This service manual provides instructions for servicing the Loadall 530-110 and 530-70 rough terrain variable reach trucks. It contains sections on the machine components including the engine, fuel and exhaust systems, cooling system, brakes, steering, driveline, hydraulics, and electrical systems.
The section on the cylinder head removal and installation provides technical specifications and instructions. It describes removing the cylinder head bolts in reverse order, lifting the cylinder head off, cleaning the mating surfaces, and installing new head bolts using a torque and angle tightening method.
The section on bedplate removal and installation cautions that it is a heavy component requiring lifting equipment. It provides instructions for removing components like the cr
Jcb 3 cx compact backhoe loader service repair manual (sn from 2495456 and up)fusefjskekkmem
This service manual provides instructions for servicing a JCB 3CX Compact backhoe loader. It contains sections covering the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The specific section summarized discusses servicing procedures for the engine crankshaft, including how it is lubricated by engine oil, how to check its condition by inspecting the bearing surfaces and diameters, and ensuring the oilways are clear.
Jcb 3 ts 8t skid steer loader service repair manual (from 2475701 and up)ujdfjjsjekfkkem
This document provides instructions for removing and installing a bedplate on an engine. Key steps include:
1. Removing components like the oil sump, flywheel, and gears to access the bedplate.
2. Carefully separating the bedplate from the crankcase using lifting bolts and equipment, being careful not to use levers.
3. Cleaning the mating surfaces, installing new bearing shells and seals, and applying anaerobic sealant to the crankcase mating surface in a continuous bead guided by a template.
4. Lifting the bedplate into place, installing bolts, and tightening them in a specific sequence and using a torque wrench and angle gauge to
Jcb js130 excavator service repair manual sn from 2373080 to 2375080fiskefjskemem
The document provides a service manual for excavator tracks. It includes sections on track components, measuring wear using technical data tables, adjusting tracks, removing and installing tracks, and storing tracks. Procedures are provided for measuring link rail surface wear, track pitch/internal pin and bush wear, and bush external wear to determine wear percentages and maintenance requirements.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb 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 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 9 tft dumper service repair manual sn from hrm1382 to hrm4003fusefjskekkmem
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.
Jcb js370 tier 4i isuzu tracked excavator service repair manual from 2090666 ...fjjsekksemmm
This document provides information about identifying JCB machines and their components. It discusses identification plates located on the machine and components that provide the model, serial number, and other details. It also summarizes the different types of fasteners used and their torque settings, distinguishing between zinc plated and Dacromet fasteners. Safety plates providing details on FOPS and ROPS protection levels are also described.
Jcb 3 cx compact backhoe loader service repair manual (sn from 2495456 and up)fusefjskekkmem
This service manual provides instructions for servicing a JCB 3CX Compact backhoe loader. It contains sections covering the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The specific section summarized discusses servicing procedures for the engine crankshaft, including how it is lubricated by engine oil, how to check its condition by inspecting the bearing surfaces and diameters, and ensuring the oilways are clear.
Jcb 3 ts 8t skid steer loader service repair manual (from 2475701 and up)ujdfjjsjekfkkem
This document provides instructions for removing and installing a bedplate on an engine. Key steps include:
1. Removing components like the oil sump, flywheel, and gears to access the bedplate.
2. Carefully separating the bedplate from the crankcase using lifting bolts and equipment, being careful not to use levers.
3. Cleaning the mating surfaces, installing new bearing shells and seals, and applying anaerobic sealant to the crankcase mating surface in a continuous bead guided by a template.
4. Lifting the bedplate into place, installing bolts, and tightening them in a specific sequence and using a torque wrench and angle gauge to
Jcb js130 excavator service repair manual sn from 2373080 to 2375080fiskefjskemem
The document provides a service manual for excavator tracks. It includes sections on track components, measuring wear using technical data tables, adjusting tracks, removing and installing tracks, and storing tracks. Procedures are provided for measuring link rail surface wear, track pitch/internal pin and bush wear, and bush external wear to determine wear percentages and maintenance requirements.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb 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 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 9 tft dumper service repair manual sn from hrm1382 to hrm4003fusefjskekkmem
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.
Jcb js370 tier 4i isuzu tracked excavator service repair manual from 2090666 ...fjjsekksemmm
This document provides information about identifying JCB machines and their components. It discusses identification plates located on the machine and components that provide the model, serial number, and other details. It also summarizes the different types of fasteners used and their torque settings, distinguishing between zinc plated and Dacromet fasteners. Safety plates providing details on FOPS and ROPS protection levels are also described.
Jcb js370 tier 4i isuzu tracked excavator service repair manual from 2050750 ...fjjsekksemmm
This document provides information about identifying machines and components from JCB, including product identification numbers, serial numbers, and component data plates. It also includes tables listing torque settings for different types and sizes of fasteners used on JCB machines, distinguishing between zinc/yellow plated fasteners and Dacromet fasteners. Safety information is provided about falling object protective structures and roll-over protective structures that may be installed on some machines.
Jcb js370 tier 4i isuzu tracked excavator service repair manual from 1909484 ...fjjsekksemmm
This document provides information about identifying JCB machines and their components. It discusses identification plates located on the machine and components that provide the model, serial number, and other details. It also summarizes the different types of fasteners used and their torque settings, distinguishing between zinc plated and Dacromet coated fasteners. Safety plates providing details on FOPS and ROPS protection levels are also described. In summary, this document outlines how to identify key details of JCB machines and components, different fastener types, and safety certification plates.
Jcb js220 tracked excavator service repair manual sn2163177 to 2168079fjjsekksemmm
This document provides information about torque settings for fasteners on JCB machines. It discusses zinc plated fasteners, which are the original type used, and Dacromet fasteners, which are an improved corrosion resistant type. Dacromet fasteners have a lower torque setting than zinc fasteners. The document provides tables with torque settings for UNF and metric fasteners under lubricated and unlubricated conditions. It stresses that the correct torque must be used depending on the type of fastener.
Jcb js210 lc with jcb dieselmax engine tracked excavator service repair manua...fjjsekksemmm
This document provides information about torque settings for fasteners on JCB machines. It discusses zinc plated fasteners, which are the original type used, and Dacromet fasteners, which are an improved corrosion resistant type. Dacromet fasteners have a lower torque setting than zinc fasteners. The document provides tables with torque settings for UNF and metric fasteners under lubricated and unlubricated conditions. It stresses that the correct torque must be used depending on the type of fastener.
Jcb 8020 mini excavator service repair manual sn 1284000 up to may 2012fjjsekksemmm
This document provides information about identifying JCB machines and their components. It describes the machine identification plate that lists the product identification number, weight, engine power, year of manufacture, and serial number. It also describes the typical format of the product identification number and engine identification number, which include information about the machine type, check letter, serial numbers, and year/country of manufacture. The document is intended to help service technicians properly identify the exact machine and components when ordering replacement parts.
Jcb 8018 mini excavator service repair manual sn 1046000 up to may 2012fjjsekksemmm
This document provides information about identifying JCB machines and their components. It describes the machine identification plate that lists the product identification number, weight, engine power, year of manufacture, and serial number. It also describes the typical format of the product identification number and engine identification number, which include information about the machine type, country of manufacture, build number, and serial number. The document emphasizes that the identification plates are important for correctly identifying the exact type of machine and ordering replacement parts.
Jcb 8016 mini excavator service repair manual sn 1155000 up to may 2012fjjsekksemmm
This document provides information about identifying JCB machines and their components. It describes the machine identification plate that lists the product identification number, weight, engine power, year of manufacture, and serial number. It also describes the typical format of the product identification number and engine identification number, which include information about the machine type, check letter, serial numbers, and year/country of manufacture. The document is intended to help service technicians properly identify the exact machine and components when ordering replacement parts.
Jcb 8014 mini excavator service repair manual sn1156000 up to may 2012fjjsekksemmm
This document provides information about identifying machines and standard torque settings for fasteners. It includes the following:
- Details on how to identify a machine using its identification plate and product identification number.
- Descriptions of different types of fasteners used on machines, including zinc plated, Dacromet, and their identifying colors and part number suffixes.
- Tables listing torque settings for UNF Grade 'S' and metric Grade 8.8 fasteners under different conditions such as lubricated or unlubricated.
- Notes about using the correct torque settings based on the type of fastener and lubrication conditions. Dacromet fasteners have lower torque settings than
Jcb 550 170 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for accessing and positioning the engine to adjust the valves. The procedure explains how to measure valve clearance using a dial indicator and adjust the clearance by turning the tappet adjuster if needed. Special tools are required to lock the tappets and correctly position the engine for adjustment.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 550 140 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 540 v180 work platform telescopic handler service repair manual sn 290200...fjjsekksemmm
This service manual provides instructions for maintaining and repairing Loadall rough terrain variable reach trucks. It contains safety warnings and covers machine components, attachments, body/framework, operator station, driveline, hydraulic and electrical systems, fasteners/fixings, consumable products, and after sales support. Proper training and personal protective equipment are required for safe operation and maintenance.
Jcb 540 v180 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for checking valve clearances at two positions of the engine, using indicator pins and a dial test indicator to measure clearance. The clearances can be adjusted by turning the valve tappet adjusters if needed.
Jcb 540 v180 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for checking valve clearances at two positions of the engine, using indicator pins and a dial test indicator to measure clearance. The procedure explains how to adjust the clearance by turning the tappet adjuster if needed.
Jcb 540 v140 work platform telescopic handler service repair manual sn 290200...fjjsekksemmm
This document is a service manual for JCB Loadall rough terrain variable reach trucks. It contains safety information and instructions for maintenance and repair. The manual advises reading all safety warnings and instructions carefully to avoid death or serious injury. Proper training and personal protective equipment are required for safe operation and maintenance of the machines.
Jcb 540 v140 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 540 v140 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for accessing and positioning the engine to adjust the valves. The procedure explains how to measure valve clearance using a dial indicator and adjust the clearance by turning the tappet adjuster if needed. Special tools are required to lock the tappets and correctly position the engine for adjustment.
Jcb 540 200 work platform telescopic handler service repair manual sn 2902000...fjjsekksemmm
This service manual provides instructions for maintaining and repairing Loadall rough terrain variable reach trucks. It contains safety warnings and covers machine components, attachments, body/framework, operator station, driveline, hydraulic and electrical systems, fasteners/fixings, consumable products, and after sales support. Proper training and personal protective equipment are required for safe operation and maintenance.
Jcb 540 200 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 540 200 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
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.
Jcb js370 tier 4i isuzu tracked excavator service repair manual from 2050750 ...fjjsekksemmm
This document provides information about identifying machines and components from JCB, including product identification numbers, serial numbers, and component data plates. It also includes tables listing torque settings for different types and sizes of fasteners used on JCB machines, distinguishing between zinc/yellow plated fasteners and Dacromet fasteners. Safety information is provided about falling object protective structures and roll-over protective structures that may be installed on some machines.
Jcb js370 tier 4i isuzu tracked excavator service repair manual from 1909484 ...fjjsekksemmm
This document provides information about identifying JCB machines and their components. It discusses identification plates located on the machine and components that provide the model, serial number, and other details. It also summarizes the different types of fasteners used and their torque settings, distinguishing between zinc plated and Dacromet coated fasteners. Safety plates providing details on FOPS and ROPS protection levels are also described. In summary, this document outlines how to identify key details of JCB machines and components, different fastener types, and safety certification plates.
Jcb js220 tracked excavator service repair manual sn2163177 to 2168079fjjsekksemmm
This document provides information about torque settings for fasteners on JCB machines. It discusses zinc plated fasteners, which are the original type used, and Dacromet fasteners, which are an improved corrosion resistant type. Dacromet fasteners have a lower torque setting than zinc fasteners. The document provides tables with torque settings for UNF and metric fasteners under lubricated and unlubricated conditions. It stresses that the correct torque must be used depending on the type of fastener.
Jcb js210 lc with jcb dieselmax engine tracked excavator service repair manua...fjjsekksemmm
This document provides information about torque settings for fasteners on JCB machines. It discusses zinc plated fasteners, which are the original type used, and Dacromet fasteners, which are an improved corrosion resistant type. Dacromet fasteners have a lower torque setting than zinc fasteners. The document provides tables with torque settings for UNF and metric fasteners under lubricated and unlubricated conditions. It stresses that the correct torque must be used depending on the type of fastener.
Jcb 8020 mini excavator service repair manual sn 1284000 up to may 2012fjjsekksemmm
This document provides information about identifying JCB machines and their components. It describes the machine identification plate that lists the product identification number, weight, engine power, year of manufacture, and serial number. It also describes the typical format of the product identification number and engine identification number, which include information about the machine type, check letter, serial numbers, and year/country of manufacture. The document is intended to help service technicians properly identify the exact machine and components when ordering replacement parts.
Jcb 8018 mini excavator service repair manual sn 1046000 up to may 2012fjjsekksemmm
This document provides information about identifying JCB machines and their components. It describes the machine identification plate that lists the product identification number, weight, engine power, year of manufacture, and serial number. It also describes the typical format of the product identification number and engine identification number, which include information about the machine type, country of manufacture, build number, and serial number. The document emphasizes that the identification plates are important for correctly identifying the exact type of machine and ordering replacement parts.
Jcb 8016 mini excavator service repair manual sn 1155000 up to may 2012fjjsekksemmm
This document provides information about identifying JCB machines and their components. It describes the machine identification plate that lists the product identification number, weight, engine power, year of manufacture, and serial number. It also describes the typical format of the product identification number and engine identification number, which include information about the machine type, check letter, serial numbers, and year/country of manufacture. The document is intended to help service technicians properly identify the exact machine and components when ordering replacement parts.
Jcb 8014 mini excavator service repair manual sn1156000 up to may 2012fjjsekksemmm
This document provides information about identifying machines and standard torque settings for fasteners. It includes the following:
- Details on how to identify a machine using its identification plate and product identification number.
- Descriptions of different types of fasteners used on machines, including zinc plated, Dacromet, and their identifying colors and part number suffixes.
- Tables listing torque settings for UNF Grade 'S' and metric Grade 8.8 fasteners under different conditions such as lubricated or unlubricated.
- Notes about using the correct torque settings based on the type of fastener and lubrication conditions. Dacromet fasteners have lower torque settings than
Jcb 550 170 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for accessing and positioning the engine to adjust the valves. The procedure explains how to measure valve clearance using a dial indicator and adjust the clearance by turning the tappet adjuster if needed. Special tools are required to lock the tappets and correctly position the engine for adjustment.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 550 140 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 540 v180 work platform telescopic handler service repair manual sn 290200...fjjsekksemmm
This service manual provides instructions for maintaining and repairing Loadall rough terrain variable reach trucks. It contains safety warnings and covers machine components, attachments, body/framework, operator station, driveline, hydraulic and electrical systems, fasteners/fixings, consumable products, and after sales support. Proper training and personal protective equipment are required for safe operation and maintenance.
Jcb 540 v180 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for checking valve clearances at two positions of the engine, using indicator pins and a dial test indicator to measure clearance. The clearances can be adjusted by turning the valve tappet adjusters if needed.
Jcb 540 v180 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for checking valve clearances at two positions of the engine, using indicator pins and a dial test indicator to measure clearance. The procedure explains how to adjust the clearance by turning the tappet adjuster if needed.
Jcb 540 v140 work platform telescopic handler service repair manual sn 290200...fjjsekksemmm
This document is a service manual for JCB Loadall rough terrain variable reach trucks. It contains safety information and instructions for maintenance and repair. The manual advises reading all safety warnings and instructions carefully to avoid death or serious injury. Proper training and personal protective equipment are required for safe operation and maintenance of the machines.
Jcb 540 v140 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 540 v140 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for adjusting the valves on a Loadall rough terrain forklift. It describes the valve train components and their operation, including the camshaft, tappets, push rods, rockers, and valves. It provides technical specifications for the valves and instructions for accessing and positioning the engine to adjust the valves. The procedure explains how to measure valve clearance using a dial indicator and adjust the clearance by turning the tappet adjuster if needed. Special tools are required to lock the tappets and correctly position the engine for adjustment.
Jcb 540 200 work platform telescopic handler service repair manual sn 2902000...fjjsekksemmm
This service manual provides instructions for maintaining and repairing Loadall rough terrain variable reach trucks. It contains safety warnings and covers machine components, attachments, body/framework, operator station, driveline, hydraulic and electrical systems, fasteners/fixings, consumable products, and after sales support. Proper training and personal protective equipment are required for safe operation and maintenance.
Jcb 540 200 telescopic handler service repair manual sn from 2902000 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
Jcb 540 200 telescopic handler service repair manual sn from 2460601 onwardsfjjsekksemmm
This service manual provides instructions for servicing the valve train system of JCB Loadall rough terrain variable reach trucks. The manual contains sections covering the engine, fuel system, cooling system, brake system, steering system, driveline, hydraulics, electrical system, and other components. The section on the engine valve train describes the system components, operation, and procedures for adjusting valve clearances and removing and installing valves.
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.
Top-Quality AC Service for Mini Cooper Optimal Cooling PerformanceMotor Haus
Ensure your Mini Cooper stays cool and comfortable with our top-quality AC service. Our expert technicians provide comprehensive maintenance, repairs, and performance optimization, guaranteeing reliable cooling and peak efficiency. Trust us for quick, professional service that keeps your Mini Cooper's air conditioning system in top condition, ensuring a pleasant driving experience year-round.
Charging Fueling & Infrastructure (CFI) Program by Kevin MillerForth
Kevin Miller, Senior Advisor, Business Models of the Joint Office of Energy and Transportation gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
Charging and Fueling Infrastructure Grant: Round 2 by Brandt HertensteinForth
Brandt Hertenstein, Program Manager of the Electrification Coalition gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
car rentals in nassau bahamas | atv rental nassau bahamasjustinwilson0857
At Dash Auto Sales & Car Rentals, we take pride in providing top-notch automotive services to residents and visitors alike in Nassau, Bahamas. Whether you're looking to purchase a vehicle, rent a car for your vacation, or embark on an exciting ATV adventure, we have you covered with our wide range of options and exceptional customer service.
Website: www.dashrentacarbah.com
Charging Fueling & Infrastructure (CFI) Program Resources by Cat PleinForth
Cat Plein, Development & Communications Director of Forth, gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
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. 15 - Engine
06 - Cylinder Head
00 - General
15 - 43 9813/8300-1 15 - 43
00 - General
Introduction .................................................... 15-43
Technical Data ............................................... 15-44
Remove and Install ....................................... 15-45
Introduction
The cylinder head is located above the cylinders
on top of the crankcase. It closes in the top of the
cylinder, forming the combustion chamber. This joint
is sealed by a cylinder head gasket.
The cylinder head also provides the space for the
passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves (PIL 15-30) and fuel
injectors (PIL 18-18).
3. 15 - Engine
06 - Cylinder Head
00 - General
15 - 44 9813/8300-1 15 - 44
Technical Data
Table 70. Cylinder Head Data
Cylinder head distortion (maximum permissible)
(1)
- End to end 0.05mm
- Side to side 0.03mm
Valve recess depth
- Inlet 0.85mm
- Exhaust 0.85mm
Valve seat angle
- Inlet 120(inclusive)
- Exhaust 90(inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10m 2.5 distance
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
4. 15 - Engine
06 - Cylinder Head
00 - General
15 - 45 9813/8300-1 15 - 45
Remove and Install
Special Tools
Description Part No. Qty.
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
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, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the thermostat, refer to (PIL 21-12).
5. Remove the fuel pipes, refer to (PIL 18-96).
6. Remove the rocker cover, refer to (PIL 15-42).
7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
5. 15 - Engine
06 - Cylinder Head
00 - General
15 - 46 9813/8300-1 15 - 46
Figure 130.
16
12841591317
210 61418 73 11
15
19
22
21
20
0° +90° +180°
Y
X
1-18 Cylinder head fixing bolts (x18) 19 Cylinder head
20 Crankcase 21 Location dowels (x2)
22 Cylinder head gasket
6. 15 - Engine
06 - Cylinder Head
00 - General
15 - 47 9813/8300-1 15 - 47
Remove
1. Progressively remove the cylinder head bolts in
reverse order, starting at bolt 18. Note that the
bolts MUST NOT be re-used. Discard the bolts.
2. Carefully lift the cylinder head from the
crankcase. If necessary use a soft face hammer.
DO NOT use a lever to separate the cylinder
head from the crankcase. Discard the head
gasket.
3. Using a suitable cleaning agent, carefully remove
all traces of the head gasket material from the
cylinder head and crankcase mating faces.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4. Check the cylinder head and crankcase mating
faces for signs of damage and distortion, refer to
Technical Data (PIL 15-06).
Before Assembly
1. Obtain the correct new cylinder head bolts. Note
that the original bolts MUST NOT be re-used.
2. Obtain the correct replacement head gasket.
Note the number of identification holes as shown
at X.
3. Make sure that all items are clean and free from
damage and corrosion.
Assemble
The cylinder head bolts are tightened using a torque
and angle method, refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
1. Replacement is the reversal of the removal
procedure.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in five stages, use the
torque and angle method, refer to Fasteners and
Fixings, General, Introduction (PIL 72-00).
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-18) to the 1st stage pre-torque.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
4.2. Then, further tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1- 18) to the 2nd stage pre-
torque.
4.3. Then, re-tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1-18) to the 3rd stage pre-torque.
4.4. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-18) to the
4th stage pre-torque. As a visual check,
matchmark the bolts to the cylinder head
before you start. When the bolts have
been angle tightened, the matchmarks will
appear as shown at Y.
4.5. Finally, angle tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1- 18) for the final stage torque.
Table 71.
Description Torque Value
Cylinder head to
crankcase bolts 1-18
- first stage torque 40N·m
- second stage torque 75N·m
- third stage torque 75N·m
- fourth stage torque 90°
- final stage torque 180°
7. 15 - Engine
09 - Bedplate
00 - General
15 - 49 9813/8300-1 15 - 49
00 - General
Introduction .................................................... 15-49
Remove and Install ....................................... 15-50
Introduction
The bedplate acts as the main strength component
of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 131.
1
2
1 Bedplate
2 Crankcase
8. 15 - Engine
09 - Bedplate
00 - General
15 - 50 9813/8300-1 15 - 50
Remove and Install
Special Tools
Description Part No. Qty.
Template for Sealant
Bedplate to Crankcase
(4 Cyl)
892/12356 1
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
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. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO (Power Take-Off)
device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
10. 15 - Engine
09 - Bedplate
00 - General
15 - 52 9813/8300-1 15 - 52
Remove
1. Remove the bedplate peripheral bolts.
2. Progressively remove the main bearing bolts in
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate.
4. Remove and discard the O-ring.
5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
Figure 133.
18
18
18
18
18
T6
T6
T6
18
12
T6
P3
13
11
A (T5)
V
YY P2
51
9
4
8
3
7
62
10
T4
T4
W
P2
B (T5)
Y Y P2
X
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)
12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
11. 15 - Engine
09 - Bedplate
00 - General
15 - 53 9813/8300-1 15 - 53
T4 Guide pins (x2 obtain locally) T5 Sealant template
T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
12. 15 - Engine
09 - Bedplate
00 - General
15 - 54 9813/8300-1 15 - 54
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Anaerobic sealant will not start to cure
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and tightened to the correct
torque value within 5 minutes (with a maximum
permissible time of 15 minutes).
Important: BEFORE installing the bedplate: DO NOT
rotate the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of the
crankcase.
Install
1. Replacement is the reversal of the removal
procedure.
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown.
4. Install the four lifting bolts T6 to the bedplate as
shown.
5. Install a new O-ring at the bedplate.
6. Use a suitable degreasing agent to clean both
sides of the lower bearing shells. Assemble the
lower bearing shells into the bedplate. Lubricate
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
7. Note: The sealant template T5 is used on
the crankcase, NOT the bedplate. The sealant
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1)
8. Locate the holes in the templates A and B using
four fixing bolts at positions Y. Use the templates
as a guide apply beads of sealant P2 around the
crankcase/bedplate mating face as shown to the
dimension specified.
Length/Dimension/Distance: 1.5mm
9. Remove the four fixing bolts at positions Y.
Remove the templates A and B, make sure
you do not smudge the sealant. Discard the
templates.
10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
beads as shown at X.
11. Make sure that the location guide pins T4 are in
position in the crankcase. Assemble the bedplate
to the crankcase use the alignment guide pins.
12. Note: The bedplate is heavy. Two people will
be required to lift and rotate the bedplate safely
on to the crankcase. Install new main bearing
bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 1st stage pre-
torque.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
13. Install the bedplate peripheral bolts. Tighten the
bolts to the correct torque value.
14. After installation and tightening the bedplate
peripheral bolts, further tighten the main bearing
bolts in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 2nd stage
pre-torque.
15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
(in sequence 1-10) for the final stage torque. Use
the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
Important: If the parts have not been tightened to the
correct torque value within the maximum 15 minute
time period, then the parts must be separated,
thoroughly cleaned and fresh sealant applied.
After Installation
1. Check that the crankshaft can be freely rotated
by hand. Remove the bedplate lifting bolts T6.
2. Carry out the procedures listed, Before removal
in reverse order.
Table 72. Torque Table
Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
1-10 (Final Stage) 180°
11 24N·m
13. 15 - Engine
12 - Crankshaft
00 - General
15 - 59 9813/8300-1 15 - 59
Component Identification
Figure 135.
B
A
A Crankcase
B Crankshaft
14. 15 - Engine
12 - Crankshaft
00 - General
15 - 60 9813/8300-1 15 - 60
Operation
Refer to Camshaft-Operation (PIL 15-15).
Lubrication
Oil is fed from the main gallery via five drillings, one
to each of the main bearings. A groove around the
diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 136.
1 Main gallery 2 Drillings (x5)
3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
15. 15 - Engine
12 - Crankshaft
00 - General
15 - 61 9813/8300-1 15 - 61
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 137.
A
A Main bearing shells
2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 138.
B
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
Figure 139.
D
C
C J-jets
D Fixing screws
16. 15 - Engine
12 - Crankshaft
00 - General
15 - 62 9813/8300-1 15 - 62
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
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. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
25. Remove the bedplate, refer to (PIL 15-09).
Remove
1. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
17. 15 - Engine
12 - Crankshaft
00 - General
15 - 63 9813/8300-1 15 - 63
Figure 140.
C
B
A
A
A Thrust Washers B Crankshaft
C Rear main bearing
2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
4. Carefully lift out the bearing shells.
Figure 141.
D
D Main bearing shells
5. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. Replacement is the reversal of the removal
procedure.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
then install cooling J jets as follows:
18. 15 - Engine
12 - Crankshaft
00 - General
15 - 64 9813/8300-1 15 - 64
Figure 142.
F
E
E J jets (x4)
F Fixing screws
3.1. Insert the cooling jets into the crankcase.
3.2. Note: There are different types of cooling
jets installed depending on the engine
application. The jets are colour coded.
3.3. Be sure to install the correct jets. Refer to
the relevant parts catalogue for the correct
cooling jet identification.
3.4. Tighten the retaining screws to the correct
torque value.
4. Install the upper bearing shells as follows:
Figure 143.
D
G
D Main bearing shells
G Bearing location tab
4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
4.3. Important: Make sure that the oil-way holes
in the bearing saddles align with the holes
in the bearing shell. If the holes are even
partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
19. 15 - Engine
12 - Crankshaft
00 - General
15 - 65 9813/8300-1 15 - 65
Figure 144.
C
B
A
A
A
H
A Thrust washers B Crankshaft
C Rear main bearing H Oil slot - thrust washers
6.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).
Table 74. Torque Values
Item Nm
F 24
20. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 66 9813/8300-1 15 - 66
03 - Main Bearing
Introduction .................................................... 15-66
Check (Condition) .......................................... 15-67
Remove and Install ....................................... 15-67
Introduction
In a piston engine, the main bearings are the
bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 145.
A
B
A Main bearing
B Main bearing bolts
21. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 67 9813/8300-1 15 - 67
Check (Condition)
1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits, refer to Technical Data
(PIL 15-12).
3. Renew any parts that are worn or not within the
specified tolerances.
Remove and Install
Special Tools
Description Part No. Qty.
Torque Wrench
(10-100Nm)
993/70111 1
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 and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
5. Remove the rocker cover, refer to (PIL 15-42).
6. Remove the fuel injectors, refer to (PIL 18-18).
7. Drain the oil from the engine, refer to (PIL 15-21).
8. Remove the oil sump, refer to (PIL 15-45).
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
Important: The connecting rod and the big-end
bearing cap have been fracture split and must be
kept together as a set. Utmost care must be taken to
avoid contamination and or damage to the fracture
split surfaces Z.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. Note that the
bolts must not be re-used, discard the bolts.
22. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 68 9813/8300-1 15 - 68
Figure 146.
X
1 2
1 Big-end bearing caps
2 Big-end bearing cap bolts
X Cast pip
3. Lift out the bearing shells from the bearing caps.
Carefully rotate the crank to disengage from the
connecting rods and gain access to the upper
bearing shells. Lift out the upper bearing shells.
It is recommended that the bearing shells are
renewed. If however they are to be reused, label
the bearing shells to make sure that they are
installed in their original positions on assembly.
Figure 147.
4
3
7Z
1
2
6
5
1 Big-end bearing cap
2 Bolts
3 Connecting rod
4 Piston
5 Piston rings
6 Lower bearing shell
7 Upper bearing shell
Z Fracture split surfaces
4. Carefully rotate the crankshaft to position the big-
end bearing caps of cylinders 1 and 4. Make sure
that the crank does not foul the connecting rods
of cylinders 2 and 3. Remove the bearing caps
and bearing shells as described in steps 1 and 2.
5. Inspect the big-end bearings for signs of damage
and excessive wear, refer to Check Condition
(PIL 15-12).
Install
1. Replacement is the reversal of the removal
procedure.
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
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24. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 69 9813/8300-1 15 - 69
4. Install the lower bearing shell to the big-end
bearing cap. Lubricate the bearing shell with
clean engine oil, then install the big-end bearing
cap to the connecting rod. Make sure that the
cast pip X on the bearing cap faces to the front
of the engine. Note: Use compressed air to clean
the fracture surfaces Z before assembly.
5. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Figure 148.
T3
T3 Angle gauge (obtain locally)
6. The bolts are tightened using a torque and angle
method, refer to Fasteners and Fixings, General,
Introduction (PIL 72-00).
Figure 149.
0° +90°
Y
After Installation
1. Carry out the procedures listed, Before Removal
in reverse order.
Table 75.
Item Torque Value
2 - 1st Stage 35N·m
2 - 2nd Stage 65N·m
2 - Final Stage 90°
25. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 70 9813/8300-1 15 - 70
06 - Front Oil Seal
Remove and Install
Special Tools
Description Part No. Qty.
Crankshaft Front Oil
Seal Installation Tool
892/01157 1
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 drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
Remove
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not
to scratch or damage the counterbore or the
crankshaft hub. Damaged or dirty sealing faces
will cause the oil seal to fail.
Figure 150.
C
A
B
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
Install
1. Make sure that the counterbore and the
crankshaft hub are clean and free from damage
and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 151.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
151.