This service manual provides instructions for servicing JCB machines 411HT, 413S, and 417HT. It contains sections on various machine systems including the engine, fuel and exhaust systems, cooling system, brake system, hydraulic system, and electrical system. The section on the fuel and exhaust system includes subsections that provide introductions, component identifications, check procedures, and removal/installation steps for the inlet manifold, outlet manifold, and general exhaust system components. Safety precautions are outlined regarding working with hot or hazardous exhaust components.
Jcb 2 dxl super loader service repair manual (from 2475501 to 2475700)ufjjsjekkemd
This service manual section provides information on servicing the cooling system for a 2DXL machine. It details the components of the cooling system, including the radiator, expansion tank, water pump, and hoses. Guidelines are provided on draining and filling the cooling system, checking for leaks, and troubleshooting common cooling system issues like low coolant level or overheating. Safety precautions are outlined, and maintenance steps like checking coolant level and quality are described.
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 45 z 1 compact excavator service repair manual sn from 2683176 to 2683220ufdjjdjfjksekmmd
This document provides a summary of key information from a service manual for compact excavators. It discusses the exhaust system, including components like the inlet manifold, outlet manifold, and catalyst. The 3-sentence summary is:
The document is a service manual that provides information on inspecting, removing, and installing components of the exhaust system for compact excavators, including the inlet manifold, outlet manifold, and catalyst, with details on their purpose, components, and maintenance procedures.
Liebherr r906 1449 classic hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual for Liebherr hydraulic excavators. It contains 18 sections that provide technical specifications, maintenance guidelines, and instructions for repairing and servicing various engine, hydraulic, electrical, and other components of the excavators. The manual is intended to assist customer support services and includes symbols to identify safety warnings and notes for procedures. It also provides guidelines for how the manual is structured and indexed.
Liebherr lh110 m 1227 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh110 c 1228 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh60 m timber hydraulic excavator service repair manualfjjsiefksekm
This document provides safety warnings and instructions for operating a hydraulic excavator. It outlines hazards associated with the machine and stresses the importance of following safety precautions to prevent injury. Specific dangers are indicated by warning signs on the machine. The document also defines the designated use of the excavator as loosening, picking up, transporting, and dumping materials while following technical safety guidelines. Any other uses are considered not in accordance with safe operation of the machine.
Liebherr lh40 c 1527 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of differential cylinders, shock absorbers, and hydraulic cylinders. It discusses mounting of standard and fine thread clamping nuts, and adjusting swing brakes. The document also includes a table of corrosion inhibitors recommended by Liebherr and another table listing base coats and paints from Liebherr available in aerosol cans. It encourages the reader to download a complete manual by clicking on a provided link.
Jcb 2 dxl super loader service repair manual (from 2475501 to 2475700)ufjjsjekkemd
This service manual section provides information on servicing the cooling system for a 2DXL machine. It details the components of the cooling system, including the radiator, expansion tank, water pump, and hoses. Guidelines are provided on draining and filling the cooling system, checking for leaks, and troubleshooting common cooling system issues like low coolant level or overheating. Safety precautions are outlined, and maintenance steps like checking coolant level and quality are described.
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 45 z 1 compact excavator service repair manual sn from 2683176 to 2683220ufdjjdjfjksekmmd
This document provides a summary of key information from a service manual for compact excavators. It discusses the exhaust system, including components like the inlet manifold, outlet manifold, and catalyst. The 3-sentence summary is:
The document is a service manual that provides information on inspecting, removing, and installing components of the exhaust system for compact excavators, including the inlet manifold, outlet manifold, and catalyst, with details on their purpose, components, and maintenance procedures.
Liebherr r906 1449 classic hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual for Liebherr hydraulic excavators. It contains 18 sections that provide technical specifications, maintenance guidelines, and instructions for repairing and servicing various engine, hydraulic, electrical, and other components of the excavators. The manual is intended to assist customer support services and includes symbols to identify safety warnings and notes for procedures. It also provides guidelines for how the manual is structured and indexed.
Liebherr lh110 m 1227 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh110 c 1228 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh60 m timber hydraulic excavator service repair manualfjjsiefksekm
This document provides safety warnings and instructions for operating a hydraulic excavator. It outlines hazards associated with the machine and stresses the importance of following safety precautions to prevent injury. Specific dangers are indicated by warning signs on the machine. The document also defines the designated use of the excavator as loosening, picking up, transporting, and dumping materials while following technical safety guidelines. Any other uses are considered not in accordance with safe operation of the machine.
Liebherr lh40 c 1527 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of differential cylinders, shock absorbers, and hydraulic cylinders. It discusses mounting of standard and fine thread clamping nuts, and adjusting swing brakes. The document also includes a table of corrosion inhibitors recommended by Liebherr and another table listing base coats and paints from Liebherr available in aerosol cans. It encourages the reader to download a complete manual by clicking on a provided link.
Liebherr lh35 1201 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Liebherr lh30 1210 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains diagrams and tables related to hydraulic cylinders and corrosion prevention. Figures 1-4 illustrate components of cylinders and their assembly while Tables 1-2 list recommended corrosion inhibitors and paints from Liebherr. The manual instructs the reader to click on a link to access the complete document.
Liebherr er 902 hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Liebherr a912 compact 1506 tier4f hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of mechanical devices like clamping nuts, differential cylinders, and shock absorbers. It discusses parts that are at risk of corrosion and recommends corrosion inhibitors and paints from Liebherr to protect those parts. The document encourages downloading a complete manual for more information.
Liebherr a910 compact 1505 tier4f hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of mechanical devices like clamping nuts, differential cylinders, and shock absorbers. It identifies parts that are at risk of corrosion and recommends corrosion inhibitors and paint coatings from Liebherr to protect those parts. The document encourages downloading a complete manual for more information.
Jcb tm320 telescopic wheel loader service repair manual sn 2681926 and upfjjsiefksekm
This service manual provides instructions for disassembling and assembling the master clutch on a loader. The summary describes:
1) Special tools are required to remove the clutch pack retainers and install a mandrel and locking plates during disassembly and assembly.
2) The cover is removed after installing jacking bolts and lifting eyes. Seals and gaskets are then removed from the cover and housing.
3) Locking plates are installed to secure the clutch assembly while removing bolts to lift out the drum, hub and pressure plate assembly.
Jcb 1253, 1202, 1553, 1554 liftall service repair manual from 6600001 to 6600785fjjsiefksekm
This document provides service information for the Liftall 1253/1202/1553/1554, including sections covering general information, identification, load charts, torque specifications, service tools, and numerical lists of tools. It contains specifications, diagrams, and instructions to aid technicians in servicing and repairing these machines.
Jcb 1253, 1202, 1553, 1554 liftall service repair manual from 2087061 to 2089561fjjsiefksekm
The document is a service manual for the Liftall 1253/1202/1553/1554 machines. It contains sections covering general information such as machine identification, load charts, torque specifications, and service tools. It also includes sections specific to the body and framework, electrics, hydraulics, and engine of the machines. The manual provides information and specifications to assist with maintenance and repair of the Liftall models.
Jcb 540 140 telescopic handler service repair manual sn from 2460601 onwardsfjjsiefksekm
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 535 v140 telescopic handler service repair manual sn from 2902000 onwardsfjjsiefksekm
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 531 70 tier 4 telescopic handler service repair manual sn from 2336575 on...fjjsiefksekm
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 526 56 tier 4 telescopic handler service repair manual sn from 2902000 on...fjjsiefksekm
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 506 36 telescopic handler service repair manual sn from 1402020 and upfjjsiefksekm
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing various clutch shaft assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly tolerances. Special tools and consumables like threadlocker and gasket material are required.
Jcb 270 skid steer loader service repair manual sn from 2675500 to 2675700fjjsiefksekm
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 following torque specifications. Special tools like templates and wrenches are listed to correctly complete the removal and installation.
Jcb 270 skid steer loader service repair manual sn from 2478301 to 2478700fjjsiefksekm
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 system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures. Precautions are given to handle the heavy crankshaft safely and ensure proper lubrication when reassembled.
Jcb 270 skid steer loader service repair manual sn from 2476302 to 2477300fjjsiefksekm
The document provides instructions for removing and installing a crankshaft on an engine. Key steps include: removing components like the drive belt, pulley, oil sump, fuel injectors and pump; positioning the engine upside down; and removing components attached to the crankshaft like the flywheel, gears and camshaft. Cleaning and inspection steps are described to check the crankshaft condition. Installation is the reverse of removal, with requirements to clean components, apply lubrication and torque fasteners to the specified values.
Jcb 205 skid steer loader service repair manual (from 2473501 to 2473800)fjjsiefksekm
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the machine's engine. The manual is intended only for qualified service technicians, as working on the engine without proper training and tools could result in injury or improper repairs.
Jcb 57 c 1 compact excavator service repair manual (kohler engine)fjjsiefksekm
This service manual section provides information on servicing the rocker assembly and fittings of an engine. It includes components, operation, checks, removal and installation, and disassembly and assembly procedures. The rocker assembly uses rocker arms and a shaft to actuate the valves via pushrods and tappets. Oil is fed to lubricate the assembly through drillings and galleries in the cylinder head and rocker shaft. Checks include inspecting for wear and clearances. Removal and installation procedures are also outlined.
Jcb 55 z 1 compact excavator service repair manual (kohler engine)fjjsiefksekm
This service manual provides instructions for servicing components of JCB machines 55Z-1 and 57C-1. The section on the engine rocker assembly provides details on checking, removing, and servicing the rocker arms, shaft, and related components. The manual instructs technicians on lubrication of these parts, disassembly/assembly procedures, and lists torque specifications for fasteners. Additional sections cover the engine oil sump, including its removal/installation and use of sealant when reinstalling.
Jcb 10 tft dumper service repair manual sn from hrn3737 to hrn3737fjjsiefksekm
This service manual provides instructions for servicing the braking system of dumpers. It contains information on health and safety when working on the brakes, technical specifications, component identification, troubleshooting, and bleeding the brakes. The braking system uses mineral oil and contains separate front and rear brake circuits for safety. Adjustment is generally not needed as the brakes are self-adjusting, but bleeding may be required if the brake lines leak fluid.
Liebherr lh35 1201 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Liebherr lh30 1210 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains diagrams and tables related to hydraulic cylinders and corrosion prevention. Figures 1-4 illustrate components of cylinders and their assembly while Tables 1-2 list recommended corrosion inhibitors and paints from Liebherr. The manual instructs the reader to click on a link to access the complete document.
Liebherr er 902 hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Liebherr a912 compact 1506 tier4f hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of mechanical devices like clamping nuts, differential cylinders, and shock absorbers. It discusses parts that are at risk of corrosion and recommends corrosion inhibitors and paints from Liebherr to protect those parts. The document encourages downloading a complete manual for more information.
Liebherr a910 compact 1505 tier4f hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of mechanical devices like clamping nuts, differential cylinders, and shock absorbers. It identifies parts that are at risk of corrosion and recommends corrosion inhibitors and paint coatings from Liebherr to protect those parts. The document encourages downloading a complete manual for more information.
Jcb tm320 telescopic wheel loader service repair manual sn 2681926 and upfjjsiefksekm
This service manual provides instructions for disassembling and assembling the master clutch on a loader. The summary describes:
1) Special tools are required to remove the clutch pack retainers and install a mandrel and locking plates during disassembly and assembly.
2) The cover is removed after installing jacking bolts and lifting eyes. Seals and gaskets are then removed from the cover and housing.
3) Locking plates are installed to secure the clutch assembly while removing bolts to lift out the drum, hub and pressure plate assembly.
Jcb 1253, 1202, 1553, 1554 liftall service repair manual from 6600001 to 6600785fjjsiefksekm
This document provides service information for the Liftall 1253/1202/1553/1554, including sections covering general information, identification, load charts, torque specifications, service tools, and numerical lists of tools. It contains specifications, diagrams, and instructions to aid technicians in servicing and repairing these machines.
Jcb 1253, 1202, 1553, 1554 liftall service repair manual from 2087061 to 2089561fjjsiefksekm
The document is a service manual for the Liftall 1253/1202/1553/1554 machines. It contains sections covering general information such as machine identification, load charts, torque specifications, and service tools. It also includes sections specific to the body and framework, electrics, hydraulics, and engine of the machines. The manual provides information and specifications to assist with maintenance and repair of the Liftall models.
Jcb 540 140 telescopic handler service repair manual sn from 2460601 onwardsfjjsiefksekm
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 535 v140 telescopic handler service repair manual sn from 2902000 onwardsfjjsiefksekm
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 531 70 tier 4 telescopic handler service repair manual sn from 2336575 on...fjjsiefksekm
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 526 56 tier 4 telescopic handler service repair manual sn from 2902000 on...fjjsiefksekm
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 506 36 telescopic handler service repair manual sn from 1402020 and upfjjsiefksekm
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing various clutch shaft assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly tolerances. Special tools and consumables like threadlocker and gasket material are required.
Jcb 270 skid steer loader service repair manual sn from 2675500 to 2675700fjjsiefksekm
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 following torque specifications. Special tools like templates and wrenches are listed to correctly complete the removal and installation.
Jcb 270 skid steer loader service repair manual sn from 2478301 to 2478700fjjsiefksekm
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 system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures. Precautions are given to handle the heavy crankshaft safely and ensure proper lubrication when reassembled.
Jcb 270 skid steer loader service repair manual sn from 2476302 to 2477300fjjsiefksekm
The document provides instructions for removing and installing a crankshaft on an engine. Key steps include: removing components like the drive belt, pulley, oil sump, fuel injectors and pump; positioning the engine upside down; and removing components attached to the crankshaft like the flywheel, gears and camshaft. Cleaning and inspection steps are described to check the crankshaft condition. Installation is the reverse of removal, with requirements to clean components, apply lubrication and torque fasteners to the specified values.
Jcb 205 skid steer loader service repair manual (from 2473501 to 2473800)fjjsiefksekm
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the machine's engine. The manual is intended only for qualified service technicians, as working on the engine without proper training and tools could result in injury or improper repairs.
Jcb 57 c 1 compact excavator service repair manual (kohler engine)fjjsiefksekm
This service manual section provides information on servicing the rocker assembly and fittings of an engine. It includes components, operation, checks, removal and installation, and disassembly and assembly procedures. The rocker assembly uses rocker arms and a shaft to actuate the valves via pushrods and tappets. Oil is fed to lubricate the assembly through drillings and galleries in the cylinder head and rocker shaft. Checks include inspecting for wear and clearances. Removal and installation procedures are also outlined.
Jcb 55 z 1 compact excavator service repair manual (kohler engine)fjjsiefksekm
This service manual provides instructions for servicing components of JCB machines 55Z-1 and 57C-1. The section on the engine rocker assembly provides details on checking, removing, and servicing the rocker arms, shaft, and related components. The manual instructs technicians on lubrication of these parts, disassembly/assembly procedures, and lists torque specifications for fasteners. Additional sections cover the engine oil sump, including its removal/installation and use of sealant when reinstalling.
Jcb 10 tft dumper service repair manual sn from hrn3737 to hrn3737fjjsiefksekm
This service manual provides instructions for servicing the braking system of dumpers. It contains information on health and safety when working on the brakes, technical specifications, component identification, troubleshooting, and bleeding the brakes. The braking system uses mineral oil and contains separate front and rear brake circuits for safety. Adjustment is generally not needed as the brakes are self-adjusting, but bleeding may be required if the brake lines leak fluid.
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.
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.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
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.
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!
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.
2. 18 - Fuel and Exhaust System
24 - Exhaust
00 - General
18 - 71 9813/2850-3 18 - 71
00 - General
Introduction .................................................... 18-71
Health and Safety .......................................... 18-72
Check (Condition) .......................................... 18-72
Introduction
The exhaust system is used to guide exhaust gases
away from the controlled combustion inside the
engine by means of an exhaust pipe. Depending
on the machine design, the exhaust gas may flow
through the following components:
• Cylinder head and exhaust manifold.
• Turbocharger to increase the engine power (if
installed).
• A catalytic converter or EGR (Exhaust Gas
Recirculation) system to reduce air pollution (if
installed).
• SCR (Selective Catalytic Reduction) (if
installed). In SCR system exhaust gases
pass through the DEF (Diesel Exhaust Fluid)
injection chamber to lower the NOx (Nitrogen
Oxide) concentration in the exhaust gases.
• A silencer or muffler to reduce noise (if
installed).
The exhaust pipe carries the toxic and noxious gases
away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
3. 18 - Fuel and Exhaust System
24 - Exhaust
00 - General
18 - 72 9813/2850-3 18 - 72
Health and Safety
Exhaust Gases
Machine exhaust gases can harm and possibly kill
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
Sparks
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
Check (Condition)
Excessive smoke from the exhaust stack combined
with a complaint of low power could be as a result of:
• Dirt or dust (unfiltered air) ingested directly into
the engine, resulting in damage to the cylinder
bores, there will also be a possible increase in
oil consumption.
• Air leaks from the air hose connections.
• Exhaust manifold leaks.
4. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 73 9813/2850-3 18 - 73
03 - Inlet Manifold
Introduction .................................................... 18-73
Component Identification ............................... 18-74
Check (Condition) .......................................... 18-74
Remove and Install ....................................... 18-75
Introduction
The inlet manifold (or intake manifold) supplies
combustion air to the cylinders in compression
ignition engines or the air/fuel mixture for spark
ignition engines (except most direct injection spark
ignition engines). Even distribution of the air or
air/fuel is important to optimize the efficiency and
performance of the engine.
The manifold is required to be air tight under pressure
and vacuum conditions and can be required to
provide mounting points for sensors, grid heaters,
throttle bodies and other components depending on
the engine type and specification.
5. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 74 9813/2850-3 18 - 74
Component Identification
Figure 344.
1
1 Inlet Manifold
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
6. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 75 9813/2850-3 18 - 75
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 fuel rail assembly. Refer to (PIL
18-18).
Figure 345.
2
3
3
4
5
12
8
9
11 10
6
7
13
1
1 Inlet manifold 2 Manifold gasket
3 Flanged hexagon bolt (x8) 4 Fuel rail mount
5 Screw (x4) 6 EGR (Exhaust Gas Recirculation) mixer tube
7 EGR Plug 8 Inlet manifold adaptor / throttle valve (not
shown)
9 Throttle O-ring 10 Flanged hexagon bolt (x4)
11 Inlet manifold bracket 12 Bolt M6 x 16mm (x1)
13 Bolt M8 x 25mm (x1)
Remove
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector.
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
4. Cap the inlet ports with blanking caps to prevent
ingress of dirt.
5. Inspect the manifold, refer to Check Condition
(PIL 18-24).
7. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 76 9813/2850-3 18 - 76
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.
5. Tighten the bolts to the correct torque value.
Table 148. Torque Values
Item Nm
3 43
8. 18 - Fuel and Exhaust System
24 - Exhaust
04 - Outlet Manifold
18 - 77 9813/2850-3 18 - 77
04 - Outlet Manifold
Introduction .................................................... 18-77
Component Identification ............................... 18-78
Check (Condition) .......................................... 18-78
Remove and Install ....................................... 18-79
Introduction
The exhaust outlet manifold collects the exhaust
gases from the multiple cylinders and deliver it to the
turbocharger (if installed) or the exhaust pipe.
9. 18 - Fuel and Exhaust System
24 - Exhaust
04 - Outlet Manifold
18 - 78 9813/2850-3 18 - 78
Component Identification
Figure 346.
A B
A Exhaust manifold
B Manifold gasket and heat shield
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
10. 18 - Fuel and Exhaust System
24 - Exhaust
04 - Outlet Manifold
18 - 79 9813/2850-3 18 - 79
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. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 347.
2
1
3
1 Exhaust manifold 2 Fixing bolts M10 x 57mm (x8)
3 Manifold gasket
Remove
1. Remove the upper four bolts.
2. Loosen the lower four bolts and lift the exhaust
manifold from the cylinder head. Remove the
bolts and discard the gasket.
3. Cap the exhaust ports to prevent ingress of dirt.
4. Inspect the manifold, refer to Check Condition
(PIL 18-24).
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Renew the manifold gasket.
3. Install the lower four bolts, together with the new
exhaust gasket to the cylinder head (screw in the
bolts approximately to a length of 8 mm).
4. Rest the manifold in position on the row of
lower bolts by locating the slots, then install the
remaining four upper bolts.
5. Tighten the bolts to the correct torque value.
Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
After Installation
1. Reconnect the oil pipes to the turbocharger (if
installed).
11. 18 - Fuel and Exhaust System
24 - Exhaust
04 - Outlet Manifold
18 - 80 9813/2850-3 18 - 80
2. Install the exhaust pipe and the silencer box.
3. Start the engine and check for exhaust leaks.
Table 149. Torque Table
Item Torque Value
(Nm)
Torque Angle
(Degrees)
2 (First Stage) 25
2 (Final Stage) +90
12. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 95 9813/2850-3 18 - 95
00 - General
Introduction .................................................... 18-95
Component Identification ............................... 18-96
Operation ....................................................... 18-97
Check (Condition) .......................................... 18-97
Check (Operation) ......................................... 18-98
Remove and Install ....................................... 18-99
Introduction
The turbocharger (turbo) is a turbine driven forced
induction device that makes an engine more efficient
and helps to produce more power for its size.
Engine exhaust gasses drive a turbine, which in turn
drives a compressor via a common shaft. The shaft
bearings are lubricated by a feed from the engine
lubrication system.
A turbocharged engine is more powerful and efficient
than a naturally aspirated engine because the turbine
forces more air, and proportionately more fuel, into
the combustion chamber than atmospheric pressure
alone.
14. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 97 9813/2850-3 18 - 97
Operation
The single stage exhaust turbocharger is installed on
this machine. On this turbocharger the electronically
controlled wastegate valve controls the charge air
pressure. The electronically controlled wastegate
valve does the following functions:
• It permits the adjustment of optimum charge air
pressure throughout the full load range
• It takes other system factors into account which
influence the exhaust gas and charge air flow.
These are mentioned below:
• exhaust gas recirculation
• charge-air cooling
• exhaust brake
• temperature and pressure of intake air
• fuel injection data
• It improves the engine torque characteristics
across the full engine speed range, particularly
for low engine speeds
• It reduces fuel consumption
• It reduces pollutant emissions
Check (Condition)
1. Visually inspect for leaks at the turbocharger.
Make sure all gaskets are in good condition,
replace as required.
2. Check the turbine and compressor blades inside
the turbocharger rotate freely and smoothly by
hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced.
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
4.2. Move the shaft sideways.
Figure 358.
4.3. Make sure that the turbine shaft running
clearance is within the specified limits.
Refer to Turbocharger, Technical Data (PIL
18-35).
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.
15. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 98 9813/2850-3 18 - 98
Figure 359.
5.2. Move the shaft axially.
5.3. Make sure that the shaft end float is within
the specified limits. Refer to Turbocharger,
Technical Data (PIL 18-35).
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 - 99 9813/2850-3 18 - 99
Remove and Install
Figure 360.
7.3,47.4
7.5
12
7
7.3,13
2
8
7.2
3
6
8.8 5
1 9
11
1 Turbocharger 2 Exhaust manifold
3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
Before Removal
1. This procedure requires service parts. Make sure
you have obtained the correct 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, make sure the
engine has cooled sufficiently before you start.
3. Remove the ignition key.
4. Get access to the engine.
5. Drain the cooling system.
Remove
1. Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose.
2. Remove the pipe clip. Undo fixing bolts and
remove the oil drain pipe. Note that the pipe pulls
17. 18 - Fuel and Exhaust System
35 - Turbocharger
00 - General
18 - 100 9813/2850-3 18 - 100
off the pipe adaptor, leaving the adaptor in place.
Cap the open ports to prevent ingress of dirt.
Discard the O-ring and the gasket.
3. Undo the banjo bolts at each end of the oil
feed pipe, remove the pipe. Cap the open ports
to prevent ingress of dirt. Discard the sealing
washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold-Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket.
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard the gasket.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Check the condition of the turbocharger (PIL
18-35)
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all `O' rings, sealing washers and
gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat shield. Be sure to position the
gasket the correct way round.
6. Tighten the nuts, bolts and banjo bolts to the
correct torque value.
Table 152. Torque Values
Item Nm
4 21
6 24
8 24
13 36
18. 18 - Fuel and Exhaust System
35 - Turbocharger
03 - Actuator
18 - 101 9813/2850-3 18 - 101
03 - Actuator
Introduction
The turbocharger actuator is used for the electronic
charge air pressure regulation. The turbocharger
actuator is also called the charge pressure regulator.
The ECM (Engine Control Module) sends a signal
to the turbocharger actuator to actuate the charge
air pressure flap (wastegate valve) and through a
mechanical linkage turbocharger actuator operates
the charge air pressure flap (wastegate valve).
Depending on the flap position, either the entire
exhaust gas is routed to the turbine or part of the
exhaust gas is routed to the exhaust pipe upstream
of the turbine.
The turbocharger actuator is cooled with coolant.
19. 18 - Fuel and Exhaust System
96 - Fuel Pipe
00 - General
18 - 114 9813/2850-3 18 - 114
Health and Safety
WARNING Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel
spray can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel
system. Before disconnecting any part of the fuel
system, thoroughly clean around the connection.
When a component has been disconnected, for
example a fuel pipe, always fit protective caps
and plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously
damage the fuel injection equipment and could be
expensive to repair.
20. 18 - Fuel and Exhaust System
96 - Fuel Pipe
00 - General
18 - 115 9813/2850-3 18 - 115
Component Identification
Figure 369.
B
G
A
A
A
A
E
F
A Pipe assembly high pressure - Rail to injector
(x4)
B Pipe assembly high pressure - Pump to rail
C Pipe low pressure - Fuel lift pump and pre-filter/
water separator (not shown)
D Pipe low pressure - Fuel filter to high pressure
pump (not shown)
E Pipe assembly low pressure - Fuel injectors to
tank
F Pipe assembly low pressure - Rail to tank
G Pipe low pressure - Return to tank
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22. 18 - Fuel and Exhaust System
96 - Fuel Pipe
00 - General
18 - 116 9813/2850-3 18 - 116
Preparation
Important: Before you disconnect or remove fuel
pipes make sure that you have the correct new parts.
The high pressure fuel pipes MUST BE REPLACED
with new ones. The new fuel pipes must remain
sealed inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one.
Obey all fuel system health and safety information.
Refer to (PIL 18-00).
1. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine-Clean (PIL
15-00).
3. Remove the protective cover. Push out the four
plastic segments. Remove the screws and lift off
the cover.
4. Remove any dirt or debris that is exposed. Refer
to Engine-Clean (PIL 15-00).
Figure 370.
A Protective cover B Plastic segments (x4)
C Screws
23. 18 - Fuel and Exhaust System
96 - Fuel Pipe
03 - High Pressure Pipe
18 - 117 9813/2850-3 18 - 117
03 - High Pressure Pipe
Remove and Install
Special Tools
Description Part No. Qty.
Socket 17MM Offset -
(HP Fuel pipes)
331/27987 1
Torque Wrench
(10-100Nm)
993/70111 1
Injector Fuel Pipes
Remove
1. The procedure describes how to remove one fuel
pipe.
1.1. Remove the fuel pipes one at a time.
Figure 371.
D
D Fuel pipe
1.2. Put an open ended spanner at the top of
nut (This will prevent damage to the nut).
Loosen the nut (Do not remove the nut at
this step).
Figure 372.
1.3. Use the 17mm deep socket special tool at
the top of nut. This will prevent damage to
the nut.
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
1.4. Loosen the nut C. Do not remove the nut at
this step.
Figure 373.
B
C
E
F
B Nut
C Nut
E Fuel pipe
F Fuel pipe
1.5. Push the fuel pipe against the injector cone
and at the same time remove the nut B.
1.6. Push the fuel pipe against the rail cone and
at the same time remove the nut C.
1.7. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.8. Remove the fuel pipe.
1.9. Seal all the open ports, use the correct parts
from the service kit.
2. Repeat step 1 to remove the other fuel pipes.
3. Discard the old fuel pipes.
Install
Important: The high pressure fuel pipes must be
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the
fuel pipe.
1. Make sure that the bleed-off adaptors are
assembled on the injectors before you install the
high pressure pipes.
2. Assemble the fuel pipes one at a time. The
procedure describes how to assemble one fuel
pipe.
24. 18 - Fuel and Exhaust System
96 - Fuel Pipe
03 - High Pressure Pipe
18 - 118 9813/2850-3 18 - 118
2.1. Put the correct end of the fuel pipe against
the correct injector cone.
2.2. Tighten the nut B with your hand.
2.3. Put the other end of the fuel pipe against the
correct rail cone.
2.4. Tighten the nut C with your hand. Nuts
must be tightened in the correct sequence.
Tighten nut B and then nut C.
2.5. Use the special tool at the top of nut B and
tighten it to the correct torque value.
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
2.6. Put the spanner at the top of nut C and
tighten it to the correct torque value.
Pump to Rail Fuel Pipes
Remove
1. To remove the fuel pipe.
1.1. Put an open ended spanner at the top of
nut (This will prevent damage to the nut).
Loosen the nut (Do not remove the nut at
this step).
Figure 374.
1.2. Loosen the nut A. Do not remove the nut at
this step.
Figure 375.
B
C
A
A Nut
B Nut
C Fuel pipe
1.3. Use the 17mm deep socket special tool at
the top of nut. This will prevent damage to
the nut.
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
1.4. Push the fuel pipe against the injector cone
and at the same time remove the nut B.
1.5. Push the fuel pipe against the rail cone and
at the same time remove the nut C.
1.6. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.7. Remove the fuel pipe.