This service manual provides instructions for servicing a skid steer loader. It contains sections covering the machine systems, including the engine, fuel system, hydraulic system, electrical system and other components. The section on the fuel injection governor describes how it controls engine speed. The governor uses springs and levers to adjust the fuel rack on the injection pump based on engine RPM. The document provides instructions for removing, testing and resetting the governor components when servicing the fuel system.
Jcb 135 hd skid steer loader service repair manual (sn 2431601 and up)fiskefjskemem
This service manual provides instructions for servicing a JCB 135 HD and 155 HD skid steer loader. It contains sections covering the machine systems, including the engine, fuel system, hydraulic system, electrical system, and other components. The document provides detailed descriptions of components, operating principles, maintenance and repair procedures, specifications, and safety information. Technicians are instructed to carefully follow the procedures in the manual to properly service the machine.
Jcb 135 skid steer loader service repair manual (from 2473501 to 2473800)fdjjsekksemxs
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the engine and its systems. The manual outlines the operating principles and components of the Perkins 400 series diesel engine used in the skid steer, including descriptions of the 4-stroke combustion cycle and the function of internal engine parts. Instructions are provided for routine maintenance, inspections, and repairs.
Jcb js160 tier 4i and t4 f excavator service repair manualfujsjefjwerkskemm
This service manual provides instructions for servicing JCB excavators models JS115 through JS190. It contains sections on the machine body and framework, operator station, engine, driveline, hydraulic system, electrical system and other components. The section on the engine covers topics like removing and installing the rocker cover, camshaft, tappets and oil sump. Precise instructions are provided along with torque specifications and safety warnings.
Jcb jcb305, js305 excavator service repair manual (from 2452101 to 2452200)fjjsjeusekkekm
This document is a service manual for an excavator model JCB305, JS305. It contains instructions for servicing and repairing components of the excavator, listed by system (e.g. engine, hydraulic system, electrical system). The manual provides technical specifications, diagrams, removal and installation instructions, and checking/inspection procedures for parts like the engine, pistons, connecting rods, and more. Safety warnings are included to treat the manual as part of the machine and follow all instructions to avoid injury during operation and maintenance.
Caterpillar cat 135 h motor grader (prefix 7mm) service repair manual (7mm000...fjjsjeskkekem
This document provides instructions for removing and installing various components of the power train system on a 135H Motor Grader, including the parking brake, tandem drive housings, drive sprockets, and final drives. It describes disconnecting transmission lines and air lines, draining transmission oil, and removing and installing various components using specialized tools while taking safety precautions. Torque specifications are provided for reinstalling components.
Jcb 3 cx compact backhoe loader service repair manual (sn from 2495456 and up)fusefjskekkmem
This service manual provides instructions for servicing a JCB 3CX Compact backhoe loader. It contains sections covering the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The specific section summarized discusses servicing procedures for the engine crankshaft, including how it is lubricated by engine oil, how to check its condition by inspecting the bearing surfaces and diameters, and ensuring the oilways are clear.
Jcb 560 80 tier 4 telescopic handler service repair manual sn from 2460601 on...fusefjjskekemm
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 purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstalling components.
Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000fusefjskekkmem
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Jcb 135 hd skid steer loader service repair manual (sn 2431601 and up)fiskefjskemem
This service manual provides instructions for servicing a JCB 135 HD and 155 HD skid steer loader. It contains sections covering the machine systems, including the engine, fuel system, hydraulic system, electrical system, and other components. The document provides detailed descriptions of components, operating principles, maintenance and repair procedures, specifications, and safety information. Technicians are instructed to carefully follow the procedures in the manual to properly service the machine.
Jcb 135 skid steer loader service repair manual (from 2473501 to 2473800)fdjjsekksemxs
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the engine and its systems. The manual outlines the operating principles and components of the Perkins 400 series diesel engine used in the skid steer, including descriptions of the 4-stroke combustion cycle and the function of internal engine parts. Instructions are provided for routine maintenance, inspections, and repairs.
Jcb js160 tier 4i and t4 f excavator service repair manualfujsjefjwerkskemm
This service manual provides instructions for servicing JCB excavators models JS115 through JS190. It contains sections on the machine body and framework, operator station, engine, driveline, hydraulic system, electrical system and other components. The section on the engine covers topics like removing and installing the rocker cover, camshaft, tappets and oil sump. Precise instructions are provided along with torque specifications and safety warnings.
Jcb jcb305, js305 excavator service repair manual (from 2452101 to 2452200)fjjsjeusekkekm
This document is a service manual for an excavator model JCB305, JS305. It contains instructions for servicing and repairing components of the excavator, listed by system (e.g. engine, hydraulic system, electrical system). The manual provides technical specifications, diagrams, removal and installation instructions, and checking/inspection procedures for parts like the engine, pistons, connecting rods, and more. Safety warnings are included to treat the manual as part of the machine and follow all instructions to avoid injury during operation and maintenance.
Caterpillar cat 135 h motor grader (prefix 7mm) service repair manual (7mm000...fjjsjeskkekem
This document provides instructions for removing and installing various components of the power train system on a 135H Motor Grader, including the parking brake, tandem drive housings, drive sprockets, and final drives. It describes disconnecting transmission lines and air lines, draining transmission oil, and removing and installing various components using specialized tools while taking safety precautions. Torque specifications are provided for reinstalling components.
Jcb 3 cx compact backhoe loader service repair manual (sn from 2495456 and up)fusefjskekkmem
This service manual provides instructions for servicing a JCB 3CX Compact backhoe loader. It contains sections covering the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The specific section summarized discusses servicing procedures for the engine crankshaft, including how it is lubricated by engine oil, how to check its condition by inspecting the bearing surfaces and diameters, and ensuring the oilways are clear.
Jcb 560 80 tier 4 telescopic handler service repair manual sn from 2460601 on...fusefjjskekemm
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 purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstalling components.
Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000fusefjskekkmem
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb js220 tracked excavator service repair manual sn from 2460501 onwardsfusjefjkskem
This service manual provides information on servicing excavator models JS200, JS210, JS220, and JS235. It contains instructions from the manufacturer and copyrighted content. The manual covers safety procedures and contains sections on various machine systems including the engine, fuel system, cooling system, driveline, hydraulics, electrical system and other components.
Jcb 3 cx backhoe loader service repair manual sn from 2509500 and upfdjjsekksemxs
This service manual provides instructions for servicing backhoe loaders models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The document provides detailed procedures, diagrams, and specifications for maintenance, repair, and removal/installation of parts. Safety warnings are included throughout advising technicians to read and understand instructions before working on the machine.
Jcb 536 70 telescopic handler service repair manual sn 2460601 and upfujsjefjwerkskemm
This service manual section contains information about JCB diesel engines. It provides a basic description of engine components and operation, including the starter motor, fuel injection system, lubrication system, and ancillary drive components. The manual identifies internal engine parts such as pistons, connecting rods, valves, bearings, and gears. It specifies that all components should be renewed if worn and that leakages should be prevented during maintenance.
Jcb tm220 telescopic wheeled loader service repair manual sn from 2679851 to ...fujsjefjwerkskemm
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 tlt 25 g teletruk (variable reach truck) service repair manual sn 2498451...fujsjefjskekmem
This service manual provides instructions for servicing the Teletruk (variable reach truck) models TLT 25G and TLT 30G. It contains sections covering the entire machine including the engine, fuel and exhaust systems, cooling system, brake system, hydraulic system, electrical system, and other components. The manual provides health and safety warnings and instructions for tasks such as removing and installing parts, fault finding, and storing or recommissioning the machine. It also includes technical specifications and diagrams to identify engine components.
Human: Thank you for the summary. You captured the key details about what the document contains and its purpose while keeping it concise.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
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.
Liebherr r974 c 1146 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1137 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1124 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1084 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1058 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Jcb tlt 30 g teletruk (variable reach truck) service repair manual sn 2498451...kmf8sueddkk
This service manual provides information for servicing the TELETRUK (VARIABLE REACH TRUCK) TLT 25G and TLT 30G models. It contains sections covering the entire machine including the engine, fuel system, cooling system, brake system, hydraulic system, electrical system, and other components. The engine section provides an overview of the 4-cylinder LPG engine and its operation, including technical specifications, component identification, health and safety guidelines, and procedures for inspection, maintenance and repair.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb tlt 30 g teletruk (variable reach truck) service repair manual sn 2317866...kmf8sueddkk
This service manual provides information for servicing the TLT 25G and TLT 30G Teletruk vehicles. It contains sections covering the machine components, including the engine. The engine section provides an overview of the 4-cylinder LPG engine and its operation, including safety information, technical specifications, component identification, and instructions for operation, fault-finding, cleaning, removal/installation, and storage/recommissioning. Diagrams are included to illustrate the engine components and the four-stroke operating cycle.
Jcb 541 70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Procedures are provided for maintenance, removal and installation of parts, and repair. Safety warnings are included throughout regarding working on and operating the machines.
Jcb js145 tier 4i and t4 f excavator service repair manualkmf8sueddkk
This service manual provides instructions for servicing components of various JCB excavator models, including removing and installing the rocker cover, tappets, tappet covers, oil sump, camshaft, and timing gears. The document outlines safety precautions, lists required tools and consumables, and provides step-by-step instructions and diagrams for servicing each component. Torque specifications are provided for fasteners.
Jcb 540 v180 telescopic handler service repair manual sn from 2902000 onwardskmf8sueddkk
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.
Jcb js145 excavator service repair manual sn 2397465 and upkmf8sueddkk
The document provides service information for excavator tracks. It includes sections on track components, checking track condition, adjusting track tension, removing and installing tracks, and storing tracks. The main components described are the steel track chain, pins, bushes, links, and tensioning/idler wheel assembly. Instructions are given on inspecting wear of these parts and taking corrective actions such as adjusting tension or replacing worn components. Technical specifications are also included for measuring track pitch, bush diameter, and link height to assess wear.
Jcb js131 tier 4i and t4 f excavator service repair manualkmf8sueddkk
This service manual provides instructions for servicing components of various JCB excavator models. The document reviewed procedures for removing and installing the rocker cover, which requires disconnecting fuel lines and electrical connectors. It also described removing and installing the camshaft, which must be done with the engine inverted to prevent parts from falling in. Proper lubrication and alignment of parts is important during installation. Safety precautions like ensuring the engine has cooled and cleaning areas are noted. Torque specifications are provided for fasteners.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 536 70 lp tier 4 telescopic handler service repair manual sn from 2460601...kmf8sueddkk
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for servicing fuel injectors, including checking operation, removing and installing individual injectors, and removing and installing injector seals.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb js220 tracked excavator service repair manual sn from 2460501 onwardsfusjefjkskem
This service manual provides information on servicing excavator models JS200, JS210, JS220, and JS235. It contains instructions from the manufacturer and copyrighted content. The manual covers safety procedures and contains sections on various machine systems including the engine, fuel system, cooling system, driveline, hydraulics, electrical system and other components.
Jcb 3 cx backhoe loader service repair manual sn from 2509500 and upfdjjsekksemxs
This service manual provides instructions for servicing backhoe loaders models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The document provides detailed procedures, diagrams, and specifications for maintenance, repair, and removal/installation of parts. Safety warnings are included throughout advising technicians to read and understand instructions before working on the machine.
Jcb 536 70 telescopic handler service repair manual sn 2460601 and upfujsjefjwerkskemm
This service manual section contains information about JCB diesel engines. It provides a basic description of engine components and operation, including the starter motor, fuel injection system, lubrication system, and ancillary drive components. The manual identifies internal engine parts such as pistons, connecting rods, valves, bearings, and gears. It specifies that all components should be renewed if worn and that leakages should be prevented during maintenance.
Jcb tm220 telescopic wheeled loader service repair manual sn from 2679851 to ...fujsjefjwerkskemm
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 tlt 25 g teletruk (variable reach truck) service repair manual sn 2498451...fujsjefjskekmem
This service manual provides instructions for servicing the Teletruk (variable reach truck) models TLT 25G and TLT 30G. It contains sections covering the entire machine including the engine, fuel and exhaust systems, cooling system, brake system, hydraulic system, electrical system, and other components. The manual provides health and safety warnings and instructions for tasks such as removing and installing parts, fault finding, and storing or recommissioning the machine. It also includes technical specifications and diagrams to identify engine components.
Human: Thank you for the summary. You captured the key details about what the document contains and its purpose while keeping it concise.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
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.
Liebherr r974 c 1146 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1137 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1124 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1084 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Liebherr r974 c 1058 hydraulic excavator service repair manualkmf8sueddkk
The document is a service manual that provides technical information for maintenance and repair of Liebherr hydraulic excavators. It contains sections on the engine, hydraulic and electrical systems, undercarriage, and other components. Symbols are used to indicate dangers, warnings, and important notes. The manual is intended to assist customer support and training, but does not replace proper technical qualifications or training.
Jcb tlt 30 g teletruk (variable reach truck) service repair manual sn 2498451...kmf8sueddkk
This service manual provides information for servicing the TELETRUK (VARIABLE REACH TRUCK) TLT 25G and TLT 30G models. It contains sections covering the entire machine including the engine, fuel system, cooling system, brake system, hydraulic system, electrical system, and other components. The engine section provides an overview of the 4-cylinder LPG engine and its operation, including technical specifications, component identification, health and safety guidelines, and procedures for inspection, maintenance and repair.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb tlt 30 g teletruk (variable reach truck) service repair manual sn 2317866...kmf8sueddkk
This service manual provides information for servicing the TLT 25G and TLT 30G Teletruk vehicles. It contains sections covering the machine components, including the engine. The engine section provides an overview of the 4-cylinder LPG engine and its operation, including safety information, technical specifications, component identification, and instructions for operation, fault-finding, cleaning, removal/installation, and storage/recommissioning. Diagrams are included to illustrate the engine components and the four-stroke operating cycle.
Jcb 541 70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Procedures are provided for maintenance, removal and installation of parts, and repair. Safety warnings are included throughout regarding working on and operating the machines.
Jcb js145 tier 4i and t4 f excavator service repair manualkmf8sueddkk
This service manual provides instructions for servicing components of various JCB excavator models, including removing and installing the rocker cover, tappets, tappet covers, oil sump, camshaft, and timing gears. The document outlines safety precautions, lists required tools and consumables, and provides step-by-step instructions and diagrams for servicing each component. Torque specifications are provided for fasteners.
Jcb 540 v180 telescopic handler service repair manual sn from 2902000 onwardskmf8sueddkk
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.
Jcb js145 excavator service repair manual sn 2397465 and upkmf8sueddkk
The document provides service information for excavator tracks. It includes sections on track components, checking track condition, adjusting track tension, removing and installing tracks, and storing tracks. The main components described are the steel track chain, pins, bushes, links, and tensioning/idler wheel assembly. Instructions are given on inspecting wear of these parts and taking corrective actions such as adjusting tension or replacing worn components. Technical specifications are also included for measuring track pitch, bush diameter, and link height to assess wear.
Jcb js131 tier 4i and t4 f excavator service repair manualkmf8sueddkk
This service manual provides instructions for servicing components of various JCB excavator models. The document reviewed procedures for removing and installing the rocker cover, which requires disconnecting fuel lines and electrical connectors. It also described removing and installing the camshaft, which must be done with the engine inverted to prevent parts from falling in. Proper lubrication and alignment of parts is important during installation. Safety precautions like ensuring the engine has cooled and cleaning areas are noted. Torque specifications are provided for fasteners.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 536 70 lp tier 4 telescopic handler service repair manual sn from 2460601...kmf8sueddkk
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for servicing fuel injectors, including checking operation, removing and installing individual injectors, and removing and installing injector seals.
Jcb 536 70 tier 4 telescopic handler service repair manual sn from 2902000 on...kmf8sueddkk
This document provides service and repair instructions for fuel injectors on JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for inspecting and replacing fuel injectors and their seals.
Jcb 225 t skid steer loader service repair manual sn from 2478301 to 2478700kmf8sueddkk
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 parts, applying sealant, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the process.
Jcb 225 t skid steer loader service repair manual sn from 2476302 to 2477300kmf8sueddkk
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 parts, applying sealant, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the process.
Jcb 155 hd skid steer loader service repair manual (sn 2431601 and up)kmf8sueddkk
This service manual provides instructions for servicing a JCB 135 HD and 155 HD skid steer loader. It contains sections covering the machine systems, including the engine, fuel system, hydraulic system, electrical system, and other components. The document provides detailed descriptions, component identification diagrams, removal and installation instructions, and safety and torque specifications for servicing the machine. Proper use of the manual requires understanding and following the instructions to safely operate and maintain the machine.
Jcb 5 cx backhoe loader service repair manual sn from 2509500 and upkmf8sueddkk
This service manual provides instructions for servicing and repairing backhoe loaders with 3CX, 4CX and 5CX engines. It contains sections on machine components, attachments, body and framework, operator station, HVAC, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system and electrical system. The manual instructs technicians to carefully study instructions before operating or maintaining equipment and to ask for assistance if anything is unclear.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
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.
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The Octavia range embodies the design trend of the Škoda brand: a fusion of
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2. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 34 9813/4450-2 18 - 34
Component Identification
Figure 268. Governor control mecha-
nism in the front housing without a BCD
A
C
E
F
D
B
A Connection for the linkage to the fuel injection
pump
B Control lever
C Lever return spring
D Governor adjustment screw
E Arm
F Start spring
Figure 269. Governor control mecha-
nism in the front housing with a BCD
G
H
J
A
B
A Connection for the linkage to the fuel injection
pump
B Control lever
G Governor main spring
H Adjuster (Angleich unit)
J Governor lever
Operation
The fuel rack is connected to the linkage, which
controls the fuel injection pump. This linkage is
located in the front case.
The engine has a mechanical governor to control the
engine speed. The governor operates for all engine
RPM (Revolutions Per Minute). The governor weight
assembly is installed on the front of the camshaft
gear. The other components of the governor are
installed in the front case.
Figure 270. Governor control mecha-
nism in the front housing without a BCD
A
C
E
F
D
B
A Connection for the linkage to the fuel injection
pump
B Control lever
C Lever return spring
D Governor adjustment screw
E Arm
F Start spring
3. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 35 9813/4450-2 18 - 35
Figure 271. Governor control mecha-
nism in the front housing with a BCD
G
H
J
A
B
A Connection for the linkage to the fuel injection
pump
B Control lever
G Governor main spring
H Adjuster (Angleich unit)
J Governor lever
The movement of the governor weight assembly
is transferred to the fuel rack on the fuel injection
pump by the control lever, the governor lever and
the linkage to the fuel injection pump. The governor
main spring connects the governor lever to the
control lever. The governor main spring controls
the movement of the governor weight assembly on
the camshaft. When the angle of the control lever
changes, the tension on the governor main spring
changes. This action controls the linkage to the fuel
rack on the fuel injection pump, which controls the
engine RPM.
The maximum fuel adjustment screw is mounted in
the front case. This adjustment regulates the fuel
injection at high engine RPM. This adjustment should
only be made by personnel with the correct training.
The fuel injection pump timing, the low idle and the
high idle are preset at the factory. Adjustments to
the pump timing and idle RPM should only be made
by personnel that have had the correct training. The
timing for the fuel injection pump should only change
if the camshaft or the crankcase are replaced. The
fuel injection pump timing should not change if the
fuel injection pump is reinstalled with a shim that is
the same size.
The fuel rack automatically returns to the excess fuel
position when the engine is stopped. The excess
fuel position helps the engine to starting in cold
conditions.
A spring connects the linkage to the fuel injection
pump and the mechanical stop control. When the
engine is first started, the spring automatically
increases the fuel flow to the cylinders.
4. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 36 9813/4450-2 18 - 36
Adjust
Special Tools
Description Part No. Qty.
Digital Tachometer 892/00284 1
The setting of the front case is only necessary if the
front case is damaged or if the front case is renewed.
Record the Governor Settings
1. If the front case is removed, install the front case.
Refer to (PIL 15-51).
2. Record the setting of the low idle stop screw and
the high idle stop screw. This is to make sure the
governor operation is restored.
3. Operate the engine until the normal operating
temperature is reached.
4. Record the engine RPM (Revolutions Per
Minute) at low idle with an optical tachometer.
Special Tool: Digital Tachometer (Qty.: 1)
5. Accelerate the engine to high idle. Record
the engine RPM as Speed A with an optical
tachometer.
Figure 272.
A
B
C
A Tamperproof caps
B Protrusion of the high idle stop screw
C Protrusion of the low idle stop screw
Figure 273.
D
E
F
G
D Idle trimmer screw
E Locknut
F High idle stop screw
G Low idle stop screw
6. Remove the tamperproof caps.
7. Record the protrusion of the high idle stop screw.
8. Record the protrusion of the low idle stop screw.
9. Release the locknut. Turn the high idle trimmer
screw four turns counterclockwise and tighten
the locknut.
10. Accelerate the engine to high idle. Record
the engine RPM as Speed B with an optical
tachometer.
11. Make sure that the recorded Speed B is lower
than the recorded Speed A.
Removal of the Old Front Case
1. Remove the fuel injection pump. Refer to (PIL
18-18).
2. Remove the crankshaft pulley. Refer to (PIL
15-12).
3. Remove the front case. Refer to (PIL 15-51).
5. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 37 9813/4450-2 18 - 37
Figure 274.
U
V
U Front case
V Gasket
4. Remove the gasket. Make sure that the face of
the front plate is clean.
5. Install the Allen head screw to the lever
assembly. Tighten the Allen head screw to the
correct torque value.
Figure 275.
H
J
H Allen head screw (M4 x 20mm x 0.70)
J Lever assembly
6. Remove the start spring and replace the start
spring with a calibration spring.
Figure 276.
K
L
K Calibration spring
L Start spring
7. Install the front case. Refer to (PIL 15-51).
7.1. Do not install a gasket. Refer to Figure 274.
8. Install the fuel injection pump. Refer to (PIL
18-18).
8.1. Install the original shim.
9. Install the crankcase adaptor into the crankcase.
10. Install the DTI (Dial Test Indicator) holder into the
crankcase adaptor.
10.1. The DTI must be graduated to the
specified dimension.
Dimension: 0.01mm
11. Assemble the DTI and the extension to the
specified dimension.
Dimension: 20mm
Figure 277.
Q
M
N
P
M DTI
N DTI holder
P Crankcase adaptor
Q Crankcase
6. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 38 9813/4450-2 18 - 38
12. Install the DTI into the DTI holder until the
extension on the DTI touches the rack of the fuel
injection pump.
13. Push the assembled DTI and the extension into
the DTI holder further to the specified distance.
Dimension: 2mm
Figure 278.
R
M
P
N
M DTI
N DTI holder
P Crankcase adaptor
R Crankcase
14. Lock the DTI holder to retain the DTI in position.
Set the DTI to the specified dimension.
Dimension: 2 ± 0.01mm
15. Push the plunger of the DTI several times to seat
the rack of the fuel injection pump. When the
plunger is gently released, check that the DTI
reads the specified dimension.
Dimension: 2 ± 0.01mm
16. If the rack of the fuel injection pump has heavy
resistance to movement:
16.1. Remove the DTI.
16.2. Remove the fuel injection pump.
16.3. Wash the fuel injection pump with a
suitable cleaner.
16.4. Install the fuel injection pump.
16.5. Repeat the steps 12 to 15.
17. Do the calibration of the fuel screw and the front
housing. Refer to (PIL 18-18).
Final Installation of the New Front Case
1. Remove the DTI and the DTI holder. Refer to
Figure 277.
2. Remove the crankcase adaptor. Refer to Figure
277.
3. Remove the fuel injection pump. Refer to (PIL
18-18).
4. Remove the front case. Refer to (PIL 15-51).
5. Remove the calibration spring and install the
original start spring. Refer to Figure 276.
6. Remove the Allen head screw from the lever
assembly. Refer to Figure 275.
7. Install the new gasket on the front case. Make
sure that the gasket is clean and free from
damage. Refer to Figure 274.
8. Install the new front case. Refer to (PIL 15-51).
9. Set the protrusion of the high idle stop screw to
the same dimensions as the stop screws on the
original front case. Refer to Figure 272.
10. Set the protrusion of the low idle stop screw to
the same dimensions as the stop screws on the
original front case. Refer to Figure 272.
11. Set the high idle trimmer screw as follows: Refer
to Figure 273.
11.1. Release the locknut.
11.2. Set the high idle trimmer screw to the fully
out position.
11.3. Turn the screw clockwise for two turns.
11.4. Tighten the locknut.
12. Install the fuel injection pump. Refer to (PIL
18-18).
13. Start the engine and allow the engine to reach
the normal operating temperature.
14. Run the engine at low idle and adjust the low
idle stop screw to the speed that was previously
recorded, prior to the original front case removal.
15. Run the engine at high idle and adjust the high
idle stop screw to the speed that was previously
recorded as Speed B.
16. Run the engine at high idle and release the
locknut.
17. Adjust the high idle trimmer screw to the speed
that was previously recorded as Speed A.
18. Tighten the locknut.
18.1. Make sure that the recorded Speed B is
lower than the recorded Speed A.
19. Make sure that the engine operates correctly.
7. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 39 9813/4450-2 18 - 39
20. Install the tamperproof cap to the high idle
trimmer screw and the high idle screw.
21. Carefully install the tamperproof cap to the fuel
screw.
Figure 279.
W
W Fuel screw
Table 98. Torque Values
Item Description Nm
H Allen head screw .4
Calibrate
Setting the Fuel Screw
1. Release the plunger of the DTI (Dial Test
Indicator). Refer to Figure 280.
Figure 280.
R
M
P
N
M DTI
N DTI holder
P Crankcase adaptor
R Crankcase
2. Do not move the position of the DTI, DTI holder
and crankcase adaptor.
3. Retain the locknut of the fuel screw in position
with a ring spanner. Refer to Figure 281.
Figure 281.
T
S
S Allen wrench
T Ring Spanner
4. Turn the Allen head screw and observe the
reading on the DTI.
8. 18 - Fuel and Exhaust System
18 - Injection
21 - Governor
18 - 40 9813/4450-2 18 - 40
5. Turn the Allen head screw until the DTI reads the
specified dimension.
Dimension: 2 ± 0.01mm
6. Tighten the locknut to the correct specified torque
value.
Torque: 6N·m
7. Make sure that the reading on the DTI is as
specified.
Dimension: 2 ± 0.01mm
8. Install and adjust the new front case. Refer to
(PIL 15-51).
9. 18 - Fuel and Exhaust System
18 - Injection
24 - Adjuster
18 - 42 9813/4450-2 18 - 42
Remove and Install
Consumables
Description Part No. Size
4101/0250 0.01L
JCB Threadlocker
and Sealer (Medium
Strength)
4101/0251 0.05L
Remove
1. Disassemble the timing gear front case. Refer to
(PIL 15-51).
2. Remove the lever assembly from the front case.
3. Remove the adjuster unit from the lever
assembly. Refer to Figure 282.
Figure 282.
G
K
G Lever assembly
K Adjuster unit
Install
1. Apply threadlocker on the first two threads of the
adjuster unit.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
2. Install the adjuster unit to the lever assembly.
3. Tighten the adjuster unit to the correct torque
value.
4. Make sure that the threadlocker does not
contaminate the plunger assembly of the
adjuster unit. The contamination of the plunger
assembly will make the adjuster unit inoperative.
5. Install the lever assembly to the front case.
6. Assemble the timing gear front case. Refer to
(PIL 15-51).
10. 18 - Fuel and Exhaust System
21 - Fuel Pump
00 - General
18 - 47 9813/4450-2 18 - 47
Remove and Install
Observe all the health and safety information. Refer
to Fuel system - Health and Safety (PIL 18-00).
Electrical Fuel Pump
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the rear access cover. Refer to (PIL 06-06).
3. Turn the fuel supply to the OFF position.
4. Disconnect the electrical connector from the fuel
pump.
5. Plug all the open ports and hoses to prevent
contamination.
6. Loosen the clamps and disconnect the hoses.
7. Put a label on the hoses to help installation.
8. Remove the bolt1 (x2) and remove the fuel pump.
Figure 284.
E
D
B
C
D
E
A
A Electrical connectors
B Bolt1 (x2)
C Fuel pump (Electrical)
D Clamps
E Hoses
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that the electric transfer pump is clean
and free from damage.
3. Bleed the fuel system. Refer to Fuel system (PIL
18-00).
Mechanical pump
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the rear access cover. Refer to (PIL 06-06).
3. Turn the fuel supply to the OFF position.
4. Disconnect the electrical connector from the fuel
pump.
5. Plug all the open ports and hoses to prevent
contamination.
6. The fuel transfer pump can be oriented in two
positions. Before you remove the fuel pump from
the crankcase, note the orientation of flange on
the fuel pump for installation.
7. Loosen the clamps and disconnect the hoses.
8. Put a label on the hoses to help installation.
9. Loosen the bolt and remove the fuel pump from
the crankcase.
9.1. If necessary, rotate the crankshaft until the
operating plunger of the fuel pump is not
under pressure to remove the fuel pump.
10. Remove the O-ring seal from the fuel pump.
Figure 285.
F G
H
J
K
F Fuel pump (Mechanical)
G Bolt2
H O-ring seal
J Bolt3
K Flange
Install
1. Clean the mating surfaces of the crankcase and
the flange on the fuel pump.
2. Make sure that the camshaft lobe for the fuel
pump is at the minimum lift before the fuel pump
is installed.
3. Make sure that the fuel pump is oriented in the
correct position.
4. Install the new O-ring seal to the fuel pump.
11. 18 - Fuel and Exhaust System
21 - Fuel Pump
00 - General
18 - 48 9813/4450-2 18 - 48
5. Lubricate the operating plunger of the fuel pump
with clean engine oil.
6. Position the fuel pump on the crankcase.
7. Make sure that the operating plunger is
positioned correctly on the camshaft lobe.
8. Install the bolt3.
9. Tighten the bolt3 to the correct torque value.
10. Connect the hoses to the fuel pump.
11. Tighten the hose clamps.
12. The inlet for the fuel pump can be rotated to the
specified angle by loosening bolt2.
Angle: 360°
12.1. The fuel inlet is adjustable to the specified
degree increments.
Angle: 15°
12.2. If adjustment is made to the position of the
fuel inlet, tighten bolt2 to the correct torque
value.
13. Turn the fuel supply to the ON position.
14. Bleed the fuel system. Refer to Fuel system (PIL
18-00).
Table 99. Torque Values
Item Description Nm
B Bolt1 9
G Bolt2 2.5
J Bolt3 6
12. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 63 9813/4450-2 18 - 63
00 - General
Introduction .................................................... 18-63
Component Identification ............................... 18-64
Operation ....................................................... 18-65
Check (Condition) .......................................... 18-65
Check (Operation) ......................................... 18-66
Remove and Install ....................................... 18-67
Store and Recommission .............................. 18-69
Introduction
A turbocharger increases the temperature and the
density of the air sent to the engine cylinder. This
condition causes a lower temperature of ignition
to develop earlier in the compression stroke. The
compression stroke is also timed in a more accurate
way with the fuel injection. The surplus air lowers
the temperature of combustion. This surplus air also
provides internal cooling.
A turbocharger improves the following aspects of
engine performance:
• Power output is increased.
• Engine torque is increased.
• Engine efficiency is increased.
Figure 289.
A
K
L
D
E
F
G
H
J
B
C
A Air intake
B Compressor housing
C Compressor wheel
D Bearing
E Oil inlet port
F Bearing
G Turbine housing
H Turbine wheel
J Exhaust outlet
K Oil outlet port
L Exhaust inlet
13. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 64 9813/4450-2 18 - 64
Component Identification
Figure 290.
A
B
J
K
L
M
B
G
H
E
W
E
V
T
D
F
C
U
Q
N
S
P
R
A Air inlet hose B Hose clamp
C Screw D Exhaust elbow
E Turbocharger F Gasket 1
G Banjo bolt H Washer
J Tube clips K Bolt1
L Tube assembly 1 M O-ring
N Bolt 2 P Tube assembly 2
Q Joint 1 R Joint 2
S Bolt 3 T Nut
U Gasket 2 V Stud
W Tube connector
14. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 65 9813/4450-2 18 - 65
Operation
The turbocharger is installed between the exhaust
manifold and the intake manifold. The turbocharger
is driven by exhaust gases which flow through the
exhaust inlet. The energy of the exhaust gas turns
the turbine wheel. Then, the exhaust gas flows out of
the turbine housing through the exhaust outlet.
The turbine wheel and the compressor wheel are
installed on the same shaft. Therefore, the turbine
wheel and the compressor wheel rotate at the same
RPM (Revolutions Per Minute). The compressor
wheel is enclosed by the compressor housing. The
compressor wheel compresses the intake air. The
intake air flows into the engine cylinders through the
inlet valves of the cylinders.
The oil from the main gallery of the crankcase
flows through the oil inlet port to lubricate the
turbocharger bearings (Bearing1 and bearing2). The
pressurised oil passes through the bearing housing
of the turbocharger. The oil is returned through the
oil outlet port to the oil pan.
The turbocharger has a wastegate. The wastegate is
controlled by the boost pressure. This allows some
of the exhaust gases to bypass the turbine wheel
at higher engine speeds. The wastegate is a type
of flapper valve that automatically opens at a preset
level of boost pressure in order to allow the exhaust
gas to flow around the turbine. The wastegate allows
the design of the turbocharger to be more effective
at lower engine speeds.
Check (Condition)
1. Inspect the compressor and turbine for damage.
2. Make sure that the compressor blades do not rub
on the housing and rotate freely. It is normal to
detect a bit of play on the blades.
3. Make sure that the shaft rotates freely.
4. Before you install the turbocharger, make sure
that the code of the component is correct for
the type of engine, as installation of the wrong
turbocharger can damage the turbo and engine
and void the warranty.
15. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 66 9813/4450-2 18 - 66
Check (Operation)
To maximise the duration of the turbocharger follow
the rules described below.
Start-up
Start the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached within
a few seconds, but it is useful to allow the moving
parts to warm up in good lubrication conditions.
Immediately increasing the engine speed after start
up will result in the turbocharger running at high rpm
with less than optimal lubrication. This may lead to
premature failure of the turbocharger.
After maintenance
When carrying out maintenance on the engine
or turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it is
completely full. After pre-lubrication, let the engine
run via the starter motor without firing (engine /
fuel pump stop out) to allow the oil to circulate
through the complete system under pressure. Upon
engine start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to work
satisfactorily.
Low temperature air or engine inactivity
If the engine has been inactive for a certain period
of time or the air temperature is very low, start
the engine and then let it run at idle speed. This
enables the oil to go into the lubrication system
before applying high loads and speeds to the engine
and turbocharger.
Engine shutdown
Before switching the engine off after intense activity,
you must allow the turbocharger to cool down, let the
engine run at idle speed for at least 2 minutes to allow
the turbocharger to cool.
Engine at idle speed
Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
16. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 67 9813/4450-2 18 - 67
Remove and Install
Remove
1. Make sure you obey the special instructions
on handling, operation and installation of the
turbocharger. Refer to (PIL 18-35).
2. Make the machine safe. Refer to (PIL 01-03).
3. 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.
4. Loosen the hose clamp and remove the air inlet
hose.
5. Remove the screw and remove the exhaust
elbow.
6. Remove the gasket 1.
7. Remove the banjo bolt and the washer.
8. Remove the fasteners and spacers from the tube
clips.
9. Remove the bolt 1 and remove the tube
assembly 1 from the crankcase.
10. Remove and discard the O-ring.
11. Remove the bolt 2 and disconnect the tube
assembly 2 from the turbocharger.
12. Remove and discard the joint 1.
13. If necessary, remove the bolt 3 and remove the
tube assembly 2 from the crankcase.
14. Remove and discard the joint 2.
15. Remove the nut and the turbocharger from the
exhaust manifold.
16. Remove and discard the gasket 2 from the
exhaust manifold.
17. If necessary, remove the stud from the exhaust
manifold.
Important: Do not use the actuator rod of the
wastegate to lift the turbocharger.
Figure 291.
A
B
J
K
L
M
B
G
H
E
W
E
V
T
D
F
C
U
Q
N
S
P
R
A Air inlet hose B Hose clamp
C Screw D Exhaust elbow
E Turbocharger F Gasket 1
G Banjo bolt H Washer
J Tube clips K Bolt1
L Tube assembly 1 M O-ring
N Bolt2 P Tube assembly 2
Q Joint 1 R Joint 2
S Bolt 3 T Nut
U Gasket 2 V Stud
W Tube connector
17. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 68 9813/4450-2 18 - 68
Install
1. Make sure that all the parts are clean and free
from contamination.
2. Check the turbocharger for wear or damage. If
the turbocharger is worn, replace the complete
turbocharger.
3. Check the actuator for correct operation. Refer to
(PIL 18-35).
4. If the actuator is damaged or does not operate
within the specified limits, replace the complete
turbocharger.
5. Clean the mating surfaces of the exhaust
manifold.
6. If removed, install the studs to the exhaust
manifold.
7. Tighten the studs to the correct torque value.
8. Install the new gasket 2 on the studs.
9. Keep the turbocharger on the exhaust manifold
at its correct position.
10. Install the nuts and tighten to the correct torque
value.
11. Make sure that the tube assembly 1 and tube
assembly 2 are clean and free from damage. If
necessary, replace the tube assemblies.
12. If removed, keep the new joint 2 at its correct
position on the crankcase with the tube assembly
2.
13. Install the bolt 3 and tighten to the correct torque
value.
14. Keep the new joint 1 at its correct position on the
tube assembly 2. Align the tube assembly 2 with
the bottom of the turbocharger.
15. Install the bolt 2 and tighten to the correct torque
value.
16. Lubricate the bearings of the turbocharger with
the clean engine oil through the oil inlet port.
17. Rotate the shaft of the turbocharger to distribute
the oil.
18. Install the new O-ring on the tube assembly 1.
19. Keep the tube assembly 1 at its correct position
on the crankcase.
20. Install the bolt 1 and tighten to the correct torque
value.
21. Install the new washer and banjo bolt to the tube
assembly 1.
22. Keep the tube assembly 1 at its correct position
on the turbocharger.
23. Install the tube clips with the fasteners and
spacers.
24. Tighten the banjo bolt to the correct torque value.
25. Make sure that the tube assemblies do not touch
any other components.
26. Clean the mating surfaces of the exhaust elbow.
27. Keep the new gasket 1 and exhaust elbow at its
correct position on the turbocharger.
28. Install the screw and tighten to the correct torque
value.
29. Make sure that the inlet hoses are clean and free
from the defects or restrictions.
30. Loosely install the hose clamps on the air inlet
hose.
31. Install the inlet hose and then tighten the hose
clamps.
Table 101. Torque Values
Item Description Nm
C Screw 32
G Banjo bolt 18
K Bolt 1 10
N Bolt 2 10
S Bolt 3 10
T Nut 25
V Stud 18
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19. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 69 9813/4450-2 18 - 69
Store and Recommission
What to do
• Before assembling the turbocharger, make sure
that the protection caps are installed on all
openings of the turbocharger.
• Make sure that the packaging is correct before
storing the turbocharger to be assembled.
• Make sure the turbocharger is pre-lubricated.
• Periodically check that the joints are sealed
against oil and air.
• Use only the specified lubricating oil.
• Check the engine oil level.
• Before switching the engine off after use, let it
run at idle speed for around 1 minute.
• Check the condition of the air and oil filter
regularly as per the maintenance schedules.
• Make sure that the engine maintenance
intervals are observed.
• Make sure that the engine and equipment are
used in a way that is not harmful to the life of
the turbocharger.
What not to do
• Do not store the turbochargers in stacks.
• Do not store the turbochargers in damp or wet
conditions.
• Do not expose the turbochargers to dust and
dirt.
• Do not lift the turbocharger by holding the
actuator rod.
• Do not increase the engine speed immediately
after start-up.
• Do not run the engine at idle speed for more
than 20-30 minutes at a time.
• Do not change the actuator settings.
Practical operating rules
1. Start-up: Start the engine and keep it at idle
speed for about a minute. The oil operating
pressure is reached within a few seconds, but
it is useful to allow the moving parts to warm
up in good lubrication conditions. Immediately
increasing the engine speed after start up will
result in the turbocharger running at high RPM
(Revolutions Per Minute) with less than optimal
lubrication. This may lead to premature failure of
the turbocharger.
2. After maintenance: When carrying out
maintenance on the engine or on the
turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it
is completely full. After pre-lubrication, let the
engine run via the starter motor without firing,
to allow the oil to circulate through the complete
system under pressure. Upon engine start-up,
make it run at idle speed for a few minutes,
allowing the oil and bearings system to work
satisfactorily.
3. Low temperature air or engine inactivity: If the
engine has been inactive for a certain period of
time or the air temperature is very low, start the
engine and then let it run at idle speed. This
enables the oil to go into the lubrication system
before applying high loads and speeds to the
engine and turbocharger.
4. Engine shutdown: Before switching off the
engine after intense use allow the turbocharger
to cool down. Therefore run the engine at idle
speed for at least 2 minutes that allow the
turbocharger to cool down.
5. Engine at idle speed: Do not run the engine at
idle speed for more than 20-30 minutes at a time.
It may cause oil leaks from the seals at the end of
the engine shaft or it can cause blue smoke from
the exhaust when the engine speed and load are
increasing.
20. 18 - Fuel and Exhaust System
35 - Turbocharger
06 - Wastegate Valve
18 - 71 9813/4450-2 18 - 71
Operation
The wastegate controls the amount of exhaust gas
that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the RPM
(Revolutions Per Minute) of the turbocharger.
When the engine operates in conditions of low boost,
a spring presses against a diaphragm in the canister.
The actuating rod will move and the wastegate
will close. Then, the turbocharger can operate at
maximum performance.
When the boost pressure increases against the
diaphragm in the canister, the wastegate will open.
The RPM of the turbocharger becomes limited. The
RPM is limited because a portion of the exhaust
gases bypass the turbine wheel of the turbocharger.
Check (Condition)
WARNING Hot oil and engine components can
burn you. Make sure the engine is cool before
doing this job.
Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin
cancer.
Important: The turbocharger is a non-serviceable
item. The pressure for the wastegate can be checked
but not adjusted. For a pressure check of the
wastegate, refer to (PIL 18-35).
Before you check the condition of the wastegate,
make sure that the inlet air and exhaust system
restrictions are within the specified limits.
1. The following levels of boost pressure indicate a
problem with the wastegate:
1.1. Too high in full load conditions.
1.2. Too low in all low boost conditions.
2. The boost pressure controls the maximum RPM
(Revolutions Per Minute) of the turbocharger,
because the boost pressure controls the position
of the wastegate. The following factors also affect
the maximum RPM of the turbocharger:
2.1. The engine rating.
2.2. The horsepower demand on the engine.
2.3. The high idle RPM
2.4. Inlet air restriction.
2.5. Exhaust system restriction.
21. 18 - Fuel and Exhaust System
35 - Turbocharger
06 - Wastegate Valve
18 - 72 9813/4450-2 18 - 72
Check (Pressure)
1. Make sure you obey the special instructions
on handling, operation and installation of the
turbocharger. Refer to (PIL 18-35).
2. Make the machine safe. Refer to (PIL 01-03).
3. 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.
4. Get access to the turbocharger. Refer to (PIL
06-06).
5. Remove the heatshield from the turbocharger.
6. Remove the guard for the wastegate.
7. Remove the boost line from the wastegate.
8. Connect an air supply to the wastegate that can
be adjusted accurately.
9. Install a DTI (Dial Test Indicator) to the
turbocharger so that the end of the actuator rod
is in contact with the plunger of the DTI. This will
measure the axial movement of the actuator rod.
10. Slowly apply air pressure to the wastegate so that
the actuator rod moves to the specified distance.
Distance: 1mm
10.1. Make sure that the air pressure applied is
within the specified limit.
Pressure: 0.52bar (7.5psi)
11. Make sure that the DTI returns to zero when the
air pressure is released.
12. Repeat the test several times to make sure that
you get an accurate reading.
13. If the wastegate does not operate correctly,
contact your JCB dealer.