This service manual provides information and instructions for servicing the Loadall 525-60 rough terrain variable reach truck. It contains sections covering the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, brake, steering, driveline, hydraulic, and electrical systems. The engine section describes the Kohler KDI 2504 TCR four-cylinder diesel engine, including component identification, operation, technical data, and servicing instructions. Safety precautions are outlined, and the four-stroke operating cycle is explained.
Jcb 672 mechanical engine service repair manualdujjsjekkekmme
This service manual provides instructions for servicing the JCB 672 Mechanical Engine. It contains original instructions verified by the manufacturer. The manual covers general information about the engine such as its basic description, technical specifications, component identification, operation, and procedures for maintenance tasks like draining fluids, cleaning, checking pressures, removing and installing components, and storing or recommissioning the engine. Safety warnings are provided throughout advising technicians to take precautions when working with hot or rotating parts, and properly dispose of waste fluids.
This document contains a table of contents and specifications for parts related to the engine, fuel, exhaust, cooling, air conditioning, and intake systems of a Massey Ferguson TH.8043 130 S3A telescopic handler. It includes over 50 numbered items with descriptions and part numbers for components such as the radiator, muffler, hoses, clamps, sensors, and other engine accessories. The parts are grouped into sections for each vehicle system and subsystems.
The document is a parts catalog for a Massey Ferguson TH.7030 ST4 telescopic handler. It lists parts for the engine, fuel, and exhaust systems across multiple pages, with each page covering a different subsystem. The parts are organized in a table with the part number, quantity, description, and any additional comments. The parts listed include components for the cooling system, air intake, exhaust system, SCR system housing, and other engine systems.
This document provides parts information for a Massey Ferguson 89410/89410(L) telescopic handler, including:
- A list of 43 parts that make up the main frame, with part numbers, quantities, descriptions, and comments.
- A list of 9 parts that make up the counterweights and attachments on the frame.
- A list of 20 parts that make up the fuel system including the fuel tank and attachments.
- A list of 27 parts that make up the engine cover.
- A list of 21 parts that make up the engine support.
- A list of 30 parts that make up the cab.
- A list of 31 parts that make
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This document provides a table of contents and component listings for the engine, fuel, and exhaust systems of a Massey Ferguson MF 9305 telescopic handler. It includes over 50 pages detailing over 1000 individual components that make up these various mechanical systems of the vehicle. The pages provide diagrams and lists of parts, their numbers, quantities, and brief descriptions.
Massey ferguson mf 9205 telescopic handler parts catalogue manualfjjskedmme
This document provides a list of parts for a Massey Ferguson MF 9205 telescopic handler, including the main frame, counterweight, engine support and cover, cab installation, cab windows and door, and tractor cab windscreen wiper. It includes the part numbers, quantities, descriptions, and comments for 76 total parts.
This document provides parts information for a Massey Ferguson 8947 telescopic handler, including:
- A list of 40 parts for the main frame with part numbers, quantities, descriptions, and comments.
- A list of 9 parts for the counterweights with similar information.
- A list of 20 parts for the fuel system including the fuel tank, lines, caps, and attachments.
- A list of 48 parts for the engine cover and attachments up to a certain serial number.
- A list of 28 parts for the engine cover and attachments from another serial number range.
- A list of 18 parts for the engine support system.
- A list of 30 parts for the
Massey ferguson mf 8947 telescopic handler (3636 11187-999) parts catalogue...fjjskedmme
This document provides a table of contents and specifications for engine, fuel, exhaust and other systems for a Massey Ferguson MF 8947 telescopic handler. It includes over 30 pages detailing individual parts, part numbers, quantities and references for the engine, drivetrain, hydraulic, electrical and other systems. The level of detail provided in the document allows for identification and ordering of replacement parts for maintenance and repair of the telescopic handler.
Jcb 672 mechanical engine service repair manualdujjsjekkekmme
This service manual provides instructions for servicing the JCB 672 Mechanical Engine. It contains original instructions verified by the manufacturer. The manual covers general information about the engine such as its basic description, technical specifications, component identification, operation, and procedures for maintenance tasks like draining fluids, cleaning, checking pressures, removing and installing components, and storing or recommissioning the engine. Safety warnings are provided throughout advising technicians to take precautions when working with hot or rotating parts, and properly dispose of waste fluids.
This document contains a table of contents and specifications for parts related to the engine, fuel, exhaust, cooling, air conditioning, and intake systems of a Massey Ferguson TH.8043 130 S3A telescopic handler. It includes over 50 numbered items with descriptions and part numbers for components such as the radiator, muffler, hoses, clamps, sensors, and other engine accessories. The parts are grouped into sections for each vehicle system and subsystems.
The document is a parts catalog for a Massey Ferguson TH.7030 ST4 telescopic handler. It lists parts for the engine, fuel, and exhaust systems across multiple pages, with each page covering a different subsystem. The parts are organized in a table with the part number, quantity, description, and any additional comments. The parts listed include components for the cooling system, air intake, exhaust system, SCR system housing, and other engine systems.
This document provides parts information for a Massey Ferguson 89410/89410(L) telescopic handler, including:
- A list of 43 parts that make up the main frame, with part numbers, quantities, descriptions, and comments.
- A list of 9 parts that make up the counterweights and attachments on the frame.
- A list of 20 parts that make up the fuel system including the fuel tank and attachments.
- A list of 27 parts that make up the engine cover.
- A list of 21 parts that make up the engine support.
- A list of 30 parts that make up the cab.
- A list of 31 parts that make
Massey ferguson mf 9305 telescopic handler europe parts catalogue manualfjjskedmme
This document provides a table of contents and component listings for the engine, fuel, and exhaust systems of a Massey Ferguson MF 9305 telescopic handler. It includes over 50 pages detailing over 1000 individual components that make up these various mechanical systems of the vehicle. The pages provide diagrams and lists of parts, their numbers, quantities, and brief descriptions.
Massey ferguson mf 9205 telescopic handler parts catalogue manualfjjskedmme
This document provides a list of parts for a Massey Ferguson MF 9205 telescopic handler, including the main frame, counterweight, engine support and cover, cab installation, cab windows and door, and tractor cab windscreen wiper. It includes the part numbers, quantities, descriptions, and comments for 76 total parts.
This document provides parts information for a Massey Ferguson 8947 telescopic handler, including:
- A list of 40 parts for the main frame with part numbers, quantities, descriptions, and comments.
- A list of 9 parts for the counterweights with similar information.
- A list of 20 parts for the fuel system including the fuel tank, lines, caps, and attachments.
- A list of 48 parts for the engine cover and attachments up to a certain serial number.
- A list of 28 parts for the engine cover and attachments from another serial number range.
- A list of 18 parts for the engine support system.
- A list of 30 parts for the
Massey ferguson mf 8947 telescopic handler (3636 11187-999) parts catalogue...fjjskedmme
This document provides a table of contents and specifications for engine, fuel, exhaust and other systems for a Massey Ferguson MF 8947 telescopic handler. It includes over 30 pages detailing individual parts, part numbers, quantities and references for the engine, drivetrain, hydraulic, electrical and other systems. The level of detail provided in the document allows for identification and ordering of replacement parts for maintenance and repair of the telescopic handler.
Massey ferguson mf 8947 t3 (a8 hh13000 99999) mf 8947 cd t3 (a8hj13000-99999...fjjskedmme
This document provides a table of contents and sections for repair and maintenance of Massey Ferguson MF 8947 T3 and MF 8947 CD T3 telescopic handlers. The sections include the engine and fuel systems, drive train, hydraulics, electrical systems, chassis, and attachments. Each section lists relevant part numbers, quantities, and descriptions.
This document provides part numbers and descriptions for engine components of Massey Ferguson MF 8937 and MF 8939 telescopic handlers, including:
- Cylinder block parts for engines without and with turbocharger.
- Crankshaft, piston, and connecting rod components for non-turbocharged and turbocharged engines.
- The document lists part numbers, quantities, descriptions and other identifying information for each component.
Massey ferguson mf 8937 8939 telescopic handlers parts catalogue manualfjjskedmme
This document provides parts information for Massey Ferguson MF 8937 and MF 8939 telescopic handlers, including cylinder block, crankshaft, pistons, connecting rods, and cylinder head parts. It lists the part numbers, quantities, descriptions and comments such as replacement requirements for various engine components up to specific serial numbers for engines with and without turbochargers.
This document contains parts lists and diagrams for components of Massey Ferguson MF 8925/8926 telescopic handlers, including the main frame, counterweights, fuel system, engine cover, engine support, and cab. It provides detailed part numbers, quantities, descriptions and comments for each item listed. Footnotes indicate some seals and components should be ordered by the meter or are not serviced.
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This document provides part numbers and descriptions for components related to the engine, starter, alternator, and air conditioning compressor for a Massey Ferguson Ideal Class 7 combine. It includes items such as engine mounts, belts, hoses, filters, drain valves, shields, bolts, and the engine, starter, alternator and compressor themselves. Technical specifications are provided for some parts.
Massey ferguson 9895 combine (effective sn hsc8101) parts catalogue manualfjjskedmme
This document provides a list of parts and their descriptions for a Massey Ferguson 9895 combine. It includes 26 items related to the combine's engine air intake and exhaust systems. The items listed are the air intake tube, turbocharger, exhaust manifold, and various hoses and clamps.
Massey ferguson 9795 rotary combine parts catalogue manualfjjskedmme
The document provides a parts list and technical specifications for the engine and cylinder block of a Massey Ferguson 9795 rotary combine. It includes over 50 individual parts for the engine and cylinder block, including the cylinder block, camshaft, liners, plugs, gaskets, bolts, and other components. The parts list includes the part numbers, quantities, descriptions, and any relevant technical specifications or comments for each part.
Massey ferguson 9790 combine eff n america sn hm36101 eff s america sn 000 c9...fjjskedmme
This document contains listings of part numbers and descriptions for decals and labels used on a Massey Ferguson 9790 combine harvester. It includes decals for both North America and South America models, listing decals for the left side, front, right side and rear of the harvester. There are over 30 different decals described for labeling various parts, warnings and safety information.
Massey ferguson 9690 combine (eff sn hm87101) parts catalogue manualfjjskedmme
This document provides a parts list for engine and engine mounting components for a Massey Ferguson 9690 combine with a Cummins QSC 8.3 engine and prior serial number HR87101. It lists 44 items including the engine assembly, alternator, belts, hoses, brackets, rails, clamps, bolts, nuts, and washers that make up the engine and mounting system. Tightening specifications or additional details are not provided.
This document provides a table of contents and specifications for engine parts of a Massey Ferguson 9560 combine from 2012-2014, including the cylinder block, engine and mounting components, fuel lines and filters, and engine electrical systems. It lists over 100 individual parts that make up these engine systems, providing part numbers, descriptions, and other technical details for each component.
This document provides a table of contents and parts lists for a Massey Ferguson 9560 combine harvester engine and related systems. It includes over 40 pages detailing over 1000 individual part numbers for components such as the cylinder block, fuel injection system, engine mounts, sensors, wiring harnesses, filters and more. The level of detail provided allows for identification and ordering of any replacement part for the combine harvester engine.
This document contains a table of contents and sections for a Massey Ferguson 9550 Combine repair manual from 2012-2014. It lists over 40 pages detailing individual systems of the combine like the engine, fuel, electrical, hydraulic, and harvesting systems. Each section includes diagrams, part numbers, and descriptions of components.
Massey ferguson 9545 9565 axial combine (2017)(hhcxx101 hhcxx999) parts cata...fjjskedmme
This document provides a table of contents and page references for the service manual of a Massey Ferguson 9545/9565 Axial Combine from 2017. It includes 22 sections covering the various systems of the combine like the engine, fuel, electrical, hydraulic, and harvesting systems. Each section includes additional pages providing parts lists, diagrams, and repair instructions for that system.
This document provides a parts list and diagrams for the exhaust system of a Massey Ferguson 9545/9565 axial combine. It lists 40 individual parts that make up the exhaust pipes, muffler, sensors, brackets and shields. The parts are identified by number and include specifications like bolt sizes and part numbers. Diagrams show how the different exhaust system components connect and attach to the engine and frame.
The document provides a table of contents for the service manual of a Massey Ferguson 9540-9560 combine. The table lists 21 sections that cover different systems of the combine like the engine and fuel system, drive system, axles, frame and more. It then provides detailed parts lists and diagrams for the engine air intake system and exhaust group.
The document is a table of contents and parts list for the engine, fuel, and exhaust systems of a Massey Ferguson 9540 combine from 2012-2014. It includes over 100 parts grouped into categories like the cylinder block, fuel lines and filters, electrical systems, and more. Each part is listed with its number, quantity, description, and any relevant technical specifications.
This document provides a parts list and technical specifications for the oil cooler and filter system on a Massey Ferguson 9530 combine from 2012-2014. It includes 30 items such as the oil cooler, housing, tubing, o-rings, washers, unions and screws that make up the oil cooling system. Precise part numbers, quantities and technical details are provided for each component.
This document is a table of contents and parts list for the engine, fuel, and exhaust systems of Massey Ferguson 9520 combines from 2012-2014. It includes over 30 pages listing over 1000 individual part numbers for components such as the engine, fuel filters, oil cooler, radiator, belts, hoses, mounts, and other related parts. The parts are organized by system and include technical specifications.
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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.
Massey ferguson mf 8947 t3 (a8 hh13000 99999) mf 8947 cd t3 (a8hj13000-99999...fjjskedmme
This document provides a table of contents and sections for repair and maintenance of Massey Ferguson MF 8947 T3 and MF 8947 CD T3 telescopic handlers. The sections include the engine and fuel systems, drive train, hydraulics, electrical systems, chassis, and attachments. Each section lists relevant part numbers, quantities, and descriptions.
This document provides part numbers and descriptions for engine components of Massey Ferguson MF 8937 and MF 8939 telescopic handlers, including:
- Cylinder block parts for engines without and with turbocharger.
- Crankshaft, piston, and connecting rod components for non-turbocharged and turbocharged engines.
- The document lists part numbers, quantities, descriptions and other identifying information for each component.
Massey ferguson mf 8937 8939 telescopic handlers parts catalogue manualfjjskedmme
This document provides parts information for Massey Ferguson MF 8937 and MF 8939 telescopic handlers, including cylinder block, crankshaft, pistons, connecting rods, and cylinder head parts. It lists the part numbers, quantities, descriptions and comments such as replacement requirements for various engine components up to specific serial numbers for engines with and without turbochargers.
This document contains parts lists and diagrams for components of Massey Ferguson MF 8925/8926 telescopic handlers, including the main frame, counterweights, fuel system, engine cover, engine support, and cab. It provides detailed part numbers, quantities, descriptions and comments for each item listed. Footnotes indicate some seals and components should be ordered by the meter or are not serviced.
Massey ferguson ideal class 7 combine parts catalogue manualfjjskedmme
This document provides part numbers and descriptions for components related to the engine, starter, alternator, and air conditioning compressor for a Massey Ferguson Ideal Class 7 combine. It includes items such as engine mounts, belts, hoses, filters, drain valves, shields, bolts, and the engine, starter, alternator and compressor themselves. Technical specifications are provided for some parts.
Massey ferguson 9895 combine (effective sn hsc8101) parts catalogue manualfjjskedmme
This document provides a list of parts and their descriptions for a Massey Ferguson 9895 combine. It includes 26 items related to the combine's engine air intake and exhaust systems. The items listed are the air intake tube, turbocharger, exhaust manifold, and various hoses and clamps.
Massey ferguson 9795 rotary combine parts catalogue manualfjjskedmme
The document provides a parts list and technical specifications for the engine and cylinder block of a Massey Ferguson 9795 rotary combine. It includes over 50 individual parts for the engine and cylinder block, including the cylinder block, camshaft, liners, plugs, gaskets, bolts, and other components. The parts list includes the part numbers, quantities, descriptions, and any relevant technical specifications or comments for each part.
Massey ferguson 9790 combine eff n america sn hm36101 eff s america sn 000 c9...fjjskedmme
This document contains listings of part numbers and descriptions for decals and labels used on a Massey Ferguson 9790 combine harvester. It includes decals for both North America and South America models, listing decals for the left side, front, right side and rear of the harvester. There are over 30 different decals described for labeling various parts, warnings and safety information.
Massey ferguson 9690 combine (eff sn hm87101) parts catalogue manualfjjskedmme
This document provides a parts list for engine and engine mounting components for a Massey Ferguson 9690 combine with a Cummins QSC 8.3 engine and prior serial number HR87101. It lists 44 items including the engine assembly, alternator, belts, hoses, brackets, rails, clamps, bolts, nuts, and washers that make up the engine and mounting system. Tightening specifications or additional details are not provided.
This document provides a table of contents and specifications for engine parts of a Massey Ferguson 9560 combine from 2012-2014, including the cylinder block, engine and mounting components, fuel lines and filters, and engine electrical systems. It lists over 100 individual parts that make up these engine systems, providing part numbers, descriptions, and other technical details for each component.
This document provides a table of contents and parts lists for a Massey Ferguson 9560 combine harvester engine and related systems. It includes over 40 pages detailing over 1000 individual part numbers for components such as the cylinder block, fuel injection system, engine mounts, sensors, wiring harnesses, filters and more. The level of detail provided allows for identification and ordering of any replacement part for the combine harvester engine.
This document contains a table of contents and sections for a Massey Ferguson 9550 Combine repair manual from 2012-2014. It lists over 40 pages detailing individual systems of the combine like the engine, fuel, electrical, hydraulic, and harvesting systems. Each section includes diagrams, part numbers, and descriptions of components.
Massey ferguson 9545 9565 axial combine (2017)(hhcxx101 hhcxx999) parts cata...fjjskedmme
This document provides a table of contents and page references for the service manual of a Massey Ferguson 9545/9565 Axial Combine from 2017. It includes 22 sections covering the various systems of the combine like the engine, fuel, electrical, hydraulic, and harvesting systems. Each section includes additional pages providing parts lists, diagrams, and repair instructions for that system.
This document provides a parts list and diagrams for the exhaust system of a Massey Ferguson 9545/9565 axial combine. It lists 40 individual parts that make up the exhaust pipes, muffler, sensors, brackets and shields. The parts are identified by number and include specifications like bolt sizes and part numbers. Diagrams show how the different exhaust system components connect and attach to the engine and frame.
The document provides a table of contents for the service manual of a Massey Ferguson 9540-9560 combine. The table lists 21 sections that cover different systems of the combine like the engine and fuel system, drive system, axles, frame and more. It then provides detailed parts lists and diagrams for the engine air intake system and exhaust group.
The document is a table of contents and parts list for the engine, fuel, and exhaust systems of a Massey Ferguson 9540 combine from 2012-2014. It includes over 100 parts grouped into categories like the cylinder block, fuel lines and filters, electrical systems, and more. Each part is listed with its number, quantity, description, and any relevant technical specifications.
This document provides a parts list and technical specifications for the oil cooler and filter system on a Massey Ferguson 9530 combine from 2012-2014. It includes 30 items such as the oil cooler, housing, tubing, o-rings, washers, unions and screws that make up the oil cooling system. Precise part numbers, quantities and technical details are provided for each component.
This document is a table of contents and parts list for the engine, fuel, and exhaust systems of Massey Ferguson 9520 combines from 2012-2014. It includes over 30 pages listing over 1000 individual part numbers for components such as the engine, fuel filters, oil cooler, radiator, belts, hoses, mounts, and other related parts. The parts are organized by system and include technical specifications.
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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.
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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.
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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.
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.
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2. 15 - Engine
00 - Engine
00 - General
15 - 3 9813/3900-3 15 - 3
00 - General
Introduction ...................................................... 15-3
Health and Safety ........................................... 15-5
Technical Data ................................................. 15-6
Component Identification ................................. 15-7
Operation ....................................................... 15-10
Diagram ......................................................... 15-14
Fault-Finding .................................................. 15-15
Drain and Fill ................................................. 15-18
Clean ............................................................. 15-19
Check (Pressure) .......................................... 15-20
Remove and Install ....................................... 15-20
Store and Recommission .............................. 15-22
Introduction
This section contains information about the complete
engine assembly. For specific engine technical
information refer to the technical data section.
Make sure that the correct engine service tools,
consumables and torque figures are used when you
perform service procedures.
Replacement of oil seals, gaskets, etc., and any
component that show signs of wear or damage, is
expected as a matter of course.
It is expected that components will be cleaned and
lubricated where required, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The Kohler KDI engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition
(C.I.). The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The
starter motor turns the engine via a pinion and teeth
on the engine flywheel.
When the engine runs the crankshaft drives the
camshaft though the gears. The camshaft opens and
closes the inlet and exhaust valves and through push
rods in time with the four stroke cycle. The engine
has 16 valves, 2 inlet and 2 exhaust valves for each
cylinder.
The crankshaft also drives a mechanical high
pressure fuel pump via gears. The pump is part of the
electronically controlled common rail fuel injection
system.
Air is drawn into the engine through the inlet
manifold and exhaust gases exit through the exhaust
manifold. The engine uses a variable geometry
turbocharger which pressurises the air at the inlet
manifold.
A mechanical lubrication oil pump is driven by the
crankshaft through gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt again driven by the crankshaft, drives a
coolant circulation pump and alternator.
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
3. 15 - Engine
00 - Engine
00 - General
15 - 4 9813/3900-3 15 - 4
Figure 135.
H
E
F
G
A
D
C
B
A Crankshaft B Crankshaft gear
C Intermediate gear D Camshaft gear
E Camshaft F Tappet
G Push rod H Valve
Figure 136.
K
C D
A
L
J
B
A Crankshaft
B Crankshaft gear
C Intermediate gear
D Camshaft control gear
J Camshaft phonic wheel
K Intermediate gear pin
L Phonic wheel positioning reference pin on
camshaft
Figure 137.
H
G
N
M
Q
P
G Rocker arm push rod
H Valve
M Articulation control valve
N Valve control bridge
P Hydraulic tappet
Q Rocker arm
4. 15 - Engine
00 - Engine
00 - General
15 - 5 9813/3900-3 15 - 5
Health and Safety
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.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system.Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine oil
in the sump. If the maximum is exceeded, the excess
must be drained to the correct level. An excess of
engine oil could cause the engine speed to increase
rapidly without control.
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.
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.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
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.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
5. 15 - Engine
00 - Engine
00 - General
15 - 6 9813/3900-3 15 - 6
Technical Data
Table 46.
Description
Engine Type KDI 2504 TCR
Emission compliance US-EPA Tier 4 final, EU
Stage IIIB
Max. operating speed 2200 RPM (Revolutions
Per Minute)
Power Output 55kW at 2200 RPM
Weight (Dry) 233kg
Number of cylinders 4
Nominal bore size 88mm
Stroke 102mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.482L
Compression ratio 17: 1
Direction of rotation
(viewed from flywheel
end)
Counterclockwise
Valves 4 per cylinder
Tappets Hydraulic
Lubricating oil pressure
(Dependent on engine
temperature and speed)
1–2.8bar (14.5–40.6psi)
Filter type Screw-on canister
Pressure to open by-
pass valve
2.5 ± 0.5bar
(36.2 ± 7.2psi)
Oil pressure switch set-
ting
0.8 ± 0.1bar
(11.6 ± 1.4psi) falling
Oil pump
(1)
Integral unit with relief
valve
Combustion system Common rail direct In-
jection
High pressure fuel pump High pressure with elec-
tronically controlled fuel
metering
(1) The oil pump is a non-serviceable part
6. 15 - Engine
00 - Engine
00 - General
15 - 7 9813/3900-3 15 - 7
Component Identification
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 138.
DC
E
H
N
P
L
M
G
F
K
J
A
B
A Flywheel housingRefer to: PIL 15-54-03. B FlywheelRefer to: PIL 15-54-00.
C Fuel filterRefer to: PIL 18-09-00. D Fuel filter drain plugRefer to: PIL 18-09-00.
E DipstickRefer to: PIL 15-45-09. F Oil filterRefer to: PIL 15-21-00.
G Oil coolerRefer to: PIL 15-69-00. H PTO (Power Take-Off) cover (If installed)
J High pressure fuel pumpRefer to: PIL
18-18-15.
K Inlet manifoldRefer to: PIL 18-24-03.
L Catalytic converterRefer to: PIL 18-24-18. M EGR (Exhaust Gas Recirculation) valveRefer to:
PIL 18-27-06.
N Engine harness P ECM (Engine Control Module)
7. 15 - Engine
00 - Engine
00 - General
15 - 8 9813/3900-3 15 - 8
Figure 139.
N
M
L
KE
JG
H
F
P
Q
R
C
B
D
A
A ThermostatRefer to: PIL 21-12-00. B Oil filler capRefer to: PIL 15-57-00.
C Cooling pumpRefer to: PIL 21-09-00. D Drive beltRefer to: PIL 15-18-03.
E Crankshaft phonic wheelRefer to: PIL
15-12-15.
F Oil sumpRefer to: PIL 15-45-00.
G Timing gear caseRefer to: PIL 15-51-21. H AlternatorRefer to: PIL 15-72-00.
J Oil sump drain plugRefer to: PIL 15-45-03. K CrankcaseRefer to: PIL 15-03-00.
L BedplateRefer to: PIL 15-09-00. M Crankcase ventilation filterRefer to: PIL
15-27-00.
N Starter motorRefer to: PIL 15-75-00. P Oil pressure sensorRefer to: PIL 15-84-21.
Q Cylinder headRefer to: PIL 15-06-00. R Outlet manifoldRefer to: PIL 18-24-04.
8. 15 - Engine
00 - Engine
00 - General
15 - 9 9813/3900-3 15 - 9
Figure 140.
E
F
G
J
H
B
A
K
C D
A InjectorRefer to: PIL 18-18-03. B Rocker coverRefer to: PIL 15-42-06.
C Turbocharger actuatorRefer to: PIL 18-35-00. D TurbochargerRefer to: PIL 18-35-00.
E Turbocharger linkRefer to: PIL 18-35-00. F Oil filler capRefer to: PIL 15-57-00.
G Low pressure fuel return pipesRefer to: PIL
18-96-06.
H EGR coolerRefer to: PIL 18-27-09.
J High pressure fuel pipesRefer to: PIL
18-96-03.
K Fuel railRefer to: PIL 18-18-12.
9. 15 - Engine
00 - Engine
00 - General
15 - 10 9813/3900-3 15 - 10
Operation
The Four Cylinder Cycle
This section describes the cycle sequence for the 4
cylinder engine.
With the crankshaft positioned as shown, the pistons
in numbers 1 and 4 cylinders are at top dead centre
and pistons in numbers 2 and 3 cylinders are at
bottom dead centre.
It is important to note that number 1 cylinder is firing
and about to start its Power stroke. Rotating the
crankshaft a further full rotation would position the
pistons as described but the engine would be at a
different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
Firing Order
A cylinder is said to be firing, when the fuel/air mixture
ignites and the piston is about to start its power
stroke.
From the stages described, it can be seen that
number 1 cylinder will be next to fire. Number 3
cylinder is starting its compression stroke and is next
in the cycle, followed by cylinders 4 and 2. The firing
order is therefore; 1, 3, 4, 2.
The stages in the four stroke cycle for each cylinder
are as follows:
Table 47. The Four Stroke Cycle
Cylinder number Piston operation Valve operation
1 The piston is at the top of its Compression stroke
and is about to start its Power stroke.
Inlet and exhaust valves closed
2 The piston is at the bottom of its Power stroke and
is about to start its Exhaust stroke.
Inlet valves closed, exhaust
valves about to open
3 The piston is at the bottom of its Induction stroke
and is about to start its Compression stroke.
Exhaust valves closed, inlet
valves about to close.
4 The piston is at the top of its Exhaust stroke and
is about to start its Induction stroke.
Valve Operation Exhaust valves
about to close, inlet valves about
to open
10. 15 - Engine
00 - Engine
00 - General
15 - 11 9813/3900-3 15 - 11
Figure 141. Typical Four Cylinder Engine
745620
CYL1 CYL2 CYL3 CYL4
A A A A
B
F
C
B
C
B
B
C
C
C B
G
G
H
H
J
J
K
K
C B C B C B
4
5
2
3
A
1
745620
CYL1 Cylinder number 1 CYL2 Cylinder number 2
CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
11. 15 - Engine
00 - Engine
00 - General
15 - 12 9813/3900-3 15 - 12
Four Stroke Cycle
Induction
As the piston travels down the cylinder, it draws
filtered air at atmospheric pressure and ambient
temperature through an air filter and inlet valves into
the cylinder.
Compression
When the piston reaches the bottom of its stroke, the
inlet valves close. The piston then starts to rise up the
cylinder compressing the air trapped in the cylinder.
This causes the temperature and pressure of the air
to rise. Fuel is injected into the cylinder when the
piston is near to TDC (Top Dead Centre).
Power
The piston continues to rise after the start of fuel
injection, causing a further increase in pressure and
temperature.
The temperature rises to a point at which the fuel/air
mixture ignites. A cylinder is said to be firing when
the fuel/air mixture ignites.
This combustion causes a very rapid rise in
both temperature and pressure. The high pressure
generated propels the piston downwards turning the
crankshaft and producing energy.
Exhaust
Once the piston has reached the bottom of its travel,
the exhaust valves open and momentum stored
in the flywheel forces the piston up the cylinder
expelling the exhaust gases.
In a running engine, these four phases are
continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle of a
four stroke engine, the crankshaft revolves twice.
Figure 142.
3
2
41
B
C
746030
1 Induction stroke 2 Compression stroke
3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC
12. 15 - Engine
00 - Engine
00 - General
15 - 13 9813/3900-3 15 - 13
Figure 143.
717620
1 2 3 4
A A A A
B C
BC B BC
C
1 Induction stroke 2 Compression stroke
3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
13. 15 - Engine
00 - Engine
00 - General
15 - 14 9813/3900-3 15 - 14
Diagram
Electrical Operation and Schematics
The schematic diagram shows a typical system.
For machine specific schematics, refer to electrical
system- general, refer to (PIL 33-00).
The schematic is shown with the ignition switch
set to position III and the transmission set to N. A
signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
CAN (Controller Area Network)bus to tell the Engine
ECU that the transmission is in Neutral.
The engine ECU provides power to the engine
compartment fusebox to energise the start relay, the
fuel pump relay, the starter motor and the fuel pump.
Figure 144.
3
4
5
6
7
8
9
10
1
2
-VE+VE
D+
Charge
W
M
-VE+VE
ECUECU
ECUECU
M
B
L
E
H
K
J
G
F
A
D
C
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU
14. 15 - Engine
00 - Engine
00 - General
15 - 18 9813/3900-3 15 - 18
Drain and Fill
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
Engine oil replacement must be completed in
accordance with the service schedules. Failure to
replace the oil replacement at the recommended
interval could cause serious engine failure.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained
with the oil.
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Park the machine on a hard level surface for
accurate measurement of the oil level.
3. Get access to the engine.
4. Place a container of suitable size beneath the
drain plug.
5. Remove the oil filler cap.
Figure 145.
A
B
C
A Oil filler cap
B Drain plug
C O-ring
CAUTION! Oil will gush from the hole when the
drain plug is removed. Keep to one side when
you remove the plug.
6. Remove the oil dipstick.
7. Remove the oil sump drain plug and O-ring from
both sides of the oil sump.
8. Drain the engine oil into an suitable container.
9. Clean and install the drain plug with a new O-
ring. Tighten the plug to the correct torque value.
10. Through one of the filler points, fill the engine with
the recommended oil to the MAX mark on the
dipstick.
Figure 146.
A
A Oil filler cap
Figure 147.
E
F
D
D Dipstick
E Maximum level mark
F Minimum level mark
11. Wipe off any spilt oil, install the filler cap and
make sure it is secure.
12. Operate the engine, until the oil pressure low
warning light has extinguished.
13. Check for oil leakage.
14. When the oil has cooled, check the oil level
again, and if necessary top up with clean engine
oil.
15. 15 - Engine
00 - Engine
00 - General
15 - 19 9813/3900-3 15 - 19
Clean
Notice: Clean the engine before you start engine
maintenance. Obey the correct procedures.
Contamination of the fuel system will cause
damage and possible failure of the engine.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine
is to be washed using a high pressure system.
Make sure that the alternator, starter motor and
any other electrical components are shielded
and not directly cleaned by the high pressure
cleaning system. Do not aim the water jet directly
at bearings, oil seals or the engine air induction
system.
Before carrying out any service procedures that
require components to be removed, the engine must
be properly cleaned.
Cleaning must be carried out either in the area of
components to be removed or, in the case of major
work, or work on the fuel system, the whole engine
and surrounding machine must be cleaned.
Stop the engine and allow it to cool for at least one
hour. DO NOT attempt to clean any part of the engine
while it is running.
1. Make sure that the electrical system is isolated.
2. Make sure that all electrical connectors are
correctly connected. If connectors are open
install the correct caps or seal with water proof
tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and brush to soak
off mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical and electronic
components such as the engine electronic
control unit (ECU), alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine.
Distance: 600mm
9. When the pressure washing is complete, move
the machine away from the wash area, or
alternatively, clean away the material washed
from the machine.
10. Before working on specific areas of the engine,
use a compressed air jet to dry off any moisture.
When the area is dry, use a soft clean brush to
remove any sand or grit particles that remain.
11. When removing components, be aware of any
dirt or debris that may be exposed. Cover any
open ports and clean away the deposits before
proceeding.
Additional cleaning must be carried out prior to
working on the high pressure fuel system. Refer to
Fuel System, General, Clean.
16. 15 - Engine
00 - Engine
00 - General
15 - 20 9813/3900-3 15 - 20
Check (Pressure)
Special Tools
Description Part No. Qty.
Pressure Gauge (0-40
Bar)
892/00278 1
1. Make the machine safe with the excavator/lift
arm lowered.
Refer to: PIL 01-03-27.
2. Make sure that the engine oil and fuel are at the
correct level.
3. Remove the pressure switch.
Refer to: PIL 15-84-21.
4. Connect a pressure gauge to the pressure switch
fitting.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
Figure 148.
A
5. Start the engine.
6. Monitor the oil pressure with respect to the oil
temperature.
7. The oil pressure should be more than the
specified value.
Pressure: 1.5bar (21.7psi)
8. Stop the engine and allow it to cool.
9. Remove the pressure gauge and install the
pressure switch.
Remove and Install
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
The lifting equipment used must be an approved
type and capable of lifting the engine safely. The
recommended lifting equipment is shown. Use a
spreader bar when lifting the engine. Never attempt
to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
an assistant. Inspect the lifting brackets for signs
of damage. The brackets must be correctly torqued
to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
rocker cover.
There will be some component differences
depending on the machine variant. Before attempting
to remove the engine ensure that all the necessary
components have either been removed, or safely
disconnected from the engine.
Before Removal
1. 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.
2. Position the machine on firm level ground. Make
the machine safe.
Refer to: PIL 01-03-27.
3. Get access to the engine.
Refer to: PIL 06-06-06.
Remove
1. Disconnect and remove the battery.
Refer to: PIL 33-03-00.
2. Drain the engine oil.
Refer to: PIL 15-00-00.
3. Drain the engine cooling system.
Refer to: PIL 21-00-00.
4. Remove the cooling pack.
5. Discharge the hydraulic pressure.
Refer to: PIL 30-00-00.
17. 15 - Engine
00 - Engine
00 - General
15 - 21 9813/3900-3 15 - 21
6. Drain the hydraulic tank. Disconnect and plug
the hydraulic pipes. Label the hoses to help
installation.
7. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to help installation.
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine
crankcase. Release the hose clips and remove
the hoses.
10. Disconnect the wiring connections from the
starter motor.
Refer to: PIL 15-75-00.
11. Disconnect the wiring connections from the
alternator.
Refer to: PIL 15-72-00.
12. Disconnect the wiring connections from the
engine sensors and actuators.
Refer to: PIL 15-84.
13. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
14. Disconnect the electrical harness at the engine
harness.
15. Uncouple the electrical harness at the
ECM (Engine Control Module) machine side
connector. Important: DO NOT touch the
connector pins on the ECM or harness
connectors. Cover the connectors to prevent
contamination.
16. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
17. Disconnect and plug the hoses at the hydraulic
pump.
18. Disconnect the wiring to the hydraulic pump.
19. Attach slings to the engine lifting eyes.
Figure 149.
A
A
B B
A Lifting eye
B Sling
20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
21. Withdraw the engine in a level attitude until it is
clear of the chassis. Raise the engine to lift it
clear of the machine.
22. Lower the engine into a suitable stand that is
capable of supporting the weight of the engine.
Install
1. Replacement is a reversal of the removal
procedure. Note the following:
2. Fill the cooling system with the correct mix of
coolant fluid.
Refer to: PIL 75-00-00.
3. Fill and Check the hydraulic fluid level.
Refer to: PIL 30-00-00.
4. Fill and Check the engine oil level.
Refer to: PIL 15-00-00.
5. On completion, check the hydraulic and cooling
system for leakage and levels.
6. Check the function of the drive and hydraulic
services.
Table 70. Torque Values
Item Nm
A 25
18. 15 - Engine
00 - Engine
00 - General
15 - 22 9813/3900-3 15 - 22
Store and Recommission
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
Engine Storage (up to 6 months)
Before you store the engine make sure that:
• The environment is not humid or exposed to
bad weather.
• The storage place is not near an electrical
panel.
• Prevent storing the engine in direct contact with
the ground.
1. Cover the engine with a proper protective sheet
to prevent it from dampness and atmospheric
contaminants.
Engine Storage (over 6 months)
1. Follows the precautions mentioned in the above
procedure.
2. Fill the engine housing with protective oil up to
the maximum level.
3. Refuel the machine with fuel additives for long
storage.
4. For machines with expansion tank:
4.1. Make sure that the coolant is up to the
maximum level.
5. For machines without expansion tank:
5.1. Fill the coolant until the pipes inside the
radiator are covered by specified distance.
Distance: 5mm
5.2. Do not overfill the radiator, but leave
sufficient space for the fuel to expand.
6. Start the engine and run it at idle speed for the
specified duration.
Duration: 2min
7. Bring the engine to 75% of the maximum rated
speed for the specified duration.
Duration: 5–10min
8. Turn off the engine.
9. Drain the fuel tank completely.
10. Spray engine oil (SAE 10W40) on the exhaust
and intake manifolds.
11. Seal the exhaust and intake ducts to prevent
contamination.
12. Clean the engine.
Refer to: PIL 15-00-00.
13. Apply protective paints on non-painted parts.
14. Loosen the alternator belt.
15. Cover the engine with a proper protective sheet
to prevent it from dampness and atmospheric
contaminants.
Engine Starting After Storage
1. Remove the protective sheet.
2. Use a cloth soaked in degreasing fluid to remove
the protective treatment from the external parts.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
3. Inject lubricating oil (not more than 2cm³) into the
intake ducts.
4. Adjust the alternator belt tension.
Refer to: PIL 15-18-00.
5. Refuel the machine.
6. Make sure that the oil and the coolant are up to
the maximum level.
7. Start the engine and run it at idle speed for the
specified duration.
Duration: 2min
8. Bring the engine to 75% of the maximum rated
speed for the specified duration.
Duration: 5–10min
9. Stop the engine.
10. While the oil is still hot, drain the protective oil in
a suitable container.
11. Put new oil up to the maximum level.
12. Replace the filters (air, oil, fuel).
13. Drain the cooling circuit completely and put new
coolant up to the maximum level.
Important: Over time, lubricants and filters lose their
properties, so it is important to consider whether they
need replacing, also based on the criteria mentioned
in the maintenance schedules.
If the engine is not to be used for an extended period,
the protective treatment procedure must be repeated
within 730d of the previous one.
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20. 15 - Engine
03 - Crankcase
00 - General
15 - 25 9813/3900-3 15 - 25
00 - General
Introduction .................................................... 15-25
Technical Data ............................................... 15-26
Clean ............................................................. 15-27
Calibrate ........................................................ 15-28
Remove and Install ....................................... 15-29
Introduction
The crankcase is the housing for the crankshaft.
The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and
connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 150.
B
A
A Crankcase
B Crankshaft
21. 15 - Engine
03 - Crankcase
00 - General
15 - 26 9813/3900-3 15 - 26
Technical Data
Table 71. Crankcase and Bedplate Data
Main bearing bolts
torque
(1)
First stage 40N·m
Second stage 70N·m
Third stage 120N·m
Peripheral bolts
Fourth stage 20N·m
Fifth stage 35N·m
(1) Torque information must be used in conjunction
with recommended procedures contained in this
manual. Failure to use the appropriate and correct
removal, replacement, dismantle and assembly
procedures may result in an engine failure in service.
Refer also to the procedures for the correct bolt
tightening sequence.
Table 72. Cylinder bore Data
Dimensional Class
(1)
Cylinder Diameter
(1)
Piston Diameter
(1)
Clearance
(1)
STD 88.003mm
(3.4647in)-88.017mm
(3.4652in)
87.943mm
(3.4623in)-87.957mm
(3.4628in)
R+0.1 88.103mm
(3.4686in)-88.117mm
(3.4691in)
88.043mm
(3.4663in)-88.057mm
(3.4668in)
+0.5 88.503mm
(3.4843in)-88.517mm
(3.4849in)
88.443mm
(3.4820in)-88.457mm
(3.4826im)
+1 89.003mm
(3.5041in)-89.017mm
(3.5046in)
88.943mm
( 3.5017in)-88.957mm
(3.5022in)
0.046mm
( 0.0018in)-0.074mm
(0.0029in)
(1) This table shows the reference values and their classification applicable for new engines only.
22. 15 - Engine
03 - Crankcase
00 - General
15 - 27 9813/3900-3 15 - 27
Clean
Oil pipes
Important: Make sure you keep a safe distance from
all of the open ports.
1. Remove all the plugs.
2. Put a pipe cleaner in all the open ports to clean
the oil pipes,as shown.
3. Use a compressed air line to remove any
remaining oil.
4. Install all the plugs with Loctite.
Figure 151.
A
A
B
A
A
A Plug B Oil pipe