This document provides instructions for removing and installing the bedplate on a 4-cylinder JCB engine. Key steps include:
1. Removing components like the engine, drive belt, oil sump, fuel pipes and injectors, rocker cover and assembly.
2. Positioning the engine upside down supported at the front cylinder block.
3. Removing the flywheel.
4. Using a template and sealant to install the new bedplate, and torquing bolts to the specified values.
JCB 536-70 LOAD CONTROL (SUPPLEMENT) Service Repair Manualjskemmse
The LCS load control system provides protection against tipping forward by progressively reducing boom lowering and tilt functions as stability limits are approached. It has two modes - Load Control mode, which is automatic, and Ground Work mode, which functions like a standard LMI. In Load Control mode, boom lowering and tilt are derated, while extend functions normally until the limit. Once reached, lowering, tilting, crowding and dumping are prevented to avoid further instability. Boom lift and retract allow load retrieval. The system uses LED indicators and switches to monitor stability and select modes.
Jcb 531 70 telescopic handler service repair manual sn 2460601 and upcdfvvv
This service manual section provides information on servicing the engine. It describes the basic operation and components of the JCB Tier 2/3 4-cylinder diesel engine. The introduction covers the engine systems and operation, including fuel injection, air intake, lubrication, and ancillary drive. Component identification diagrams show the major internal engine parts.
Perkins 2200 series 2206 f e13ta industrial engine (model pp3 engine) service...jknsmmem
- This document provides instructions for disassembling and assembling various components of an industrial engine, including removal and installation procedures.
- It describes safely draining fluids and contains warnings about ensuring parts are clean to prevent contamination.
- The first sections cover removing and installing the fuel priming pump, fuel filter base, and associated components like filters, sensors, and hoses.
This document provides specifications for conveyor belts used in Japan. It specifies requirements for ply construction belts used at surface temperatures between -30 to 50°C. It defines classifications for belts based on nominal belt strength, width, and cover rubber performance. Requirements are provided for cover rubber performance, ply construction performance, adhesion, trough performance, linearity, sectional structure, joints, dimensions, and tolerances. Belts must be tested according to methods described and meet performance standards in the tables provided to comply with this industrial standard.
Scania industrial and marine engines 12 litre engine service repair manualkfkseekmmm
This document provides work instructions for servicing various components of 12 liter Scania industrial and marine engines, including the complete engine, cylinder head, turbocharger, pistons, flywheel, timing gears, camshaft, crankshaft, cylinder block, and lubrication system. It describes procedures for removing, inspecting, repairing, and replacing parts like the cylinder head, valves, pistons, cylinder liners, flywheel, timing gears, camshaft, and more. Specifications and required special tools are also provided.
3508 CATERPILLAR GENERATOR SET PARTS CATALOG MANUAL CAWManual Labs
This CATALOG MANUAL CAW for 3508 CATERPILLAR GENERATOR SET PARTS offers an in-depth look at the features of the generator set parts. With it, you'll have access to detailed product specs, diagrams and schematics to help you better understand how the parts are installed and used.
JCB 536-70 LOAD CONTROL (SUPPLEMENT) Service Repair Manualjskemmse
The LCS load control system provides protection against tipping forward by progressively reducing boom lowering and tilt functions as stability limits are approached. It has two modes - Load Control mode, which is automatic, and Ground Work mode, which functions like a standard LMI. In Load Control mode, boom lowering and tilt are derated, while extend functions normally until the limit. Once reached, lowering, tilting, crowding and dumping are prevented to avoid further instability. Boom lift and retract allow load retrieval. The system uses LED indicators and switches to monitor stability and select modes.
Jcb 531 70 telescopic handler service repair manual sn 2460601 and upcdfvvv
This service manual section provides information on servicing the engine. It describes the basic operation and components of the JCB Tier 2/3 4-cylinder diesel engine. The introduction covers the engine systems and operation, including fuel injection, air intake, lubrication, and ancillary drive. Component identification diagrams show the major internal engine parts.
Perkins 2200 series 2206 f e13ta industrial engine (model pp3 engine) service...jknsmmem
- This document provides instructions for disassembling and assembling various components of an industrial engine, including removal and installation procedures.
- It describes safely draining fluids and contains warnings about ensuring parts are clean to prevent contamination.
- The first sections cover removing and installing the fuel priming pump, fuel filter base, and associated components like filters, sensors, and hoses.
This document provides specifications for conveyor belts used in Japan. It specifies requirements for ply construction belts used at surface temperatures between -30 to 50°C. It defines classifications for belts based on nominal belt strength, width, and cover rubber performance. Requirements are provided for cover rubber performance, ply construction performance, adhesion, trough performance, linearity, sectional structure, joints, dimensions, and tolerances. Belts must be tested according to methods described and meet performance standards in the tables provided to comply with this industrial standard.
Scania industrial and marine engines 12 litre engine service repair manualkfkseekmmm
This document provides work instructions for servicing various components of 12 liter Scania industrial and marine engines, including the complete engine, cylinder head, turbocharger, pistons, flywheel, timing gears, camshaft, crankshaft, cylinder block, and lubrication system. It describes procedures for removing, inspecting, repairing, and replacing parts like the cylinder head, valves, pistons, cylinder liners, flywheel, timing gears, camshaft, and more. Specifications and required special tools are also provided.
3508 CATERPILLAR GENERATOR SET PARTS CATALOG MANUAL CAWManual Labs
This CATALOG MANUAL CAW for 3508 CATERPILLAR GENERATOR SET PARTS offers an in-depth look at the features of the generator set parts. With it, you'll have access to detailed product specs, diagrams and schematics to help you better understand how the parts are installed and used.
This document provides electrical schematics for the cab of Caterpillar 924K, 926M, 930K, 930M, 938K, and 938M wheel loaders. It includes a component location chart showing the installed location of components, a connector location chart showing connector numbers and locations, and detailed schematic diagrams of the cab electrical systems with callouts for components. The schematics use standard symbols and provide part numbers, locations, and descriptions to identify components within the various electrical circuits.
Kobelco sk250 10 hydraulic excavator service repair manualfjsjjekdkme
This document outlines general precautions and guidelines for repairing excavator equipment according to the shop manual. It discusses preparing for disassembly, safety during disassembly and assembly, handling hydraulic and electrical equipment, welding repairs, and environmental issues. The outline notes that the copyright belongs to Kobelco and outlines rules for copying or distributing the manual's contents. It also introduces the international unit system used in specifications.
Jcb 531 70 tier 4 telescopic handler service repair manual sn from 2902000 on...fjjsekksemmer
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 components. The main sections include checking injector operation with leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly and high pressure fuel injection pump. Torque specifications are provided for reinstalling components.
Allison AT, MT, HT Series Operator's manual.pdfRolandasPetkus
This document is an operator's manual that provides information about Allison automatic transmissions, including the AT, MT, and HT series models. It describes the basic components and operation of Allison automatics, such as the torque converter and lockup clutch. It also covers shift selector positions, driving tips, power takeoff operation, care and maintenance procedures, and customer service information.
Jcb 540 140 telescopic handler service repair manual from 2902000dufjsjekkkemm
This document provides service information for the valve train system of JCB diesel engines. It includes component identification diagrams, technical specifications for inlet and exhaust valves, descriptions of valve operation and procedures for adjusting and removing/installing valves. Valve clearance adjustment and replacement procedures are described to ensure proper valve timing and sealing.
Allis chalmers models d 17, d-17 series iii and d-17 series iv tractor servic...ufjjdjkksdekmd
This shop manual provides service information for Allis-Chalmers tractor models D-14, D-15, D-15 Series II, D-17, D-17 Series III, and D-17 Series IV. It describes the front system components, including single wheel tricycle, dual wheel tricycle, and wide front axle configurations. Procedures are provided for removing and servicing the front wheel assemblies, pedestals, and forks. The manual also includes an index and condensed service data covering specifications for the diesel and non-diesel engine variants.
The document is a catalog from Electromate that describes Harmonic Drive gearheads and planetary gear units. It provides an overview of Harmonic Drive's product lines including their Harmonic Planetary (HPG), High Torque (HPGP), Standard (HPN), and other gearhead series. The document discusses the operating principles of planetary gear units, lists technical specifications for various gearhead models, and outlines their applications in robotics, aerospace, factory automation, and other industries. It also provides a brief history of Harmonic Drive and highlights their innovative gearing technologies developed over 50+ years.
Allison 1000-2000 Series Service Manual.pdfRolandasPetkus
This document provides an overview of the Allison 1000/2000 series transmissions. It describes the key features and components including:
- Five speeds forward with overdrive fifth gear, plus reverse and neutral controlled electronically through six solenoids.
- Planetary gear sets and five clutch packs provide the gear ratios and shifting.
- Fully automatic operation controlled by the transmission control module (TCM).
- Common hydraulic system and oil pump provides pressure for clutches and lubrication.
- Variety of shift selector positions available depending on model and application.
Este manual técnico descreve os procedimentos de manutenção e reparo para motores MWM 4.10/T/TCA. Ele contém instruções detalhadas sobre a remoção e instalação de componentes do motor, testes de diagnóstico e especificações técnicas. Ferramentas especiais são necessárias para realizar alguns procedimentos.
Case ih puma 200 tractor service repair manualudfjjsekkemm
This document is a service manual for Puma 170 CVX, Puma 185 CVX, Puma 200 CVX, Puma 215 CVX, and Puma 230 CVX tractors. It contains information on the engine, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, hydraulic systems, pneumatic system, hitches and couplings, frames and ballasting, steering, wheels, cab climate control, and electrical systems. The manual provides part numbers and repair instructions for components of each system.
75mm tank gun M2 for medium tank M3 (Grant) Maintenance ManualRimsky Cheng
This document provides a 3-paragraph summary of a military manual describing the 75mm tank gun M2 mounted on medium tank M3s. It includes characteristics of the gun such as its flat trajectory, drop-type breechblock, and ability to fire 15-pound projectiles at rates up to 20 rounds per minute. It also describes the gun group including the tube, breech ring, breechblock, extractors, and firing mechanism. Finally, it provides general data on the gun and mount including weights, dimensions, ballistics, and maximum elevation and traverse capabilities.
El documento proporciona especificaciones técnicas e información sobre códigos de avería para varios modelos de calefactores AT, incluyendo rangos de valores para sensores, esquemas eléctricos y descripciones breves de los códigos de error.
Jcb 540 v180 telescopic handler service repair manual sn from 2902000 onwardscdfvvv
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.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upcdfvvv
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
This document provides electrical schematics for the cab of Caterpillar 924K, 926M, 930K, 930M, 938K, and 938M wheel loaders. It includes a component location chart showing the installed location of components, a connector location chart showing connector numbers and locations, and detailed schematic diagrams of the cab electrical systems with callouts for components. The schematics use standard symbols and provide part numbers, locations, and descriptions to identify components within the various electrical circuits.
Kobelco sk250 10 hydraulic excavator service repair manualfjsjjekdkme
This document outlines general precautions and guidelines for repairing excavator equipment according to the shop manual. It discusses preparing for disassembly, safety during disassembly and assembly, handling hydraulic and electrical equipment, welding repairs, and environmental issues. The outline notes that the copyright belongs to Kobelco and outlines rules for copying or distributing the manual's contents. It also introduces the international unit system used in specifications.
Jcb 531 70 tier 4 telescopic handler service repair manual sn from 2902000 on...fjjsekksemmer
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 components. The main sections include checking injector operation with leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly and high pressure fuel injection pump. Torque specifications are provided for reinstalling components.
Allison AT, MT, HT Series Operator's manual.pdfRolandasPetkus
This document is an operator's manual that provides information about Allison automatic transmissions, including the AT, MT, and HT series models. It describes the basic components and operation of Allison automatics, such as the torque converter and lockup clutch. It also covers shift selector positions, driving tips, power takeoff operation, care and maintenance procedures, and customer service information.
Jcb 540 140 telescopic handler service repair manual from 2902000dufjsjekkkemm
This document provides service information for the valve train system of JCB diesel engines. It includes component identification diagrams, technical specifications for inlet and exhaust valves, descriptions of valve operation and procedures for adjusting and removing/installing valves. Valve clearance adjustment and replacement procedures are described to ensure proper valve timing and sealing.
Allis chalmers models d 17, d-17 series iii and d-17 series iv tractor servic...ufjjdjkksdekmd
This shop manual provides service information for Allis-Chalmers tractor models D-14, D-15, D-15 Series II, D-17, D-17 Series III, and D-17 Series IV. It describes the front system components, including single wheel tricycle, dual wheel tricycle, and wide front axle configurations. Procedures are provided for removing and servicing the front wheel assemblies, pedestals, and forks. The manual also includes an index and condensed service data covering specifications for the diesel and non-diesel engine variants.
The document is a catalog from Electromate that describes Harmonic Drive gearheads and planetary gear units. It provides an overview of Harmonic Drive's product lines including their Harmonic Planetary (HPG), High Torque (HPGP), Standard (HPN), and other gearhead series. The document discusses the operating principles of planetary gear units, lists technical specifications for various gearhead models, and outlines their applications in robotics, aerospace, factory automation, and other industries. It also provides a brief history of Harmonic Drive and highlights their innovative gearing technologies developed over 50+ years.
Allison 1000-2000 Series Service Manual.pdfRolandasPetkus
This document provides an overview of the Allison 1000/2000 series transmissions. It describes the key features and components including:
- Five speeds forward with overdrive fifth gear, plus reverse and neutral controlled electronically through six solenoids.
- Planetary gear sets and five clutch packs provide the gear ratios and shifting.
- Fully automatic operation controlled by the transmission control module (TCM).
- Common hydraulic system and oil pump provides pressure for clutches and lubrication.
- Variety of shift selector positions available depending on model and application.
Este manual técnico descreve os procedimentos de manutenção e reparo para motores MWM 4.10/T/TCA. Ele contém instruções detalhadas sobre a remoção e instalação de componentes do motor, testes de diagnóstico e especificações técnicas. Ferramentas especiais são necessárias para realizar alguns procedimentos.
Case ih puma 200 tractor service repair manualudfjjsekkemm
This document is a service manual for Puma 170 CVX, Puma 185 CVX, Puma 200 CVX, Puma 215 CVX, and Puma 230 CVX tractors. It contains information on the engine, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, hydraulic systems, pneumatic system, hitches and couplings, frames and ballasting, steering, wheels, cab climate control, and electrical systems. The manual provides part numbers and repair instructions for components of each system.
75mm tank gun M2 for medium tank M3 (Grant) Maintenance ManualRimsky Cheng
This document provides a 3-paragraph summary of a military manual describing the 75mm tank gun M2 mounted on medium tank M3s. It includes characteristics of the gun such as its flat trajectory, drop-type breechblock, and ability to fire 15-pound projectiles at rates up to 20 rounds per minute. It also describes the gun group including the tube, breech ring, breechblock, extractors, and firing mechanism. Finally, it provides general data on the gun and mount including weights, dimensions, ballistics, and maximum elevation and traverse capabilities.
El documento proporciona especificaciones técnicas e información sobre códigos de avería para varios modelos de calefactores AT, incluyendo rangos de valores para sensores, esquemas eléctricos y descripciones breves de los códigos de error.
Jcb 540 v180 telescopic handler service repair manual sn from 2902000 onwardscdfvvv
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.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upcdfvvv
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 536 70 lp tier 4 telescopic handler service repair manual sn from 2460601...cdfvvv
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for servicing fuel injectors, including checking operation, removing and installing individual injectors, and removing and installing injector seals.
Jcb 536 70 tier 4 telescopic handler service repair manual sn from 2902000 on...cdfvvv
This document provides service and repair instructions for fuel injectors on JCB Loadall vehicles. It describes injector components and identification, includes a check procedure using diagnostic tools, and outlines removal and installation steps. Special tools are required for tasks like leak testing and installing injector seals. Torque specifications are provided for reinstalling injectors and seals.
Jcb 535 95 telescopic handler service repair manual sn 2460601 and upcdfvvv
This service manual section provides information on servicing the engine. It describes the basic operation and components of the JCB Tier 2/3 4-cylinder diesel engine. The introduction covers the engine systems and operation, including fuel injection, air intake, lubrication, and ancillary drive. Component identification diagrams show the major internal engine parts.
Jcb 526 56 telescopic handler service repair manual sn 2460601 and upcdfvvv
This service manual section provides information on servicing the engine. It describes the basic operation and components of the JCB Tier 2/3 4-cylinder diesel engine. The introduction outlines the engine systems and operation, including fuel injection, valve actuation, lubrication, cooling and starting. Component identification diagrams show the major internal and external engine parts.
Jcb 225 t skid steer loader service repair manual sn from 2478301 to 2478700cdfvvv
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine overview, attachments, body/framework, operator station, HVAC, engine, fuel/exhaust, cooling, brakes, driveline, hydraulics, and electrical systems. The section summarized focuses on servicing the engine crankshaft, including removal/installation instructions and specifications. Technicians are advised to follow all safety procedures, use the proper tools, and replace all worn parts.
Jcb 225 t skid steer loader service repair manual sn from 2476302 to 2477300cdfvvv
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine overview, attachments, body/framework, operator station, HVAC, engine, fuel/exhaust, cooling, brakes, driveline, hydraulics, and electrical systems. The document provides an introduction to servicing the engine crankshaft, including guidelines on checking crankshaft condition and removing/installing the crankshaft. Technicians are instructed to follow all safety procedures, use the proper tools, and replace all necessary components.
Jcb 155 hd skid steer loader service repair manual (sn 2431601 and up)cdfvvv
This service manual provides information for servicing a JCB 135 HD and 155 HD skid steer loader. It contains sections covering the machine systems, including the engine, fuel system, hydraulic system, electrical system, and other components. The document provides illustrations and instructions for removal, installation, maintenance, and repair of parts. Safety precautions are described, requiring technicians to fully understand the manual before operating or servicing the machine.
Jcb 135 hd skid steer loader service repair manual (sn 2431601 and up)cdfvvv
This service manual provides instructions for servicing a JCB skid steer loader models 135 HD and 155 HD. It contains sections covering the machine systems including the engine, fuel system, hydraulic system, electrical system, and other components. The document provides detailed descriptions of components, operating principles, maintenance and repair procedures, specifications, and safety information. Technicians are instructed to carefully follow the procedures in the manual to properly service the loader and ensure safe operation.
Jcb 5 cx backhoe loader service repair manual sn from 2509500 and upcdfvvv
This service manual provides instructions for servicing components of JCB backhoe loaders models 3CX, 4CX, and 5CX. It contains sections covering various systems of the machine including the engine, fuel and exhaust systems, cooling system, brake system, hydraulic system, and electrical system. The manual instructs technicians on removing, installing, and servicing components and includes diagrams identifying parts. Safety warnings are provided throughout advising technicians to follow instructions carefully and wear proper protective equipment when servicing machines.
Jcb 4 cx backhoe loader service repair manual sn from 2509500 and upcdfvvv
This service manual provides instructions for servicing components of JCB backhoe loaders models 3CX, 4CX, and 5CX. It contains sections covering various systems of the machine including the engine, fuel and exhaust systems, cooling system, brake system, hydraulic system, and electrical system. The manual instructs technicians on removing, installing, and servicing components and includes diagrams identifying parts. Safety warnings are provided throughout advising technicians to follow instructions carefully and wear proper protective equipment when servicing machines.
Jcb 3 cx backhoe loader service repair manual sn from 2509500 and upcdfvvv
This service manual provides instructions for servicing components of JCB 3CX, 4CX, and 5CX backhoe loaders, including the machine, attachments, body, operator station, HVAC, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, electrical system, fasteners, consumable products, and after sales. The manual contains safety warnings and instructions for removing and installing components. It provides identification diagrams and specifications for proper servicing.
Caterpillar cat 305.5 e mini hydraulic excavator (prefix mx5) service repair ...cdfvvv
The document provides instructions for servicing components of a 305.5E Mini Hydraulic Excavator engine. It describes procedures for removing and installing the crankshaft rear seal, flywheel housing, crankshaft pulley, and crankshaft front seal. The summaries provide tools needed and step-by-step instructions for each procedure.
Caterpillar cat 303 e cr mini hydraulic excavator (prefix smg) service repair...cdfvvv
The document provides instructions for removing and installing a governor and fuel injection pump on a Caterpillar 303E CR Mini Hydraulic Excavator. It describes removing 11 parts in 11 steps to remove the governor, including bolts, springs, plates and shafts. It then describes installing the governor in 11 corresponding steps. Separate sections provide 3 steps to remove the fuel injection pump and 4 steps to install it, noting the importance of matching shim thicknesses. Another section outlines 4 steps for removing fuel injectors and 4 steps for installing them.
Caterpillar cat 303.5 e mini hydraulic excavator (prefix rse) service repair ...cdfvvv
The document provides instructions for disassembling and assembling the swing motor and swing drive of a 303.5E Mini Hydraulic Excavator. It lists 32 steps for disassembly, removing components like valves, springs, spools, checks valves, plates, and gears. It then lists 28 steps for assembly, installing these components in reverse order. Precautions are provided for parts under spring force. Required tools include bearing pullers, crossblocks, and retaining ring pliers.
Caterpillar cat 140 h motor grader (prefix cca) service repair manual (cca000...cdfvvv
1) The document provides assembly instructions for a piston pump used in a 140H motor grader.
2) It describes 57 assembly steps involving over 30 individual parts like pistons, springs, seals, and manifolds.
3) Special tools and cleanliness are emphasized to prevent damage during assembly, and proper break-in is noted after assembly is complete.
Caterpillar cat 140 h motor grader (prefix 8km) service repair manual (8km000...cdfvvv
This document provides instructions for removing and installing various engine components on a Caterpillar 140H motor grader, including:
- Inlet and exhaust valves
- Valve guides
- Valve seat inserts
- Engine oil filter base
The instructions include lists of required tools, step-by-step procedures, diagrams, and safety notices for each component.
Caterpillar cat 140 g motor grader (prefix 13w) service repair manual (13w004...cdfvvv
This document provides instructions for servicing the hydraulic pump and control valves on a Caterpillar 140G motor grader. It describes how to remove and install the hydraulic pump, including disconnecting hoses and removing mounting hardware. It also details how to disassemble and assemble the pump for component replacement. Separate instructions are provided for removing and installing the hydraulic control valves as an assembly, and then further disassembling the valves.
Jcb tlt 30 g teletruk (variable reach truck) service repair manual sn 2498451...cdfvvv
This service manual provides information for servicing the TLT 25G and TLT 30G Teletruk vehicles. It contains sections covering the machine components, including the engine. The engine section provides an overview of the 4-cylinder LPG engine and its operation, including safety information, technical specifications, component identification, and instructions for operation, fault-finding, cleaning, removal/installation, and storage/recommissioning. Diagrams are included to illustrate the engine components and 4-stroke operating cycle.
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!
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 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.
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!
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.
The Octavia range embodies the design trend of the Škoda brand: a fusion of
aesthetics, safety and practicality. Whether you see the car as a whole or step
closer and explore its unique features, the Octavia range radiates with the
harmony of functionality and emotion
2. 15 - Engine
00 - Engine
00 - General
15 - 3 9823/0050-1 15 - 3
00 - General
Introduction ...................................................... 15-3
Health and Safety .......................................... 15-11
Technical Data ............................................... 15-12
Component Identification ............................... 15-15
Operation ....................................................... 15-22
Diagram ......................................................... 15-29
Fault-Finding .................................................. 15-30
Drain and Fill ................................................. 15-49
Clean ............................................................. 15-49
Check (Pressure) .......................................... 15-51
Remove and Install ....................................... 15-54
Store and Recommission .............................. 15-58
Introduction
For: JCB Tier 2/3 Elec Engine 4 Cyl
..................................................... Page 15-3
For: JCB Tier 2/3 Mech Engine 4 Cyl
..................................................... Page 15-6
(For: JCB Tier 2/3 Elec Engine 4 Cyl)
This section contains information about the complete
engine assembly. For specific engine technical
information refer to the technical data section.
Make sure that the correct engine service tools,
consumables and torque figures are used when you
perform service procedures.
Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
damage is expected as a matter of course.
It is expected that components will be cleaned and
lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The JCB ecoMax engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The
starter motor turns the engine via a pinion and teeth
on the engine flywheel. Refer to: PIL 15-75.
When the engine runs the crankshaft drives the
camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. The engine has 16 valves,
2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a high pressure fuel pump
via gears. The pump is part of the electronically
controlled common rail fuel injection system. Refer
to: PIL 18-00.
Air is drawn into the engine, via the inlet manifold
and exhaust gases exit via the exhaust manifold.
The engine uses a VGT (Variable Geometry
Turbocharger) which pressurises the air at the inlet
manifold. Refer to PIL 18-36.
A mechanical lubrication oil pump is driven by
the crankshaft via gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt driven by the crankshaft, drives a
coolant circulation pump, alternator, radiator cooling
3. 15 - Engine
00 - Engine
00 - General
15 - 4 9823/0050-1 15 - 4
fan and other ancillaries such as an air conditioning
compressor.
Figure 172.
1
4
8
5
9
6
2
3
10
6
7
1 Flywheel 2 Crankshaft
3 Camshaft 4 Inlet valves (x8)
5 Exhaust valves (x8) 6 Push rods (x8)
7 High pressure fuel pump drive gear 8 Turbocharger
9 Lubrication oil pump 10 Front end drive belt
4. 15 - Engine
00 - Engine
00 - General
15 - 5 9823/0050-1 15 - 5
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 173.
1 Rocker assembly 2 Valve bridge piece (x8)
3 Valve spring (x16) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft / connecting rod
(x4)
11 Front crankshaft oil seal 12 Flywheel
13 High duty PTO (Power Take-Off) idler gear (if
installed)
5. 15 - Engine
00 - Engine
00 - General
15 - 6 9823/0050-1 15 - 6
Figure 174.
1a
1
5
2
3
4
7
6
8
9
10
11
1 Flywheel 1A Flywheel - crankshaft fixing bolts (x8)
2 Fuel injector (atomiser) (x4) 3 Flywheel hub
4 Crankshaft drive gear 5 High duty PTO idler gear (if installed)
6 Camshaft drive gear 7 Lubrication oil pump
8 High pressure fuel pump drive gear 9 Camshaft
10 Tappet (x8) 11 Push rod (x8)
(For: JCB Tier 2/3 Mech Engine 4 Cyl)
This section contains information about the complete
engine assembly. For specific engine technical
information refer to the technical data section.
Make sure that the correct engine service tools,
consumables and torque figures are used when you
perform service procedures. Renewal of oil seals,
6. 15 - Engine
00 - Engine
00 - General
15 - 7 9823/0050-1 15 - 7
gaskets, etc., and any component showing obvious
signs of wear or damage is expected as a matter
of course. It is expected that components will be
cleaned and lubricated where appropriate, and that
any opened hose or pipe connections will be blanked
to prevent excessive loss of hydraulic fluid, engine oil
and ingress of dirt.
Basic Description
The JCB DieselMax engine is a 4 cylinder diesel
engine in which the fuel is ignited by compression
ignition (C.I.). The engine operates on a four stroke
cycle.
The engine is started by an electric starter motor. The
starter motor turns the engine via a pinion and teeth
on the engine flywheel, refer to (PIL 15-75).
When the engine runs the crankshaft drives the
camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. The engine has 16 valves,
2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a mechanical fuel
injection pump via gears. The pump injects fuel via
injectors, or atomisers into each cylinder in time with
the four stroke cycle.
Air is drawn into the engine, via the inlet manifold
and exhaust gases exit via the exhaust manifold. The
engine uses an exhaust driven turbocharger which
pressurises the air at the inlet manifold, refer to (PIL
18-36).
A mechanical lubrication oil pump is driven by
the crankshaft via gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt driven by the crankshaft, drives a
coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
8. 15 - Engine
00 - Engine
00 - General
15 - 9 9823/0050-1 15 - 9
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
As viewed on the right hand side. Refer to Figure 176.
Figure 176.
1
8
9
16
15
3
2
13
14
11
10
12
7
6
6d
6c
6b
6a
5
4
1 Rocker assembly 2 Valve bridge piece (x8)
3 Valve spring (x8) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft/connecting rod
(x4)
11 Front crankshaft oil seal 12 Front end drive belt pulley
13 Flywheel 14 Starter motor pinion
10. 15 - Engine
00 - Engine
00 - General
15 - 11 9823/0050-1 15 - 11
Health and Safety
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system.Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
11. 15 - Engine
09 - Bedplate
00 - General
15 - 76 9823/0050-1 15 - 76
Remove and Install
(For: JCB Tier 2/3 Elec Engine 4 Cyl, JCB
Tier 2/3 Mech Engine 4 Cyl)
Special Tools
Description Part No. Qty.
Template for Sealant
Bedplate to Crankcase
(4 Cyl)
892/12356 1
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO (Power Take-Off)
device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
13. 15 - Engine
09 - Bedplate
00 - General
15 - 78 9823/0050-1 15 - 78
Remove
1. Remove the bedplate peripheral bolts.
2. Progressively remove the main bearing bolts in
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate.
4. Remove and discard the O-ring.
5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
Figure 201.
18
18
18
18
18
T6
T6
T6
18
12
T6
P3
13
11
A (T5)
V
Y
Y P2
5
1
9
4
8
3
7
6
2
10
T4
T4
W
P2
B (T5)
Y Y P2
X
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)
12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
14. 15 - Engine
09 - Bedplate
00 - General
15 - 79 9823/0050-1 15 - 79
T4 Guide pins (x2 obtain locally) T5 Sealant template
T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
15. 15 - Engine
09 - Bedplate
00 - General
15 - 80 9823/0050-1 15 - 80
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Anaerobic sealant will not start to cure
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and tightened to the correct
torque value within 5 minutes (with a maximum
permissible time of 15 minutes).
Important: BEFORE installing the bedplate: DO NOT
rotate the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of the
crankcase.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown.
4. Install the four lifting bolts T6 to the bedplate as
shown.
5. Install a new O-ring at the bedplate.
6. Use a suitable degreasing agent to clean both
sides of the lower bearing shells. Assemble the
lower bearing shells into the bedplate. Lubricate
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
7. Note: The sealant template T5 is used on
the crankcase, NOT the bedplate. The sealant
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1)
8. Locate the holes in the templates A and B using
four fixing bolts at positions Y. Use the templates
as a guide apply beads of sealant P2 around the
crankcase/bedplate mating face as shown to the
dimension specified.
Length/Dimension/Distance: 1.5mm
9. Remove the four fixing bolts at positions Y.
Remove the templates A and B, make sure
you do not smudge the sealant. Discard the
templates.
10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
beads as shown at X.
11. Make sure that the location guide pins T4 are in
position in the crankcase. Assemble the bedplate
to the crankcase use the alignment guide pins.
12. Note: The bedplate is heavy. Two people will
be required to lift and rotate the bedplate safely
on to the crankcase. Install new main bearing
bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 1st stage pre-
torque.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
13. Install the bedplate peripheral bolts. Tighten the
bolts to the correct torque value.
14. After installation and tightening the bedplate
peripheral bolts, further tighten the main bearing
bolts in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 2nd stage
pre-torque.
15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
(in sequence 1-10) for the final stage torque. Use
the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
Important: If the parts have not been tightened to the
correct torque value within the maximum 15 minute
time period, then the parts must be separated,
thoroughly cleaned and fresh sealant applied.
After Installation
1. Check that the crankshaft can be freely rotated
by hand. Remove the bedplate lifting bolts T6.
2. Carry out the procedures listed, Before removal
in reverse order.
Table 106. Torque Table
Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
16. 15 - Engine
12 - Crankshaft
00 - General
15 - 85 9823/0050-1 15 - 85
Component Identification
(For: JCB Tier 2/3 Elec Engine 4 Cyl, JCB
Tier 2/3 Mech Engine 4 Cyl)
Figure 202.
B
A
A Crankcase
B Crankshaft
17. 15 - Engine
12 - Crankshaft
00 - General
15 - 86 9823/0050-1 15 - 86
Operation
(For: JCB Tier 2/3 Elec Engine 4 Cyl, JCB
Tier 2/3 Mech Engine 4 Cyl)
Refer to Camshaft-Operation (PIL 15-15).
Lubrication
Oil is fed from the main gallery via five drillings, one
to each of the main bearings. A groove around the
diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 203.
1 Main gallery 2 Drillings (x5)
3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
18. 15 - Engine
12 - Crankshaft
00 - General
15 - 87 9823/0050-1 15 - 87
7 Crankshaft oil seal 8 Crankshaft oil seal
19. 15 - Engine
12 - Crankshaft
00 - General
15 - 88 9823/0050-1 15 - 88
Check (Condition)
(For: JCB Tier 2/3 Elec Engine 4 Cyl, JCB
Tier 2/3 Mech Engine 4 Cyl)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 204.
A
A Main bearing shells
2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 205.
B
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
Figure 206.
D
C
C J-jets
D Fixing screws
20. 15 - Engine
12 - Crankshaft
00 - General
15 - 89 9823/0050-1 15 - 89
Remove and Install
(For: JCB Tier 2/3 Elec Engine 4 Cyl, JCB
Tier 2/3 Mech Engine 4 Cyl)
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
25. Remove the bedplate, refer to (PIL 15-09).
Remove
1. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
21. 15 - Engine
12 - Crankshaft
00 - General
15 - 90 9823/0050-1 15 - 90
Figure 207.
C
B
A
A
A Thrust Washers B Crankshaft
C Rear main bearing
2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
4. Carefully lift out the bearing shells.
Figure 208.
D
D Main bearing shells
5. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
then install cooling J jets as follows:
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23. 15 - Engine
12 - Crankshaft
00 - General
15 - 91 9823/0050-1 15 - 91
Figure 209.
F
E
E J jets (x4)
F Fixing screws
3.1. Insert the cooling jets into the crankcase.
3.2. Note: There are different types of cooling
jets installed depending on the engine
application. The jets are colour coded.
3.3. Be sure to install the correct jets. Refer to
the relevant parts catalogue for the correct
cooling jet identification.
3.4. Tighten the retaining screws to the correct
torque value.
4. Install the upper bearing shells as follows:
Figure 210.
D
G
D Main bearing shells
G Bearing location tab
4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
4.3. Important: Make sure that the oil-way holes
in the bearing saddles align with the holes
in the bearing shell. If the holes are even
partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
24. 15 - Engine
12 - Crankshaft
00 - General
15 - 92 9823/0050-1 15 - 92
Figure 211.
C
B
A
A
A
H
A Thrust washers B Crankshaft
C Rear main bearing H Oil slot - thrust washers
6.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).
Table 108. Torque Values
Item Nm
F 24
25. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 93 9823/0050-1 15 - 93
03 - Main Bearing
Introduction .................................................... 15-93
Check (Condition) .......................................... 15-94
Remove and Install ....................................... 15-94
Introduction
(For: JCB Tier 2/3 Elec Engine 4 Cyl, JCB
Tier 2/3 Mech Engine 4 Cyl)
In a piston engine, the main bearings are the
bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 212.
A
B
A Main bearing
B Crankshaft