The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstallation.
Toyota CBT4 ELECTRIC POWERED TOWING TRACTOR Service Repair Manualufjdjjksekmem
This is the Highly Detailed factory service repair manual for theTOYOTA CBT4 ELECTRIC POWERED TOWING TRACTOR, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.TOYOTA CBT4 ELECTRIC POWERED TOWING TRACTOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General
Battery
Controller
Electrical System Troubleshooting
Motor
Drive Unit
Front Axle
Rear Axle
Steering
Brake
Body
Frame
Appendix
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveTOYOTA CBT4 ELECTRIC POWERED TOWING TRACTOR Service Repair Workshop Manual.
Thanks for visiting!
Liebherr r926 1235 classic hydraulic excavator service repair manualufjdjjksekmem
The document is a service manual for Liebherr hydraulic excavators. It contains 18 sections that provide technical data, design descriptions, and service/setup instructions for the machines. The manual is intended to assist customer support but does not replace proper training. It includes symbols to identify dangers, requirements, and expected results. The sections cover general information, tools, technical specifications, the engine/motor, couplings, hydraulic and electrical systems, swing/travel components, and options like the cab.
Liebherr r914 compact hydraulic excavator service repair manualufjdjjksekmem
This document is a service manual for an MJFCIFSS machine. It contains sections covering technical data, maintenance instructions, and descriptions of the drive group, cooling system, hydraulics, electrical system, travel gearbox, steel parts, operator cab, lubrication system, slewing gearbox, and diagnosis procedures. The manual is copyrighted by MJFCIFSS.
Liebherr lh150 m 1230 (tier4f) hydraulic excavator service repair manualufjdjjksekmem
The document discusses corrosion prevention and protection for hydraulic cylinders and shock absorbers. It includes figures and tables on the components of differential cylinders and shock absorbers, recommended corrosion inhibitors, parts at risk for corrosion, and coatings and paints for protection. It also contains tables with information on operating conditions, servo control, variable displacement pumps, power testing, secondary pressures, and primary pressure relief valves.
Liebherr lh150 c 1231 (tier4f) hydraulic excavator service repair manualufjdjjksekmem
The document discusses corrosion prevention and protection for hydraulic cylinders and shock absorbers. It includes figures and tables on the components of differential cylinders and shock absorbers. It also provides information on recommended corrosion inhibitors, paints and coatings, operating conditions, control systems, pressure regulation, and relief valves. The document encourages downloading a complete manual for further details.
Liebherr lh60 c hydraulic excavator service repair manualufjdjjksekmem
This document provides safety warnings and instructions for operating a hydraulic excavator. It outlines hazards associated with the machine and stresses the importance of following safety precautions to prevent injury. Specific dangers are indicated by warning signs on the machine. The document also defines the designated use of the excavator as loosening, picking up, transporting, and dumping materials while following technical safety guidelines. Any other uses are considered not in accordance with safe operation of the machine.
Liebherr lh24 1198 hydraulic excavator service repair manualufjdjjksekmem
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains diagrams and tables related to hydraulic cylinders and corrosion prevention. Figures 1-4 illustrate components of cylinders and their assembly while Tables 1-2 list recommended corrosion inhibitors and paints from Liebherr. The manual instructs the reader to click a link to access the complete document.
Liebherr lh22 c 1209 hydraulic excavator service repair manualufjdjjksekmem
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Toyota CBT4 ELECTRIC POWERED TOWING TRACTOR Service Repair Manualufjdjjksekmem
This is the Highly Detailed factory service repair manual for theTOYOTA CBT4 ELECTRIC POWERED TOWING TRACTOR, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.TOYOTA CBT4 ELECTRIC POWERED TOWING TRACTOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General
Battery
Controller
Electrical System Troubleshooting
Motor
Drive Unit
Front Axle
Rear Axle
Steering
Brake
Body
Frame
Appendix
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveTOYOTA CBT4 ELECTRIC POWERED TOWING TRACTOR Service Repair Workshop Manual.
Thanks for visiting!
Liebherr r926 1235 classic hydraulic excavator service repair manualufjdjjksekmem
The document is a service manual for Liebherr hydraulic excavators. It contains 18 sections that provide technical data, design descriptions, and service/setup instructions for the machines. The manual is intended to assist customer support but does not replace proper training. It includes symbols to identify dangers, requirements, and expected results. The sections cover general information, tools, technical specifications, the engine/motor, couplings, hydraulic and electrical systems, swing/travel components, and options like the cab.
Liebherr r914 compact hydraulic excavator service repair manualufjdjjksekmem
This document is a service manual for an MJFCIFSS machine. It contains sections covering technical data, maintenance instructions, and descriptions of the drive group, cooling system, hydraulics, electrical system, travel gearbox, steel parts, operator cab, lubrication system, slewing gearbox, and diagnosis procedures. The manual is copyrighted by MJFCIFSS.
Liebherr lh150 m 1230 (tier4f) hydraulic excavator service repair manualufjdjjksekmem
The document discusses corrosion prevention and protection for hydraulic cylinders and shock absorbers. It includes figures and tables on the components of differential cylinders and shock absorbers, recommended corrosion inhibitors, parts at risk for corrosion, and coatings and paints for protection. It also contains tables with information on operating conditions, servo control, variable displacement pumps, power testing, secondary pressures, and primary pressure relief valves.
Liebherr lh150 c 1231 (tier4f) hydraulic excavator service repair manualufjdjjksekmem
The document discusses corrosion prevention and protection for hydraulic cylinders and shock absorbers. It includes figures and tables on the components of differential cylinders and shock absorbers. It also provides information on recommended corrosion inhibitors, paints and coatings, operating conditions, control systems, pressure regulation, and relief valves. The document encourages downloading a complete manual for further details.
Liebherr lh60 c hydraulic excavator service repair manualufjdjjksekmem
This document provides safety warnings and instructions for operating a hydraulic excavator. It outlines hazards associated with the machine and stresses the importance of following safety precautions to prevent injury. Specific dangers are indicated by warning signs on the machine. The document also defines the designated use of the excavator as loosening, picking up, transporting, and dumping materials while following technical safety guidelines. Any other uses are considered not in accordance with safe operation of the machine.
Liebherr lh24 1198 hydraulic excavator service repair manualufjdjjksekmem
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains diagrams and tables related to hydraulic cylinders and corrosion prevention. Figures 1-4 illustrate components of cylinders and their assembly while Tables 1-2 list recommended corrosion inhibitors and paints from Liebherr. The manual instructs the reader to click a link to access the complete document.
Liebherr lh22 c 1209 hydraulic excavator service repair manualufjdjjksekmem
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Liebherr lh22 1197 hydraulic excavator service repair manualufjdjjksekmem
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Liebherr er 922 hydraulic excavator service repair manualufjdjjksekmem
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Liebherr a922 rail litronic hydraulic excavator service repair manualufjdjjksekmem
The document appears to be a technical manual or instruction set that includes diagrams and tables. It discusses the mounting of clamping nuts and suspension components, along with the components of differential cylinders and shock absorbers. The document also provides recommendations for corrosion inhibitors and lists base coats and paints that can be used in aerosol cans. It encourages the reader to click on a link for more information or to download the full PDF document.
Jcb tm420 telescopic wheel loader service repair manual sn 2454001 and upufjdjjksekmem
This service manual provides instructions for disassembling and assembling the master clutch on a loader. The summary describes:
1) Special tools are required to remove the clutch pack retainers and install a mandrel and locking plates during disassembly and assembly.
2) The cover is removed after installing jacking bolts and lifting eyes. Seals and gaskets are then removed from the cover and housing.
3) Locking plates and bolts are used to secure the clutch assembly while removing bolts to separate the drum, hub, and pressure plate assembly.
Jcb 540 140 telescopic handler service repair manual sn from 2902000 onwardsufjdjjksekmem
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 535 v125 telescopic handler service repair manual sn from 2902000 onwardsufjdjjksekmem
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 533 105 telescopic handler service repair manual sn from 2460601 onwardsufjdjjksekmem
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine body and framework, operator station, engine, fuel and exhaust, cooling, brake, steering, hydraulic and electrical systems. The engine section provides technical data and instructions for servicing parts like the valves, connecting rods, pistons, and more. Proper safety procedures and use of specialized tools are emphasized throughout.
Jcb 531 70 tier 4 telescopic handler service repair manual sn from 2902000 on...ufjdjjksekmem
The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstallation.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing various clutch shaft assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly tolerances. Special tools and consumables like threadlocker and gasket material are required.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section on the semi-automatic gearbox provides instructions for removing and installing the gearbox, checking clutch shaft end floats, and installing new seals and gaskets. Special tools and consumable products like threadlocker and gasket material are listed.
Jcb 260 skid steer loader service repair manual sn from 2478301 to 2478700ufjdjjksekmem
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the installation.
Jcb 260 skid steer loader service repair manual sn from 2476302 to 2477300ufjdjjksekmem
The document provides instructions for removing and installing a crankshaft on an engine. Key steps include: removing components like the drive belt, pulley, oil sump, fuel injectors and rocker assembly; positioning the engine upside down; and removing components attached to the crankshaft like the flywheel, gears, and oil pump. Instructions are given for checking the crankshaft condition and measuring diameters. The crankshaft is lubricated via oil drillings and cross drillings must be clear. Precautions are listed for the heavy crankshaft component.
Jcb 175 skid steer loader service repair manual (from 2473501 to 2473800)ufjdjjksekmem
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the machine's engine. The manual advises treating it as part of the machine and keeping it in good condition for replacement. It also warns of hot surfaces that can cause burns and moving parts that can cause injury.
Jcb 155 skid steer loader service repair manual (from 2473501 to 2473800)ufjdjjksekmem
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the machine's engine. The manual advises treating it as part of the machine and keeping it in good condition for reference.
Jcb 135 skid steer loader service repair manual (from 2473501 to 2473800)ufjdjjksekmem
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on general information, safety, technical specifications, component identification, operation, maintenance, troubleshooting and repair of the engine and its systems. The document outlines the four-stroke operating cycle and firing order of the four-cylinder engine. It also provides illustrations of the external engine components and diagrams to identify internal parts.
Jcb 9 tst dumper service repair manual sn from hpt2080 to hpt2080ufjdjjksekmem
This service manual provides instructions for servicing the components of a dumper vehicle, including the machine body and framework, operator station, engine, fuel and exhaust system, cooling system, brake system, steering system, driveline, hydraulic system, electrical system, fasteners and fixings, and consumable products. The document provides detailed removal and installation instructions for fuel system components like high pressure fuel pipes, low pressure fuel pipes, and injector bleed-off pipes. Safety precautions for working on the fuel system are emphasized.
Jcb 9 tst dumper service repair manual sn from hps2406 to hps3751ufjdjjksekmem
This service manual provides instructions for servicing the components of a dumper vehicle, including the machine body and framework, operator station, engine, fuel and exhaust system, cooling system, brake system, steering system, driveline, hydraulic system, electrical system, fasteners and fixings, and consumable products. The document provides detailed removal and installation instructions for fuel system components like high pressure fuel pipes, low pressure fuel pipes, and injector bleed-off pipes. Safety precautions for working on the fuel system are emphasized.
Jcb 5 cx backhoe loader service repair manual sn from 2509500 and upufjdjjksekmem
This service manual provides instructions for servicing the backhoe loader models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The sample document focuses on servicing the crankshaft and main bearings of the engine. It provides details on lubrication, inspection procedures, removing and installing the crankshaft, installing new main bearing shells, checking clearances, and required torque specifications.
Jcb 4 cx backhoe loader service repair manual sn from 2509500 and upufjdjjksekmem
This service manual provides instructions for servicing the backhoe loader models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The sample document focuses on servicing the crankshaft and main bearings of the engine. It provides details on lubrication, inspection procedures, removing and installing the crankshaft, installing new main bearing shells, checking clearances, and torque specifications.
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.
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!
Liebherr lh22 1197 hydraulic excavator service repair manualufjdjjksekmem
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Liebherr er 922 hydraulic excavator service repair manualufjdjjksekmem
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Liebherr a922 rail litronic hydraulic excavator service repair manualufjdjjksekmem
The document appears to be a technical manual or instruction set that includes diagrams and tables. It discusses the mounting of clamping nuts and suspension components, along with the components of differential cylinders and shock absorbers. The document also provides recommendations for corrosion inhibitors and lists base coats and paints that can be used in aerosol cans. It encourages the reader to click on a link for more information or to download the full PDF document.
Jcb tm420 telescopic wheel loader service repair manual sn 2454001 and upufjdjjksekmem
This service manual provides instructions for disassembling and assembling the master clutch on a loader. The summary describes:
1) Special tools are required to remove the clutch pack retainers and install a mandrel and locking plates during disassembly and assembly.
2) The cover is removed after installing jacking bolts and lifting eyes. Seals and gaskets are then removed from the cover and housing.
3) Locking plates and bolts are used to secure the clutch assembly while removing bolts to separate the drum, hub, and pressure plate assembly.
Jcb 540 140 telescopic handler service repair manual sn from 2902000 onwardsufjdjjksekmem
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 535 v125 telescopic handler service repair manual sn from 2902000 onwardsufjdjjksekmem
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 533 105 telescopic handler service repair manual sn from 2460601 onwardsufjdjjksekmem
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine body and framework, operator station, engine, fuel and exhaust, cooling, brake, steering, hydraulic and electrical systems. The engine section provides technical data and instructions for servicing parts like the valves, connecting rods, pistons, and more. Proper safety procedures and use of specialized tools are emphasized throughout.
Jcb 531 70 tier 4 telescopic handler service repair manual sn from 2902000 on...ufjdjjksekmem
The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstallation.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing various clutch shaft assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly tolerances. Special tools and consumables like threadlocker and gasket material are required.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section on the semi-automatic gearbox provides instructions for removing and installing the gearbox, checking clutch shaft end floats, and installing new seals and gaskets. Special tools and consumable products like threadlocker and gasket material are listed.
Jcb 260 skid steer loader service repair manual sn from 2478301 to 2478700ufjdjjksekmem
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the installation.
Jcb 260 skid steer loader service repair manual sn from 2476302 to 2477300ufjdjjksekmem
The document provides instructions for removing and installing a crankshaft on an engine. Key steps include: removing components like the drive belt, pulley, oil sump, fuel injectors and rocker assembly; positioning the engine upside down; and removing components attached to the crankshaft like the flywheel, gears, and oil pump. Instructions are given for checking the crankshaft condition and measuring diameters. The crankshaft is lubricated via oil drillings and cross drillings must be clear. Precautions are listed for the heavy crankshaft component.
Jcb 175 skid steer loader service repair manual (from 2473501 to 2473800)ufjdjjksekmem
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the machine's engine. The manual advises treating it as part of the machine and keeping it in good condition for replacement. It also warns of hot surfaces that can cause burns and moving parts that can cause injury.
Jcb 155 skid steer loader service repair manual (from 2473501 to 2473800)ufjdjjksekmem
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on safety, maintenance, troubleshooting and repair of the machine's engine. The manual advises treating it as part of the machine and keeping it in good condition for reference.
Jcb 135 skid steer loader service repair manual (from 2473501 to 2473800)ufjdjjksekmem
This service manual provides information for servicing a JCB skid steer loader engine. It contains sections on general information, safety, technical specifications, component identification, operation, maintenance, troubleshooting and repair of the engine and its systems. The document outlines the four-stroke operating cycle and firing order of the four-cylinder engine. It also provides illustrations of the external engine components and diagrams to identify internal parts.
Jcb 9 tst dumper service repair manual sn from hpt2080 to hpt2080ufjdjjksekmem
This service manual provides instructions for servicing the components of a dumper vehicle, including the machine body and framework, operator station, engine, fuel and exhaust system, cooling system, brake system, steering system, driveline, hydraulic system, electrical system, fasteners and fixings, and consumable products. The document provides detailed removal and installation instructions for fuel system components like high pressure fuel pipes, low pressure fuel pipes, and injector bleed-off pipes. Safety precautions for working on the fuel system are emphasized.
Jcb 9 tst dumper service repair manual sn from hps2406 to hps3751ufjdjjksekmem
This service manual provides instructions for servicing the components of a dumper vehicle, including the machine body and framework, operator station, engine, fuel and exhaust system, cooling system, brake system, steering system, driveline, hydraulic system, electrical system, fasteners and fixings, and consumable products. The document provides detailed removal and installation instructions for fuel system components like high pressure fuel pipes, low pressure fuel pipes, and injector bleed-off pipes. Safety precautions for working on the fuel system are emphasized.
Jcb 5 cx backhoe loader service repair manual sn from 2509500 and upufjdjjksekmem
This service manual provides instructions for servicing the backhoe loader models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The sample document focuses on servicing the crankshaft and main bearings of the engine. It provides details on lubrication, inspection procedures, removing and installing the crankshaft, installing new main bearing shells, checking clearances, and required torque specifications.
Jcb 4 cx backhoe loader service repair manual sn from 2509500 and upufjdjjksekmem
This service manual provides instructions for servicing the backhoe loader models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The sample document focuses on servicing the crankshaft and main bearings of the engine. It provides details on lubrication, inspection procedures, removing and installing the crankshaft, installing new main bearing shells, checking clearances, and torque specifications.
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.
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.
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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.
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.
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.
Dahua provides a comprehensive guide on how to install their security camera systems. Learn about the different types of cameras and system components, as well as the installation process.
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.
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
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.
2. 18 - Fuel and Exhaust System
18 - Injection
03 - Injector
18 - 60 9813/7600-3 18 - 60
03 - Injector
Introduction .................................................... 18-60
Component Identification ............................... 18-61
Check (Operation) ......................................... 18-61
Remove and Install ....................................... 18-62
Introduction
The fuel Injectors are electronically controlled and
incorporate a small solenoid valve. The injectors are
supplied with pressurised fuel by the high pressure
fuel injection pump and when energised, the injector
atomizes the fuel into a fine mist so that it can burn
easily by the vehicle’s engine.
The fuel injectors are mounted in the inlet manifold
so that fuel is sprayed directly at the inlet valves. A
fuel supply rail connects all of the fuel injectors to the
fuel supply.
The injector tips are located inside the combustion
chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by O-ring.
Figure 390.
5 1 4
6
52
3
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
3. 18 - Fuel and Exhaust System
18 - Injection
03 - Injector
18 - 61 9813/7600-3 18 - 61
Component Identification
Figure 391.
N
A
B
D F
G
H
M
C
J
L
E
A Multi-point injector nozzle
B Needle
C Spacer
D Nut
E Valve
F Solenoid coil
G Valve spring
H Calibration dowel
J Injector spring
L Electrical connector
M Return port (bleed off)
N High pressure port and filter element
Check (Operation)
Special Tools
Description Part No. Qty.
Injector Leak-off Test
Kit ((Electronic Engine))
892/12350 1
Injector Cap Kit 892/12359 1
The injectors can be tested using Servicemaster
diagnostics and by means of a leak off test. To test
for a defective injector first use Servicemaster to
diagnose the problems with the high pressure fuel
injection equipment, specifically when the engine
does not start.
Leak Off Test
The leak off test kit must be installed on the engine
and the ServiceMaster must be used to test the
engine.
1. Operate the engine until it reaches its normal
operating temperature.
2. Stop the engine. Remove the bleed off pipe at
each injector. Refer to (PIL 18-96). Cap the open
connectors on the pipes with the caps in the
injector leak off test kit.
Special Tool: Injector Leak-off Test Kit
((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
3. Connect the test pipes to the leak off ports on the
four injectors.
4. Position the four plastic bottles as upright as
possible. Keep the test equipment clear of
components that get hot when the engine is
operated.
5. Connect a test pipe to the leak off ports on the
High Pressure valve outlet. Cap the open pipe.
6. Make sure it is safe to start the engine.
7. Use ServiceMaster to control the tests. Refer to
Fuel Injection - Check Operation (PIL 18-18).
7.1. Fuel System Diagnostic Test (Cranking
Only).
7.2. Fuel System Diagnostic Tests (Engine
Running).
8. Examine the fuel levels in the test bottles. If the
difference between any of the levels is more than
10 ml. this indicates that there are one or more
defective injectors.
9. Remove the test equipment and replace the
bleed off pipes. Refer to (PIL 18-96).
4. 18 - Fuel and Exhaust System
18 - Injection
03 - Injector
18 - 62 9813/7600-3 18 - 62
Figure 392.
A
A
A
A
B
A Injectors (x4)
B HP valve
Remove and Install
The following procedure is for one injector, the
procedures are identical for all injectors.
Note: The original injector calibration codes are
located on a label on the rocker cover.
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. Get access to the engine.
3. Remove the high pressure fuel pipes. Refer to
Fuel Pipes (PIL 18-96).
4. Remove the fuel bleed off fuel pipes. Refer to
Fuel Pipes (PIL 18-96).
5. Remove the rocker cover, refer to (PIL 15-42).
6. Record which injector is for which cylinder. The
injectors must be installed in the same positions.
Note: If a fuel injector is defective, it must be
replaced.
Remove
1. Remove the injector clamp retaining bolt and lift
the clamp away.
5. 18 - Fuel and Exhaust System
18 - Injection
03 - Injector
18 - 63 9813/7600-3 18 - 63
Figure 393.
X 14
3
2
1 Injector
2 Injector clamp
3 Retaining bolt
4 Injector sleeve
X Injector bleed-off port
2. Remove and discard the sealing washer. Label
the injector to make sure it is installed in its
original cylinder. Put a clean protective cap over
the nozzle of the injector.
3. Remove and discard the O-ring.
Figure 394.
5
7
6
5 Protective cap
6 Protective cap
7 Sealing washer
Install
Important: The fuel injectors are not interchangeable
between cylinders or other engines. Make sure you
install the injectors in the same positions. If a new
or different injector is installed, the engine electronic
control unit (ECU) must be re-programmed. Refer to
(PIL 33-45), Engine Electronic Control Unit, Vehicle
Set Up Data.
When new or different injectors are installed, record
the calibration code. Record which cylinder the
injector is installed into. Refer to (PIL 33-45), Engine
Electronic Control Unit, Vehicle Set Up Data.
6. 18 - Fuel and Exhaust System
18 - Injection
03 - Injector
18 - 64 9813/7600-3 18 - 64
Figure 395.
B
A
C
D
A Correction factor (20 characters)
B Manufacturers reference
C JCB part number
D Injector serial number
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
or surface contamination will cause the injector
sealing O-ring to fail.
3. Install a new O-ring.
4. Install a new sealing washer.
5. Make sure that the injector is installed in the
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the
engine. Make sure the injector is pushed fully into
the cylinder head.
6. Tighten the injector clamp bolt to the correct
torque value.
After Installation
1. Replace the rocker cover, refer to (PIL 15-42).
2. Renew the high pressure fuel pipes, Refer to Fuel
Pipes (PIL 18-96).
3. Replace the low pressure fuel pipes, Refer to
Fuel Pipes (PIL 18-96).
4. Start the engine and check for fuel leaks.
Table 171. Torque Values
Item Nm
3 28
4 39
7. 18 - Fuel and Exhaust System
18 - Injection
07 - Injector Seal
18 - 65 9813/7600-3 18 - 65
07 - Injector Seal
Remove and Install
Special Tools
Description Part No. Qty.
Injector Seal
Installation Tool
(Electronic Engine)
892/12346 1
Injector Sleeve
Installation/Removal
Tool
892/12348 1
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. Clean the engine. Refer to Engine- Clean (PIL
15-00).
Figure 396.
B
A
C
D
A Rocker cover B Bolts
C Gasket D Injector seals
8. 18 - Fuel and Exhaust System
18 - Injection
07 - Injector Seal
18 - 66 9813/7600-3 18 - 66
Remove
1. Get access to the engine.
2. Remove the high pressure fuel pipes. Refer to
Fuel Pipes (PIL 18-96).
3. Remove the rocker cover from the cylinder head.
Refer to (PIL 15-42).
4. Put wooden supports under the rocker cover and
tap out the injector seals using the special tool.
Discard the seals.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
Figure 397.
EF
G
E Injector seal installation tool
F Injector seals
G Wooden supports
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Remove all oil and sludge contamination from
inside the valve chamber.
3. Renew the injector seals. Put supports under the
rocker cover and tap in the new seals using the
special tool.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
Figure 398.
E
F
G
E Injector seal installation tool
F Injector seals
G Wooden supports
4. Renew the rocker cover gasket.
5. Prevent damage to the seals. Put sleeves/covers
on the injectors. Apply a rubber lubricant to the
seals.
Special Tool: Injector Sleeve Installation/
Removal Tool (Qty.: 1)
6. Install the rocker cover. Refer to (PIL 15-42).
After Installation
1. The high pressure fuel pipes must be replaced
with new parts. Refer to Fuel Pipes (PIL 18-96).
2. Start the engine and check for oil and fuel leaks.
9. 18 - Fuel and Exhaust System
18 - Injection
12 - Rail
18 - 67 9813/7600-3 18 - 67
12 - Rail
Introduction .................................................... 18-67
Remove and Install ....................................... 18-68
Introduction
The fuel rail also known as a common rail, is a
pipe resembling a rail that is used to deliver fuel
to individual fuel injectors on internal combustion
engines. It is designed to have an outlet for each
injector, an inlet for a fuel supply and an outlet for a
fuel bleed off.
The fuel rail also incorporates an attached fuel
pressure sensor and a fuel valve. DO NOT
remove the high pressure fuel valve or the fuel
pressure sensor from the rail. If these components
are defective replace the complete common rail
assembly.
Figure 399.
A
D
C
E
B
F
A Fuel pressure sensor
B Outlet
C Bleed off
D High pressure fuel valve
E Inlet
F Rail assembly
10. 18 - Fuel and Exhaust System
18 - Injection
12 - Rail
18 - 68 9813/7600-3 18 - 68
Remove and Install
Before Removal
1. Obey all fuel system health and safety
information. Refer to (PIL 18-00).
2. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
3. Clean the engine. Refer to Engine-Clean (PIL
15-00).
4. Remove the high pressure fuel pipes. Refer to
Fuel Pipes (high pressure) - Remove and Install
(PIL 18-96).
5. Remove the fuel bleed off pipe at the rail. Refer to
Fuel Pipes (low pressure) - Remove and Install
(PIL 18-96).
Remove
1. Disconnect the electrical connector at the high
pressure fuel valve.
2. Disconnect the electrical connector at the fuel
pressure sensor.
3. Remove the bolts and lift off the common rail
assembly.
Seal the common rail assembly inside a clean plastic
bag until it is ready for use. If the assembly is
defective discard it and get a new one.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Tighten the bolts to the correct torque value.
When renewing the rail assembly make sure to
replace all of the high pressure fuel pipes. Refer to
(PIL 18-96).
Figure 400.
A
D
C
B
FE
E
A Fuel pressure sensor
B High pressure fuel pipe
C Fuel bleed off pipe
D High pressure fuel valve
E Bolts
F Rail assembly
Table 172. Torque Values
Item Nm
C 24
11. 18 - Fuel and Exhaust System
18 - Injection
15 - Pump
18 - 70 9813/7600-3 18 - 70
Component Identification
Figure 401.
12
7
1
8 2 10
3
9
13
4 2
5
6
11
1 Fuel injection pump
2 Pump fixing nuts (x3)
3 Injection pump gear cover
4 Inlet metering valve electrical connector
5 Fuel temperature sensor electrical connector
6 Fuel pipe connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector, injector bleed off
9 Drive shaft nut
10 Drive gear
11 Injection pump O-ring oil seal
12 High pressure fuel outlet port
13 Gear cover O-ring oil seal
Operation
The high pressure fuel injection pump is driven via a
gear on the engine and rotates at half engine speed.
The pump comprises of two sections, the transfer
pump and the high pressure pump.
Although the pump does not control fuel injection
timing, it is still timed in relation to engine phasing.
By timing the pump pressure pulses, the load on the
engine timing gears is reduced together with reduced
mechanical noise.
Transfer Pump Operation
The integral transfer pump is a vane type. An
engine driven rotor houses four vanes in slots.
The rotor rotates inside an eccentric liner. The
vanes are held in contact with the liner by springs.
Fuel is drawn into the pump chamber at port X,
pressurised by the decreasing volume inside the
chamber and expelled at port Y. Fuel pressure
generated by the transfer pump is limited to a
specified pressure by an integral pressure regulating
valve. This pressure is maintained regardless of
engine speed.6bar (87.0psi)
Figure 402.
A
D
C
B
X Y
E
A Rotor
B Vanes (x4)
C Eccentric liner
D Springs
E Regulating valve
X Port X
Y Port Y
High Pressure Pump Operation
Fuel passes to the high pressure pump via the IMV
(Inlet Metering Valve). The ECM (Engine Control
12. 18 - Fuel and Exhaust System
18 - Injection
15 - Pump
18 - 71 9813/7600-3 18 - 71
Module) controlled IMV determines the amount of
fuel transferred to the high pressure pump. The
plunger actuator block is located on the engine driven
eccentric shaft. When the shaft rotates the actuator
block operates the two plungers. As one plunger is
pushed up its chamber the other is pushed down by
its spring.
State 1 - Charging
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries.
When the eccentric shaft is in the position shown
force from spring moves the plunger down its
chamber. Pressure in the chamber falls below the
rail pressure and the delivery valve closes. Transfer
pressure is now sufficient to force inlet valve off its
seat and allow the fuel to fill the chamber.
Figure 403.
A
B
E
C
F
D
A Eccentric shaft
B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F Spring
State 2 - Pumping
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries.
When the eccentric shaft is in the position shown the
actuator block moves the plunger up its chamber.
Fuel pressure in the chamber rises and forces the
inlet valve on to its seat. As the plunger is pushed
further up its chamber the fuel pressure exceeds that
of the rail pressure and the delivery valve is forced off
its seat. Fuel is forced into the rail at high pressure.
Figure 404.
A
B
E
C
D
A Eccentric shaft
B Actuator block
C Plunger
D Inlet valve
E Delivery valve
13. 18 - Fuel and Exhaust System
18 - Injection
15 - Pump
18 - 72 9813/7600-3 18 - 72
Remove and Install
Special Tools
Description Part No. Qty.
Crankshaft Turning Tool
(95.25mm PCD)- JCB
4 Cylinder Ecomax and
Dieselmax
892/01147 1
Crankshaft /
Camshaft Timing Pin
(444/448/672 Engine)
892/01148 1
Tamper proof Cover
Removal Tool
892/01154 1
Pump Gear Removal
Tool
892/01155 1
C-Shaped Ring
Spanner
892/01179 1
Torque Wrench
(10-100Nm)
993/70111 1
Important: The following procedures include removal
and replacement of fuel system components. Before
starting the procedures the engine assembly must be
cleaned. Clean the engine. Refer to Engine- Clean
(PIL 15-00).
Important: Service procedures on the high pressure
fuel pump can only be carried out by specialist
personnel with the relevant training and equipment.
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. Get access to the engine.
3. Remove the high pressure fuel pipe at port 12,
refer to Fuel Pipes- Remove and Install. Cap all
open ports and pipes, refer to (PIL 18-96).
4. To improve access to the pump, remove the fuel
filter, refer to (PIL 18-09).
Important: When removing components dirt and
debris may become exposed or dislodged. Stop the
removal procedures and clean away the exposed
deposits. Refer to Engine- Clean (PIL 15-00).
Figure 405.
12
7
1
8 2 10
3
9
13
4 2
5
6
11
1 Fuel injection pump
2 Pump fixing nuts (x3)
3 Injection pump gear cover
4 IMV (Inlet Metering Valve) electrical connector
5 Fuel temperature sensor electrical connector
6 Fuel pipe connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector, injector bleed off
9 Drive shaft nut
10 Drive gear
11 Injection pump O-ring oil seal
12 High pressure fuel outlet port
13 Gear cover O-ring oil seal
Remove
1. Release the fuel pipe couplings at the inlet
connection 6 and bleed-off connections 7 and 8
on the pump. Cap all open ports and pipes.
2. Uncouple the electrical connectors at the IMV
and the fuel temperature sensor.
3. Remove the bedplate plug.
14. 18 - Fuel and Exhaust System
18 - Injection
15 - Pump
18 - 73 9813/7600-3 18 - 73
Figure 406.
A
C
1
1 Bedplate plug
A Crankshaft / Camshaft timing pin
C Crankshaft turning tool
4. Use the crankshaft turning tool to turn the
crankshaft until the timing pin engages in the
crankshaft timing hole.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1)
Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 1)
5. Use the gear removal tool and a suitable ratchet
drive to remove the fuel injection pump gear
cover.
Special Tool: Pump Gear Removal Tool (Qty.: 1)
6. Remove the drive shaft nut.
Figure 407.
B
3
11
F G
H
E
3 Gear cover
11 Drive shaft nut
B Gear removal tool
E Pump gear removal tool, comprises:
F Pump gear removal tool (Reaction cap)
G Pump gear removal tool (Body)
H Pump gear removal tool (Bolt)
7. Remove the nuts. Use the special C shaped
ring spanner to remove the nut closest to the
crankcase. Make sure you remove all nuts (X3).
8. Install the reaction cap over the pump shaft.
Screw the body to the housing. Use a suitable
ratchet drive and socket to screw the bolt in until
you feel a slight resistance.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
Special Tool: Pump Gear Removal Tool (Qty.: 1)
15. 18 - Fuel and Exhaust System
18 - Injection
15 - Pump
18 - 74 9813/7600-3 18 - 74
Figure 408.
2
H
G
F
10
2 Fixing nuts
10 Injection pump drive gear
F Pump gear removal tool (Reaction cap)
G Pump gear removal tool (Body)
H Pump gear removal tool (Bolt)
9. The injection pump drive gear is located on a
taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel pump. Tap the end of the bolt H with a
soft faced hammer. When the taper breaks there
will be an audible sound. Note: The pump drive
gear connects to the injection pump drive shaft by
means of taper lock alone, there is no mechanical
locking key.
10. Remove the service tools. Withdraw the pump
from the flywheel housing.
Install
1. Make sure that the taper surfaces on the injection
pump drive shaft and gear are clean and free
from oil and damage.
Figure 409.
9
2
2 12
10
2 Fixing nuts
9 Gear pump nut
10 Drive gear
12 Drive shaft
2. Make sure that the oil seal is correctly located on
the pump mounting face.
Figure 410.
16
16 Oil seal
3. Locate the pump on to the mounting studs.
Locate the drive gear over the pump drive shaft.
4. Install the fixing nuts and tighten to the correct
torque value.
5. Install the gear pump nut and tighten to the
correct torque value. Note: If a washer is supplied
with a replacement pump, Do not install the
washer. Secure the gear with the gear pump nut
only.
6. Use the tamperproof cover removal tool to install
the gear cover. Make sure its sealing O-ring is
correctly installed. Tighten the gear cover to the
correct torque value.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Special Tool: Tamper proof Cover Removal Tool
(Qty.: 1)
16. 18 - Fuel and Exhaust System
18 - Injection
15 - Pump
18 - 75 9813/7600-3 18 - 75
Figure 411.
B
3
3 Gear cover
B Tamperproof cover removal tool
After Installation
1. Remove the crankshaft turning tool.
2. Remove the crankshaft timing pin and install the
bedplate plug.
3. Reconnect the fuel pipe couplings at the inlet
connection, reconnect the bleed-off connections
on the pump.
4. Install a new high pressure fuel pipe, remove
the protective caps from the ports, refer to Fuel
Pipes- Remove and Install, refer to (PIL 18-96).
5. Connect the electrical connectors at the IMV and
the fuel temperature sensor.
6. Replace the fuel filter, refer to (PIL 18-09).
7. Start the engine and check for fuel leaks.
Figure 412.
12
7 8
4
5
6
4 IMV electrical connector
5 Fuel temperature sensor electrical connector
6 Fuel pipe connector (inlet)
7 Fuel pump bleed-off connection
8 Fuel pump bleed-off connection
12 High pressure fuel outlet port
Table 173. Torque Values
Item Nm
2 24
3 70
9 65
17. 18 - Fuel and Exhaust System
18 - Injection
27 - High Pressure Rail Valve
18 - 76 9813/7600-3 18 - 76
27 - High Pressure Rail Valve
Introduction .................................................... 18-76
Operation ....................................................... 18-77
Check (Operation) ......................................... 18-77
Remove and Install ....................................... 18-78
Introduction
The HPV (High Pressure Valve) is an integral part
of the common fuel rail assembly, If the valve
is defective replace the complete common rail
assembly. (Refer to PIL 18-18).
Figure 413. High pressure valve location
Figure 414.
A
B
A HPV
B Solenoid coil
18. 18 - Fuel and Exhaust System
18 - Injection
27 - High Pressure Rail Valve
18 - 77 9813/7600-3 18 - 77
Operation
In certain operating conditions, the HPV (High
Pressure Valve) controls the fuel pressure inside the
common rail.
When the valve opens, fuel is bled from the rail back
to the fuel tank, reducing the fuel pressure inside the
fuel rail. The valve is actuated by a solenoid coil and
features proportional control. The fuel flow through
the valve is proportional to the current supplied to
the coil. The current value is controlled by the ECM
(Engine Control Module) using PWM (Pulse Width
Modulation).
During normal engine operation, the fuel pressure is
controlled solely by the IMV (Inlet Metering Valve),
refer to (PIL 18-18).
In some operating circumstances, the IMV is unable
to alter the fuel pressure in the common rail quickly
enough. At these times, the ECM activates the HPV.
Typically the valve is used in the following conditions:
• Extreme transients, for example if the operator
goes from full throttle to no throttle quickly.
• When the fuel is cold.
In the event of an IMV failure, the ECM compensates
by altering the control of the HPV to ensure the
engine performance is sufficient to limp home.
Check (Operation)
For the full inspection and testing procedure, refer to
the help files in ServiceMaster.
19. 18 - Fuel and Exhaust System
18 - Injection
27 - High Pressure Rail Valve
18 - 78 9813/7600-3 18 - 78
Remove and Install
This part is a non-serviceable component, if it
is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
20. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 90 9813/7600-3 18 - 90
Component Identification
Figure 418.
1
1 Inlet Manifold
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
21. Thank you very much for
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22. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 91 9813/7600-3 18 - 91
Remove and Install
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 419.
2
3
3
4
5
12
8
9
11 10
6
7
13
1
1 Inlet manifold 2 Manifold gasket
3 Flanged hexagon bolt (x8) 4 Fuel rail mount
5 Screw (x4) 6 EGR (Exhaust Gas Recirculation) mixer tube
7 EGR Plug 8 Inlet manifold adaptor / throttle valve (not
shown)
9 Throttle O-ring 10 Flanged hexagon bolt (x4)
11 Inlet manifold bracket 12 Bolt M6 x 16mm (x1)
13 Bolt M8 x 25mm (x1)
Remove
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector.
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
4. Cap the inlet ports with blanking caps to prevent
ingress of dirt.
5. Inspect the manifold, refer to Check Condition
(PIL 18-24).
23. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 92 9813/7600-3 18 - 92
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.
5. Tighten the bolts to the correct torque value.
Table 177. Torque Values
Item Nm
3 43
24. 18 - Fuel and Exhaust System
24 - Exhaust
04 - Outlet Manifold
18 - 93 9813/7600-3 18 - 93
04 - Outlet Manifold
Introduction .................................................... 18-93
Component Identification ............................... 18-94
Check (Condition) .......................................... 18-94
Remove and Install ....................................... 18-95
Introduction
For: JCB T4F 4.4 over 55kw Electronic
Dieselmax Turbocharged Aftercooled
Engine, JCB Tier 4F Engine 4 Cyl, JCB Tier
4i /T4F <55kW Engine 4 Cyl ...... Page 18-93
Otherwise .................................. Page 18-93
(For: JCB T4F 4.4 over 55kw Electronic
Dieselmax Turbocharged Aftercooled
Engine, JCB Tier 4F Engine 4 Cyl, JCB
Tier 4i /T4F <55kW Engine 4 Cyl)
Figure 420.
A B
A Exhaust manifold
B Manifold gasket and heat shield
(Otherwise)
The exhaust outlet manifold collects the exhaust
gases from the multiple cylinders and delivers it to
the turbocharger or the exhaust pipe.