel characteristics These oils are less stable than mineral oll derived fuels when stored and they wil readily degrade producing fatty acids, methanol and water, none of which are desirable in the FIE. These effects are known to be accelerated when the fuel is storedin the presence of air and water together. An extract “common statement’ from the FIE manufactures specifies that "The fuel injecton equipment manufacturers can accept no. liability whatsoever for failure attributable to operating their products with fuels for which the products were not designed, and no warranties or representations are made as to the possible effects of running these products with such fuels" The three most common Fame types are RME - Rapeseed methyl ester (preferred crop in Europe) SME - Soyabean methyl ester (preferred crop in USA), Less common FAME's can be derived from animal fats (eg. modified beef extracts) and reclaimed cooking oils. 820 Biodiesel Biodiesel refers to pure fuel before its blended with diesel fuel 2 Chemically Modified Vegetable Oils (FAME/VOME) ([} 1-25). When biodiesel is blended ‘with diesel fuel it i referred to as B5, B20 eto, where the number indicates the percentage of biodiesel in the fuel, for exemple BS contains 5% biodiesel Biodiesel has different characteristics than mineral based fuels in that it is able to mix with water and ‘therefore will have @ high water retention capacity this could lead to seals swelling, fuel system corrosion and seal damage. Biodiesels will “loud at higher temperatures than mineral based fuels. To explain Cloud Point - the lowest temperature at which fluid can flow and performs its functions is referred to as Pour Point, ‘Just prior to reaching its Pour Point the diesel fluid becomes ‘cloudy’ due to crystallization of waxy Constituents - this is know as Cloud Point. Using diesel at temperature below its cloud point can result, 4-25 '9606'3000-04 1-25w Section 1 - General Information Technical Data in fiter clogging. To prevent this happening pre- heating will be required. Using 820 biodiesel can result in unburnt fuels, accumulating in the engine oil, ultimately this can affect the engine oil efficiency ‘and lead to engine damage (with standard diesel any unburnt fuel evaporates off the lubricating al). Biodiesels must be stored to exclude water absorption and oxidation, ‘The natural properties of biodiesel make it a good medium for micro bacterial growth, these microbes: can cause fuel system corrosion and early fue fier, blocking, It will be necessary to consult and seek advice from your fue! supplier, the effectiveness of conventional antibacterial additives when used in biodiesel is still boing investigated in the fuel industry.4 high percentage biodiesel mixture (220%) can lead to fuel gelling and fiter blocking in low temperature operation, it may also effect the power and performance of the engine Fuel System Data ‘Sulphur Content High sulphur content can cause engine wear, (High sulphur fuel is not normally found in North America Europe or Australia) If you have to use high sulphur fuel you must change the engine oll more frequently © Table 6. Sulphur Content ([) 1-26) Low sulphur fuels must have the appropriate fuel lubicity additives, these lubricity improvers must not create residual deposits that biock the fuel system, €.9, injectors, fiters etc. Contact your fuel Supplier AcauTion A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel ‘system when high sulphur fuels are used. enea2 ‘Table 5. Sulphur Content Tominimise the rik of engine damage when wsing® [percentage of culpher nol Chars lnlrval 820 min, there oe adatonal service requirements. [pereeniage DSenice Requirements for use of "B20 Biodiesel (01-29) Less than 05 Normal wn : DSt10 0.75 of normal the recommended actions are not taken there may be the following consequences:- low temperature More tien, 1.0) D160 of normel fiter clogging- inectors lacquering 7 sticking- deterioration of seals and rubber hoses- cortosion of metal parts in the fuel system- engine performance probiomsThese risks wil be increased f the fuel hos been poorly stored, that is deterorated through cxidation and/or water absorption 1-26 ‘#80602000-04 1-26Ww Section 1 - General Information Technical Data Fuel System Data Effects of Fuel Contaminates ‘The effect of dir, water and other contaminants in diesel can be disastrous for injection equipment: = Dirt - A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven running and poor fuel detivery. ~ Water - water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dit, causing rapid wear, corresion and in severe cases, even seizure. It is vitally important that water is prevented from reaching the fuel injection equipment The fiterwater trap must be drained regularly = Wax - Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's loud point, causing @ restriction in fuel flow resulting in rough engine running, Special winter fuels may be available for engine operation at temperatures below O°C (32°F), These fuels have a lower viscosity and limit wax formation, 1-27 ‘#80602000-04 1-27Ww Section 1 - General Information Technical Data Lubrication System Data Lubrication System Data Fiter ype ‘Serew-on canister win eran Tea) Pressure to open by-pass valve 1.8 bar (23 Ibfin®) i pressure rail valve seting 45 bar (5 Ton?) [Oil pressure switch setting 0.6 bar falling (9 Ibfin’) (Oi pampe Integral unit with ret valve (1) The olf pump is a nomserviceable part 1-28 ‘#80602000-04 1-28w Section 1 - General Information Technical Data Cooling System Data Cooling System Data Radiator cap pressure setting Tar (14.5 lbvin®) Thermostat ‘Wax element with by-pass blanking Thermostat operating temperature: nominal temperature 88°C (190°) ~ start to open temperature 85 - 90°C (187 - 84°F) = full open temperature TORT BIOF) revel fay open) ‘Simm (0.354in) Fan belt ype Front end accessory dive (FEAD) Fan belt (FEAD) adjustment ‘Automatic belt tensioner Fan belt (FEAD) type Matigroove belt ‘Coolant Temperature Switch/Sender range ‘seo 2 Electrical Equipment Data (1) 1-30) Water pump“ Bolt on, belt driven unit (1) The water pump is @ non-serviceable par. 1-29 '9606'3000-04 4-29Ww Section 1 - General Information Technical Data Electrical Equipment Data Electrical Equipment Data Alternator Make Tekra~ AK Rating = option 1 7aV, 95 Amp = option 2 2BV, 55 Amp (Coaling Internal Fan Weterminal For engine speed indication Altemator speed 218 x engine speed ‘Starter Motor Make Takra- AZF 45 Rating option 4 av, 42 KW = option 2 Dav, 22 (Operating range “BD to #120°C (22 to 248°F) Number of pinion teeth 1 (1) Never operate the starter motor longer than 20 seconds. Allow at least 2 minutas for cooling and battery recovery before operating again. Overheating caused by excessive operation will seriously damage the starter motor. 1-30 39062000-04 7:30Ww Section 1 - General Information Technical Data Electrical Equipment Data (Switches: (Cold start advance switch = set temperature 55°C rising (131F) switch mode Normally cosed tightening torque ¥6Nm max (12 1b) “Thread diameter Mi2x1 ‘Coolant temperature switch/sender Dual function ewitchisender ~ set temperature (switch) TDC 1ST (234 +15 AF) mode (switch) Normally open Tightening torque 16 Nm max (12 1b) Thread diameter Minx tS = Temperature v resistance table Temperature °C CF) Resistance - Ohms +/- 10% 25077) 500 50 (122) Tera 7100 (272) a9 110 (230) 2 (Oil pressure owitch eet pressure (0.6 bar faling (@ bain?) Tewitdh mode Normally closed = max pressure 27-5 bar (398 Ibin) max working pressure 18.8 bar (200 Ibin’) ~fightening torque 16.Nm max (12 1b “thread diameter Mi0x 15 1:31 39062000-04 7:34Section 1 - General Information Torque Settings Zine Plated Fasteners and Dacromet Fasteners Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines, The two types of fasteners can be readily identified by colour and part number suffix, => Table 6. Fastener Types (14-32), Table 6, Fastener Types Fastener Colour Part No, Suffix Type Zino and | Golden finish Fleg 13157 12z) Yellow Dacromet | Mottled siver finish |'D' (e.g 1815737120) Note: As the Dacromet fasteners have a lower torque setting than the Zine and Yellow fasteners, the torque figures used must be relevant tothe type of fastener. Note: A Dacromat bolt should not be used in conjunction with a Zine or Yellow plated net, as this could change the torque characteristics of the torque setting further. For the same reason, @ Dacromet nut should not be used with a Zine or Yellow plated bolt Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification Note: Dacromet bolls, due to thelr high corrosion resistance are used in areas where rust could occur, Dacromet bots are only used for extemal applications. They are not used in applications such as gearbox or engine joint seams or internal applications. Bolts and Screws Use the following torque setting tables only where no torque setting is specified in the text Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. ‘Torque settings are given forthe following conditions: Condition 1 ~ Unr-lubricated fasteners ~ Zine fasteners — Yellow plated fasteners, Condition 2 = Zine flake (Dacromet) fasteners Lubricated zinc and yellow plated fasteners — Where there is a natural lubrication, For example, cast iron components Verbus Ripp Bolts Fig 9. Torque setings for these bolts are determined by the application. Refer to the relevant procedure for the required settings, 1-32 '9606'3000-04 1-32Section 1 - General Information Torque Settings Zine Plated Fasteners and Dacromet Fasteners Table 7. Torque Settings - UNF Grades’ Fasteners Bolt Size Hexagon (AIF) Condition 4 Condition 2 in. mm in, Nm] kofm | ft | Nm | kofm | Worm oa a3 76 2 [at as | wo | 10 | 74 aie 7a 2 23a | 23 | 14 | 200 | 20 | 17 38 35 one 40 | 47 | 205 | 360 | 37 | 265 76 14 8 640 | 65 | 472 | 870 | 58 | 420 12 727 3a 96.00 | 100 | 723 | @80 | 90 | 649 oe 743 Tae 7400 | 143 | 1032 | 1280 | 128 | 029 oe 759 Tee 7960 | 200 | 146 | 1770 | 180 | 1305 eg 790 Tie 3430 | 350 | 2830 | 3090 | 315 | 2279 78 222 Tsn6 3470 | 558 | 4034 | 4920 | 502 | 2629 7 24 1172 ao | 830 | e004 | 7920 | 746 | S300 718 aT 178 Tero | i204 | e717 | 10630 | toaa | 7eao 114 384 28 16460 | 1678 | 12140 | 1481.0 | 1510 | 10923 Table &. Torque Settings - Metric Grade 8.8 Fasteners. Bolt Size Hexagon (AIF) Condition 1 Condition 2 180 Metric Thread mm mm Nm | kotm | abt | Nm | kofm | iret Ms 3 3 se | 06 | 43 | 52 | 05 | 38 We 3 0 os | io | 73 | 90 | 09 | 66 a 3 % 20 | 24 | t77 | 220 | 22 | 162 Mio 70 7 470 | 48 | 347 | 0 | 44 | 317 Mia 7 Ey 0 | 85 | 612 | 40 | 75 | 66 Mis 6 24 250 | 209 | 112 | 1040 | 168 | 1957 20 20 30 4000 | 408 | 2050 | 3600 | 367 | 2655 Maa 24 36 e000 | 704 | 5089 | 6210 | 633 | 4580 M30 30 6 13720 | 7309 | 10119 | 12350 | 1259 | 709 Mas % 5 23000 | 2446 | 17604 | 21500 | 2200 | 16024 1-33 9806/3000-04 1-33w Section 1 - General Information Torque Settings Table 9. Metric Grade 10.9 Fasteners Zine Plated Fasteners and Dacromet Fasteners Bolt Size Hexagon (AIF) Condition 1 Condition 2 180 Metrie Thread mm mm Nm | kotm | itt | Nm | kofm | iret Ms 3 3 ai | 08 | 60 | 73 | o7 | 54 We 6 0 Be | 14 | 12 | 2s | 13 | 92 Me 8 8 340 | 35 | 250 | 300 | 30 | 228 Mio 70 7 70 | 68 | 44 | 000 | 61 | a2 Miz 72 7 7160 | 118 | 685 | 1040 | 106 | 767 Mie 6 24 2880 | 204 | 2124 | 2500 | 24 | 1010 M20 20 30 20 | 873 | 4145 | 5060 | 516 | B732 M24 24 3 710 | 980 | T9 | 8740 | Got | 6M46 30 30 % 19300 | 1968 | 14235 | 17370 | 177.1 | 12814 M36 36 35 33740 | 3440 | 24885 | 30360 | 3006 | 22302 Table 10. Metric Grade 12.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 180 Metric Thread mm mm Nm | kotm | ibe | Nm | kofm | weet M5 3 3 os | 10 | 72 | 88 | 08 | 65 M6 6 0 766 | 17 | 2 | 0 | 15 | 14 co 3 % 400 | 41 | 25 | 20 | 37 | 255 m0 0 7 wo | 81 | 590 | 720 | 73 | saa wiz R 9 7390 | 142 | t028 | 1250 | 127 | 022 Mie 16 24 3450 | 362 | 2644 | 3110 | 317 | 2204 M20 20 30 ara0 | 887 | 471 | GOTO | O19 | a7 Maa 24 % 71650 | 1188 | 8682 | 1080 | 1088 | 7780 M30 30 8 23160 | 2962 | 17082 | 20840 | 2125 | 1874 M36 36 35 40490 | 4129 | 20864 | 36440 | 3716 | DeBr7 4-34 '9606'3000-04 4-34Ww Section 1 - General Information Torque Settings Zine Plated Fasteners and Dacromet Fasteners Table 11. Torque Settings - Rivet Nut Bolts/Screws Bolt Size 180 Metric Thread mm Nm | kofm | ibe Me 3 72] 04 08 Ma a zo | 03 | 20 MS 5 60 | 06 | 45 Me 6 700 | 10 | 75 Me @ 20 | 25 | 180 M0 70 40 | 49°~(|:« 38S Miz @ Eo Table 12, Torque Settings - Internal Hexagon Headed Cap Screws (Zine) Bolt Size 180 Metric Thread Nm | kgtm | ibe tt M3 20 | 02 | 15 wa 60 | 06 | 45 MS a 30 we wo | 18 | 140 Me “0 | 47 | 340 m0 ao | 93 | 670 Miz 7600 | 162 | 1170 we m0 | 400 | 2020 mie 560.0 | 660 | 4060 M20 7700 | 780 | S680 M24 7ae20 | 1980 | 830 1:35 39062000-04 7:38w Section 1 - General Information Torque Settings ‘O' Ring Face Seal System Adaptors Screwed into Valve Blocks ‘Adaptor screwed into vaive blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port. Hydraulic Connections Table 13. Torque Settings - BSP Adaptors. Hydraulic Connections BSP Adaptor | Hexagon (AIF) Size in, mam Nm | kgtm | iret 11a 790 eo | 18 | 130 36 220 310 | 32 | 230 12 70 a0 | 50 | 360 38 30.0 600 | 61 | 440 34 320 aio | 82 | 600 1 380 130 | 131 | 950 714 50.0 2060 | 210 | 1820 Table 14. Torque Settings - SAE Connections SAE Tube | SAE Port | Hexagon (AF) Size | ThreadSize| mm Nm kgt m lot ft a 78-20 769 200-280 20-28 765-185 e oe 8 oA 460-540 47-55 340-400 3 wa 16 m2 00-1050 | 97-107 | 800-770 0 Te 14 270 7300-1400 | 132-143 | 960-1040 12 | 116-12 38 1900-2100 | 194-214 | 1410-1550 | 156-12 384 2000-3100 | 206-316 | 2160-2300 20 158 a6 2800-380.0 | 285-387 | 2100-2800 1-36 9806/3000-04 1-36w Section 1 - General Information Torque Settings Hoses Screwed into Adaptors Hoses 10-B screwed into adaptors 10-A seal onto an “O° ring 10-C which is compressed into a 45° seat machined into the face of the adaptor port Fig 10. ‘Table 15, BSP Hose - Torque Settings Hydraulic Connections Note: Dimension 10.D wil vary depending upon the torque applied. BSP Hose Size | Hexagon (AF) in, mam Nm kot m lot tt 1 140 740-1600 | 14-16 703-118 4 190 240-270 24-27 77-199 we 20 330-400 34-44 243-235 12 270 440-500 45-64 324-369 ae 300 58.0-650 59-668 428-479 34 320 | 840-920 | 86-94 | 619-678 | 7 380 7150-1260 | 117-128 | 648-028 Ta m0 7ee0-2000 | 183-204 | 1384-1475 112 550 2480-2600 | 249-265 | 1600-1918 1-37 9806/3000-04 1-37wy Section 1 - General Information Torque Settings ‘Adaptors into Component Connections with Bonded Washers Table 16. BSP Adaptors with Bonded Washers - Torque Settings Hydraulic Connections BSP Size in. Nm | kgtm | weet 18 200 | 21 | 160 174 a0 | 34 | 250 3 70 | 76 | 850 12 7020 | 103 | 750 Be 720 | 124 | 900 34 730 | 187 | 1350 7 2030 | 207 | 1600 7114 3050 | 31.0 | 2250 112 3050 | 31.0 | 2250 1-38 9806/3000-04 1-38Section 1 - General Information Torque Settings Hydraulic Connections Ww "Torque Stop' Hose System 7g Fig 11. ‘Torque Stop’ Hoses 11-B screwed into adaptors 11-A ‘seal onto an ‘O' ring 11-C which is compressed into 2 45° ‘seat machined in the face of the adaptor port. To prevent the ‘©’ ting being damages as a result of over tightening, “Torque Stop’ Hoses have an additional shoulder 11-D, which acts as a physical stop. Note: Minimum dimension 11-E fixed by shoulder 11-D. ‘Table 17. BSP “Torque Stop’ Hose - Torque Settings BSP Hose Size | Hexagon (A/F) im, mm nm | kgtm | west Te 740 i a 114 780 270 | 27 | 200 a 20 wo | 41 | 300 2 270 30 | 56 | 400 5 30.0 eo | 66 | 480 3/4 32.0 %o | 97 | 700 1 36.0 1200 | 122 | 600 114 50.0 1800 | 103 | 1400 112 35.0 2480 | 240 | 1800 1-39 9806/3000-04 1-39Ww Section 1 - General Information Torque Settings Torque + Angle Explanation Torque + Angle Explanation Insufficient preload of 2 bolted joint can cause major problems, such as cylinder head warp, leaking gasket joints etc. There are several methods of achieving an accutate preload of a bolted joint, the two main methods used on the JOB 444 engine are: 1) Torque Control Tightening 2) Angle Control Tightening 1. Torque Control Tightening Using @ torque meter to control the torqus is the most popular means of controling preload, and in the majority of instances this method Is adequate. It should be noted that with this process, the majority of the torque is used to overcome friction, therefore slight variations inthe fictional condtions can lead to large changes in the bolt preload 2 Angle Control Tightening ‘Where a more precise preloadis required, the torque + angle’ tightening method is used. The bolt is tightened to @ predetermined torque (this may be ddone in stages), and then as afinal sequence, the bolt is tightened to a predetermined angle - this method of, tightening the bolts results in a smaller variation in the final preload Itis citcal that the predetermined tightening angle is accurately achieved, failure to tighten accurately to the specified angle could result in the bolt preload being incorrect - this will lead to eventual failures, It's good practice to replace all bolts that have been tightened using the torque + angle procedure 1-40 9806/3000-04 1-40Ww Section 1 - General Information Torque Settings Torque + Angle Tightening Procedure Torque + Angle Tightening Procedure ‘The following example explains the recommended torque + engle procedure, A torque angle gauge should be used for accuracy, but asa visual check, the bots can be match A marked as descnbed below. 1 Tighten the bolt to the specified torque (specified torque values will be detailed in the relevant 0 sections). — 2 Markaline across the centre ofthe bolt, anda second line on the part to be clamped - the two lines should, be aligned, as shown at A 3 Marka third line at the specified torque angle - inthis instance the additional torque angie is 90°. This line must be marked the specified angle in a clockwise B direction (to further tighten the bolt), as shown at B 4 In some instances, angle torque tightening can be ‘specified in two stages, for instance in this example, the first angle quoted is 90° (shown at B), and then a second angle of 180°. The additional 180° angle is from the LAST tightened position - as shown at C. 5 Tighten the bolt so thet the line on the bolt aligns with the angle(s) marked on the item to be clamped - +90 remember, to ensure complete accuracy an angle gauge should be used. +180 — Fig 12. 1-41 9806/3000-04 1-41Ww Section 1 - General Information Torque Settings Engine Torque Figures Engine Torque Figures This section details all the torque figures tobe used onthe tem, JOB 444 Engine. Some of the torques MUST be used in Conjunction with the recommended procedures contained = Table 33. Rocker Shaft Bolts ([) 1-48) in this manual, for instance if the torques need to be = Table 53. Starter Motor Bolts ([) 1-56) applied in a specific sequence. For convenience, the list =» " ne belowis arranged in alphabetical order to help you quickly Table 38. Thermostat Housioa Bolts (1) 4-60) locate the item, 3 Table 48. Turbo Charger to Exhaust Manifold Nuts (04-54 Item 2 Table 40. Water Heater Outlet Connector ([) 1-51) 2 Table 20. Bedplate Bolts ([) 1-43) 2 Table 39. Water Inlet Connector Bolts (1) 1-50) 2 Table 43. Cold Start Advance Switch ([) 1-52) 3 Table 41. Weter Pump Bolts (1) 1-51) 2 Table 18. Cylinder Head Bolts ([) 1-43) 3 Table 42. Water Temperature Sender/Switch (182) 2 Table 45, Exhaust Manifold Bolts (7) 1-53) 2 Table 29, Fan Belt Tensioner Bolts ([) 1-47) > Table 27. Flywheel Housing Bolts ([) 1-46) 3 Table 26. Flywheel Hub to Crank Bolts ([} 1-46) 3 Table 50. Flywheel to Crankshaft Hub Bolts (B45) 3 Tablo 51. Front Pulley to Crankshaft Bolts ([) 1-55) 3 Tablo 37. Fuel injection Pump Cap (1) 1-50) % Tablo 44, Fuel Lift Pump Bolts ([} 1-53) % Table 21. Fuel Pump Retaining Nuts ([) 1-44) 2 Table 22. Gear Case to Cylinder Bolts ([) 1-44) 2 Table 47. High Prossure Fuel Pi 1-54) Table 24, Idler Blanking Plug ([) 1-45) % Table 26, idler Gear Hub Assembly Bolts ([\ 1-48) 3 Table 32. Injection Pump Gear Nut ([} 1-48) 2 Table 31. Injection Pump Lock Pin ((\1-48) 2 Table 34. Injector Clamp Bolts ([} 1-49) 2 Table 19. Injector Sleeve ([) 1-43) 3 Table 46, Inlet Manifold Bolts (7) 1-53) 3 Table 62. Lifting Bracket Bolts ([) 1-55) 2 Table 36. Oi Cooler To Cylinder Block (1) 1-49) 2 Table 23. Oi Pump Bolts ([)1-45) 2 Table 30. Ol! Sump Retaining Botts ([} 1-47) 3 Table 28. Piston Conrod End Cap Bolts ([) 1-47) 3 Table 49. Power Take Off (PTO) Pump Bolts +54 3 Table 38. Rocker Cover Bolts ([) 1-49) 1-42 '9806/3000-04 1-42wy Section 1 - General Information Torque Settings Table 18. Cylinder Head Bolts Engine Torque Figures Trem Nm Ibf ft (Cylinder head to block bolts x 12 first stage torque 40 30 = second stage torque 7% 56 + third stage torque 7% 86 - fourth stage torque - 7 + final stage torque : 7 Note: Torque information MUST be used in conjunetion with recommended procedures contained in this manual. “Angle Table 19. Injector Sleeve Tem Nm Ibfft Injector Sleeve 3642 27-31 ‘Angle Table 20. Bedplate Bolts Fig 14. Tem Nim bff Angle Bodplate to block’> Botts A- inital snug torque 5087 . Botts 8 ma 48 . Botts A -second stage 15 as : Bots A final stage ange torque - +180" Note: Torque information MUST be used in conjunction with recommenced procedures contained in this mana 1-43 ‘#80602000-04 1-43w Section 1 - General Information Torque Settings Engine Torque Figures Table 21. Fuel Pump Retaining Nuts Trem Fuel pump retaining nuts Nm Ib ft 2228 16-19 Table 22. Gear Case to Cylinder Bolts “Angle tem Nm Ibfft Angle ‘Gear case to cylinder block bolts 31-35 23-26 1-44 '9606'3000-04 1-44w Section 1 - General Information Torque Settings Engine Torque Figures Table 23. Oil Pump Bolts im fim Ange $ ge eit i 6 Fig te Table 24 ler Blanking Plog Tam ee oer ering pug Soma. co 1a Sano 1-45wy Section 1 - General Information Torque Settings Engine Torque Figures Table 28. Idler Gear Hub Assembly Bolts Trem Idler gear hub assembly bolts Nm Ibfft Angle 6070 44.52 5 ‘Table 26. Flywheel Hub to Crank Bolts Tem Nm Ibfft Angle Flywheel hub to crank gear bolts 4351 3238 Table 27. Flywheel Housing Bolts item Nm bfft Angle Flywheel housing to gearcase bolts = M10 batts (x 6) 4351 9298 = Me bots x 12) 228 16-19 1-46 '9606'3000-04 1-46wD Section 1 - General Information Torque Settings Engine Torque Figures Table 28. Piston Conrod End Cap Bolts Trem Nm Ibfft Angle PPiston conrod end cap bolts"! first stage torque 358 = second stage torque 648 + third stage angle torque Note: Torque information MUST be used in conjunetion with recommended procedures contained in this manual. Fig 23, Table 29. Fan Belt Tensioner Bolts Tem Nm Ibfft Angle Fan belt tensioner retaining bolts 22:26 16-19 Z Fig 24. Table 30. Oil Sump Retaining Bolts tem Nm Ibfft Angle (Oil sump retaining bolts A 2228 16-19 Oil sump plug B 40.60 30-44 1-47 9806/3000-04 1-47wD Section 1 - General Information Torque Settings Engine Torque Figures Table 31. Injection Pump Lock Pin Trem Nm Ibfft Angle Injection pump lock pin 12 ® : Table 32. Injection Pump Gear Nut tem Nm Ibfft Angle Injection pump gear retaining nut” first stage torque 25188 - = second stage torque 9% Br . Note": Torque information MUST be used in conjunction with recommended procedures contained in this manual. Table 33. Rocker Shaft Bolts tem Nm Ibfft Angle Rocker shaft to cylinder head bolts A 22:28 16-19 S Note: The valve lash adjusting screw B must have a minimum turning torque of 12Nm. f the turning torque is less than 12Nm, then a new adjusting screw must be ited, 1-48 9806/3000-04 1-48wD Section 1 - General Information Torque Settings Table 34. Injector Clamp Bolts Engine Torque Figures Trem Nm Ibfft Angle Injector clamp bots 22:28 16-19 : ‘Table 35, Rocker Cover Bolts Tem Nm Ibfft Angle Rocker cover retaining bolts 2024 16-19 - Table 36. Oil Cooler To Cylinder Block tem Nm Ibfft Angle (Gil cooler housing to cylinder block boltsA 22:26 16-19 : il cooler matrix to oll cooler housing bolts 21-25 15-18 5 B (Ol filter drain plug © 35.40 28.20 2 1-49 '9606'3000-04 1-49wy Section 1 - General Information Torque Settings Engine Torque Figures Table 37. Fuel Injection Pump Cap. Vem FIP tamper-proof cap Nm Ibfft Angle 6575 48-56 : Table 38. Thermostat Housing Bolts Tem ‘Thermostat housing retaining bolts Nm Ibfft Angle 2228 16-19 Table 39, Water Inlet Connector Bolts Tem \Water inlet connector retaining belts Nm Ibfft Angle 2228 16-19 - 1-50 '9606'3000-04 1-50Torque Settings Engine Torque Figures wD Section 1 - General Information Table 40, Water Heater Outlet Connector Trem Nm Ibfft Angle \Water heater outiet connector 25-30 19:22 Table 41. Water Pump Bolts item Nm Ibfft_ Angle Water pump retaining bolts 2226 16-19 i, 1-51 39062000-04 754w Trem (Water temperature senderiswitch Section 1 - General Information Torque Settings Engine Torque Figures ‘Table 42, Water Temperature SenderiSwitch Nm Ib ft 6 12 Table 43. Cold Start Advance Switch “Angle Tem Nm Ibfft Angle Cold start advance switch 18 2 - 4-52 '9606'3000-04 1-52wy Section 1 - General Information Torque Settings Engine Torque Figures Table 44, Fuel Lift Pump Bolts + final stage angie torque Trem Nm Ibfft Angle Fuel it pump retaining bolts 22:28 16-19 3 Fig 39. Table 45. Exhaust Manifold Bolts tem Nm Ibfft Angle [Exhaust manifold retaining bolts first stage 28 9 : +90" Fig 40. Table 46. inlet Manifold Bolts tem Nm Ibfft Angle Inlet manifold retaining bots 2228 16-19 3 1-53 '9606'3000-04 1-53wy Section 1 - General Information Torque Settings Engine Torque Figures Table 47. High Pressure Fuel Pipes Tem High pressure fuel pipes Nm Ibfft Angle 2529 19:22 ‘Table 48. Turbo Charger to Exhaust Manifold Nuts Trem Nm Ibfft Angle ‘Turbo charger to exhaust manifold 2226 16-10 retaining nuts Table 49, Power Take Off (PTO) Pump Bolts item Nm bff Angle Power take off (PTO) pump bolts = SAE"A'- M10 bots 4351 2238 = SAE"8!- M12 bots 73.89 54-66 Fig 44, 1-54 ‘#80602000-04 1-54wD Section 1 - General Information Torque Settings Engine Torque Figures Table 50. Flywheel to Crankshaft Hub Bolts Trem Nm Ibfft Angle Flywheel to crankshaft hub retaining ots” + first stage torque 40 30 . = second stage torque 120 89 - - final stage angle torque 7 = +120" Note": Torque information MUST be used in conjunction with recommended procedures contained in this manual. Table 51. Front Pulley to Crankshaft Bolts Tem Nm Ibfft Angle Front pulley to crankshaft retaining bolts first stage torque 3 s - second stage torque 7 86 : final stage ange torque 7 - +180" Note": Torque information MUST be used in conjunction with recommended procedures contained in this manual. Table 52. Lifting Bracket Bolts Tem Nm Ibfft Angle Lifting bracket retaining bolts 4351 32.38 a 1-55 39062000-04 7-55wy Trem ‘Starter motor retaining bolts Section 1 - General Information Torque Settings Engine Torque Figures Table 53. Starter Motor Bolts Nm Ibfft Angle 4351 32.38 : 1-56 '9606'3000-04 1-56w Section 1 - General Information Lubricants and Capacities Engine Lubricating New engines DO NOT require 2 running.in period. The enginelmachine should be used in a normal work cycle immediately, lazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in, Under no cireumstances should the engine be allowed to idle for extended periods; (2.9. warming up without load). ‘A minimum API CF4 grade oll must be used, Superior grade iis may be more appropriate for heavy duty applications (such as sustained high loads and operation at elevated temperatures). ‘The choice of lubricant viscosity should be made based on the lowest ambient temperature at which the machine will be started and the maximum ambient temperature at which itwill operate, The following table provides guidance as to the temperature range that can be accommodated by standard oil viscosities and can be used to select an approptiate grade. > Table 64. ([11-57) Table 54. Gil Viscosity | Minimum Maximum ‘Temperature °C (°F) | Temperature °C (°F) =40 (-40) +30 (66) =40 (-40) +1060) ‘SAE 5W20_| - 30 (-22) +1060) ‘SAE SWA0_| = 30(-22) +40 (108) ‘SAE TOW30 | - 20 (4) ¥ 40 (104) SAE TEWA0 | - 15 (8) ¥50(122) ‘SAE OW30 ‘SAE OW20 Recommended Oils Table 55. Specification ‘AGEA E2.BZA2, API GF4/SG Engine Oi! JCB High Performance” JCB Extreme Performance ‘AGEA ESIBSIAS, API CH-4ISI (1) Not sutablo for gonerator set applications Engine Oil Capacity Choose the grade of oil to suit the temperature range as detailed. = Table 4. ([}1-57). The engine oll capacity, including fiter and clean sumpis 12litres MIN and 15 litres MAX mark on the dipstick Table 56. Tem Capacity litres (UK Gal) Minimum 226) Maximum G3) Engine 1-57 '9606'3000-04 1-57Ww Section 1 - General Information Lubricants and Capacities Coolant Mixtures: Coolant Mixtures A WARNING Antifreeze can be harmful, Obey the manufacturer's instructions when handling full strength or diluted antifreeze. 7444 The protection provided by JCB Four Seasons Antifreeze and Summer Coolant is shown below. If any other ant- {freeze is used, refer to the manufactures instructions and ensure that @ corrosion inhibitor is included. DO NOT use ‘solutions of more than 60% or less than 50% of damage to the cooling system will occur. '55% Solution - Maintains circulation down to 36 deg C (- 33 deg F), protects against damage down to -41 deg © (- 42 deg F) The strength of the antifreeze solution must be checked at least once a year, preferably at the beginning of the cold period, Itis an advantage to leave the anti-reeze in all the year round as it gives continued protection against corrosion. Always renew the antifreeze every two years. A 50% antifreeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boling point. It should be noted that serious damage to the cooling system can occur if corrosion inhibitors ere not used 1-58 ‘#80602000-04 1-58Section 1 - General Information Service Aids Sealing, Retaining and Care Compounds Part Number Description and Application 410273800 RIV slicone sealant - oll pan to bedplate 320700831 [Anaerobic sealant- bedplats to block [Anaerobic sealant- gear case to block [Anaerobic sealant fywheel housing to gear case 320700825 Rubber lubricant Gel- injector Sleeve O-ing Rubber lubricant Gal- rear crankshaft oll seal Rubber lubricant Gal- front crankshaft oll seal 32000872 [Anaerobic Adhesive - all core plugs 410273500 [Anaerobic retaining adhesive - Injector sleeve threads aOASST Gleaner and Gegreaser -Tor degreasing components prior to use of anaerobic sealant a10472800 Degreaser a0473200 Gasket remover 1-59 '9606'3000-04 1-59w Section 1 - General Information Service Tools General Engine Tools ‘The following “general service tools are recommended to perform safe and correct engine repair procedures. When applicable, the JCB part number will be shown immediately below the too tile, If theres no part number, the tool is not available from JCB Service. In this instance, the tool can be purchased trom any good tool store. Fig 49. Piston Ring Expander Tool Fig 51. Dial Test Indicator Use in a number of applications where itis necessary to measure accurate dimensions. Use to instal piston rings on to the piston, Ensures the rings are fitted without damage or distortion Fig 50. Piston Ring Compressor Tool Use to compress the piston rings in preparation for fiting | the piston assembly into the cylinder bore. Fig 52. Valve Spring Compressor Tool Use fo install and remove valve spring eallets 1-60 '9606'3000-04 1-60Section 1 - General Information Service Tools General Engine Tools Use to loosen and tighten allstar dive fasteners. Use in ‘conjunction with a good quality, calibrated torque Fig 54, 892/00292 Oil Filter Wrench Fig 55, 892100041 Bore De-Glazing Too! new piston rings) Fig 53. Star Drive (Torx@) Heavy Duty Set Fig 56. Torque + Angle Too! wrench Use to accurately torque bolts. The torque * angle method is used extensively on the JCB 444 Engine, Use to install or remove spin-on fiter canister. = Fig 57. Star Drive (Torx®) Heavy Duty Socket Bit (T40 size) Use to loosen and tighten the coolant pump retaining bolts. Use in conjunction with @ good quality, calibrated torque vrench. De-glazing tool for eylinder bares (fo aaslat beddingin of 1-61 39062000-04 7-64w Section 1 - General Information Service Tools ‘Specialist Engine Tools Specialist Engine Tools The following “specialist’ service tools are required to Perform safe and correct engine repair procedures. The tools can be ordered using the tool part number detailed, For reference, a copy of the tool drawings is included in ‘section 10, If the tools are to be made locally, the correct grade of material must be used. S Fig 58. 892/01146 Cylinder Block Core Plug Fitting Tool Use to correctly it iinder block core plugs. Too! includes handle and different size cups to suit various size core plugs d Fig 60, 892/01148 Timing Pin (Crankshaft) Use to correctly align the crankshaft at top dead centre: (TDC). Fig 61, 892/01148 Timing Pin (Camshaft) Fig 59, 892/01147 Crankshaft Turning Tool Use to manually turn the erankshafi, for instance when setting top dead centre (TDC). 4 x mounting holes to suit ‘crankshaft pulley. Use to align the camshaft in the correct timed position ‘when removingffiting the fuel injection pump. EP Fig 62. 892/01149 Template For Application Of Oil ‘Sump Sealant Use to ensure correct sealant application Note: Correct posiioning of the sealant is critical io prevent leaks 1-62 '9606'3000-04 1-62Section 1 - General Information Service Tools ‘Specialist Engine Tools Fig 63. 892/01150 Oil Sump Location Dowels (2 off required) uring fitin, 2 good joint and prevent leaks. Fig 64, 892/01151 Injector Sleeve Fitting/Removing Tool are prevfitted on cylinder head assemblies. Fig 65. 892/01152 Valve Stem Seals Fitting Too! Fig 66. 892/01154 Fuel Injection Pump, Tool For Removing The Tamper-proof Cover Use to correctly align the sump, preventsump movernent Use to gain access to the FIP gear retaining locknut. The tool is used to remove the tamper proof cover. ‘Note: Correct positioning ofthe sump is cricalto ensure S B ver Fig 67. 892/01155 Fuel Injection Pump Gear Removal Too! Use to remove the gear from the fuel injection pump shaft Use to ft and remove the injector sleeves. The sleeves 0 am) Fig 68, 892101157 Crankshaft Front Oil Seal Fitting Tool Use to correctly fit the crankshaft front oll seal Use to eneure positve engagement ofthe valve stem seals, 1-63 39062000-04 71-63wy Section 1 - General Information Service Tools ‘Specialist Engine Tools Oe SS e480 Fig 69. 892/01156 Crankshaft Rear Oil Seal Fitting Tool Use to correctly fit the crankshaft rear oll seal Se Pa Fig 70. 892101158 Crankshaft Rear Oil Seal Alignment Toot Use to position the crankshaft rear oll seal before using fiting tool 89201158. This tool must be used to position the seal, otherwise the lip of the seal may be ‘inverted during the fting process - leading to potential oll leak. Fig 71. 692101160 (x 2) Lifting Brackets Use to safely it and lower the engine, lifting brackets are purposed designed Fig 72, 892101159 Rocker Cover Injector Seals Fitting Too! Use to correclly sat and ft the rocker cover injector seals, Fig 73. 892101168 Dummy Injector {Usein place of te injactor to check engine compression. End drilled and tapped 1/8-288SP to accept universal adaptor fitting 1-64 '9606'3000-04 1-64Section 1 - General Information Service Tools ‘Specialist Engine Tools Fig 74, 892101173 Sealant Applicator and correctly. ‘Note: For reference ui ‘sizes: 1.5mm bead for anaerobic sealant, 4.0 mm bead for sicone sealant Use to apply the anaerobic andlicone sealant evenly Fig 76. 892/01179 °C’ Shaped Ring Spanner Use to access the inner mounting nut ofthe fuel injection pump. <> aazinites Fig 75. 892101169 Top Dead Centre (TDC) Setting Too! Use to correctly setthe No. 1 piston to TOC (firing) when Temoving and replacing the fuel injection pump. Fig 77. 892101175 Template For Application Of Bedplate To Engine Block Anaerobic Sealant Use to ensure correct sealant application Note: Correct positioning of the sealant is entical 10 censure joint integrity. 1-65 '9606'3000-04 1-65Section 1 - General Information Service Tools ‘Specialist Engine Tools Fig 78, 892101176 Template For Application Of Gear Case To Engine Block Anaerobic Sealant Use to ensure correct sealant application ‘Note; Correct positioning of the sealant is critical to ensure joint integrity cco41200 Fig 80. Engine Mounting Frame For use with a suitable engine stand. Manufacture locally. = Service Too! Drawings ([)1-67) Se? Fig 81. 892101259 Crankshaft Rear Oil Seal Spacer Ring For use with specific engine builds only - See parts catalogue. Fig 82. 320107182 Fuel Return Line Tubing (Clear) For dagnosing air ingress into the fuel system. 1-66 Fig 79, 892101176 Template For Application Ot Flywheel Housing To Gear Case Anaerobic Sealant Use to engure correct sealant application ‘Note; Correct positioning ofthe sealant is cnical to ‘ensure joint integrity '9606'3000-04 1-66Ww Section 1 - General Information Service Tools Service Tool Drawings Service Tool Drawings 892/01146 - Core Plug Fitting Tool Fig 83. 1-67 39062000-04 1-67Ww Section 1 - General Information Service Tools Service Tool Drawings 892/01147 - Crankshaft Turning Tool Fig 84. 1-68 39062000-04 7-68Section 1 - General Information Service Tools Service Tool Drawings 892/01148 - Timing Pin eo Lc 45" sor enos jl ab MATERIAL: 10.0 DIA SILVER STEEL FINISH: CHEMICAL BLACK = PEE OATH nike Fig 85. 4-69 '9606'3000-04 1-69Ww Section 1 - General Information Service Tools Service Tool Drawings 892/01149 - Sump Sealant Template gaa3 aq 8829 : j a8 @ as ot { i i so i i i i 2 i + ! jp | a | } t s i i t £ i s ~ | s i x a T ! Ty i wali + %, I al J hreR\A-caRoBOARO “| ‘| “OMENSions a i Fig 88. 770 39062000-04 1-70wD Section 1 - General Information Service Tools Service Tool Drawings 892/01150 - Oil Sump Location Dowel s.e4 4 2 x 30" 7.96 7.86 8-125 oe? Fig 87. 174 ‘#80602000-04 74wD Section 1 - General Information Service Tools Service Tool Drawings 892/01151 - Injector Sleeve Removal Tool Fig 88. 172 ‘#80602000-04 1-72wD Section 1 - General Information Service Tools Service Tool Drawings 892/01152 - Valve Stem Seal Fitting Tool 200 2x as zea iN oes 4 0 28 vEDIUN DIAMONO KARL 8.17.3 O-RING GROOVE Fig 89. 1-73 ‘#80602000-04 1-73Ww Section 1 - General Information Service Tools Service Tool Drawings 892/01154 - FIP Cover Removal Tool Fig 90. 1-74 ‘#80602000-04 1-74Section 1 - General Information Service Tools Service Tool Drawings 892/01155 - FIP Gear Removal Tool (\ NZ | Fig 91. 1-75 '9606'3000-04 41-75Ww Section 1 - General Information Service Tools Service Tool Drawings 892/01157 - Crankshaft Front Seal Fitting Tool Fig 92. 1-76 ‘#80602000-04 1-76Service Tools Service Tool Drawings Ww Section 1 - General Information 892/01156 - Crankshaft Rear Seal Fitting Tool oh a! (Ore eT oll Fig 93. 177 ‘#80602000-04 1-77wD Section 1 - General Information Service Tools Service Tool Drawings 892/01158 - Crankshaft Rear Seal Alignment Tool su REE BOE 892/01159 - Injector Seal Fitting Tool 2xas 1 928 Mepis DIAWOND KNURL Fig 96. 1-78 ‘#80602000-04 1-78wD Section 1 - General Information Service Tools Service Too! Drawings 892/01168 - Dummy Injector FIT O 14.1% 1.6 SEC Nitalte*ataing’ Fig 96. 1-79 ‘#80602000-04 1-79wD Section 1 - General Information Service Tools Service Tool Drawings 892/01169 - Top Dead Centre (TDC) Setting Tool MATERIAL: 8S970:1991 230407 (EN1A) Fig 97. 1-80 9806/3000-04 1-80Ww Section 1 - General Information Service Tools Service Tool Drawings Engine Mounting Frame 51a 0 tas 112 [20 H7 thru Plate 25 198 a8 \ ; plo 284 tron “hgh sz7PcD 2 100 — +24 —| con40100 sara 2 1692 138 —+ Fig 98. 1-81 9806/3000-04 1-81w Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification = Engine Repair Parts and Kits Identification ([) 1-62) detail the repair parts ana kits available from JCB Service. When applicable, the femoval and replacement, or dismanting and assembly procedures contained in this manual wll make a reference to the parts and kits on these pages. For instance, Rocker Cover - Removal and Replacement - Section 12 details the rocker cover removal and replacement procedure. On this page, there is a sub-heading termed ‘Service Parts’, listed under this heading are items available as replacement parts. The items are identified exactly as listed in the following pages, 2g, item 1 - Rocker Cover Gasket Kit, item 1.1 - Rocker Cover Gasket, etc. ‘The kits are identified for your reference, when applicable a complete kit can be ordered, or the individual parts. Refer to the engine parts catalogue for the relevent part numbers. For convenience, the kit ttles and page cross references are identified as follows, tem Page Rocker Cover Gasket Kit 2 (01-83) Crankshaft Assembly Kit 2 (01-83) Piston Kit(NA) > (21-84) Piston Kit (TC) 2 (D184 Piston Kit(TCA) 2 (01-86) Top Gasket Kit (NA) 2 (01-86) Top Gasket Kit (TC/TCA) 2 (D487) Bottom Gasket Kit 2 (01-88) Oil Pan (sump) Sealant Kit 2 (01-89) cylinder Head KitNATC) 2 (01-89) cylinder Head Kit (TCA) 2 (21-89) Cylinder Head Gasket Kit(#0.25) > (1-90) Cylinder Head Gasket Kit(#0.50) > ([ 1-90) Main Bearing Kit (Sta) 2 (049) ‘Thrust Wesher Kit (Sta) 2 (049) Item Page Big End Bearing Kit (Sta) 2 (01-92 Engine Overhaul Kit (NA) 2 (01-99 Engine Overhaul Kit (TC) 2 (01-99 Engine Overhaul Kit (TCA) 2 (01-95) Starter Motor Kit 2 (01-96) Alternator Kit 201-97 1-82 9806/3000-04 1-82w Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification ia oa 7 en : 4.1 Rocker cover seal f 1 io neti : . "eres i , ta, oe : aoe : iene ssn aS 7 “eS fe Item Description Qty caer ale ; 24 Crankshaft - machining 1 2 22 cmtactoc tech ee ete 24 Zeroleak plug 1 aeons ; th plane ; tte esr sores 1-83 9806/3000-04 1-83wD Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification Tem Description ay 2 Piston kt NA 1 3.1 Piston assy NA (NSP) 1 3 32 Piston ing kt sta 1 33 Retainer piston pin 1 item Description aly 4 Piston et TC 1 44 Piston assy TC (NSP) 1 42 Piston ring kt ste 1 43 Relainer- piston pin 1 784 seosano008 1-84Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification Tem Description ay 5 Piston kt TOA 1 5.41 Piston assy TCA (NSP) 4 52 Pistonsing kt etd 4 53 Retainer piston pin 1 1-85 39062000-04 7:85Ww Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification em Description © Top gasket kit NA 6.1 Cylinder head gasket 62 Valve stem seal 16.3 Thermostat heg o-seal 6.4 Gasketiinlet manifold 16.5 Gasket exhaust manifold NA 6.6 Intake heater gasket 67 Cooler cover gasket 6.8 Gasket - water inlet pipe 6.9 Washer-- fuel injector 6.10 Seal - fuel injector 16.11 O-ring - plugs, oll cooler housing 16.12 Orting - oil cooler matrix 6.13 O-ring - fuel ltt pump 16.14 Bonded seal - oll pressure sender, cold start switch 16.15 Bonded seal - temperature sender switch 16.18 Bonded seal - water outlet connector 1.1 Rocker cover seal 1.2 Injector seal 1.3. Injector cap 14 Fuel pipe cap 15 O-ring leak-oft rail 16 Oxing filer cap 1-86 9806/3000-04 1-86Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification item Description 7 Top gasket kit TOrTCA 7.1 Gasket /heat-shield 7.2 Gasket eto manifold 73 Copperwasher 74 Oxing 7.5 Sealing washer ol drain 4.4 Rocker cover seal 1.2. Injector seal 1.3 Injector cap 1.4 Fuel pipe cap 1.5 Oxingleek-of rail 4.8 O-ing filer cap 6.1 Piston assy TCA (NSP) 82 Pistonring kt std 63 Retainer- piston pin 1 64 — Gasketinlet manifola 1 65 Gasket exhaust manifoldNA 1 86 Intake heater gasket 1 67 Cooler cover gasket 1 68 Gasket water inlet pipe 1 89 Washer -fuel injector 4 610 Seal - fuel injector 4 "A 6.11 Oving- plugs, cl cooler housing 2 Se 6.12 Oxing- ol cooler mati 2 Fig 106. 6.13 Oving- fue! itt pump 1 6.14 Bonded seal ol pressure sender, 2 cold start witch 615 Bonded seal temperature sender 4 ston 616 Bonded seal - water cutet 1 connector 1-87 9808300004 1-87Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification fear Bescipton oy Bom gestatt i 1 Water pump gasket ; 82 Oleeat ter ; ea teea rae ‘ 4 Olpanseaian ‘ aS Sedenvomgatscdsan 4 eo seatet ‘ a7 Olean pag oneg 2 exo sear ' jam ang ‘ Fo ee Item Description Qty: 20 Olpenceaantit : 8.4 Oil pan sealant 1 9 ee: * 8.5 Sealant template oil pan 1 ata ‘No 87 Onng-azain pug ‘ ONS Fig 107. 1-88 '9606'3000-04 1-88Ww Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification em Description ‘ay 10 Cylinder head Kit NATO 10.1 Cylinder Head Machining” 102 GAValves Inlot 103 GAValves Exhaust Fig 108, (1). Referto Technical Data, Section 1, for machining information and tolerances. am Description ty 11 Oylinder head Kit TCA 11.1 Cylinder Head Machining” 10.2 GA Valves Inlet 103 GAValves Exhaust Fig 109. (1) Refer to Technical Data, Section 1, for machining information and tolerances. 1-89 9806/3000-04 1-89w Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification em Description 12 Cylinder head gasket kit +0.25 12.1 Cylinder head gasket +0.25 Qty fem Deseription 13. Cylinder head gasket kit +0.50 13.1. Cylinder head gasket +0.50 Fig 111. 1-90 '9606'3000-04 1-90Ww Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification em Description ‘ay 14 Main bearing kit std 14.1 Bearing - Main Upper std”) 14.2 Bearing - Main Lower std” 143 Bearing - Main Upper Rear std” 144° Bearing- Main Lower Rearsta”” (1) Items not available separately, part of kit tem 14, tem Description ty 18 Thrustwasher kit ste 151. Bearing - Main Thrust Washer 2 1-91 ‘#80602000-04 1-94w Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification item — Description ay 46 Big-end bearing kitstd 4 a 18.41 Beating Big-end std 8 > 16.1 Fig 144 1-92 ‘#80602000-04 1-92Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification Description ay 17 Engine overhaul kit NA std 1 17.1 Bolt -M8 x 57 Con. Rod 8 alg 3 Piston it NA 4 © Top gooket it 1 8 Bottom gacket kt 1 1-93 seosano008 1-93em Description 18 Engine ovethaul kit TC std 17.1 Bolt -MB x 87 Con. Rod 4 Piston kit TO © Top gasket kit 8 Bottom gasket kit Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification 1-94 '9606'3000-04 1-94Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification Tem Description ay 19 Engine overhaul kit TCA std 1 x 17-1 Bolt -MB x 87 Con. Rod 8 5 Piston kit TCA 4 © Top gasket kit 1 8 Bottom gasket kit 1 Fig 117. 1-95 '9606'3000-04 1-95Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification Tem Description ‘ay 50 Starter motor kit 1 50.1 Starter solenoid 1 50.2 Sundry parts kit (bolts, o-ring) 1 50.3 Brush holder assembly 1 50.4 Brush kit 1 Fig 118. 1-96 /9806/3000-04 1-96Section 1 - General Information Service Parts and Repair Kits Engine Repair Parts and Kits Identification Trem 60 60.4 602 603 604 Description ‘Alternator kit Thru bot kt Pulley Nut and spacer Regulator and brush box assembly wang Fig 19. 1-97 '9606'3000-04 1-97Section 1 - General Information Engine Lifting Lifting Information Refer to the Technical Data section forthe various engine weights The ling equipment used must be an approved type and capable of lifting the engine safely. The recommended liting equipments shown at 120-B. Never attempt to manualy lit heavy components such as the cylinder head, crankshaft etc on your own, Always use iting equipment, or obtain the help of an assistant Ingpect the liting brackets 120-A for signs of damage. The brackets must be correctly torquedto the engine biock, the correct torque figure for the bracket retaining bolts is 43- 51Nm, Make sure the lifing equipment does not damage any of the engine dressing and the rocker cover. Fig 120. 1-98 '9606'3000-04 1-98Ww Section 1 - General Information Operating Procedures Starting the Engine Pre-Start Notes 4A warNinc (On turbo-charged machines, do not keep the accelerator pedal fully depressed when the engine has started. Do not race the engine until the oil pressure low light has gone out. Racing the engine too soon could damage the turbo-charger due to insufficient lubrication, tei Several factors will influence the starting performance of the engine, these include ‘The ambient temperatures ‘The condition of the battery The viscosity of the engine oil Fig 121. The condition of the starter motor The engine does not require any cold starting aids for temperatures down to ~18°C. If the engine is operating in temperatures below -18°C, then a pre-heater is available, The heater fits in the inlet manifold as shown, and is linked into the machine's electrical system In severe cold cimate conditions, a block heater can be installed, Make sure that all the necessary machine pre-start checks have been completed, these will include — engine oil level ~ engine coolant level = battery connections = fuel tank has sufficient fuel = fuel prevfters drained = the machine is safe and ready to start 1-99 ‘#80602000-04 1-99wD Section 1 - General Information Operating Procedures ‘Starting the Engine Start Procedure 1. Make sure that all machine controls are in the neutral position 2 Ma pre-heater is ited, turn the starter key A to the to the preheat position Il, If applicable to your equipment, the wearing light onthe instrument ouster will extinguish when pre-heat is complete A caution Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least 2 minutes. one 3. Turn the starter key to the starter engage position il and hold it there until the engine starts. Do not operate the starter for more than 20 seconds. Noto: Ifthe engine does not start atthe first attempt, rum the key to the off (O) position and allow the starter to cool for a fow minutes and then repeat stops 2 and 3 4 As soon as the engine starts, release the key which vill return to the run position, 5 Engine Checks After Start-up (1-101) A 0 Fig 122. 7-100 39062000-04 1-100w Section 1 - General Information Operating Procedures Engine Checks After Start-up - white Starting the Engine abnormal 6 Check for any lubricating oll leakage, particulaly 4 WARNING around joints and connectors. On turbo-charged machines, do not keep the accelerator pedal fully depressed when the enginehas 7 Check the fuel injection pump circuit for leakage, started, Do not race the engine until the oil pressure including fuel ins, fue fiers) and injection pump low light has gone out. Racing the engine too soon could damage the turbo-charger due to insufficient 8 Check the coolant system for signs of leakage lubrication. partcualy around the radiator and hose wen4i connections 4 WaRNING Stop the engine and investigate the cause if any of the following conditions occur: 1. The warning lights fall to go off when the engine has been started 2 The alarm is still sounding when the engine has been started, 3 The warning lights illuminate and the alarm sounds when the engine is running. e242 Check the following items after the engine has been started 1. Make sure that al the engine instrumentation warring lights have extinguished 2 De mot over accelerate the engine until the “oll pressure low warning light has extinguished 3 It any waming indicator fails to extinguish, or if they illuminate while the engine is running, make the machine safe, slop the engine and investigate the cause 4 Listen for engine noise, any abnormal noise must be investigated fo determine the cause 5 Check the exhaust smoke colour, generally after the engine has reached operating. tempereture, the exhaust colour should be a8 detailed: = colourless orlight blue normal - black ~ abnormal 1401 39062000-04 1-101wy Section 1 - General Information Operating Procedures Engine Running-in Procedure New engines DO NOT require a running: period, The enginefmachine should be used in a normal work cycle immediately. Glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if engine duty is too light from new, Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load) ‘A minimum API CF4 grade oil must be used. Superior grade oils may be more appropriate for heavy duty applications (such as sustained high loads and operation at elevated temperatures). Rafer also to Lubricants and Capacities, Section 1. Starting the Engine LO; Fig 123. 1-102 /9806/3000-04 1-102Section 1 - General Information Operating Procedures Starting the Engine Stopping the Engine 1. Make sure that all machine controls are in the neutral position A cauTION Allow turbocharged engines to run at approximately 1000 rpm and reduced load for 2 to 3 minutes before shut down. This will allow the turbocharger to cool. Failure to follow this procedure could result in turbocharger damage. Ene 2. tis recommended that turbocharged engines are run at 1000 RPM (approximately) and reduced load for 2 = 3 minutes before shut down. This will allow the turbocharger to cool and return to idle speed while engine oil pressure is stl available for lubrication. 3. Turmthe starter key to the OFF (0) position, as shown ata, A 0 Fig 124. 1-103 '9606'3000-04 1-103Section 1 - General Information Operating Procedures Starting the Engine Page left intentionally blank 4-404 9808300004 4104Section 3 Routine Maintenance Service Manual - JCB 444 Mechanical Engine Section 4 - General Information Section 2- Care and Safety ‘Section 3 - Routine Maintenance ‘Section 4 - Systems Deseription ‘Section 5 - Fault Finding Section 6 - Test Procedures ‘Section 7 - Fuel System Section 8 - Cooling System ‘Section 9 - Lubrication Systom ‘Section 10 - Electrical System ‘Section 11 - Induction and Exhaust Sy ‘Section 12 - Base Engine Publication No. '9806/3000-04 teat a oh aNotes: Section 3 - Routine Maintenance 3-0 '9606'3000-04 3-0Section 3 - Routine Maintenance Contents Contents Page No. Routine Maintenance Introduction 3-4 Maintenance Procedures... 3-1 Cleaning the Engine .. 3-2 High Pressure Cleaning 3-2 Lubricants - Health and Safety 3-3 Hygiene 3-3 Storage 3-3 Weste Disposal wniiaicunsinntistadsininiivaieainttianncaunat®= 9 First Aid - Oil 3-3 Spillage 3-4 Fires 3-4 Service Schedules 3-5 Engine Oil and Filer... 3-8 Checking the Oil Level 3-8 Changing the Oil and Fitter 3-9 Engine Cooling System 3-10 Coolant Mixtures 3-10 Checking the Coolant Level 3-10 Changing the Coolant 3-11 Front End Accessory Drive (FEAD) Belt 3-12 Engine Fuel SYSteM .orcsseonnnnsnnnnnnnnnnnnnnnnnnee 9°13 Draining the Water Separator and Fuel Filter 3-13 Changing the Filter Element 3-14 Changing the Water Separator Pre- Filter ..crsnnnnnnewnnnnne 315 Priming the Fuel Syste 3-16 Air Intake System ic 3-18 Engine Breather . oe 3-19 Cleaning the Engine Breather Gauze 3-19Section 3 - Routine Maintenancew Section 3 - Routine Maintenance Routine Maintenance Introduction Maintenance Procedures. The following Routine Maintenance section refers to the engine only, General references will be made to the machine A warning Machinery utilizing the engine must be correctly parked and prepared, for example safety strut fitted, prior to completing maintenance tasks on the engine. Maintenance must be completed by suitably qualified personnel, You or others could be killed or seriously injured if the machine is not correctly prepared and maintained. ane1s When the engine is installed in a machine, it will be necessary to make sure that the machine is correctly parked and prepared to safely complete the routine maintenance tasks. Refer to the machine's documentation, To obtain the best performance from your engine, make sure that the service tasks are completed at the recommended period - see Service Schedules. If the machinefengine is working in adverse conditions, then the service intervals should be reduced, examples of adverse conditions are: operating in a very dusty environment = operating continuously at high engine load ~ operating in an environment with lots of chaff = operating in an extremely hot and cold environment — operating continuously on slopes — operating continuously at high alitude = operating in an environment with high humidity = operating with a low quality Fuel Note: See Technical Data, Fuel Specifications, Section 1, for mare information relating to recommended fuels. ‘All maintenance procedures must be completed by ‘suitably qualified personnel 34 '9606'3000-04 3-4wD Section 3 - Routine Maintenance Routine Maintenance Cleaning the Engine Cleaning the Engine Do not attempt to clean any pat ofthe engine wil itis running, Stop the engine and allow it to cool for atleast one \ hour. Disconnect the machine batery. A UZ \ Use an approved water solute degesserto stn any ol e \ deposits. Wash with clean water and allow the engine to dry. High Pressure Cleaning A caution ‘The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. mea Special precautions must be taken if the engine is to be ‘washed using a high pressure cleaning system as follows 11 Do not aim the jet wash directly at the fuel injector ‘seals (shown at A). 2 Donotwash any part of the = fuel injection pump cold start device - electrical shut off solenoid (ESOS) + electrical connections 3 Care should be taken, when an engine is ceanedwith a high pressure cleaning system. 4 Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system, ‘The engine or certain components could be damaged by pressure washing systems, 32 39062000-04 32w Section 3 - Routine Maintenance Routine Maintenance Lubricants - Health and Safety Lubricants - Health and Safety It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned ith lubricants read it too Hygiene JCB lubricants are not a their intended purposes. hrisk when used property for However, excessive or prolonged skin contact can remove the natural fats from your skin, causing otyness and ination, Low viscosity oils are more likely to do this, so take special care when handling used ols, which might be cuted with fuel contamination Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene, For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following Storage ‘Avays keep lubricants out ofthe reach of children, Never store lubricants in open or unlabelled containers Waste Disposal 4 caution It is illegal to pollute drains, sewers or the ground, Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. intaat4 ‘All waste products should be disposed of in accordance with all the relevant regulations, ‘The collection and disposal of used oil should be in accordance with any local regulations, Never pour used tengine oil into sewers, drains or on the ground. New Oil ‘There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices, Used Oil Used engine crankcase lubricants contain harmful ‘contaminants, Here are precautions to protect your health when handling used engine oil 1 Avoid prolonged, excessive or repeated skin contact with used ol 2 Apply @ barrier cream to the skin before handling used oil 3 Note the following when removing engine oil from skin ‘a Wash your skin thoroughly with soap and water b Using a nail brush will help, © Use special hand cleansers to help clean dirty hands. d Never use petrol, diesel fuel, or paratfin for washing. 4 Avoid skin contact with oll soaked clothing. 5 Don't keep oily rags in pockets. 6 Wash dity clothing before re-use, 7 Throw away oil-soaked shoes First Aid - Oil Eyes Inthe case of eye contact, flush with water for 15 minutes Ifinitation persists, get medical attention. 33 seosano008 33wy Section 3 - Routine Maintenance Routine Maintenance ‘Swallowing If oll is swallowed do not induce vomiting. Get medical advice. ‘Skin Inthe case of excessive skin contact, wash with soap and water. Spillage ‘Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area, Fires Extinguish with carbon dioxide, dry chemical or foam. Fire- fighters should use self-contained breathing apparatus. Lubricants - Health and Safety 3-4 '9606'3000-04 34wD Section 3 - Routine Maintenance Routine Maintenance Service Schedules Service Schedules ‘A badly maintained engine is a danger to the operator and the people working around him, Make sure that the regular maintenance and lubrication jobs listed in the service ‘schedules are done to keep the engine in a safe and efficient working condition, A warning Machinery utilizing the engine must be correctly parked and prepared, for example safety strut fitted, prior to completing maintenance tasks on the engine. Maintenance must be completed by suitably qualified personnel. You or others could be killed or seriously injured if the machine is not correctly prepared and maintained. anes Apart from the daily jobs, the schedules are based on machine running hours Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use @ machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. Calendar equivalents: 10 Hours = Daily 50 Hours = Weekly 500 Hours = Six Months 1000 Hours = Yearly 2000 Hours = 2 Years 6000 Hours = 6 Years ‘The tick boxes indicate the frequency, for example, ‘il and Filter Change’ is ingleated every 500 hours, The first change would therefore be at 500 hours.then the next change at 1000 hours, then 1500 hours etc. Service schedules differ depending on engine application Make sure you refer to the correct schedule as follows 2 Table 1. All_ Applications Except Generator Set Applications (13-6) 2 Table 2. Generator Set Applications Only ([)3-7) 35 39062000-04 35w Section 3 - Routine Maintenance Routine Maintenance Service Schedules Table 1. All Applications Except Generator Set Applications Pre-sarl Gold Checks Service Points and | Operation “10 Hr |60 Hr] 500 | 1000 [2000 [6000 Fluid Levels He [Hr [Hr He ENGINE Oillevel ~Chedk a Cootant Qualiy/Tevel ~ Check o Goclant or Oil Leaks ~Chesk a Fuel iter and Water Seaimentor = Shack or Cotainaton ao Oil and Fiter 2 = Change a Fuel Fiter® ~Change a [AI Hoses - Condition “Check a Radiator® “Clean a Front End Accessory Drive (FEAD) Belt Check a Condtion ‘Ar Gleaner Outer Element ® = Change a [Air Cleaner Inner Element ~Change a Valve Clearances ~ Check and Adjust a Breather Gauze ® “Clean a Oil Filler and Dipstick O-7ngs "Change a Tow idle Speed “Check and Adjust a Cooling system “Drain and Fil a Rocker Cover Sealand injector Seals “Change a Front End Accessory Drive (FEAD) Belt “Change a Injectors “Change a Injector(s) Leak OFF Rail Change a High Pressure Fual Lines “inspect a (1) operating under arduous conditions, change the engine oil and fiter every 250 hours. 2) Tho ail service interval will be affected if there is a high sulphur content in the fuel. Refer to Technical Data, Fuel System Data, for more information, (9) Mf Dieseimax engines are operated with 820 Biodiesel, change the oll and fiter every 260 hours. A minimum specification of CH4 oil must be used. Only Dieselmax engines manufactured from 2007 are suitable for operation with 20 Biodiesel. Other service requirements apply, refer to Technical Data, Fuel System Data, for more information. (4) Check the machine's operator handbook for the fuel sedimenter fiter change frequency. ©) operating in dusty adverse working environments, more frequently. (6) SA, SB, SC engines only 3-6 '9606'3000-04 3-6w Section 3 - Routine Maintenance Routine Maintenance Service Schedules Table 2. Generator Set Applications Only re-start Gold Checks Service Points and — [Operation “10 Hr|60 Hr] 600 | 1000 [2000 [6000 Fluid Levels He [Hr [Hr He ENGINE Oillevel ~Chedk a Cootant Qualiy/Tevel ~ Check o Goclant or Oil Leaks ~Chesk a Fuel iter and Water Seaimentor = Shack or Cotainaton ao Oil and Fiter 2 = Change a Fuel Fiter® ~Change a [AI Hoses - Condition “Check a Radiator® “Clean a Front End Accessory Drive (FEAD) Belt Check a Condtion ‘Ar Gleaner Outer Element ® = Change a [Air Cleaner Inner Element ~Change a Valve Clearances ~ Check and Adjust a Breather Gauze ® “Clean a Oil Filler and Dipstick O-7ngs "Change a Tow idle Speed “Check and Adjust a Cooling system “Drain and Fil a Rocker Cover Sealand injector Seals “Change a Front End Accessory Drive (FEAD) Belt “Change a Injectors “Change a Injector(s) Leak OFF Rail Change a High Pressure Fual Lines “inspect a (1) operating under arduous conditions, change the engine oil and fiter every 250 hours. 2) Tho ail service interval will be affected if there is a high sulphur content in the fuel. Refer to Technical Data, Fuel System Data, for more information, (9) Mf Dieseimax engines are operated with 820 Biodiesel, change the oll and fiter every 260 hours. A minimum specification of CH4 oil must be used. Only Dieselmax engines manufactured from 2007 are suitable for operation with 20 Biodiesel. Other service requirements apply, refer to Technical Data, Fuel System Data, for more information. (4) Check the machine's operator handbook for the fuel sedimenter fiter change frequency. ©) operating in dusty adverse working environments, more frequently. (6) SA, SB, SC engines only 3-7 '9606'3000-04 3-7wD Section 3 - Routine Maintenance Routine Maintenance Engine Oil and Filter Engine Oil and Filter AcauTion It is illegal to pollute drains, sewers or the ground, Clean up all spilt fluids andior lubricants. Used fiuids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. intaat4 WARNING oll Oil is toxic. If you swallow any oll, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oll more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oll thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. inta23 Checking the Oil Level Fig 2. Engine oll and oil fiter change must be completed in accordance with the service schedules, Failure to change the oil and fiter at the recommended interval could cause serious engine failure. 1 Patk and make the machine safe in accordance with the machine handbook instructions. 2 Check that the oil level is between the two marks on the dipstick 2-4. 3. If necessary, add recommended oil through one of the the filer points 2-B. 38 seosano008 38Ww Section 3 - Routine Maintenance Routine Maintenance Changing the Oil and Filter Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the ol. 1 Place @ container of suitable size beneath the drain plug 3-c. 4 caution il will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. Bo6 2 Remove drain plug 3-C and its ‘0'ring 3-D. Let the cil drain out, then clean and refit the drain plug with a rnew'O’ ring. Torque tighten the plug to 40 - 60. Nm (30 = 44 Ib fh, 3. Loosen and remove fer housing drain plug 3-E. Let the oil fully drain. Refit the plug. Torque tighten the plug to 40 - 60 Nm (30 - 44 Ibf 4 Unscrew the filer canister 3-F, using a chain wrench it necessary. Engine Oil and Filter 5 Clean the seal face of the fer head 3-6. 6 Smear the seal 3-H on the new fiter canister with clean engine ol 7 Screwin the new fiter canister - hand tight only. AcauTion It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations, Use authorised waste disposal sites, 8 Through one ofthe filler points 3-B,fllthe engine with ‘the recommended ol to the MAX mark on the dipstick 3-A Wipe off any spit ol, refit the filler cap and make sure itis secure. 9 Operate the engine until the oil pressure low warning light has extinguished. Check for oll leakage. When the oil has cocled, check the oil level again, and if necessary top up with clean engine cl, 39 39062000-04 39w Section 3 - Routine Maintenance Routine Maintenance Engine Cooling System Engine Cooling System Coolant Mixtures ‘The protection provided by JCB Four Seasons Antifreeze and Summer Coolant is shown below. If any other ant- treeze is used, refer to the manufacturer's instructions and tengure that a Corrosion inhibit is included. DO NOT use solutions of more than 50% or damage tothe engine may occur Solution | Maintains culation | Protects against down to damage down to: 30% “35S (ITF) ABC (49) ‘The strength ofthe anti-reeze solution must be checked at least once a year, preferably at the beginning of the cold period It is an advantage to leave the antireeze in all the year round @s it gives continued protection against corrosion. ‘Always renew the anti-freeze every two years. ‘A. 50% antifreeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boling point. WARNING ‘Antifreeze can be harmful. Obey the manufacturer's. instructions when handling full strength or diluted antifreeze. Checking the Coolant Level ‘The procedures below describes a typical coolant package installation A WwaRNinG ‘The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray ‘out and burn you. Make sure that the engine is cool before you work on the cooling system. e332 1 Patk and make the machine safe in accordance with the machine handbook instructions. Check the level of coolant in the expansion bottle 4- AA If necessary remove the filer cap and top upto the level indicated. Refit the filer cap and make sure it is tight. Run the engine for a while to raise the coolant to ‘working temperature and pressure. Stop the engine ‘and check for leaks. A 3-40 '9606'3000-04 3-10wD Section 3 - Routine Maintenance Routine Maintenance Engine Cooling System Changing the Coolant ‘The procedures below describes a typical coolant package installation, A warninc ‘The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray ‘out and burn you. Make sure that the engine is cool before you work on the cooling system. Pes 1. Patk and make the machine safe in accordance with the machine handbook instructions, Stop the engine and lett cool down, 2 Carefully loosen cap 5-A just enough to let any pressure escape. Remove the cap when all pressure is released 3. Disconnect the bottom radiator hose at §-B and allow the coolant to drain 4 Flush the system by pouring clean water into filler port BA, 5 Reconnect the radiator hose. 6 Fil the expansion bottle 5-C, using the necessary ant-reeze solution, to the level indicated, 7 Check for leaks, 8 Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine ‘and check for leaks, Check the level in the expansion bottle and top up if necessary. 31 ‘#80602000-04 31w Section 3 - Routine Maintenance Routine Maintenance Front End Accessory Drive (FEAD) Belt A spring loaded tensioning unit 6-A ensures that the front end accessory drive belt (EAD) 6-B is kept at the correct tension 4 WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2338 4 WARNING Turning the Engine Do not try to turn the engine by pulling the fan or fan jury or premature component Front End Accessory Belt (FEAD) Inspection ‘At the recommended service interval, visually inspect the belt for damage 1. Patk and make the machine safe in accordance with the machine handbook instructions, Stop the engine and lett cool down, 2 Renew the belt fit has cracks or ifitis frayed or has pieces of material missing (as shown at 6-C). It the belt does need replacing follow the procedures described below: Front End Accessory Belt (FEAD) Replacement 1 Patk and make the machine safe in accordance with the machine handbook instructions. Stop the engine and let it cool down, 2 Use a 16mm socket located on the hexagon spigot ‘ut 6-D, carefully rotate the tensioner against spring. force in the direction shown. Do not use excessive force or the tensioner will be damaged. 3 Keep holding the tensioner against the spring force ‘and lift the belt off the dtive tensioner pulley. 4 Slowly release the spring force by rotating the tensioner unit in the opposite direction Engine Cooling System 5 Before fiting the new belt, check that the tensioner roller and the fan pulley rotate smocthly and that there is no play in the bearings. 6 Fit the new belt using a reversal of the above procedures, Fig 6. 3-12 '9606'3000-04 3-12wD Section 3 - Routine Maintenance Routine Maintenance Engine Fuel System Engine Fuel System Draining the Water Separator and Fuel Filter A cauTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. ints 1. Patk and make the machine safe in accordance with the machine handbook instructions. 2 Dizin off any water in the element 7A by turing tap 7B. 3. Drain off any water in the water separator bowl 7A by turning tap 7B. DO NOT disconnect the water in fuel electrical connector 7¢, 4. Ithereis sediment in the bowl after draining, support the bowl and release the locking ring 7D. 5 Wash the bow! in clean fuel 6 Refitthe bowl, secure in position with locking ring 7D. 7 Make sure that the water in fuel electrical connector TC is correct fitted Fig 7. 343 ‘#80602000-04 3413wD Section 3 - Routine Maintenance Routine Maintenance Engine Fuel System Changing the Filter Element 1. Park and make the machine safe in accordance with the machine handbook instructions, A cauTION Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly ‘clean around the connection. When a component has. been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt ‘entering the fuel system. Ditt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair. 2 Thoroughly clean the outside ofthe fiter housing and ‘round the fiter head. 3 Loosen the drain tap 8B and allow the waterituel to drain into a suitable container. 4 Remove the low pressure fuel lines 8C. Mark the pipes prior to removal to ensure they are refittedin the. correct position, 5 Release the fiter strap retaining screw 8D andi the filter clear, Note: Some installations have @ washer fitted between the strap and the cooler housing - keep the washer to reuse. 6 Install new fiter element 8A, Make sure that the black dot is aligned with the locating hole in the strep. Torque tighten the fiter strap retaining screw 8D to 24 Nm (17-7 Ib. 7 Reconnect the fuel lines 8C and BE. Note: Some engine configurations have a dipstick retaining bracket located at the fiter strap retaining screw. When tightening the filter strap screw ensure that the dipstick bracket does not fou! the fiter element 8 Bleed the fuel system, Priming the Fuel System (7) 3-16) 344 39062000-04 314wD Section 3 - Routine Maintenance Routine Maintenance Engine Fuel System Changing the Water Separator Pre- Filter Note: Refer to the machine handbook for information relating to the location of the pre-fiter and water separator. 1. Patk and make the machine safe in accordance with the machine handbook instructions. 4 caution Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt ‘entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair. Ene? 2 Drain and remove the water separator bow 9C. Draining the Water Separator _and Fuel Fitor (2) 3-13) 3 To remove the fiter element 9A, release locking ring ‘9B and discard element, 4 Fit new element and secure in position with locking ring 9B, 5 Refit water separator bow 9C. 8 Make eure that the water in fuel electrical connector 9D is correctly fitted 345 ‘#80602000-04 345wy Section 3 - Routine Maintenance Routine Maintenance Priming the Fuel System Acaution Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. en A warninc Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates, your skin, get medical help immediately. mm -— at kei’ bo The entry of air into the fuel eystem can cause problems such as diffcuit engine starting and unstable engine running, ‘Typically, the source of the airs offen through leaks in the lovr pressure side of the fuel system (the fuel feed lines to the fue! injection pump). Air can enter the fuel system ifthe following occurs: = A fuel system component has been disconnected, For example, when renewing the fuel filter. — A leak in the low pressure side of the fuel system during engine operation, or the low pressure pipes have been disconnected = The fuel tank is allowed to drain during normal operation, = Draining of the water separator pre-fter and not priming afterwards. = The fue! fiter seals are leaking. The fue! it pump is fauity (spit claphragm oF loose stub pipes). = The high pressure fuel pipes disconnected. have been 1. Disconnect the fuel feed line 10A at the fuel injection pump. 2 Operate the fue! lit pump priming lever 108 or 106 ntl air free fuel exits from the fuel line. Note: If no fuel is moved when the fuel ft pump priming lever 10B is operated, then the pump diaphragm may have rested in a maximum lt’ position. To move the diaphragm, Engine Fuel System use the starter Key (0 turn the engine, then try the priming lever again. 3 Reconnect the fusl feed line 10A. 4 Run the engine at idle and operate the throttle between iale and half speed (1200 rpm) repeatedly {for 2 minutes. Note: The engine should never be run at full speed or full load unt the fuel system has been properly purged of ar. 5. Ifthe engine runs smoothly fora short time, and then begins to run roughly or stops, check for air in the fuel system. Use the method below to help diagnose air ingress into the system: Any air in the fuel system will pass through the fuel injection pump and be expelled via the fuel return line. a Disconnect the fuel retuin line line to tank) at the engine connection 10X. In its place, connect a length of clear plastic uel line tubing (see Service Tools). Allow the other end of the tubing to drain into @ suitable clean container. b_ Startthe engine and run at idle for 3 minutes, © Runthe engine at half speed for 3 minutes. d__ Examine the clear tubing for signs of air bubbles. If no bubbles are present, then air is not being drawn into the fuel system, If there are air bubbles, check all seals and connections. Tighten or replace each item in the low pressure side ofthe system, 3-16 '9606'3000-04 3-16(wD Section 3 - Routine Maintenance Routine Maintenance Engine Fuel System Fig 10. 347 ‘#80602000-04 347w Section 3 - Routine Maintenance Routine Maintenance Air Intake System Air Intake System Engine performance and durability will be severely affected ifthe quality ofthe air intake is poor. ‘A dity and blocked air cleaner element will reduce the ‘amount of air entering the combustion chamber which can cause engine misfiring, black smoke and low output power. Airty and blocked air fiter can also lead to abrasion of the cylinder bores and valves (referred to as “dusting). This will cause excessive oll consumption, black smoke, low output power and a reduced engine life. Refer to the machine's operator handbook for the air fiter element removal and replacement procedures. Inspect hoses and fitings for splits and poor clamping which may allow unfiltered air to enter the engine In hostile environments, change the air fier elements more frequently In some applications, an ar iter pre-cleaner can be fitted ‘A typical air fiter installation is shown, 11-A is the outer ‘element and 11-B isthe inner element. Item 11-C shows a potential problem as the hose has split allowing dirty Unfiltered air to enter the engine, Fig 11. 3-18 '9606'3000-04 3-18w Sect n 3 - Routine Maintenance Routine Maintenance Engine Breather Engine Breather Cleaning the Engine Breather Gauze ‘The breather gauze is located inside the rocker cover as shown at 12A. It should be cleaned or changed at the recommended interval - = Service Schedules ([) 3-6 1 Patk the machine safe in accordance with the machine handbook instructions. 2 Remove the rocker cover, refer to Rocker Cover, Section 12, 3 Loosen and remove the filter gauze cover retaining screws 128, 4 Remove the fiter gauze cover 12C and the fiters, 120, Using a suitable and safe cleaning solvent clean the filters (or fit new fiters), make sure any residual oil has been fully removed, Make sure the fters are fully dried before refitting Fit the gauze fiters. Apply JCB Threadocker to screws 12B, Make sure that the tapped holes in the rocker cover are clean and free from excessive oll Torque tighten the screws 12B to 8-10 Nm (6-7 lf). Fig 12. 3-19 '9606'3000-04 3-19Section 3 - Routine Maintenance Routine Maintenance Engine Breather Page left intentionally blank 3-20 ‘9608;3000-04 3-20Section 4 Systems Description Service Manual - JCB 444 Mechanical Engine Section 4 - General Information Section 2- Care and Safety ‘Section 3 - Routine Maintenance ‘Section 4 Systems Deseription ‘Section 5 - Fault Finding Section 6 - Test Procedures ‘Section 7 - Fuel System Section 8 - Cooling System ‘Section 9 - Lubrication Systom ‘Section 10 - Electrical System ‘Section 11 - Induction and Exhaust Sy ‘Section 12 - Base Engine Publication No. '9806/3000-04 1s teat hoNotes: Section 4 - Systems Description '9606'3000-04 40Contents Ww Section 4 - Systems Description Contents Page No. Engine Overview Component Identification 44 External aed Internal 7 asta Scnndadtntatt et Te Basic Description 4-1 The Four Stroke Cycle... icici san rinse 4 14 Camshaft and Valve Operation 4-16 The Four Cylinder Cycle - JCB 444 Engine 4-17 Firing Order .. seliotostiniibnnntaienchiostananyite d= 17, Timing Gears 4-19 Timing ian tients he A) Valve Train 4-21 Front End Accessory Drive (FEAD) Belt System 4-24 Lubrication System Basic Description 4-27 Oil Pump 4-29 Oil Cooler and Filter 4-34 Oil Cooler Matrix 4-31 Oil Filter 4-31 Camshaft Lubrication 4-33 Crankshaft Lubrication .... hitaecinssinimansdgntuoninyrannnsticns Ma BAe Rocker Assembly Lubrication 4-35 Piston Cooling and Small End Bearing Lubrication 4-36 Fuel System Basic Description we 4-37 Pre-FilterWater Separator, Lit Pump and Fuel Filter 4-39 Pre Fillrater SeparaOr nnn 4-39 Lift PUMP on 4-39 Fuel Filter cindtiat adh Lcinttatactte dame 430. Fuel Injection Pump - Injection Cycle 4-41 State A - Charging .. 4-44 State B - Injecting 4-41 Fuel Injector Pump - Governor . 4-43 State A - Increasing Engine Speed ... wn 4-43 State B - Decreasing Engine Speed. 4-43 Features of the Delphi DP210/DP310 Fuel injection Pump 4-45 Cold Start Advance - Shown at A 4-45 Hydraulic Light Load Advance ...c.nnnnntsnnnnne ee = 45: Variable Fuelling - Shown at B 4-45 Latch Valve nn 4-45 ESOS - Electric Shut Off Solenoi 4-45 Turbo Boost Carr (irbacharged anges ont) 4-45 Injectors and Combustion .. iiniigusinnn 4247 Injectors 4-47 Combustion 4-48 Induction, Exhaust and Breather Systems Induction and Exhaust Systems 4-49 Naturally Aspirated 4-49 Turbocharged 4-50 Intercooled .... a aon tecnica A BR Exhaust Gas Recirculation (EGR) 4-53Section 4 - Systems Description Contents Contents Engine Breather .. ‘SA, SB, SC Engines SD, SF Engines Cooling System Description Thermostat State A - ‘Closed’ - Engine Cooled State B - ‘Open’ - Engine Hot Injectors Coolant Pump Electrical System Electrical Circuit Schematic. Electrical Components Page No. 4-54 4-54 4-56 4-57 4-59 4-59 4-59 4-60 4-61 4-62 4-6 4-iiWw Section 4 - Systems Description Engine Overview ‘Component Identification Engine Overview Component Identification External ‘The following identifies the main components of a typical engine assembly visible from the exterior. Some vatiants may cif in detail Fig 1. SB Type engine shown 44 '9606'3000-04 41wD Section 4 - Systems Description Engine Overview ‘Component Identification Table 1. Engine - As viewed on the left hand side 2 1 Rocker cover 12 Fuel fiter 2 Fuol injectors and high pressure fuel pipes 18 Lubrication oil filler cap 3 Lubrication ol filer cap 14 Lubrication ol fiter 4 Timing gear case 18 Lubrication ol cooler housing 5 Flywheel housing 16 Lubrication ol dip stick 6 Bed plate 17 Low duty PTO (blanking cover if no device is ftted) 7 Lubrication oll pan (sump) 18 Water temperature sender (cold stert) 8 Engine iting eye 19 Low pressure fuel ine (to tank) © AirIniet manifola 20 Oil drain plug (sump) 10 Fuel injection pump 21 Oil pressure switch 44 Fuel it pump 22 Inlet manifold induetion heater (iffittea) 42 '9606'3000-04 42wD Section 4 - Systems Description Engine Overview ‘Component Identification 20 Fig 2. SB Type engine shown 43 '9606/3000-04 43w Section 4 - Systems Description Engine Overview ‘Component Identification Table 2. Engine - As viewed on the right hand side Brig? (O49 1 Rocker cover 41 Exhaust manifold 2 Breather chamber inspection cover 12. Aternator and pulley assembly (drive belt not fted) 3 Cylinder block 13 Coolant pump drive pulley (drive belt not fitted) 4 Timing gear case 14 Coolant pump housing (cylinder block) 5 Flywheel housing 15 Coolant inlevradiator hose connector 6 Bed plate 16 Heavy duty PTO (blanking cover if no device is fitted) 7 Lubrication oll pan (sump) 17 Starter motor assembly 8 Engine iting eye 18 Turbocharger oil drain line (turbocharged engines only) © Turbocharger (turbocharged engines only) 19 Turbocharger oll feed line turbocharged engines only) 10 Turbocharger waste gate actuator assembly 20 Oil drain plug (sump) 44 '9606'3000-04 44Section 4 - Systems Description Engine Overview ‘Component Identification Fig 3. SB Type engine shown ‘Table 3. Engine - As viewed on the crankshaft pulley (front) end Figs. (049) 1 Rocker cover 9 Drive bett tensioner and pulley 2 Oylinder head 10 Coolant pump and drive pulley assembly 3 Cylinder block 11 Idler pulley 4 Bed plate 12 Alternator and dive pulley assembly 5 Lubrication oil pan (sump) 13. Cab heater water hose connector 6 Crankshaft pulley 14 Coolant temperature sender 7 Front end accessory drive belt 15 Coolant thermostat housing/radiator hose connector 8 Idler pulley '9606'3000-04 45wD Section 4 - Systems Description Engine Overview ‘Component Identification Fig 4. SB Type engine shown Table 4. Engine - As viewed on the flywheel! (rear) end BFigé. (ED 1 Rocker cover 4 Fuelinjection pump drive gear cover 2 Cylinder head 5 Flywheel housing 3. Flywheel 46 '9606'3000-04 46Ww Section 4 - Systems Description Engine Overview ‘Component Identification Internal ‘The following indentiies the main intemal components of a typical engine assembley. Some variants may differ in detall Fig 5. Engine - As viewed on the front right side 2 Table 5. (1) 4-8) 47 '9606'3000-04 47Ww Section 4 - Systems Description Engine Overview ‘Component Identification Table 5. Engine - As viewed on the front right side Brig &. (47) 1 [Racker assembly 7__ [Connecting rod assembly (4 off 2 [Valve bridge piece (@ off) @ | Grankshart 3 [Valve spring (16 off) ‘@ | Main bearing -crankshatt (af 4 |inlet valve (8 of) 40 _ [Big end bearing - crankshafvconnecting rod (4 off 5 _ [Exhaust valve (@ off) 11 [Front crankshaft oll seal 16 _ [Piston assembly (4 off 12 _ [Front end drive belt pulley {62 _ [Piston ring - top compression (4 off 13_| Flywheel '6b_ [Piston ring- 2nd compression (4 off 7a_|Starter motor pinion {Ge [Piston ring - oil control (4 off) 15 _ [High duty PTO. toler gear (fitted) 6d [Gudgeon pin 4 off) 76 _|High duty PTO, device drive gear (fitted) 48 '9606'3000-04 48Ww Section 4 - Systems Description Engine Overview ‘Component Identification Fig 6. Engine - As viewed on the rear left side 2 Table 6. ([)4-10) 49 '9606'3000-04 49Section 4 - Systems Description Engine Overview ‘Component Identification Table 6. Engine - As viewed on the rear left side 4) 1 [Flywheel @ [Lubrication ol pump Ta_| Flywheel - crankshaft fixing bolts (@ of) 70 | Fuel injection pump drive gear 2 | Fuel injector (atomiser) (4 off) 71 | Camshaft compound gear - dive totem 10 3 | Flywheel hub: 12 | Camshaft dive gear ‘4 [Rear crankshaft oll seal 13_|Camshat 5 _ | Grankshatt dive gear 14 [Tappet (6 off 6 [High duty PTO. ider gear (fitted) 75 [Push rod (of) 7__ [High duty PTO. device dive gear (fitted) 16 _| Fuel pump actuator pin 8 [Low duty PTO. device (i fited) 4-10 '9606'3000-04 410Ww Section 4 - Systems Description Engine Overview Basic Description Description ‘The JCB 444 engine is @ 4 cylinder diesel engine in which the fuel is ignited by compression ignition (C.). The dine operates on a four stroke cycle, => The Four Stroke Cycle (1) 4-14) ‘The engine is started by electric starter motor 7-4, The motor turns the engine via a pinion and teeth on the engine fiywhee! 7-2, When the engine runs the crankshaft 7-3 dives the camshaft 7-4 via gears. The camshaft opens and closes the inlet and exhaust valves 7-5 and 7-6 via push rods 7-7 in time with the four stroke cycle. The engine has 16 valves, 2 inlet and 2 exhaust valves for each cylinder. The crankshaft also drives @ mechanical fuel injection pump 7-8 via gears, The pump injects fuel via injectors, or atomisers 7-9 into each cylinder in time with the four stroke cycle. Fuel is pumped from a fuel tank to the injection ump by means of lift pump 7-10 driven by cam lobes on the camshaft Airis: drawn into the engine via inlet manifold 7-11 and exhaust gasses exit via exhaust manifold 742 On turbocharged engines an exhaust driven turbocharger 7= 19 pressurises air at the inlet manifold ‘A mechanical lubrication oil pump 7-14 is driven by the crankshaft via gears. The pump pressurises and circulates oil for engine lubrication and cooling purposes, ‘A drive belt 7-18 again driven by the crankshaft, drives a coolant circulation pump, alternator, radiator cooling fan and other ancliiaries such as an air conditioning compressor. 41 9806/3000-04 41Ww Section 4 - Systems Description Engine Overview Basic Description Fig7. 2 Table 7. (1)4-13) 4-12 '9806/3000-04 412w Section 4 - Systems Description Engine Overview Table 7. Engine - As viewed on the rear left side Basie Description SFig7 (0 + | Starter motor 3 [Fuel injectors (4 of) 2 [Fiywhes! 70 [Fuel t pump 3 [Cronishat 47 Init manifold 4] Cemenat 72 [Exhaust manifold 5 [Inlet valves (@ of 73 __| Turbocharger 3 [Exhaust valves (6 off) 14 [Lubrication off pimp 7 [Push rods (@ of) 75 | Frontend dive belt 8 [Fuelinjedion pump 413 ‘#80602000-04 443w Section 4 - Systems Description Engine Overview The Four Stroke Cycle The Four Stroke Cycle 1 Induction ‘As the piston travels down the cylinder it draws filtered air at atmospheric pressure and ambient temperature through an air fiter and inlet valves into the oylinder 2 Compression ‘When the piston reaches the bottom of ts stroke the inlet valves close, The piston then stats to rise up the cylinder compressing the air trapped in the cylinder. ‘This causes the temperature and pressure of the air to rise. Fuel is injected into the cylinder when the piston is near to top dead centre. 3 Power The piston continues 10 rise after the start of fuel injection causing a further increase in pressure and temperature. The temperature rises to a point at ‘which the fueVair mixture ignites. A cylinder is seid to be ‘firing’ when the fuel/air mixture ignites. This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downward turning the crankshaft and producing energy. Exhaust ‘Once the piston has reached the bottom ofits travel, the exhaust valves open and momentum storedin the ‘lywhee! forces the piston up the cylinder expelling the exhaust gases. In a running engine these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of @ {our stroke engine, the crankshaft revolves twice. 414 '9606'3000-04 414wD Section 4 - Systems Description Engine Overview The Four Stroke Cycle TDC | Top dead contre 445 ‘#80602000-04 45Ww Section 4 - Systems Description Engine Overview The Four Stroke Cycle Camshaft and Valve Operation ‘As the crankshaft rotates the camshaft also rotates, driven by a gear on the crankshaft. The inlet and exhaust valves are opened by lobes on the camshaftin time with the cycle. The diagrams show the position of the camshaft at each part of the four stroke cycle. It can be seen that for a complete cycle the camshaft revolves once. Since the crankshaft revolves twice during the cycle it follows that the camsheftis driven at half crankshatt (engine) speed 4-16 9806/3000-04 416w Section 4 - Systems Description Engine Overview The Four Cylinder Cycle - JCB 444 Engine The Four Cylinder Cycle - JCB 444 Engine The four stroke cycle of the JCB 444 engine is as described in The Four Stroke Cycle 2 The Four Stroke Cyclo([}4-14). This section describes the cycle ‘Sequence for the 4 cylinders of the engine. 2 Fig 10. ([) 4-18) With the crankshaft positioned as shown the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons in numbers 2 and 3 cylinders are at bottom dead centre Itis important to note that number 1 cylinder is “fring! and ‘about to stat its Power stroke. Rotating the crankshaft 2 further 360 degrees would position the pistons as described but the engine would be at a different stage in its four stroke cycle, with number 1 cylinder about to start its Induction strok ‘The stages in the four stroke cycle for each cylinder are as, follows: Cylinder Number 1 ‘The piston is at the top ofits Compression stroke andis about to start its Power stroke, Velve Operation Inlet and exhaust valves closed Cylinder Number 2- ‘The piston is at the bottom of ts Power stroke and is about to-startits Exhaust stroke. Valve Operation Inlet valves closed, exhaust valves about to, open Cylinder Number 3- ‘The piston is at the bottom of ts Induction stroke and is about to start its Compression stroke. Valve Operation Exhaust valves closed, inletvalves about to close Cylinder Number 4- ‘The piston is atthe top ofits Exhaust stroke andis about to Star its Induetion stroke, Valve Operation Exhaust valves about to close, inlet valves about to open Firing Order A cylinder is said to be ‘fring’ when the fuel/air mixture ignites and the piston is about to stat its power stroke, From the stages described it can be seen that number 1 ‘oylinder will be next o fire. Number 3 cylinders starting its ‘compression stroke and is next in the cycle, followed by cylinders 4 and 2. The firing order is therefore; 4, 3, 4, 2. Table 8. Key Fig (D4) CYLT | Cylinder number # A [Camehat CYL2 [Cylinder number2 @ | Camehat lobe - rit vaive operation CYL3 [Cylinder number 3 | Camshaftiobe Exhaust vaive operation CLA Cylinder number 4 F [Front of engine 7 [Exhaust valves 2 inet valves 3 [Crankshaft 4 [Crankshaft gear 3 [Camshaft aive gear a7 ‘#80602000-04 447Ww Section 4 - Systems Description Engine Overview The Four Cylinder Cycle - JOB 444 Engine evr vz cyLs cvs Al Fig 10. 2 Table 8. (4-17) 4-18 '9806/3000-04 418w Section 4 - Systems Description Engine Overview Timing Gears Timing Gears ‘Thetiming gears are locatedinside casing at he flywheel end of the engine 2 Fig 11. ([) 4-20) ‘All the gears are driven via the crankshaft gear 11-A as follows: 1. Camshaft gear 11-B. The camshaft is driven at half crankshaft speed. 2 Fuel injection pump gear 11-C, The fuel injection ump is driven via compound gear 11-D fited to the camshaft. The pump rotates at haif crankshaft speed pump gear 11-E. The lubrication oil pump is driven drecty by the crankshaft gear 4 Heavy Duty PTO Gear 11-F (if ited). The PTO is driven by the crankshaft gear via idler gear 11-G, 5 Low Duty PTO Gear 11-H (if fitted). The PTO is driven by the camshaft gear 11-B. Timing ‘The engine must be “timed’ so that the camshaft operates the valves and the fuel injection pumpinjects the fuel at the ‘correct times relative to the crankshaft postion Valve timing is achieved by ensuring that the camshatt ive gear B is meshed to the crankshaft geer A at their correct angular positions, >The Four Stroke Cycle (1) 4-14) for more information about valve timing, “Timing ofthe fue! injection pumpis nat dependent on drive ‘gear meshing. The pump drive shaft is supplied locked at the correct angular position relative to erankshafticamshatt position, With the crank and camshaft positioned correctly {using temporary locking pins), the pump is fitted to drive ‘gear 11-C and its drive shaft unlocked Table 9. Key Fig ft. (0420) A [Crankshaft gear E_[Oipump gear | Camshaf gear ® [Reavy duty PTO davice gear i fited) © | Fuel injection pump gear [Heavy duty PTO ile gear (fied) | Compound eamshart gear FH [Low duty PTO device gear (ited) 419 ‘#80602000-04 419Ww Section 4 - Systems Description Engine Overview Timing Gears Fig 11. 2 Table 9. ([)4-19) 4-20 9806/3000-04 4-20w Section 4 - Systems Description Engine Overview Valve Train Valve Train ‘The valve train system opens and closes the valves with correct timing in relation to the piston movements 2 Fig 12. ([14-22), = Fig 13. (114-29) ‘The camshaft dive gear 13-1 is driven by the orankshaft gear 13-2 at half the speed of the crankshaft. Camshaft lobes 13-3a, two for each cylinder, (operating exhaust and inlet valves) actuate the valve tappets 13-4 Each push rod 13-8 has one end in a valve tappet and the other end under a rocker arm, 13-6a or 13-6b as applicable, Adjusting screw 13-6 has a ball shaped end that locates in the push rod The adjusting screw is used for setting the valve clearance When the camshaft 13-3 rotates the cam lobes act on the tappets. The push rods act on the rockers which pivot on. shaft 13-7, depressing two valves at once via the bridge piece 13-9. The screw is self locking in the rocker by means of @ tapered thread. Wave washers 13-8 act like springs to keep the rockers in their correct positions along the shaft 13-7 and prevent them contacting one another. The rockers incorporate a swivel ip 13-64, ensuring alignment with the bridge piece 13-8. This prevents excessive wear Each valve has a compression spring 13-10. The function Of the spring is to close the valve and at the same time fetuin the rocker arm and push rod ensuring that the tappets follow the camshaft lobes. The springs located on the valve stem 13-17 by a retainer 13-11 and spit collets 13-12 ‘The valves extend through the cylinder head. There are no sleeves or valve guides in the cylinder head, The valves are made from a special metal to provide a long service life. Damaged or worn valves cannot be lapped or re- ‘ground and must be replaced with new ones, Each valve stem has an oll seal 13-13, Valve seat inserts 13-14 are pressed into the cylinder head, The seat inserts are also made from a special metal to provide for a long service life. Damaged or worn seat inserts can be removed and replaced with new ones. Table 10. Component Identification Dig (D4) DFig 3. (DLA 1 [Camshaft drive gear 8 | Wave washers (8 off) 2 ‘Crankshaft gear 9 Bridge pieces (8 off) 3 |Camshat 40 [Valve springs (16 of 3a [Lobes 41 [Retainer (6 off 4 [Tappa @ oh 42 Colts G2 of) 5 [Push rods off 43] Oi eval valve stems (76 of) Ga | Rockere- let (of) 14 | Valve evatinserts 16 off 6b Rockers - exhaust (4 off) 15 | Inlet valves (8 off) Ca Adjusting screws (8 off) 16 | Exhaust valves (8 off) Be _|Saiveltip- rockers 47 [Valve stem 7 [Rocker shat 421 ‘#80602000-04 4-21Ww Section 4 - Systems Description Engine Overview Valve Train 2 Table 40. ([)4-24) 4-22 9806/3000-04 4-22Ww Section 4 - Systems Description Engine Overview Valve Train Fig 13. 2 Table 10. (1)4-2) 4-23 9806/3000-04 4-23Ww Section 4 - Systems Description Engine Overview Front End Accessory Drive (FEAD) Belt System Front End Accessory Drive (FEAD) Belt System ‘The crankshaft pulley is used to drive the coolant pump via 2 drive belt. In addition to the coolant pump the drive belt can also be configured to drive engine mounted accessories including Alternator Cooling fan Air conditioning compressor ‘The belt is maintained at a constant tension by a spring loaded tensioner. To achieve the necessary beltpulley contact area the belt is routed around idler wheels as required, The configuration varies depending on the accessories fitted Drive belt configurations (A | > With air conditioning compressor, no cooling fan (114-25) 1B | Without air conditioning compressor, no ‘cooling fan (7) 4-25) (¢ | 5 With air conditioning compressor, cooling fan pulley fitted ([) 4-26) 1D | Without air conditioning compressor, cooling fan pulley fitted ((} 4-26) 424 ‘#80602000-04 4-24Section 4 - Systems Description Engine Overview Front End Accessory Drive (FEAD) Belt System 4 ® 4 ay 4 Quy, 5 3 6 3 4 7 ©) y x 2 = 1 1 Fig 14. With air conditioning compressor, no cooling fan Table 11. Key = Fig 14. With air conditioning compressor, no ‘cooling fan (P) 4-26) , > Fig 15. Without air ‘conditioning compressor, no cooling fan ([)4-25) 1 [Crankshaft drive pulley Coolant pump drive pulley [Alternator dive pulley Idler pulley Tensioner pulley [Air conditioning compressor dive pulley Fig 16, Without air conditioning compressor, no ‘cooling fan 4-25 9806/3000-04 4-25Section 4 - Systems Description Engine Overview Front End Accessory Drive (FEAD) Belt System € © ° 6 ae ‘ 5 5 \e 3 3 4 7 = x 5 4 4 = Fig 16, With air conditioning compressor, cooling fan pulley fitted Table 12. Key = Fig 14. With air conditioning compressor, no [cooling fan ([) 4-26) , > Fig 15. Without air ‘conditioning compressor, no cooling fan ([\4-25), > Fig 16. (4-26), 2 Fig 17. (1) 4-26) 1 [Crankshaft drive pulley Coolant pump drive pulley ‘Alternator dive pulley Tier pulley Tensioner pulley Cooling fan drive pulley Air conditioning compressor drive pulley (1). Idler pulley positions differ slightly depending on the size of the fan pulley fitted. (2) Different fan pulley size options are available. This enables a choice of farvengine speed ratios. Fig 17. Without air conditioning compressor, cooling fan pulley fitted 4-26 9806/3000-04 4-26Section 4 - Systems Description Lubrication System Basic Description ‘The lubtication system distributes oil around the engine by 2 system of galleries and drilings in the cylinder block and cylinder head. The oll lubricates and seals the moving parts of the engine, reducing friction and wear. In adcition the oil plays an important role in cooling the engine by carrying heat from the engine to the cooler A piston cooling jet sprays oil onto the underside ofthe pistons to keep them cool, Piston Cooling and Small End Bearing Lubrication (1) 4-36) Oils drawn from the oil pan (sump) 18-1 by the integral of pump 18-3 via the strainer 18-2. The strainer prevents any large particles of debris passing through, which may damage the pump. The oil passes from the outlet side of the pump through a felief valve which limits the maximum oil pressure by venting oll back to the inlet side of the pump, = Oil Pump ([3 4-29). From the pump the oll passes through the cooler 18-4 and fiter 18-5, = Oil Cooler and Filter ([) 4-31). After cooling and ftering, oll passes into the main il gallery 18-11, An oll pressure switch 18-12 senses oil pressure. From the main gallery oil is delivered, via diilings 18-7, to the crankshaft main bearings, rocker assembly (driling 18-8) , camshaft (diling 18-8) and iming gears (driling 18-9) Note that ailing 18-8 is through the cylinder block and cylinder head, When the high pressure oil has passed through the bearings it revers to sump pressure and “spiash’ lubricates intemal components such as rocker tips, eam lobes and timing gear teeth, Gravity drains the ll via galleries in the cylinder head and blook, back into the ol pan (sump). A drain slot allows cil to dain from the timing case back tothe cil pan, Table 13. Key 2 Fig 18. (14-28) 1 Oilpan (sump) 2 Suction strainer 3. Ollpump 4 Olleooler Fiter ‘Camshaft - high pressure oil feed Crankshaft main bearings - high pressure oil feed Rocker assembly - high pressure ol feed PTO idler gear bearingfiming case - high pressure oll feed 10 External high pressure oil feed connection (engine block) - Turbo charger (iffited) 11. Main high pressure oll feed gallery (engine block) Table 14. Colour Key 4-28) Green Oil at sump pressure Red Oil athigh pressure Pink Oil at lower pressure but higher than sump pressure 4-27 9806/3000-04 4-27Ww Section 4 - Systems Description Lubrication System Basic Description Fig 18. 4-28 ‘#80602000-04 4-28Ww Section 4 - Systems Description Lubrication System il Pump Oil Pump 2 Fig 19. (1) 4-30) ‘The oil pump 19-4 is a rotor type located inside the timing gear case. The pump is driven by gears via the crankshaft ‘The pump consists of two rotors, one running inside the other. The outer rotor 19-2 has one more lobe than the inner rotor 19-3 and tums on a different axis When rotated the gap between the inner and outer rotor lobes increases, drawing oil in through the inlet port 19-4. ‘After a half rotation the gap reaches a maximum, the inlet ports closed and the outlet port 19-5 opened, Further rotation causes the gap between the lobes to diminish, forcing the oll out through the outlet port A pressure relief valve assembly 19-6 is integral with the ump body. As cl pressure increases it acts on a spool 19- 8 to overcome the pressure of spring 19-7. As the spool moves it uncovers a port allowing pressurised oil directly back to the inlet port 19-4, In practice the spool is continually opening and closing to maintain the correct oi! pressure value. The valve is not adjustable Table 15. Key 3 Fig 19. (7) 4-30 il pump Outer rotor Inner rotor Inlet port utiet port Relief valve assembly Relief valve spring '2. Relief valve port return to inlet port 4 Relief valve epool 82 Relief valve pressure port - connected to port 6 © Oil pump connecting ports - engine bed plate 4-29 9806/3000-04 4-29Ww Section 4 - Systems Description Lubrication System il Pump $30 seosano008 4-30Ww Section 4 - Systems Description Lubrication System il Gooler and Fitter Oil Cooler and Filter 2 Fig 20. ([94-92) 3 [Oil galeny-rom cooler to fiter head ‘The oil cooler and filter are incorporated in a housing 20-1 10 | Oil gallery - from fiter head to main of gallery bolted to the side ofthe cylinder Block The housing allows [17 | OWA port. transfer of lubricating ail from the cylinder block tothe oll ji presar cooler 20-5 and filter head 20-3, Coolant also transfers to Je] ON presets ei the housing and passes over the oll cooler matrix 20.6 | 18 Oi filler causing heat to exchange from the ol to the coolent. 74 [Fifer element Cooled and filtered oil then passes back into the main oil ‘15 [Up seal galley inthe block via port 20-10 16 | Valve plate 17 | Spring ‘An engine oll filler point is also included via cap 20-2 and port 20-11 which aligns with a port in the block ‘A [Oilfiter state - engine running Cooler Matrix B [Oi fiter state - engine stopped Oil though the cooler matrix 20 -8 is a separate component, itis a non serviceable part and must not be removed from the housing. The housingfcooler assembly is leak tested during manufacture to minimise the risk of cross contamination of coolant and lubricating ol Oil Filter ‘The cil filter 20-13 is a ‘spin on’ type which serews on and olf the fiter head 20-3, Engine running - shown at 20-A. The oil pump delivers oil at pressure to the filter via port 20-9. The lip seal 20-18 is forced off its seat and oll flows through a large area paper element 20-14, Filtered oll enters the inner part of the fiter and forces down the valve plate 20-16 against spring 20- 17. Oil then leaves the fiter and fiter head via port 20-10. Engine stopped - shown at 20-B. With the engine stopped oil pressure in the galleries and fiter decays. As it does so, valve plate 20-16 is pushed on its seat under the action of, ‘spting 20-17, preventing oil draining down from the engine galleries. Lip seal 20-15 also falls on its seat and oll is prevented from draining from the filter assembly. These ‘eatures help protect the engine from ol starvation on start up. Table 16. Key Fig 20. (432 ‘Oil cooler and filter ROUSING ‘Oilfiler cap Oilfiter head Oil fiter drain down plug Oil cooler matrix ‘Sealing gasket - housing to cylinder block Coolant gallery ‘Oil gallery - from pump to cooler oa seossno008 4-31

JCB 444 Engine Mechanical Service Manual

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JCB 444 Engine Mechanical Service Manual

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