This service manual provides instructions for maintaining and servicing Loadall rough terrain variable reach trucks. It contains sections on the machine body and framework, operator station, engine, braking and other systems. The engine section provides procedures for cleaning, checking, draining fluids, removing and installing the engine. It stresses the importance of safety, using the correct tools and cleaning components thoroughly before maintenance to prevent contamination.
Jcb 225 skid steer loader service repair manual (from 2196001 to 2201001)ufjjjsksekemme
This document provides instructions for servicing JCB engines including 225, 225T, 260, 260T, 280, 300, 300T, 320T, 330 models. It details procedures for cleaning the engine, checking engine compression and oil pressure, removing and installing the engine, and storing engines. Key steps include using the correct lifting equipment, disconnecting all electrical, fuel, cooling and hydraulic components, sealing openings to prevent contamination, and filling with oil for short term storage. Precautions are listed to prevent damage to components from high pressure washing.
New holland w230 c wheel loader service repair manualfusjfjskekmsme
This document provides instructions for removing the engine from a wheel loader. It outlines 11 steps, which include draining fluids, disconnecting batteries and wiring harnesses, and using lifting straps to raise the hood. The goal is to safely remove the engine while properly marking and draining components to facilitate reinstallation. Key steps include draining the coolant and oil, disconnecting the batteries, and inserting a lifting bar through straps to raise the hood and access the engine.
New holland w110 d zbar tier4b wheel loader service repair manualfusjfjskekmsme
This service manual section provides instructions for removing the engine from a W110 D wheel loader. The key steps include draining fluids, disconnecting battery and wiring harnesses, and removing mounting hardware. Tags and labels are used to identify disconnected parts for reinstallation. Safety precautions are noted, such as using lifting straps when raising components.
New holland ts115 a tractor service repair manualfusjfjskekmsme
The document provides repair and service information for tractor models TS100A, TS110A, TS115A, TS125A, TS130A, TS135A, T6010, T6020, T6030, T6050, and T6070. It contains sections on general safety, product identification, specifications, dimensions, and repair instructions for engine, transmission, brakes, hydraulics and other systems. Safety precautions are highlighted, including wearing proper protective equipment and following maintenance procedures only when the engine is off.
New holland tn85 fa tractor service repair manualfusjfjskekmsme
This document is a service manual for TN75FA-TN85FA-TN95FA tractors. It contains sections on general guidelines, the engine, clutch, transmissions, and other systems. Each section provides specifications, diagrams, removal and installation instructions, and procedures for inspection and repair. The manual is intended exclusively for use by trained service technicians.
New holland tm190 tractor service repair manualfusjfjskekmsme
This document is a repair manual that provides instructions for servicing TM120, TM130, TM140, TM155, TM175, and TM190 tractors. It contains sections covering the general information, engine, clutch, transmission, drivelines, front and rear axles, brakes, hydraulics, steering, electrical systems, and cab. Safety precautions and maintenance instructions are provided throughout. The manual is intended solely for use by authorized service technicians according to the repair procedures specified.
New holland tk90 a tractor service repair manualfusjfjskekmsme
This document appears to be a repair manual for tractor models TK75VA, TK80A, TK80MA, TK90A, TK90MA, and TK100A. It contains sections on general instructions, safety procedures, the engine, clutch, transmissions, rear mechanical drive, braking system, hydraulics, steering, suspension, electrical systems, and emissions warranty information. The manual provides guidance on maintenance, repairs, proper installation of seals and bearings, and safety compliance.
New holland td5010 tractor service repair manualfusjfjskekmsme
This document is a service manual for TD series tractor models TD5010 through TD5050. It contains sections covering general information, the engine, clutch, gearbox, transmission, brakes, hydraulics, steering, axles, auxiliary equipment, electrical systems, and the cab. Each section provides specifications, diagrams, troubleshooting information, removal and installation instructions, and repair procedures for the various systems. Safety warnings are provided, noting that maintenance and repair should only be performed by trained technicians using the proper tools and following the instructions carefully.
Jcb 225 skid steer loader service repair manual (from 2196001 to 2201001)ufjjjsksekemme
This document provides instructions for servicing JCB engines including 225, 225T, 260, 260T, 280, 300, 300T, 320T, 330 models. It details procedures for cleaning the engine, checking engine compression and oil pressure, removing and installing the engine, and storing engines. Key steps include using the correct lifting equipment, disconnecting all electrical, fuel, cooling and hydraulic components, sealing openings to prevent contamination, and filling with oil for short term storage. Precautions are listed to prevent damage to components from high pressure washing.
New holland w230 c wheel loader service repair manualfusjfjskekmsme
This document provides instructions for removing the engine from a wheel loader. It outlines 11 steps, which include draining fluids, disconnecting batteries and wiring harnesses, and using lifting straps to raise the hood. The goal is to safely remove the engine while properly marking and draining components to facilitate reinstallation. Key steps include draining the coolant and oil, disconnecting the batteries, and inserting a lifting bar through straps to raise the hood and access the engine.
New holland w110 d zbar tier4b wheel loader service repair manualfusjfjskekmsme
This service manual section provides instructions for removing the engine from a W110 D wheel loader. The key steps include draining fluids, disconnecting battery and wiring harnesses, and removing mounting hardware. Tags and labels are used to identify disconnected parts for reinstallation. Safety precautions are noted, such as using lifting straps when raising components.
New holland ts115 a tractor service repair manualfusjfjskekmsme
The document provides repair and service information for tractor models TS100A, TS110A, TS115A, TS125A, TS130A, TS135A, T6010, T6020, T6030, T6050, and T6070. It contains sections on general safety, product identification, specifications, dimensions, and repair instructions for engine, transmission, brakes, hydraulics and other systems. Safety precautions are highlighted, including wearing proper protective equipment and following maintenance procedures only when the engine is off.
New holland tn85 fa tractor service repair manualfusjfjskekmsme
This document is a service manual for TN75FA-TN85FA-TN95FA tractors. It contains sections on general guidelines, the engine, clutch, transmissions, and other systems. Each section provides specifications, diagrams, removal and installation instructions, and procedures for inspection and repair. The manual is intended exclusively for use by trained service technicians.
New holland tm190 tractor service repair manualfusjfjskekmsme
This document is a repair manual that provides instructions for servicing TM120, TM130, TM140, TM155, TM175, and TM190 tractors. It contains sections covering the general information, engine, clutch, transmission, drivelines, front and rear axles, brakes, hydraulics, steering, electrical systems, and cab. Safety precautions and maintenance instructions are provided throughout. The manual is intended solely for use by authorized service technicians according to the repair procedures specified.
New holland tk90 a tractor service repair manualfusjfjskekmsme
This document appears to be a repair manual for tractor models TK75VA, TK80A, TK80MA, TK90A, TK90MA, and TK100A. It contains sections on general instructions, safety procedures, the engine, clutch, transmissions, rear mechanical drive, braking system, hydraulics, steering, suspension, electrical systems, and emissions warranty information. The manual provides guidance on maintenance, repairs, proper installation of seals and bearings, and safety compliance.
New holland td5010 tractor service repair manualfusjfjskekmsme
This document is a service manual for TD series tractor models TD5010 through TD5050. It contains sections covering general information, the engine, clutch, gearbox, transmission, brakes, hydraulics, steering, axles, auxiliary equipment, electrical systems, and the cab. Each section provides specifications, diagrams, troubleshooting information, removal and installation instructions, and repair procedures for the various systems. Safety warnings are provided, noting that maintenance and repair should only be performed by trained technicians using the proper tools and following the instructions carefully.
New holland t6020 tractor service repair manualfusjfjskekmsme
The document is a service manual that covers hydraulic, pneumatic, electrical, and electronic systems for tractor models T6010 through T6070. It contains sections on primary and secondary hydraulic power systems, hydraulic command systems, electrical power systems, electronic systems, fault codes, engines, transmissions, axles, brakes, frames, cabs, hitches, and more. Each section contains technical data, functional descriptions, diagnostics, and service procedures.
New holland t4040 supersteer tractor service repair manualfusjfjskekmsme
This document is a service manual for T4020, T4030, T4040, and T4050 tractor models. It contains sections on general guidelines, the engine, clutch, transmissions, drive lines, front and rear mechanical transmissions, power take-off, brakes, hydraulic systems, steering, axle and wheels, cab air conditioning, electrical system, platform/cab/bodywork, and technical support. Each section provides specifications, diagrams, removal and installation instructions, disassembly and assembly procedures, adjustments, and fault finding information for the various components.
New holland t9.565 tractor service repair manualfusjfjskekmsme
This service manual provides information for servicing the engines, fuel systems, air intake systems, cooling systems, exhaust systems, and other components of various tractor models. It includes specifications, maintenance procedures, and troubleshooting information to assist technicians in repairing components. The manual is intended to be used by qualified dealership personnel when performing maintenance and repairs.
New holland t9.530 tier 4 b (final) tractor service repair manualfusjfjskekmsme
This document contains safety guidelines for operating agricultural tractors and equipment. It outlines general safety rules regarding slopes, passengers, impaired operation, hitching implements, overhead hazards, and more. Personal protective equipment is recommended. Machine components should be inspected before operation and all guards kept in place. Proper shutdown and parking procedures help prevent injury or accidents.
New holland t9.505 [zcf200001 ] tractor service repair manualfusjfjskekmsme
This document is a service manual for CNH America LLC tractor models T9.390, T9.450, T9.505, T9.560, T9.615, and T9.670 from PIN ZCF200001 and above and PIN ZDF200001 and above. The manual contains safety rules, instructions for servicing and assembly, product identification information, torque specifications, and sections covering the engine, transmission, axles, brakes, hydraulics, electrical systems, and other components of the tractors.
New holland t9.450 [zdf200001 ] tractor service repair manualfusjfjskekmsme
This document is a service manual for Case IH T9.390, T9.450, T9.505, T9.560, T9.615, and T9.670 tractors. It provides instructions for removing and installing the engine and crankcase on the different tractor models, which include 9L tractors, 13L single turbo tractors, and 13L two stage turbocharger tractors. The manual also contains sections on other engine components like air cleaners, cooling systems, and exhaust systems.
New holland t8.350 powershift transmission (pst) tractor service repair manualfusjfjskekmsme
Plug or cap all ports and lines.
RAIL13TR04235AA 13
14. Remove the two bolts (1) securing the oil cooler
mounting bracket.
RAIL13TR04236AA 14
47794972 10/11/2014
10.1 [10.001] / 6
Engine - Engine and crankcase
15. Disconnect the harness connectors (1) for the fuel
pump and injectors.
RAIL13TR04238AA 15
16. Disconnect the fuel lines (1) from the fuel pump and
injectors. Plug or cap all lines.
RAIL13TR04239AA 16
17. Disconnect the harness connector (
New holland t8.320 tractor service repair manual (pin zfre03123 and above)fusjfjskekmsme
This document is a service manual for CNH Industrial T8.320, T8.350, T8.380, T8.410, T8.380 SmartTraxTM, and T8.410 SmartTraxTM tractors with Powershift Transmissions (PST). The manual contains sections covering the engine, power coupling, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, hydraulic systems, hitches and drawbars, steering, wheels, tracks and track suspension, cab climate control, and electrical systems. Each section provides detailed information and specifications to service and repair the components.
New holland t4.85 tractor service repair manualfusjfjskekmsme
This document is a service manual for T4.85, T4.95, and T4.105 tractors. It contains over 200 sections covering all major systems of the tractors, including the engine, transmission, brakes, hydraulics, steering, electrical systems, and more. Each section provides information and instructions for servicing and repairing the various components. Safety guidelines are also provided at the beginning to help technicians perform repairs safely.
New holland t4.80 n tractor service repair manualfusjfjskekmsme
This document is a service manual that provides technical specifications and repair/maintenance instructions for various tractor models and components, including the engine, clutch, transmission, four-wheel drive system, front axle system, and other parts. It includes detailed sections on the engine and its systems, the clutch and transmission components, and the four-wheel drive and front axle assemblies. The manual also lists the engine used for each tractor model and market.
New holland ls160 skid steer loader service repair manual valid from serial n...fusjfjskekmsme
This document provides the table of contents for the repair manual for New Holland LS160 and LS170 skid steer loaders. It lists 10 sections that cover topics like the engine, transmission, brakes, hydraulics, frames, and electrical system. The summary also notes that the manual contains safety precautions and instructions for tasks like supporting the machine, operating the boom and cab, and craning the skid steer. Overall, the document outlines the organization and contents of the repair manual for servicing and maintaining the LS160 and LS170 skid steer loaders.
Hyster k005 (h5.00 xm europe) forklift service repair manualfusjfjskekmsme
This document provides repair instructions for various components of a forklift, including:
1. The counterweight can be removed using lifting eyebolts and a lifting device, taking precautions about stability and weight.
2. The hood can be removed by disconnecting gas cylinders and wiring, and must be properly adjusted upon installation for operator restraint.
3. The overhead guard is removed using lifting devices and fasteners, and its isolators should be inspected. LED backup lights are non-repairable units.
Hyster g004 (s120 fts) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for manual and electronic main control valves used in hydraulic lift trucks. It describes:
- There are two main control valve types - manual and electronic. Both are mounted to the cowl.
- The electronic main control valve incorporates an emergency lowering valve and is divided into steering control, lift/lower, tilt, auxiliary, and outlet sections.
- Removal procedures include disconnecting wiring harnesses and hydraulic hoses, removing the steering control unit, and removing O-rings from the main control valve.
Hyster f019 (h12.00 xm 12ec europe) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for a differential assembly. It describes removing the differential carrier from the axle housing and then disassembling the differential carrier. The main steps are:
1. Removing the differential carrier from the axle housing by draining oil, disconnecting drive shafts and brakes, and removing mounting bolts.
2. Removing the ring gear and main differential assembly from the carrier by taking off the bearing caps, adjusting rings, and thrust screw.
3. Removing the drive pinion and pinion carrier by securing the pinion with a bar, removing the mounting nuts and bolts, and lifting it out along with any shims.
The document provides detailed instructions for each
Hyster d138 (n50 fa) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for single and double reach carriages on lift trucks. It describes the components of the reach carriages including the inner and outer frames connected by scissor linkages. Procedures are provided for replacing components like forks, the load backrest extension, and removing and installing the side-shift frame. Detailed steps are outlined for tasks like disassembling and cleaning the side-shift frame components. Safety warnings and cautions are included throughout.
Hyster d024 (s135 ft) forklift service repair manualfusjfjskekmsme
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster c187 (s2.50 xl europe) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for alternators used in lift trucks. It describes two types of alternators - Type A and Type B. Type A alternators have a diode set and diode bridge, while Type B uses zener diodes in the diode bridge. The document includes cautions for repair, descriptions of alternator components and operation, and step-by-step instructions for removal, disassembly, cleaning, and reassembly of the alternators. Diagrams are provided showing views and components of the different alternator types.
Hyster c004 (s70 e) forklift service repair manualfusjfjskekmsme
The document provides descriptions and repair procedures for steering axles on various lift truck models. It describes the components of the steering axle assembly including the axle frame, steering cylinder, and spindle and hub assemblies. The steering axles use either a stub shaft mount or rubber mounts to connect to the lift truck frame. The repair section provides procedures for removing and installing the steering axle based on the type of mount, including disconnecting hydraulic lines, removing mounting hardware, and reinstalling with new seals, bushings, and fittings. Special attention is required when putting lift trucks on blocks or stands during maintenance to ensure stability.
Hyster b454 (w30 zc) forklift service repair manualfusjfjskekmsme
This document provides safety procedures for working near a mast and repair procedures for a reach carriage. When working near a mast, it must be fully lowered or secured with safety chains. Repairs should only be done by trained technicians. The reach carriage can be removed from the mast for repairs. Procedures are provided for removing and replacing parts like the load backrest, forks, and load rollers. Safety precautions are emphasized, including using lifting devices and securing heavy parts to prevent injuries.
Hyster b454 (w25 zc) forklift service repair manualfusjfjskekmsme
This document provides safety procedures for working near a mast on a forklift. Key points include:
- Lower the mast completely or install safety chains if the mast must be raised for repairs. Remove all parts that can move.
- Never put any body part under the mast unless it is fully lowered or chained. Turn off power and remove keys.
- Raise the mast just enough to install safety chains around the inner and outer weldments before working on it.
- Be aware of forks which can be at head height when mast is raised and ensure safe access via ladder when working on mast from the side.
New holland t6020 tractor service repair manualfusjfjskekmsme
The document is a service manual that covers hydraulic, pneumatic, electrical, and electronic systems for tractor models T6010 through T6070. It contains sections on primary and secondary hydraulic power systems, hydraulic command systems, electrical power systems, electronic systems, fault codes, engines, transmissions, axles, brakes, frames, cabs, hitches, and more. Each section contains technical data, functional descriptions, diagnostics, and service procedures.
New holland t4040 supersteer tractor service repair manualfusjfjskekmsme
This document is a service manual for T4020, T4030, T4040, and T4050 tractor models. It contains sections on general guidelines, the engine, clutch, transmissions, drive lines, front and rear mechanical transmissions, power take-off, brakes, hydraulic systems, steering, axle and wheels, cab air conditioning, electrical system, platform/cab/bodywork, and technical support. Each section provides specifications, diagrams, removal and installation instructions, disassembly and assembly procedures, adjustments, and fault finding information for the various components.
New holland t9.565 tractor service repair manualfusjfjskekmsme
This service manual provides information for servicing the engines, fuel systems, air intake systems, cooling systems, exhaust systems, and other components of various tractor models. It includes specifications, maintenance procedures, and troubleshooting information to assist technicians in repairing components. The manual is intended to be used by qualified dealership personnel when performing maintenance and repairs.
New holland t9.530 tier 4 b (final) tractor service repair manualfusjfjskekmsme
This document contains safety guidelines for operating agricultural tractors and equipment. It outlines general safety rules regarding slopes, passengers, impaired operation, hitching implements, overhead hazards, and more. Personal protective equipment is recommended. Machine components should be inspected before operation and all guards kept in place. Proper shutdown and parking procedures help prevent injury or accidents.
New holland t9.505 [zcf200001 ] tractor service repair manualfusjfjskekmsme
This document is a service manual for CNH America LLC tractor models T9.390, T9.450, T9.505, T9.560, T9.615, and T9.670 from PIN ZCF200001 and above and PIN ZDF200001 and above. The manual contains safety rules, instructions for servicing and assembly, product identification information, torque specifications, and sections covering the engine, transmission, axles, brakes, hydraulics, electrical systems, and other components of the tractors.
New holland t9.450 [zdf200001 ] tractor service repair manualfusjfjskekmsme
This document is a service manual for Case IH T9.390, T9.450, T9.505, T9.560, T9.615, and T9.670 tractors. It provides instructions for removing and installing the engine and crankcase on the different tractor models, which include 9L tractors, 13L single turbo tractors, and 13L two stage turbocharger tractors. The manual also contains sections on other engine components like air cleaners, cooling systems, and exhaust systems.
New holland t8.350 powershift transmission (pst) tractor service repair manualfusjfjskekmsme
Plug or cap all ports and lines.
RAIL13TR04235AA 13
14. Remove the two bolts (1) securing the oil cooler
mounting bracket.
RAIL13TR04236AA 14
47794972 10/11/2014
10.1 [10.001] / 6
Engine - Engine and crankcase
15. Disconnect the harness connectors (1) for the fuel
pump and injectors.
RAIL13TR04238AA 15
16. Disconnect the fuel lines (1) from the fuel pump and
injectors. Plug or cap all lines.
RAIL13TR04239AA 16
17. Disconnect the harness connector (
New holland t8.320 tractor service repair manual (pin zfre03123 and above)fusjfjskekmsme
This document is a service manual for CNH Industrial T8.320, T8.350, T8.380, T8.410, T8.380 SmartTraxTM, and T8.410 SmartTraxTM tractors with Powershift Transmissions (PST). The manual contains sections covering the engine, power coupling, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, hydraulic systems, hitches and drawbars, steering, wheels, tracks and track suspension, cab climate control, and electrical systems. Each section provides detailed information and specifications to service and repair the components.
New holland t4.85 tractor service repair manualfusjfjskekmsme
This document is a service manual for T4.85, T4.95, and T4.105 tractors. It contains over 200 sections covering all major systems of the tractors, including the engine, transmission, brakes, hydraulics, steering, electrical systems, and more. Each section provides information and instructions for servicing and repairing the various components. Safety guidelines are also provided at the beginning to help technicians perform repairs safely.
New holland t4.80 n tractor service repair manualfusjfjskekmsme
This document is a service manual that provides technical specifications and repair/maintenance instructions for various tractor models and components, including the engine, clutch, transmission, four-wheel drive system, front axle system, and other parts. It includes detailed sections on the engine and its systems, the clutch and transmission components, and the four-wheel drive and front axle assemblies. The manual also lists the engine used for each tractor model and market.
New holland ls160 skid steer loader service repair manual valid from serial n...fusjfjskekmsme
This document provides the table of contents for the repair manual for New Holland LS160 and LS170 skid steer loaders. It lists 10 sections that cover topics like the engine, transmission, brakes, hydraulics, frames, and electrical system. The summary also notes that the manual contains safety precautions and instructions for tasks like supporting the machine, operating the boom and cab, and craning the skid steer. Overall, the document outlines the organization and contents of the repair manual for servicing and maintaining the LS160 and LS170 skid steer loaders.
Hyster k005 (h5.00 xm europe) forklift service repair manualfusjfjskekmsme
This document provides repair instructions for various components of a forklift, including:
1. The counterweight can be removed using lifting eyebolts and a lifting device, taking precautions about stability and weight.
2. The hood can be removed by disconnecting gas cylinders and wiring, and must be properly adjusted upon installation for operator restraint.
3. The overhead guard is removed using lifting devices and fasteners, and its isolators should be inspected. LED backup lights are non-repairable units.
Hyster g004 (s120 fts) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for manual and electronic main control valves used in hydraulic lift trucks. It describes:
- There are two main control valve types - manual and electronic. Both are mounted to the cowl.
- The electronic main control valve incorporates an emergency lowering valve and is divided into steering control, lift/lower, tilt, auxiliary, and outlet sections.
- Removal procedures include disconnecting wiring harnesses and hydraulic hoses, removing the steering control unit, and removing O-rings from the main control valve.
Hyster f019 (h12.00 xm 12ec europe) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for a differential assembly. It describes removing the differential carrier from the axle housing and then disassembling the differential carrier. The main steps are:
1. Removing the differential carrier from the axle housing by draining oil, disconnecting drive shafts and brakes, and removing mounting bolts.
2. Removing the ring gear and main differential assembly from the carrier by taking off the bearing caps, adjusting rings, and thrust screw.
3. Removing the drive pinion and pinion carrier by securing the pinion with a bar, removing the mounting nuts and bolts, and lifting it out along with any shims.
The document provides detailed instructions for each
Hyster d138 (n50 fa) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for single and double reach carriages on lift trucks. It describes the components of the reach carriages including the inner and outer frames connected by scissor linkages. Procedures are provided for replacing components like forks, the load backrest extension, and removing and installing the side-shift frame. Detailed steps are outlined for tasks like disassembling and cleaning the side-shift frame components. Safety warnings and cautions are included throughout.
Hyster d024 (s135 ft) forklift service repair manualfusjfjskekmsme
This document provides instructions for repairing the hydraulic gear pump assembly for various lift truck models. It describes removing the pump from the transmission housing and draining hydraulic fluid from the tank. The pump is then disassembled by removing housings, seals, gears, and plates. Individual parts are cleaned, inspected for wear, and replaced as needed. Reassembly involves installing new seals and plates and reattaching the housings. Finally, the pump is reinstalled on the transmission housing with fittings attached to hydraulic lines.
Hyster c187 (s2.50 xl europe) forklift service repair manualfusjfjskekmsme
This document provides repair procedures for alternators used in lift trucks. It describes two types of alternators - Type A and Type B. Type A alternators have a diode set and diode bridge, while Type B uses zener diodes in the diode bridge. The document includes cautions for repair, descriptions of alternator components and operation, and step-by-step instructions for removal, disassembly, cleaning, and reassembly of the alternators. Diagrams are provided showing views and components of the different alternator types.
Hyster c004 (s70 e) forklift service repair manualfusjfjskekmsme
The document provides descriptions and repair procedures for steering axles on various lift truck models. It describes the components of the steering axle assembly including the axle frame, steering cylinder, and spindle and hub assemblies. The steering axles use either a stub shaft mount or rubber mounts to connect to the lift truck frame. The repair section provides procedures for removing and installing the steering axle based on the type of mount, including disconnecting hydraulic lines, removing mounting hardware, and reinstalling with new seals, bushings, and fittings. Special attention is required when putting lift trucks on blocks or stands during maintenance to ensure stability.
Hyster b454 (w30 zc) forklift service repair manualfusjfjskekmsme
This document provides safety procedures for working near a mast and repair procedures for a reach carriage. When working near a mast, it must be fully lowered or secured with safety chains. Repairs should only be done by trained technicians. The reach carriage can be removed from the mast for repairs. Procedures are provided for removing and replacing parts like the load backrest, forks, and load rollers. Safety precautions are emphasized, including using lifting devices and securing heavy parts to prevent injuries.
Hyster b454 (w25 zc) forklift service repair manualfusjfjskekmsme
This document provides safety procedures for working near a mast on a forklift. Key points include:
- Lower the mast completely or install safety chains if the mast must be raised for repairs. Remove all parts that can move.
- Never put any body part under the mast unless it is fully lowered or chained. Turn off power and remove keys.
- Raise the mast just enough to install safety chains around the inner and outer weldments before working on it.
- Be aware of forks which can be at head height when mast is raised and ensure safe access via ladder when working on mast from the side.
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
Custom Solutions: We understand that every project is unique, which is why we offer custom crane solutions tailored to your specific requirements. Whether you need modifications, attachments, or specialized equipment, we can design and implement solutions that meet your needs.
At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Your VW's camshaft position sensor is crucial for engine performance. Signs of failure include engine misfires, difficulty starting, stalling at low speeds, reduced fuel efficiency, and the check engine light. Prompt inspection and replacement can prevent further damage and keep your VW running smoothly.
Learn why monitoring your Mercedes' Exhaust Back Pressure (EBP) sensor is crucial. Understand its role in engine performance and emission reduction. Discover five warning signs of EBP sensor failure, from loss of power to increased emissions. Take action promptly to avoid costly repairs and maintain your Mercedes' reliability and efficiency.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
What Are The Immediate Steps To Take When The VW Temperature Light Starts Fla...Import Motorworks
Learn how to respond when the red temperature light flashes in your VW with this presentation. From checking coolant levels to seeking professional help, follow these steps promptly to prevent engine damage and ensure safety on the road.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
2. 15 - Engine
00 - Engine
00 - General
15 - 27 9813/9050-1 15 - 27
Drain and Fill
Refer to: PIL 15-21-00.
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 coupled. If connectors are open fit 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 soft bristle
brush to soak off caked 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 connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
Length/Dimension/Distance: 600mm
3. 15 - Engine
00 - Engine
00 - General
15 - 28 9813/9050-1 15 - 28
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:
PIL 18-00-00.
Check (Condition)
Start the engine and check for:
• Excessive smoke
• Excessive vibration
• Excessive noise
• Overheating
• Performance
• Unusual smells.
4. 15 - Engine
00 - Engine
00 - General
15 - 29 9813/9050-1 15 - 29
Check (Leaks)
Before you start the machine, do a check for oil leaks:
1. Make the machine safe.
2. Get access to the engine compartment (if
applicable)
3. Check the engine and the area below for oil
leaks.
4. Close the engine cover (if applicable).
5. If necessary, contact your JCB dealer.
Check (Pressure)
Special Tools
Description Part No. Qty.
Pressure Gauge (0-70
Bar)
892/00346 1
This test is used to diagnose suspected poor
compression in one or more of the engine cylinders.
Use ServiceMaster to control the test.
Engine Oil Pressure
Use the following procedures to measure the engine
oil pressure. Several factors can influence the engine
oil pressure, the following conditions are assumed:
• The correct engine oil has been used. Refer to:
PIL 15-21-00.
• The engine oil level is correct. Refer to: PIL
75-03-03.
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. Get access to the engine.
3. Disconnect the electrical connector to the oil
pressure switch, remove the switch from the oil
cooler housing.
4. Install a suitable adaptor into the vacant pressure
switch port (M10 x 1.5mm thread) and a pressure
test gauge. Make sure that the gauge has a
sealing washer as shown.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
5. 15 - Engine
00 - Engine
00 - General
15 - 30 9813/9050-1 15 - 30
Figure 133.
A
B
A Oil pressure switch
B Sealing washer
5. Start the engine and allow a few seconds to
gain oil pressure, increase the engine revs to
the rated speed. Record the pressure gauge
reading. Check that the pressure is within the
specified tolerance.
Refer to: PIL 15-00-00.
6. Remove the pressure gauge and install the
pressure switch.
High Lubrication Oil Pressure
High oil pressure will be evident when starting in cold
conditions. Typically the pressure will be 1 to 2 bar
and higher in cold operation, the pressure should
drop when the engine reaches normal operating
temperature.
If the pressure remains high when operating
temperature is achieved, check the oil level, if this is
correct, suspect the oil pressure relief valve is at fault.
Low Lubrication Oil Pressure
Several factors can be the cause of low lubricating
oil pressure:
• Low oil level - typically evident as a loss of
pressure when operating on uneven ground or
on a gradient.
• Blocked oil filter - a blocked filter will show as a
gradual loss of pressure.
• Blocked suction strainer (pick-up pipe) -
typically evident as low pressure on start up,
if the blockage frees itself in the sump, the
pressure will pick up to normal.
• Coolant in the oil - coolant in the lubricating oil
will show as a milky discolouration of the oil and
an increase in oil level. Check for damaged core
plugs, lubricating oil cooler, cylinder head and/
or gasket.
• Fuel in the oil - fuel in the oil will result in thin'
black lubricating oil, the oil will also have a
diesel fuel smell. Check the fuel injection pump
(FIP) shaft seal, piston ring wear, lift pump
diaphragm damage or injector leakage if fuel is
evident in the oil.
• Damaged oil pump - oil pressure will be high at
low oil temperature but fall when oil becomes
hotter.
6. 15 - Engine
00 - Engine
00 - General
15 - 31 9813/9050-1 15 - 31
Remove and Install
Special Tools
Description Part No. Qty.
Fuel Injector equipment
Cap Kit (430 Engine)
320/B9321 1
Lifting Brackets (430
Engine)
320/B9421 1
Engine Lifting Spreader
Bar
892/01382 1
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.
Component Identification
The following component identification is for a typical
engine installation. 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.
Figure 134.
N
H
M
G
B
AA
A
J
PQ
Figure 135.
FF
E
D
R
A
A
7. 15 - Engine
00 - Engine
00 - General
15 - 32 9813/9050-1 15 - 32
Figure 136.
L
S
K
C
A Engine mounting bolts
B Front lifting bracket - front
C Lifting bracket fixing bolts
D Fuel pipe - return to tank
E Fuel pipe - feed from lift pump
F Electrical connector - ECM (Engine Control
Module)
G Electrical connections - alternator
H Hose connection - cab heater
J Electrical connections - starter motor
K Rear lifting bracket
L Gearbox/hydraulic pump to engine mounting
bolts
M Top coolant hose
N Bottom coolant hose
P Air inlet hose
Q Turbocharger outlet hose
R Charge air inlet hose
S Exhaust pipe
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.
3. Discharge the hydraulic pressure.
4. Get access to the engine.
Remove
1. Disconnect and remove the battery.
2. Drain the engine oil.
Refer to: PIL 15-21-00.
3. Drain the engine coolant.
Refer to: PIL 21-00-00.
4. Remove the cooling pack.
5. Disconnect the air inlet hose.
6. Disconnect the turbocharger outlet hose.
7. Disconnect the charge air hose.
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine
block connectors. Release the hose clips and
disconnect the hoses.
10. Disconnect the top coolant hose.
11. Disconnect the bottom coolant hose.
12. Disconnect the wiring connections from the
starter motor.
Refer to: PIL 15-75-00.
13. Disconnect the wiring connections from the
alternator.
Refer to: PIL 15-72-00.
14. Disconnect the fuel supply and return pipes.
Plug all the open ports and hoses to prevent
contamination.
Special Tool: Fuel Injector equipment Cap Kit
(430 Engine) (Qty.: 1)
15. Disconnect the electrical harness at the ECM
machine side connector. Important: Do not touch
the connector pins on the ECM or harness
connectors. Cover the connectors to prevent
contamination.
16. Make sure that all relevant harnesses and hoses
are unclipped from the engine and tied out of the
way.
17. If necessary, drain the hydraulic tank. Disconnect
and plug the hydraulic suction and delivery lines
at the transmission pump and gear pump. Label
the hoses to aid installation.
18. Remove the gearbox/hydraulic pump to engine
retaining bolts and pull the gearbox/hydraulic
pump clear of the engine.
8. 15 - Engine
00 - Engine
00 - General
15 - 33 9813/9050-1 15 - 33
18.1. Make sure that the torque converter stays
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Special Tool: Lifting Brackets (430 Engine) (Qty.:
1)
Special Tool: Engine Lifting Spreader Bar (Qty.:
1)
20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
21. Raise the engine and lift it clear of the machine.
22. Lower the engine into a suitable stand that is
capable of supporting the weight of the engine.
Figure 137.
T
U
A
A
A Lifting brackets
T Lifting equipment
U Spreader bar
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. It is vitally important that the torque converter
is installed at the gearbox and engine flywheel
correctly. Failure to locate the torque converter
correctly will result in damage to the gearbox oil
pump on engine start up.
9. 15 - Engine
00 - Engine
00 - General
15 - 34 9813/9050-1 15 - 34
3. Fill the cooling system.
Refer to: PIL 21-00-00.
3.1. When you fill the cooling system make
sure you use the correct water/antifreeze
mixture. A 50% mixture should be
maintained even if frost protection is not
required.
Refer to: PIL 75-09-03.
4. Fill and check the hydraulic fluid level.
5. Fill and check the engine oil level. Make sure the
correct oil is used.
Refer to: PIL 75-03-03.
6. Check the hydraulic, fuel and cooling systems for
leaks.
7. Check the operation of all drive and hydraulic
services.
10. 15 - Engine
00 - Engine
00 - General
15 - 35 9813/9050-1 15 - 35
Store and Recommission
Engines should be stored in the original shipping
packaging. Damaged or disturbed packaging should
be made weatherproof immediately.
If an engine is shipped with oil, it should be stored in
the correct (upright) position.
If an engine is shipped dry of oil, after 6 months it
should be filled with oil to the correct level and re-
inhibited, refer to hot test description.
All floor stock engines should be stored under cover
in dry conditions and not subjected to extreme
variations in temperature or humidity.
If an engine is to be placed into storage, all external
signs of surface coating damage or corrosion should
be cleaned and re-coated. Electrical connectors and
components should be coated with a protective
spray.
Capping Engine Openings
All openings on the engine must be suitably capped
to prevent ingress of water and contamination by
foreign particles.
11. 15 - Engine
00 - Engine
00 - General
15 - 36 9813/9050-1 15 - 36
Figure 138.
B
A
D
C
E
F
A ECM (Engine Control Module) machine harness
connector cap
B Machine harness interconnect connector cap
C Fuel pipe – return to tank cap D Fuel pipe – feed from lift pump cap
E Coolant circuit bleed pipe cap F Air intake cap
12. 15 - Engine
00 - Engine
00 - General
15 - 37 9813/9050-1 15 - 37
Figure 139.
G
H
J
K
L
M
G Turbocharger intake cap H Coolant top hose cap
J Turbocharger compressor outlet cap K Coolant bottom hose cap
L Cab heater feed and return spigots M Heavy duty PTO (Power Take-Off)
13. 15 - Engine
00 - Engine
00 - General
15 - 38 9813/9050-1 15 - 38
Figure 140.
N
N Turbocharger exhaust outlet (tape over)
12 Month Revalidation Procedure
1. Pre-inspection:
1.1. Inspect packaging for signs of damage.
1.2. Inspect the caps for signs of damage.
1.3. Inspect openings for signs of water or dirt
ingress.
1.4. Inspect the engine for signs of external
corrosion.
1.5. Inspect the engine for signs of fluid leaks.
2. From storage:
2.1. Remove the air intake caps.
2.2. Make sure the engine oil level is correct.
2.3. Using a suitable power supply at the correct
voltage, crank the engine over for the
specified time period.
Duration: 20s
2.4. During cranking, check that the oil pressure
switch opens using a multimeter. The switch
is closed when there is no or low oil
pressure and opens when oil pressure
reaches a set point. After three separate
cranking periods, If the oil pressure switch
does not open (indicating no, or low oil
pressure), contact your JCB engine dealer.
2.5. Recap all engine openings.
2.6. Coat any exposed bare metal with a
suitable product.
2.7. Electrical connectors and components
should be coated with a protective spray if
exposed.
2.8. Cover in weatherproof packaging.
2.9. Place in storage, under cover on level
ground or shelving.
2.10. Record details of work as required.
2.11. Do not expose to extremes of temperature
or humidity.
Notice: Do not operate the starter motor for more
than 20s at one time. Let the starter motor cool for
at least 2min.
Table 59. Oil Pressure Switch Set Points
Oil pressure switch
closed
>0.6bar (8.7psi)
Oil pressure switch open <0.6bar (8.7psi)
OEM Commissioning Check on Engine
Installation After More Than 12 Months
1. Flush the coolant system with proprietary
flushing solution.
2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
3. Hot test engine according to the hot test profile.
Refer to Table 60.
4. Drain engine oil and replace engine oil filter.
5. Refill with the correct oil and inhibit the cooling
system using the correct product.
6. Record details of work as required.
Hot Test Description
WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
the manufacturer's instructions and safety
precautions.
All engines despatched from JCB will have been
subjected to a hot test (checking items such as oil
pressure, engines speeds, torque values etc.) and
therefore the interior surfaces will have been coated
with engine oil.
All coolant galleries are coated with CRODAFLUID
PA75 corrosion inhibitor.
Stored engines will require re-inhibiting every 12
months, this will include hot testing the engine using
a dynamometer. The hot test profile is:
Table 60. Hot Test Profile
Stage Mode Speed
(rpm)
Torque
(Nm)
Time
(secs)
1 Speed/
Torque
830 0 50
2 Speed/
Torque
1300 50 60
14. 15 - Engine
06 - Cylinder Head
00 - General
15 - 47 9813/9050-1 15 - 47
Component Identification
Figure 142.
A
B
C
A Cylinder head bolts
B Cylinder head
C Cylinder head gasket
15. 15 - Engine
06 - Cylinder Head
00 - General
15 - 48 9813/9050-1 15 - 48
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
This procedure requires service parts. Make sure
you have obtained the correct parts before you start.
Refer to the Parts Catalogue.
1. Make the machine safe.
Refer to: PIL 01-03.
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. Drain the coolant.
Refer to: PIL 21-00-00.
5. Remove the engine wiring harness.
6. Remove the ECM (Engine Control Module).
Refer to: PIL 33-45-06.
7. Remove the thermostat.
Refer to: PIL 21-12-00.
8. Disconnect the CCV (Crankcase Ventilation)
pipes.
Refer to: PIL 15-28-00.
9. Remove the fuel injector cover.
Refer to: PIL 18-18-04.
10. Remove the high pressure fuel pipes.
Refer to: PIL 18-96-03.
11. Remove the injector leak-off, leak-off pipe to fuel
filter, and return to tank low pressure fuel pipes.
Refer to: PIL 18-96-06.
12. Remove the fuel injectors.
Refer to: PIL 18-18-03.
13. Remove the fuel rail.
Refer to: PIL 18-18-12.
14. Remove the EGR (Exhaust Gas Recirculation)
system.
Refer to: PIL 18-27-00.
15. Remove the exhaust manifold pressure sensor
assembly.
Refer to: PIL 15-84-16.
16. Remove the exhaust manifold and turbocharger
assembly.
Refer to: PIL 18-24-04.
17. Remove the glow plugs.
Refer to: PIL 15-80-00.
18. Disconnect the charge air inlet hose.
19. Remove the rocker cover.
Refer to: PIL 15-42-06.
20. Remove the rocker assembly.
Refer to: PIL 15-42-00.
16. 15 - Engine
06 - Cylinder Head
00 - General
15 - 49 9813/9050-1 15 - 49
Figure 143.
12
1
2 3
45
6
9
10 7
8
0° +90 °
Y
11
12
X13
1-10 Cylinder head fixing bolts (x10) 11 Cylinder head
12 Location dowels (x2) 13 Cylinder head gasket
X Cylinder head gasket identification holes Y Matchmarks
21. Remove the push rods. Make a note of the
order to make sure that they are installed in their
original positions.
Remove
1. Progressively remove the cylinder head bolts in
reverse order, starting at bolt 10. 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: PIL 15-06-00.
Before Install
1. Obtain the correct new cylinder head bolts. The
original bolts MUST NOT be re-used.
17. 15 - Engine
06 - Cylinder Head
00 - General
15 - 50 9813/9050-1 15 - 50
2. Obtain the correct replacement head gasket.
Note the number of cylinder head gasket
identification holes.
3. Make sure that all items are clean and free from
damage and corrosion.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
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 three stages, use the
torque and angle method.
Refer to: PIL 72-00-00.
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-10) to the 1st stage pre-torque.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
4.2. Tighten the bolts, starting with the middle
pair and working outwards (in sequence 1-
10) to the 2nd stage pre-torque.
4.3. Repeat the 2nd stage pre-torque. Refer to
step 4.2.
4.4. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-10) to
the final stage 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. Refer to Figure 143.
Table 63. Torque Table
Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
1-10 (Final Stage) 90°
18. 15 - Engine
12 - Crankshaft
00 - General
15 - 61 9813/9050-1 15 - 61
Check (Condition)
1. Measure the crankshaft journal diameters to
confirm they are within service limits.
Refer to: PIL 15-12-00.
Figure 147.
B
A
C
A Crankcase
B Crankshaft
C Crankshaft position sensor target wheel
2. Check the main bearing surfaces for damage and
excessive wear.
Figure 148.
D
D Main bearing shells
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oilways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling saddle jets are
clear. If the saddle jets cannot be cleared, replace
the saddle jets.
Figure 149.
E
E Saddle jets
19. 15 - Engine
12 - Crankshaft
00 - General
15 - 62 9813/9050-1 15 - 62
Remove and Install
Special Tools
Description Part No. Qty.
Template for Sealant
Bedplate to Crankcase
(430 Engine)
320/02333 1
Crankshaft Turning Tool
(Major Repair) (430
Engine)
320/A3170 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 the 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. Drain the engine oil.
Refer to: PIL 15-21-00.
4. Remove the engine.
Refer to: PIL 15-00-00.
5. Remove the fuel filter.
Refer to: PIL 18-09-03.
6. Remove the drive belt.
Refer to: PIL 15-18-03.
7. Remove the crankshaft pulley.
Refer to: PIL 15-12-12.
8. Remove the front crankshaft oil seal.
Refer to: PIL 15-12-06.
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
10. Remove the dipstick.
11. Remove the dipstick tube.
Refer to: PIL 15-45-09.
12. Remove the bolts (x2) and disconnect the
turbocharger oil drain pipe.
13. Remove the oil sump.
Refer to: PIL 15-45-00.
14. 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 15-06-00.
15. Remove the starter motor.
Refer to: PIL 15-75-00.
16. Remove the flywheel.
Refer to: PIL 15-54-00.
17. Remove the rear crankshaft oil seal.
Refer to: PIL 15-12-09.
18. Remove the flywheel housing.
Refer to: PIL 15-54-03.
19. Remove the oil pump.
Refer to: PIL 15-60-00.
20. Remove the bolt securing the fuel hose to the
bedplate.
Figure 150.
E
E Fuel pipe retaining bolt
21. Remove the main bearing caps.
Refer to: PIL 15-12-03.
22. Set the engine to TDC (Top Dead Centre).
20. 15 - Engine
12 - Crankshaft
00 - General
15 - 63 9813/9050-1 15 - 63
Special Tool: Crankshaft Turning Tool (Major
Repair) (430 Engine) (Qty.: 1)
Remove
1. Remove the bedplate peripheral bolts.
Figure 151.
OO
O
OO
2 3 710 6
1 4 89 5
O
O
N
P
O
1-10 Main bearing bolts (x10) N Bedplate
O Bedplate peripheral bolts (x12) P O-ring
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.
Figure 152.
R
R
N
N Bedplate
R Lifting bolts (obtain locally)
4. Remove the bedplate.
21. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
22. 15 - Engine
12 - Crankshaft
00 - General
15 - 64 9813/9050-1 15 - 64
5. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
6. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
Figure 153.
A
B
A Thrust washers
B Crankshaft
C Rear main bearing
7. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
8. Carefully lift out the bearing shells.
Figure 154.
D
D Main bearing shells
9. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put labels on the shells to make sure that they
are installed in their original positions during
assembly.
10. Inspect the crankshaft and main bearings for
damage and excessive wear.
Refer to: PIL 15-12-00.
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. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
23. 15 - Engine
12 - Crankshaft
00 - General
15 - 65 9813/9050-1 15 - 65
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the upper bearing shells as follows:
Figure 155.
D
Y
G
D Main bearing shells
G Bearing location tab
Y Oil-way holes
3.1. Use a suitable degreasing agent to make
sure that the surfaces of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
3.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
3.3. 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.
3.4. Lubricate the upper bearing shells with
clean engine oil.
4. 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. Make sure that the
connecting rods are located onto the crankshaft
journals.
4.1. Make sure that the connecting rods are
located onto the crankshaft journals.
4.2. Make sure that the crankshaft is installed
so that the engine timing is correct. The
single mark on the crankshaft drive gear
must locate between the two marks on the
camshaft drive gear.
Figure 156.
L
M
J
K
J Camshaft drive gear timing marks
K Crankshaft drive gear timing mark
L Camshaft drive gear
M Crankshaft drive gear
5. Install the thrust washers as follows:
24. 15 - Engine
12 - Crankshaft
00 - General
15 - 66 9813/9050-1 15 - 66
Figure 157.
C
A
A
H
B
A Thrust washer
B Crankshaft
C Rear main bearing
H Oil slot - thrust washers
5.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
5.2. Make sure that they are installed in the
correct positions, with the two oil slots
facing outwards from the bearing saddle.
5.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
5.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged.
6. Check that the crankshaft end float is within
service limits.
Refer to: PIL 15-12-00.
7. Install the four lifting bolts to the bedplate as
shown.
8. Lubricate the lower bearing shells with clean
engine oil. If the bearings have been removed,
make sure that the location tab engages in the
slot as shown.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
9. The sealant template is used on the crankcase,
NOT the bedplate.
Special Tool: Template for Sealant Bedplate to
Crankcase (430 Engine) (Qty.: 1)
10. Locate the location tabs on the template using
a location dowel and a fixing bolt. Use the
templates as a guide apply a bead of sealant
around the crankcase/bedplate mating face as
shown to the dimension specified.
Length/Dimension/Distance: 1.5mm