The document provides instructions for servicing components of an excavator, including removing and installing the engine drive belt and oil filter. It identifies belt and filter components, describes inspection and adjustment procedures, and outlines safety practices. Steps include checking belt tension, replacing loose or damaged belts, and adjusting alternator or tensioner position. For the oil filter, it details draining oil first, then removing pipes and filters, and installing new seals and filters, ensuring proper torque on reinstallation.
Jcb tm220 telescopic wheeled loader service repair manual sn from 2128886 to ...fjjskqwaekfksmem
This service manual provides instructions for servicing the rocker and fittings on the TM180 and TM220 loader engines. The document describes how to remove and install the rocker assembly, disassemble and assemble the rocker arms, and remove and install the rocker cover. Technical specifications are also provided for rocker shaft dimensions, tappet clearances, and tappet dimensions. The operation of the hydraulic tappets is explained, along with difficult operating conditions that could cause play.
Jcb tm180 telescopic wheeled loader service repair manual sn from 2096873 to ...fjjskqwaekfksmem
This service manual provides instructions for servicing the rocker and fittings on the TM180 and TM220 loader engines. The document describes how to remove and install the rocker assembly, disassemble and assemble the rocker arms, and remove and install the rocker cover. Technical specifications are also provided for rocker shaft dimensions, tappet clearances, and tappet dimensions. The operation of the hydraulic tappets is explained, along with difficult operating conditions that could cause play.
Jcb js235 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document is a service manual that provides instructions for servicing excavator engines. It contains sections on general information, component identification, operation, adjustment, removal and installation of valves. The summary focuses on valves:
The manual contains information on servicing excavator engine valves, including identifying components, operating principles, adjusting clearances, and removing and installing valves. Proper valve clearance is critical and the manual describes using a dial indicator to measure clearances and adjusting screws to set them correctly. Valves must be removed using a spring compressor and installed in the proper orientation.
Jcb js220 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document provides service information for JCB excavators models JS200, JS210, JS220, and JS235. It contains instructions for maintenance, repair, and operation of the machine. The document includes sections covering the machine body and framework, operator station, engine, hydraulic and electrical systems, and other components. It provides technical specifications, diagrams, and step-by-step instructions for tasks like adjusting engine valves and replacing parts. Safety notices throughout warn technicians to fully understand procedures before working on the machine.
Jcb js210 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document provides service information for JCB excavators models JS200, JS210, JS220, and JS235. It contains instructions for maintaining and repairing different systems of the excavator such as the engine, fuel system, hydraulic system, electrical system, and other components. The document provides technical specifications, diagrams, maintenance and repair procedures. It is intended to be used as a manual by service technicians when servicing or repairing components of the excavator. Safety warnings are provided throughout advising technicians to fully understand instructions before working on the machine.
Jcb js200 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document is a service manual that provides instructions for servicing excavator engines. It contains sections on general information, components, operation, adjustment, removal and installation of valves. The summary focuses on valves:
The manual contains information on servicing excavator engine valves, including identifying components, measuring clearances, adjusting clearances, and removing and installing valves. Proper valve clearance is important for correct timing in relation to piston movement.
This document contains technical specifications and emissions data for various JCB excavator models. It includes sections on noise emissions, vibration emissions, and fluids/lubricants specifications. Tables of data provide the A-weighted sound pressure and power levels, whole-body vibration values, and fluid capacities for different models. Guidelines are given for minimizing operator exposure to noise and vibration.
This document contains technical specifications and emissions data for various JCB excavator models. It includes sections on noise emissions, vibration emissions, and fluids/lubricants specifications. The noise and vibration emissions data lists the equivalent continuous A-weighted sound pressure and sound power levels for different models and engine ratings, to help customers comply with European emissions directives. Tables of representative whole-body vibration values during common operating duties are also provided.
Jcb tm220 telescopic wheeled loader service repair manual sn from 2128886 to ...fjjskqwaekfksmem
This service manual provides instructions for servicing the rocker and fittings on the TM180 and TM220 loader engines. The document describes how to remove and install the rocker assembly, disassemble and assemble the rocker arms, and remove and install the rocker cover. Technical specifications are also provided for rocker shaft dimensions, tappet clearances, and tappet dimensions. The operation of the hydraulic tappets is explained, along with difficult operating conditions that could cause play.
Jcb tm180 telescopic wheeled loader service repair manual sn from 2096873 to ...fjjskqwaekfksmem
This service manual provides instructions for servicing the rocker and fittings on the TM180 and TM220 loader engines. The document describes how to remove and install the rocker assembly, disassemble and assemble the rocker arms, and remove and install the rocker cover. Technical specifications are also provided for rocker shaft dimensions, tappet clearances, and tappet dimensions. The operation of the hydraulic tappets is explained, along with difficult operating conditions that could cause play.
Jcb js235 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document is a service manual that provides instructions for servicing excavator engines. It contains sections on general information, component identification, operation, adjustment, removal and installation of valves. The summary focuses on valves:
The manual contains information on servicing excavator engine valves, including identifying components, operating principles, adjusting clearances, and removing and installing valves. Proper valve clearance is critical and the manual describes using a dial indicator to measure clearances and adjusting screws to set them correctly. Valves must be removed using a spring compressor and installed in the proper orientation.
Jcb js220 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document provides service information for JCB excavators models JS200, JS210, JS220, and JS235. It contains instructions for maintenance, repair, and operation of the machine. The document includes sections covering the machine body and framework, operator station, engine, hydraulic and electrical systems, and other components. It provides technical specifications, diagrams, and step-by-step instructions for tasks like adjusting engine valves and replacing parts. Safety notices throughout warn technicians to fully understand procedures before working on the machine.
Jcb js210 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document provides service information for JCB excavators models JS200, JS210, JS220, and JS235. It contains instructions for maintaining and repairing different systems of the excavator such as the engine, fuel system, hydraulic system, electrical system, and other components. The document provides technical specifications, diagrams, maintenance and repair procedures. It is intended to be used as a manual by service technicians when servicing or repairing components of the excavator. Safety warnings are provided throughout advising technicians to fully understand instructions before working on the machine.
Jcb js200 excavator service repair manual sn 1783500 and upfjjskqwaekfksmem
This document is a service manual that provides instructions for servicing excavator engines. It contains sections on general information, components, operation, adjustment, removal and installation of valves. The summary focuses on valves:
The manual contains information on servicing excavator engine valves, including identifying components, measuring clearances, adjusting clearances, and removing and installing valves. Proper valve clearance is important for correct timing in relation to piston movement.
This document contains technical specifications and emissions data for various JCB excavator models. It includes sections on noise emissions, vibration emissions, and fluids/lubricants specifications. Tables of data provide the A-weighted sound pressure and power levels, whole-body vibration values, and fluid capacities for different models. Guidelines are given for minimizing operator exposure to noise and vibration.
This document contains technical specifications and emissions data for various JCB excavator models. It includes sections on noise emissions, vibration emissions, and fluids/lubricants specifications. The noise and vibration emissions data lists the equivalent continuous A-weighted sound pressure and sound power levels for different models and engine ratings, to help customers comply with European emissions directives. Tables of representative whole-body vibration values during common operating duties are also provided.
Jcb 4220 fastrac service repair manual sn from 2184000 onwardsfjjskqwaekfksmem
This service manual section provides information on servicing the timing gears for Fastrac agricultural tractors models 4160, 4190, and 4220. It includes identification of timing gear components such as the camshaft gear, idler gear, and crankshaft gear. Procedures are provided for removing and installing the front case, which houses the timing gears, and related components like the timing gear case. Technical specifications are also included, such as recommended temperatures for heating timing gears during installation and permissible levels of wobble and backlash for the gears.
Jcb 4190 fastrac service repair manual sn from 2184000 onwardsfjjskqwaekfksmem
This service manual section provides information on servicing the timing gears for Fastrac agricultural tractors models 4160, 4190, and 4220. It includes identification of timing gear components such as the camshaft gear, idler gear, and crankshaft gear. Procedures are provided for removing and installing the front case, which houses the timing gears, and related components like the timing gear case. Technical specifications are also included, such as recommended temperatures for heating timing gears during installation and permissible levels of wobble and backlash for the gears.
Jcb 4160 fastrac service repair manual sn from 2184000 onwardsfjjskqwaekfksmem
This service manual section provides information on servicing the timing gears for Fastrac agricultural tractors models 4160, 4190, and 4220. It includes identification of timing gear components, technical specifications, operating instructions, and procedures for removing and installing the timing gears and related components like the front case and flywheel. The timing gears must be properly timed to ensure the camshaft operates the valves at the correct times relative to the crankshaft position. Safety precautions are outlined and it is stressed that the operator's manual should be thoroughly understood before working on the machine.
Jcb 550 170 telescopic handler service repair manual sn from 2902000 onwardsfjjskqwaekfksmem
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine body and framework, operator station, engine, fuel and exhaust, cooling, brake, steering, hydraulic and electrical systems. The engine section provides technical data and instructions for servicing parts like the valves, connecting rods, pistons, and more. Safety notices warn that the operator's manual must be read before operating the machine.
Jcb 550 170 telescopic handler service repair manual sn from 2460601 onwardsfjjskqwaekfksmem
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfjjskqwaekfksmem
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 541 70 tier 4 telescopic handler service repair manual sn from 2336575 on...fjjskqwaekfksmem
The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their components. The main sections include checking injector operation with leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly and high pressure fuel injection pump. Torque specifications are provided for reinstalling components.
Jcb 536 70 lp tier 4 telescopic handler service repair manual sn from 2902000...fjjskqwaekfksmem
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It describes injector components and identification, includes a check procedure using diagnostic tools, and outlines removal and installation steps. Special tools are required for tasks like leak testing and installing injector seals. Torque specifications are provided for tightening injector clamps and sleeves.
Jcb 270 t skid steer loader service repair manual.sn from 2478301 to 2478700fjjskqwaekfksmem
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics and electrical systems. The section summarized here provides instructions for removing and installing a crankshaft from an engine, which involves removing other engine components, cleaning surfaces, checking part conditions and diameters, and installing new parts as needed. Torque specifications and safety cautions are also provided.
Jcb 270 t skid steer loader service repair manual sn from 2675500 to 2675700fjjskqwaekfksmem
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces before reinstalling with new bolts and ensuring proper torque is applied.
Liebherr r926 1345 classic hydraulic excavator service repair manualfjjskqwaekfksmem
This document is a service manual for Liebherr hydraulic excavators. It contains technical specifications and instructions for maintenance and repair. The manual is divided into sections covering the engine, hydraulic and electrical systems, swing mechanisms, tracks and other components. Safety symbols are introduced and procedures are marked for requirements, actions, and expected results. The manual is intended to assist technicians while not replacing proper training. It is produced and copyrighted by Liebherr.
Jcb 270 t skid steer loader service repair manual sn from 2476302 to 2477300fjjskqwaekfksmem
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the installation.
Jcb 100 c 1, 85z-1, 86c-1, 90z-1 mini excavator service repair manual from 25...fjjskqwaekfksmem
The document provides service information for an excavator including:
- It contains original instructions for 100 C-1, 85 Z-1, 86 C-1, and 90 Z-1 excavator models.
- Users must study the operator's manual to safely operate and maintain the machine.
- The manual is divided into sections covering the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, driveline, hydraulics, electrics, and other components.
This service manual contains instructions for servicing various JCB machines. It includes sections on the machine body and framework, operator station, engine, fuel and exhaust systems, cooling system, brakes, steering, driveline, hydraulic system, electrical system, fasteners and fixings, consumable products, and after sales support. The engine section provides details on Kubota diesel engines commonly used in JCB machines, including specifications, component identification diagrams, descriptions of the four-stroke operating cycle, and safety information.
Jcb 3 tst hydrostatic dumper service repair manualfjjskqwaekfksmem
This service manual contains instructions for servicing various JCB machines. It provides technical specifications and component identification for Kubota engines that power some JCB machines. The document discusses the four-stroke operating cycle of 4-cylinder and 3-cylinder engines. It includes diagrams labeling engine components and explaining the induction, compression, power, and exhaust strokes in the ignition cycle. Safety warnings are provided throughout for working on engines and their hot or rotating components.
This service manual provides information for maintaining and servicing JCB machines with Kubota engines. The document includes sections on safety procedures, technical specifications for Kubota D1703 and V2203-M engines, component identification diagrams, and an explanation of the four-stroke engine cycle. Safety warnings cover hot components, turning the engine, high pressure washing, and working with fuel, oil and other fluids.
Jcb 3 cx backhoe loader service repair manual (from 2442701)fjjskqwaekfksmem
This service manual provides instructions for servicing a backhoe loader engine. It contains sections on various engine systems and components. The section on the flywheel describes flywheel components and their functions. It provides procedures for removing and installing the flywheel and gear ring. The section provides detailed instructions and safety information to correctly service these components.
Caterpillar cat 966 h wheel loader (prefix a6g) service repair manual (a6g000...fjjskqwaekfksmem
The document provides instructions for disassembling and assembling the piston pump of a 966H wheel loader. It lists 37 steps for disassembly that involve removing components like bolts, seals, springs, pistons, and covers. It then lists 15 steps for assembly that involve installing these same components in the reverse order of disassembly. The instructions include illustrations to clarify the procedure and notes about safety and required tools.
Liebherr r926 1087 classic hydraulic excavator service repair manualfjjskqwaekfksmem
This document is a service manual for Liebherr hydraulic excavators. It contains technical specifications and instructions for maintenance and repair. The manual is divided into sections covering the engine, hydraulic and electrical systems, swing mechanisms, tracks and other components. Safety symbols are introduced and procedures are marked for requirements, actions, and expected results. The manual is intended to assist technicians while not replacing proper training. It is produced and copyrighted by Liebherr.
Caterpillar cat 938 g wheel loader (prefix 6ws) service repair manual (6ws000...fjjskqwaekfksmem
This document provides assembly instructions for a Flexxaire fan on a 938G wheel loader. It describes how to assemble the shifter block, hub, actuator bearings/control shaft, install an O-ring on the main shaft, and install main bearing cups. The instructions include illustrations and notes about lubrication, torque specifications, and verifying clearances at various steps.
Jcb 4220 fastrac service repair manual sn from 2184000 onwardsfjjskqwaekfksmem
This service manual section provides information on servicing the timing gears for Fastrac agricultural tractors models 4160, 4190, and 4220. It includes identification of timing gear components such as the camshaft gear, idler gear, and crankshaft gear. Procedures are provided for removing and installing the front case, which houses the timing gears, and related components like the timing gear case. Technical specifications are also included, such as recommended temperatures for heating timing gears during installation and permissible levels of wobble and backlash for the gears.
Jcb 4190 fastrac service repair manual sn from 2184000 onwardsfjjskqwaekfksmem
This service manual section provides information on servicing the timing gears for Fastrac agricultural tractors models 4160, 4190, and 4220. It includes identification of timing gear components such as the camshaft gear, idler gear, and crankshaft gear. Procedures are provided for removing and installing the front case, which houses the timing gears, and related components like the timing gear case. Technical specifications are also included, such as recommended temperatures for heating timing gears during installation and permissible levels of wobble and backlash for the gears.
Jcb 4160 fastrac service repair manual sn from 2184000 onwardsfjjskqwaekfksmem
This service manual section provides information on servicing the timing gears for Fastrac agricultural tractors models 4160, 4190, and 4220. It includes identification of timing gear components, technical specifications, operating instructions, and procedures for removing and installing the timing gears and related components like the front case and flywheel. The timing gears must be properly timed to ensure the camshaft operates the valves at the correct times relative to the crankshaft position. Safety precautions are outlined and it is stressed that the operator's manual should be thoroughly understood before working on the machine.
Jcb 550 170 telescopic handler service repair manual sn from 2902000 onwardsfjjskqwaekfksmem
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine body and framework, operator station, engine, fuel and exhaust, cooling, brake, steering, hydraulic and electrical systems. The engine section provides technical data and instructions for servicing parts like the valves, connecting rods, pistons, and more. Safety notices warn that the operator's manual must be read before operating the machine.
Jcb 550 170 telescopic handler service repair manual sn from 2460601 onwardsfjjskqwaekfksmem
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfjjskqwaekfksmem
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 541 70 tier 4 telescopic handler service repair manual sn from 2336575 on...fjjskqwaekfksmem
The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their components. The main sections include checking injector operation with leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly and high pressure fuel injection pump. Torque specifications are provided for reinstalling components.
Jcb 536 70 lp tier 4 telescopic handler service repair manual sn from 2902000...fjjskqwaekfksmem
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It describes injector components and identification, includes a check procedure using diagnostic tools, and outlines removal and installation steps. Special tools are required for tasks like leak testing and installing injector seals. Torque specifications are provided for tightening injector clamps and sleeves.
Jcb 270 t skid steer loader service repair manual.sn from 2478301 to 2478700fjjskqwaekfksmem
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics and electrical systems. The section summarized here provides instructions for removing and installing a crankshaft from an engine, which involves removing other engine components, cleaning surfaces, checking part conditions and diameters, and installing new parts as needed. Torque specifications and safety cautions are also provided.
Jcb 270 t skid steer loader service repair manual sn from 2675500 to 2675700fjjskqwaekfksmem
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces before reinstalling with new bolts and ensuring proper torque is applied.
Liebherr r926 1345 classic hydraulic excavator service repair manualfjjskqwaekfksmem
This document is a service manual for Liebherr hydraulic excavators. It contains technical specifications and instructions for maintenance and repair. The manual is divided into sections covering the engine, hydraulic and electrical systems, swing mechanisms, tracks and other components. Safety symbols are introduced and procedures are marked for requirements, actions, and expected results. The manual is intended to assist technicians while not replacing proper training. It is produced and copyrighted by Liebherr.
Jcb 270 t skid steer loader service repair manual sn from 2476302 to 2477300fjjskqwaekfksmem
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the installation.
Jcb 100 c 1, 85z-1, 86c-1, 90z-1 mini excavator service repair manual from 25...fjjskqwaekfksmem
The document provides service information for an excavator including:
- It contains original instructions for 100 C-1, 85 Z-1, 86 C-1, and 90 Z-1 excavator models.
- Users must study the operator's manual to safely operate and maintain the machine.
- The manual is divided into sections covering the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, driveline, hydraulics, electrics, and other components.
This service manual contains instructions for servicing various JCB machines. It includes sections on the machine body and framework, operator station, engine, fuel and exhaust systems, cooling system, brakes, steering, driveline, hydraulic system, electrical system, fasteners and fixings, consumable products, and after sales support. The engine section provides details on Kubota diesel engines commonly used in JCB machines, including specifications, component identification diagrams, descriptions of the four-stroke operating cycle, and safety information.
Jcb 3 tst hydrostatic dumper service repair manualfjjskqwaekfksmem
This service manual contains instructions for servicing various JCB machines. It provides technical specifications and component identification for Kubota engines that power some JCB machines. The document discusses the four-stroke operating cycle of 4-cylinder and 3-cylinder engines. It includes diagrams labeling engine components and explaining the induction, compression, power, and exhaust strokes in the ignition cycle. Safety warnings are provided throughout for working on engines and their hot or rotating components.
This service manual provides information for maintaining and servicing JCB machines with Kubota engines. The document includes sections on safety procedures, technical specifications for Kubota D1703 and V2203-M engines, component identification diagrams, and an explanation of the four-stroke engine cycle. Safety warnings cover hot components, turning the engine, high pressure washing, and working with fuel, oil and other fluids.
Jcb 3 cx backhoe loader service repair manual (from 2442701)fjjskqwaekfksmem
This service manual provides instructions for servicing a backhoe loader engine. It contains sections on various engine systems and components. The section on the flywheel describes flywheel components and their functions. It provides procedures for removing and installing the flywheel and gear ring. The section provides detailed instructions and safety information to correctly service these components.
Caterpillar cat 966 h wheel loader (prefix a6g) service repair manual (a6g000...fjjskqwaekfksmem
The document provides instructions for disassembling and assembling the piston pump of a 966H wheel loader. It lists 37 steps for disassembly that involve removing components like bolts, seals, springs, pistons, and covers. It then lists 15 steps for assembly that involve installing these same components in the reverse order of disassembly. The instructions include illustrations to clarify the procedure and notes about safety and required tools.
Liebherr r926 1087 classic hydraulic excavator service repair manualfjjskqwaekfksmem
This document is a service manual for Liebherr hydraulic excavators. It contains technical specifications and instructions for maintenance and repair. The manual is divided into sections covering the engine, hydraulic and electrical systems, swing mechanisms, tracks and other components. Safety symbols are introduced and procedures are marked for requirements, actions, and expected results. The manual is intended to assist technicians while not replacing proper training. It is produced and copyrighted by Liebherr.
Caterpillar cat 938 g wheel loader (prefix 6ws) service repair manual (6ws000...fjjskqwaekfksmem
This document provides assembly instructions for a Flexxaire fan on a 938G wheel loader. It describes how to assemble the shifter block, hub, actuator bearings/control shaft, install an O-ring on the main shaft, and install main bearing cups. The instructions include illustrations and notes about lubrication, torque specifications, and verifying clearances at various steps.
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
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At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
Charging Fueling & Infrastructure (CFI) Program Resources by Cat PleinForth
Cat Plein, Development & Communications Director of Forth, gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
Charging and Fueling Infrastructure Grant: Round 2 by Brandt HertensteinForth
Brandt Hertenstein, Program Manager of the Electrification Coalition gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Expanding Access to Affordable At-Home EV Charging by Vanessa WarheitForth
Vanessa Warheit, Co-Founder of EV Charging for All, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Charging Fueling & Infrastructure (CFI) Program by Kevin MillerForth
Kevin Miller, Senior Advisor, Business Models of the Joint Office of Energy and Transportation gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
2. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 79 9813/2700-2 15 - 79
03 - Drive Belt
Introduction .................................................... 15-79
Health and Safety .......................................... 15-80
Component Identification ............................... 15-80
Check (Condition) .......................................... 15-81
Adjust ............................................................ 15-81
Remove and Install ....................................... 15-83
Introduction
Original Belt Configuration
The alternator adjusting lever makes sure that the
front end accessory drive belt (FEAD) is kept at the
correct tension.
Figure 143.
B
A
A Alternator
B Adjusting lever
Alternate Belt Configuration
A tensioning screw, which adjusts the tightening
pulley travel, makes sure that the front end accessory
drive belt (FEAD) is kept at the correct tension.
Figure 144.
A
B
A Tightening pulley
B Tensioning screw
3. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 80 9813/2700-2 15 - 80
Health and Safety
Notice: A drive belt that is loose can cause
damage to itself and/or other engine parts.
Component Identification
Figure 145. Original Belt Configuration
C
A
D
B
A Crankshaft drive pulley
B Drive belt
C Coolant pump drive pulley
D Alternator drive pulley
Figure 146. Poly-V Belt Configuration
B
A
D
C
E
A Crankshaft drive pulley
B Tensioner pulley
C Coolant pump drive pulley
D Alternator drive pulley
E Poly-V belt
4. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 81 9813/2700-2 15 - 81
Check (Condition)
At the recommended service interval, visually inspect
the drive belt for damage.
1. Make the machine safe. Refer to (PIL 01-03).
2. Stop the engine and let it cool down.
3. Replace the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Adjust
Original Belt Configuration
The belt must always be replaced every time it is
removed, even if it has not reached the scheduled
hours for replacement.
1. Pull the alternator in the direction of the arrow.
Figure 147.
A
C
B
D
A Alternator
B Top mounting bolt
C Bottom mounting bolt
D Drive belt
2. Tighten the top mounting bolt to the correct
torque value.
Torque: 25N·m
3. Tighten the bottom mounting bolt to the correct
torque value.
Torque: 40N·m
4. While tensioning the alternator, first install the top
mounting screw and then the bottom mounting
screw.
5. Measure the tension of the belt at the point
shown.
Figure 148.
E
E Tension measuring point
5. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 82 9813/2700-2 15 - 82
6. The tension of the belt should between the
specified values.
Weight/Force: 350–450N
7. If the tension values do not match the specified,
tighten the screws, then repeat the steps 1 to 6.
Alternate Belt Configuration
The belt must always be replaced every time it is
removed, even if it has not reached the scheduled
hours for replacement.
1. Make sure that the ribs of the belt are engaged
correctly into the grooves of the pulleys.
Figure 149.
B
A
A Drive belt
B Pulley pin
2. Make sure that the pulley pin is at the bottom of
the guide groove.
3. Tighten the screw, that attaches the pulley, to the
correct torque value.
Torque: 45N·m
4. Hold the tensioning screw with an Allen key.
5. Tighten the nut on the plate to secure the
tightening screw.
Torque: 45N·m
Figure 150.
D
E
C
F
C Screw
D Tensioning screw
E Nut
F Plate
6. Measure the tension of the belt at the point
shown.
Figure 151.
G
G Tension measuring point
7. The tension of the belt should between the
specified values.
Frequency: 149–196Hz
8. Run the engine for the specified duration.
Duration: 15–20min
9. Repeat the step 6 to 7.
10. The Poly-v drive belt is not adjustable. If the
tension value is not within the specified range
replace the drive belt.
6. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 83 9813/2700-2 15 - 83
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Get access to the drive belt. Refer to (PIL 15-18).
3. Disconnect the battery. Refer to (PIL 33-03).
4. Loosen the nut and tighten the screw until it
touches the pulley shaft. Refer to Figure 152.
5. Loosen the bolt that attaches the pulley to the
pulley shaft, up to the specified distance. Refer
to Figure 152.
Distance: 32mm
6. Loosen the screw, the belt tensioner pulley will
move up. Refer to Figure 152.
6.1. If the pulley will not move, pull the belt
tensioner pulley up.
7. Remove the drive belt. Refer to Figure 152.
Figure 152.
A
B
C
F
D
G
E
A Nut
B Screw
C Pulley shaft
D Bolt
E 32mm
F Tensioner pulley
G Existing drive belt
Install
1. Pull the belt tensioner pulley up. Refer to Figure
153.
Figure 153.
F
F Tensioner pulley
2. Insert the new drive belt on the pulleys. Refer to
Figure 154.
Figure 154.
J
H
J
H New drive belt
J Pulleys
3. Make sure that the ribs of the drive belt are
engaged correctly into the grooves of the pulleys.
4. Tighten the screw until the pulley shaft reaches
the bottom of the guide groove. Refer to Figure
155.
7. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 84 9813/2700-2 15 - 84
Figure 155.
B
C
B Screw
C Pulley shaft
5. Tension the drive belt.
6. Tighten the pulley bolt to the correct specified
torque value.
Torque: 45N·m
7. Tighten the nut.
8. Connect the battery.
9. Close the engine cover.
10. Check the belt tension after the engine operation
for the specified time.
Duration: 15min
8. 15 - Engine
18 - Engine Belt
21 - Tensioner
15 - 85 9813/2700-2 15 - 85
21 - Tensioner
Remove and Install
This procedure is applicable for machines installed
with Poly-V drive belt.
Important: The drive belt must always be replaced
every time it is removed, even if it has not reached
the scheduled hours for replacement.
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Remove the drive belt. Refer to (PIL 15-18).
3. Remove the tensioning screw.
4. Remove the screw that secures the tightening
pulley.
5. Remove the tightening pulley.
Figure 156.
A
B
C
A Tensioning screw
B Screw
C Tightening pulley
Install
1. Insert the screw in the tightening pulley.
2. Manually tighten the screw on to the pulley pin up
to the stop; Loosen the screw again by one turn.
3. The screw must be out by the specified distance
from the surface of the tightening pulley.
Distance: 32mm
4. Install the drive belt. Refer to (PIL 15-18).
5. Install the tightening screw on to the plate, up to
the stop on the pulley pin.
6. Tension the drive belt.
Figure 157.
A
B
E
D
C
A Tensioning screw
B Screw
C Tightening pulley
D Pulley pin
E 32mm
9. 15 - Engine
21 - Oil Filter
00 - General
15 - 89 9813/2700-2 15 - 89
Component Identification
Figure 158.
A
B
A Oil Filter
B Element
Figure 159.
C
D
B
A
A Cartridge holder cover
B Oil filter support
C Oil returning into the circuit
D Oil returning to the crankcase
Figure 160.
H
E
A
B
GF
A Cartridge holder cover
B Oil filter support
E Oil filter cartridge
F Outgoing fitting from filter
G Water/oil heat exchanger
H Crankcase
10. 15 - Engine
21 - Oil Filter
00 - General
15 - 90 9813/2700-2 15 - 90
Check (Level)
Engine oil and oil filter replacement must be
completed in accordance with the service schedules.
Failure to replace the oil and filter at the
recommended interval could cause serious engine
failure.
1. Make the machine safe. Refer to (PIL 01-03).
2. Park the machine on a hard level surface for
accurate measurement of the oil level.
3. Get access to the engine.
4. Check that the oil level is between the two marks
on the dipstick.
Figure 161.
B
A
C
A Dipstick
B Maximum level mark
C Minimum level mark
5. If necessary, add recommended oil through one
of the filler points.
Figure 162.
D
D Oil filler caps
Remove and Install
Before Removal
1. Drain the engine oil, refer to Engine-General,
Drain and Fill (PIL 15-00).
Refer to: Engine > General > General > Drain and
Fill (Page 15-17).
Remove and Install
1. Remove the clamps and remove the pipes from
the oil cooler unit.
Figure 163.
D
E
F
D Clamps
E Pipes
F Oil cooler
2. Use a suitable container to recover any residual
oil.
3. Loosen the element holder cap.
Figure 164.
H
G
J
G Element holder cap
H Oil filter support
J Element
4. Remove the cap and the oil filter element from
the oil filter support.
5. Remove the cartridge from the cap and discard.
11. 15 - Engine
21 - Oil Filter
00 - General
15 - 91 9813/2700-2 15 - 91
Figure 165.
J
G
K
G Element holder cap
J Element
K Seal
6. Remove and replace the seals.
7. Apply clean oil on the seals.
8. Put the element on the cap.
9. Install the cap on the oil filter support.
10. Tighten the cap to the correct torque value.
11. Install the pipes on the support.
12. Secure the pipes with the clamps.
13. Through one of the filler points, fill the engine with
the recommended oil to the MAX mark on the
dipstick.
Figure 166.
L
L Oil filler caps
14. Wipe off any spilt oil, install the filler cap and
make sure it is secure.
15. Operate the engine, until the oil pressure low
warning light has extinguished.
16. Check for oil leakage.
17. When the oil has cooled, check the oil level
again, and if necessary top up with clean engine
oil.
Table 53. Torque Values
Item Nm
B 35
G 25
12. 15 - Engine
27 - Crankcase Ventilation Filter
03 - Separator
15 - 103 9813/2700-2 15 - 103
03 - Separator
Remove and Install
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
Before removal
1. Make the machine safe with the lift arm lowered.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the crankcase ventilation filter
Refer to: Engine > Crankcase Ventilation Filter
(Page 15-97).
Remove
1. Remove all the pipes from the separator.
Figure 171.
E
F
A
E
G
D
A Separator
D Crankcase
E Clamp
F Pipe
G Pipe1
2. Remove the screws.
Figure 172.
A
C
B
A Separator
B Screw
C Gasket
3. Remove the separator with the gasket.
Install
1. Check that the contact surfaces are free from
impurities.
2. Always examine the condition of the pipes, and
replace them if there is any doubt regarding the
integrity of their seal.
3. Always replace the gasket after each assembly.
4. Install the gasket on the separator.
Figure 173.
A
D
CB
A Separator
B Screw
C Gasket
D Crankcase
5. Attach the holder on the crankcase with the
screws.
6. Tighten the screws to the correct torque value.
13. 15 - Engine
27 - Crankcase Ventilation Filter
03 - Separator
15 - 104 9813/2700-2 15 - 104
Figure 174.
AE G
F E
A Separator
E Clamp
F Pipe
G Pipe1
7. Attach the pipes on the separator with the clamp.
After installation
1. Install the crankcase ventilation filter
Refer to: Engine > Crankcase Ventilation Filter
(Page 15-97).
2. Start the engine and check for leaks.
Table 54. Torque Values
Item Nm
B 10
14. 15 - Engine
30 - Valve
00 - General
15 - 107 9813/2700-2 15 - 107
00 - General
Introduction .................................................. 15-107
Technical Data ............................................. 15-108
Component Identification ............................. 15-109
Operation ..................................................... 15-111
Adjust .......................................................... 15-113
Calibrate ...................................................... 15-113
Remove and Install ..................................... 15-115
Introduction
The valve train system opens and closes the
valves with correct timing in relation to the piston
movements.
Each push rod has one end in a valve tappet and
the other end under a rocker arm, or as applicable.
Hydraulic tappets are used which automatically
adjust the clearance between the valve and push
rods.
The valves extend through 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 reground and must be replaced with new
ones. Each valve stem has an oil seal.
The Valve seat inserts 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.
15. 15 - Engine
30 - Valve
00 - General
15 - 108 9813/2700-2 15 - 108
Technical Data
Table 55. Inlet and Exhaust Valve Data
Max lift Inlet 9.64mm @ 101° After
TDC (Top Dead Centre)
Max lift Exhaust 9.84mm @ 115° Before
TDC
Inlet opens (top of ramp) 6° Before TDC
Inlet closes 28° After TDC
Exhaust opens 41° Before TDC
Exhaust closes 6° After TDC
Valve stem diameter
- Inlet 6.928–6.943mm
- Exhaust 6.918–6.933mm
Valve spring free length 51.1mm
Valve guide bore diame-
ter
- min 6.958mm
- max 6.973mm
Valve face angle
- Inlet 60.5°
- Exhaust 45.17°
Valve length 131.9–132.4mm
Valve sealing Stem seal with sealing
washer
Valve head depth (below
cylinder head surface)
- Inlet 0.89–1.39mm
- Exhaust 0.95–1.45mm
Valve rim thickness 2.98–3.38mm
Valve Clearances (en-
gine cold)
- Inlet 0.19–0.27mm
(1)
- Exhaust 0.56–0.64mm
(1)
(1) The values refer to the tappet adjuster end of the
valve rockers.
16. 15 - Engine
30 - Valve
00 - General
15 - 109 9813/2700-2 15 - 109
Component Identification
Figure 175.
H
E
F
G
A
D
C
B
A Crankshaft B Crankshaft gear
C Intermediate gear D Camshaft control gear
E Camshaft F Camshaft tappet
G Rocker arm push rod H Valve
17. 15 - Engine
30 - Valve
00 - General
15 - 110 9813/2700-2 15 - 110
Figure 176.
K
C D
A
L
J
B
A Crankshaft
B Crankshaft gear
C Intermediate gear
D Camshaft control gear
J Camshaft phonic wheel
K Intermediate gear pin
L Phonic wheel positioning reference pin on
camshaft
Figure 177.
H
G
N
M
Q
P
G Rocker arm push rod
H Valve
M Articulation control valve
N Valve control bridge
P Hydraulic tappet
Q Rocker arm
18. 15 - Engine
30 - Valve
00 - General
15 - 111 9813/2700-2 15 - 111
Operation
The camshaft drive gear is driven by the crankshaft
gear at half the speed of the crankshaft. Camshaft
lobes, two for each cylinder, (operating exhaust and
inlet valves) actuate the valve tappets.
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot
on the camshaft, depressing two valves at the same
time via the bridge piece.
The screw is self locking in the rocker by means of
a tapered thread. Springs and holders are used to
keep the rockers in their correct positions along the
camshaft and prevent them contacting one another.
The rockers incorporate a swivel tip to ensure
alignment with the bridge piece. This prevents
excessive wear.
Each valve has a compression spring. The function
of the spring is to close the valve and at the same
time return the rocker arm and push rod to ensure
that the tappets follow the camshaft lobes. The spring
is located on the valve stem by a retainer and split
collets.
Figure 178.
H
E
F
G
A
D
C
B
A Crankshaft B Crankshaft gear
C Intermediate gear D Camshaft control gear
E Camshaft F Camshaft tappet
G Rocker arm control rod H Valve stem
19. 15 - Engine
30 - Valve
00 - General
15 - 112 9813/2700-2 15 - 112
Figure 179.
L
H
N
R
Q
W
P
M
J
S
U
V
K
T
H Valve stem J Rocker arm body
K Hydraulic tappet L Rocker arm distancing spring
M Rocker arm pin holder N Retainer
P Collets Q Oil seal - valve stems
R Valve seat inserts S Oil flow line
T Valve tappet U Discharge rocker arm
V Suction rocker arm W Spring
20. 15 - Engine
30 - Valve
00 - General
15 - 113 9813/2700-2 15 - 113
Adjust
There is no valve adjustment possible on this engine.
Calibrate
Valve Seat check
1. Thoroughly clean the valves and their seats with
suitable degreasing agent.
2. Measure the seal width of each valve and the
valve recess from the cylinder head.
Table 56.
Valve Recess Wear Limit
0.110-0.150mm
(0.0043-0.0059in)
1.100mm (0.0433in)
If the dimensions measured do not comply with the
above- mentioned values, replace the valves.
The seats must be replaced by a rectification
workshop.
Make sure you always lubricate the valve and valve
seat contact surfaces to prevent oxidation.
Figure 180.
B
A
D
C
A Valve Seat
B Cylinder head
C Valve recess
D Seal width
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22. 15 - Engine
30 - Valve
00 - General
15 - 114 9813/2700-2 15 - 114
Valve Springs
1. Use a vernier caliper to measure the free length
of the spring.
2. With a dynamometer, subject the spring to two
different loads and check that the length of the
spring corresponds to the values given in the
table below.
Table 57.
Item Load (Kg) Length (mm)
Z Without load 48.35
Z1 20.4 30.00
Z2 34.8 22.00
Figure 181.
A Z1
Z
Z2
A Valve spring
Valve Guides Check
1. With a micrometer, measure the diameter of the
valve stem.
2. With a internal dial gauge, measure the diameter
of the valve guides.
3. After the guides are installed in the cylinder head,
measure the height of the guides from the rocker
arm support surface.
4. Make sure you take the measurements in
different points to find any ovalisation and/or
concentrated wear.
Table 58.
Item Dimension
(mm)
Clearance
(mm)
Wear limit
(mm)
D 5.978 -
5.990
E 5.030 -
6.042
0.040 -
0.064
0.100
F 7.000 -
7.020
Figure 182.
F
E
D
C
B
A
A Valve guide
B Valve stem
C Rocker arm support surface
D Valve stem diameter
E Valve guide diameter
F Valve guide height
Valve Guides Replacement
The intake and exhaust guides are both made out
of grey iron with pearlitic phosphoric matrix and they
have the same dimensions.
The guides are not pre-finished, so they must be
processed after press-fitting along with the seats.
Contact a workshop for these operations.
Table 59.
Item Dimensions (mm)
A 10.000 - 10.015
B 10.045 - 10.054
23. 15 - Engine
30 - Valve
00 - General
15 - 115 9813/2700-2 15 - 115
Figure 183.
A
B
A Valve guide diameter
B Valve guide housing diameter
Remove and Install
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the thermostat. Refer to (PIL 21-12).
5. Remove all of the fuel injector pipes. Refer to (PIL
18-96).
6. Remove the inlet manifold. Refer to (PIL
18-24-03).
7. Remove the exhaust manifold. Refer to (PIL
18-24-04).
8. Remove the fuel injectors. Refer to (PIL 18-18).
9. Remove the rocker cover. Refer to (PIL
15-42-06).
10. Remove the rocker assembly. Refer to (PIL
15-42).
11. Remove the cylinder head assembly. Refer to
(PIL 15-06).
12. Measure the valve recession as follows:
12.1.Clean the area around the valve heads to
remove the carbon deposits.
12.2.Measure the valve recession with a DTI
(Dial Test Indicator).
12.3.If the valve recession is more than the
specified limits, get a new or repaired
cylinder head assembly.
Remove
1. Install the spring compressor tool in one of the
bolt holes for the rocker arm cover.
2. Make sure you change the position of the spring
compressor tool according to the valves to be
removed.
24. 15 - Engine
30 - Valve
00 - General
15 - 116 9813/2700-2 15 - 116
Figure 184.
B
C
A
A Rocker arm cover attaching holes
B Spring compressor tool
C Valve stem
3. Use the spring compressor tool to compress the
valve spring equally.
Figure 185.
G
E
F
C
D
C Valve stem
D Retainer
E Spring
F Cotter
G Valve stem seal
4. Use a magnet to pull out the cotter.
5. Remove the spring compressor tool and lift off
the retainer and valve spring.
6. Turn the cylinder head and remove the valve.
Figure 186.
C
H
C Valve stem
H Cylinder head
7. When you remove the valves, record the position
of each valve.
8. Use a suitable valve stand to keep the valves
together and to identify them with their respective
cylinder.
Figure 187. Valve stand
EXHAUST
CYL. 1 CYL. 2 CYL. 3 CYL. 4
INLET
EXHAUST
INLET
EXHAUST
INLET
EXHAUST
INLET
9. Remove the valve stem seal. Discard the seal.
Figure 188.
G
G Valve stem seal
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.