This document provides service and repair instructions for fuel injectors in 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 tightening injector clamps and sleeves.
New holland l228 tier 4 b (final) europe skid steer loader service repair manualfjsjfkskefmem
This document provides service information for Tier 4B engines used in New Holland C227, C232, L221, and L228 skid steer and compact track loaders. It contains over 150 sections covering the engine and all related systems, with detailed removal and installation instructions. Safety precautions are provided throughout regarding handling heavy components, draining fluids, battery and refrigerant handling.
New holland cx720 combine harvesters service repair manualfjsjfkskefmem
The document provides an overview and component locations of the primary hydraulic power system for a New Holland agricultural vehicle. The system uses a closed-center load sensing pump to supply oil to circuits for steering, header height control, straw elevator functions, lateral flotation, reel adjustment, and unloading tube control. Key components include hydraulic pumps and motors, valves, cylinders, filters, accumulators, and manifolds.
New holland cs540 combine harvesters service repair manualfjsjfkskefmem
This document is a repair manual for New Holland agricultural equipment models CS520, CS540, CS640, CS660, and CL560. It contains sections on the machines' distribution systems, power production, power train, travelling systems, body and structure, tool positioning, and crop processing. The sections contain chapters that provide technical data, functional descriptions, diagnostic information, and service procedures for the machines' components and systems. The manual uses a coding system to uniquely identify each piece of technical information and allow users to easily search for the specific information they need.
New holland cr7.90 combine harvesters service repair manualfjsjfkskefmem
This document is a service manual for CNH Industrial combine harvesters and covers models CX7.80 through CR10.90. It contains over 200 sections on the various systems of the combines, including the engine, transmission, hydraulics, electrical systems, attachments and more. Safety guidelines are provided at the beginning emphasizing disengaging machinery, reducing pressures, and using proper protective equipment during maintenance.
New holland c227 tier 4 b final [ndm471836 ]north america compact track load...fjsjfkskefmem
This document is a service manual for New Holland C227, C232, L221, and L228 compact track loaders and skid steer loaders that comply with Tier 4B emissions standards. It contains sections covering the engine, power coupling, front and rear axle systems, hydrostatic drive, brakes and controls, hydraulic systems, frames and ballasting, wheels, tracks and track suspension, cab climate control, electrical systems, front loader and bucket, platform, cab, bodywork, and decals. Safety and environmental rules are also provided regarding the handling and disposal of fluids, fuels, and other materials.
Caterpillar cat d4 e track tractor service repair manual (77w01664 and up)fjsjfkskefmem
This document provides instructions for removing and installing a fuel priming pump on a Caterpillar D4E track-type tractor with a 3304 engine. The removal procedure involves turning off the fuel supply line valve, removing bolts and washers to detach the pump from its base, disconnecting a tube assembly, and removing two bolts to detach the base from the cylinder block. The installation procedure is the reverse of removal. Proper cleanliness and containment of fluids is emphasized.
Caterpillar cat d4 e track tractor (prefix 68x) service repair manual (68x007...fjsjfkskefmem
The document provides instructions for removing and installing the fuel priming pump, removing and installing the fuel filter base, removing the fuel transfer pump, and disassembling the fuel transfer pump on a Caterpillar D4E track-type tractor with a 3304 engine. The procedures include illustrations and describe disconnecting fuel lines, removing bolts and parts, checking gaskets, and containing fluids.
Caterpillar cat d4 e track tractor (prefix 68x) service repair manual (68x000...fjsjfkskefmem
This document provides instructions for removing and disassembling fuel system components on a Caterpillar D4E track-type tractor with a 3304 engine. The procedures include:
1. Removing the fuel priming pump by taking off bolts, washers and a gasket.
2. Removing the fuel filter base by disconnecting a fuel line, removing bolts and washers, and taking off a gasket.
3. Disassembling the fuel transfer pump by removing tubes, bolts, an O-ring seal, and taking apart the pump housing, piston, springs, and valves.
New holland l228 tier 4 b (final) europe skid steer loader service repair manualfjsjfkskefmem
This document provides service information for Tier 4B engines used in New Holland C227, C232, L221, and L228 skid steer and compact track loaders. It contains over 150 sections covering the engine and all related systems, with detailed removal and installation instructions. Safety precautions are provided throughout regarding handling heavy components, draining fluids, battery and refrigerant handling.
New holland cx720 combine harvesters service repair manualfjsjfkskefmem
The document provides an overview and component locations of the primary hydraulic power system for a New Holland agricultural vehicle. The system uses a closed-center load sensing pump to supply oil to circuits for steering, header height control, straw elevator functions, lateral flotation, reel adjustment, and unloading tube control. Key components include hydraulic pumps and motors, valves, cylinders, filters, accumulators, and manifolds.
New holland cs540 combine harvesters service repair manualfjsjfkskefmem
This document is a repair manual for New Holland agricultural equipment models CS520, CS540, CS640, CS660, and CL560. It contains sections on the machines' distribution systems, power production, power train, travelling systems, body and structure, tool positioning, and crop processing. The sections contain chapters that provide technical data, functional descriptions, diagnostic information, and service procedures for the machines' components and systems. The manual uses a coding system to uniquely identify each piece of technical information and allow users to easily search for the specific information they need.
New holland cr7.90 combine harvesters service repair manualfjsjfkskefmem
This document is a service manual for CNH Industrial combine harvesters and covers models CX7.80 through CR10.90. It contains over 200 sections on the various systems of the combines, including the engine, transmission, hydraulics, electrical systems, attachments and more. Safety guidelines are provided at the beginning emphasizing disengaging machinery, reducing pressures, and using proper protective equipment during maintenance.
New holland c227 tier 4 b final [ndm471836 ]north america compact track load...fjsjfkskefmem
This document is a service manual for New Holland C227, C232, L221, and L228 compact track loaders and skid steer loaders that comply with Tier 4B emissions standards. It contains sections covering the engine, power coupling, front and rear axle systems, hydrostatic drive, brakes and controls, hydraulic systems, frames and ballasting, wheels, tracks and track suspension, cab climate control, electrical systems, front loader and bucket, platform, cab, bodywork, and decals. Safety and environmental rules are also provided regarding the handling and disposal of fluids, fuels, and other materials.
Caterpillar cat d4 e track tractor service repair manual (77w01664 and up)fjsjfkskefmem
This document provides instructions for removing and installing a fuel priming pump on a Caterpillar D4E track-type tractor with a 3304 engine. The removal procedure involves turning off the fuel supply line valve, removing bolts and washers to detach the pump from its base, disconnecting a tube assembly, and removing two bolts to detach the base from the cylinder block. The installation procedure is the reverse of removal. Proper cleanliness and containment of fluids is emphasized.
Caterpillar cat d4 e track tractor (prefix 68x) service repair manual (68x007...fjsjfkskefmem
The document provides instructions for removing and installing the fuel priming pump, removing and installing the fuel filter base, removing the fuel transfer pump, and disassembling the fuel transfer pump on a Caterpillar D4E track-type tractor with a 3304 engine. The procedures include illustrations and describe disconnecting fuel lines, removing bolts and parts, checking gaskets, and containing fluids.
Caterpillar cat d4 e track tractor (prefix 68x) service repair manual (68x000...fjsjfkskefmem
This document provides instructions for removing and disassembling fuel system components on a Caterpillar D4E track-type tractor with a 3304 engine. The procedures include:
1. Removing the fuel priming pump by taking off bolts, washers and a gasket.
2. Removing the fuel filter base by disconnecting a fuel line, removing bolts and washers, and taking off a gasket.
3. Disassembling the fuel transfer pump by removing tubes, bolts, an O-ring seal, and taking apart the pump housing, piston, springs, and valves.
Caterpillar cat d4 e track tractor (prefix 2cb) service repair manual (2cb000...fjsjfkskefmem
This document provides instructions for removing and disassembling the fuel injection pump housing and governor from a Caterpillar D4E track-type tractor powered by a 3304 engine. The removal procedure involves disconnecting fuel lines and other components, then using lifting equipment to remove the housing. The disassembly process describes removing various parts like covers, lifters, bearings, and the camshaft from the housing. The assembly section outlines installing bearings, the camshaft, washer and other parts back into the housing.
Caterpillar cat e70 b excavator (prefix 5tg) service repair manual (5tg00001 ...fjsjfkskefmem
This document provides service information for the travel drive and motor of an E70B excavator model. It includes three pages of specifications and diagrams of the excavator's components. The bulk of the document describes the functional construction and operating principles of the travel drive and motor system. It explains how the swash plate motor, counter-balance valve, parking brake, and reduction gears work together to convert hydraulic pressure into rotational force to power the tracks and control travel speed.
The document provides instructions for properly installing Duo-Cone seals. It describes the components of a Duo-Cone seal and the assembly process. Critical steps include cleaning and inspecting the seal ring, rubber toric, and housing to ensure they are free of contamination or damage before installation. The seal ring and toric must be aligned and installed within specified tolerances to prevent leaks.
Caterpillar cat d6 r track tractor (prefix 7gr) service repair manual (7gr000...fjsjfkskefmem
This document provides instructions for removing and installing a bulldozer blade on a D6R track-type tractor. It lists the required tools and safety precautions. The removal process involves disconnecting hydraulic hoses, removing caps and bolts from the lift cylinders and stabilizer link, and using tooling to support the push arms. Reinstallation is the reverse of the removal process.
Caterpillar cat 3054 c industrial engine (prefix 334) service repair manual (...fjsjfkskefmem
- The document provides installation instructions for a fuel injection pump on a 3054C industrial engine.
- It describes 11 steps for installing the pump, including installing seals, bolts, gears, tubes and ensuring proper timing.
- Proper installation of the spacer and tightening of bolts is emphasized to prevent contact with the pump shaft.
Caterpillar cat d5 htsk ii track skidder (prefix 7eg) service repair manual (...fjsjfkskefmem
This document provides instructions for servicing the valves, valve guides, valve seat inserts, water directors, pistons, and connecting rods of a D5H Track-Type Skidder Series II engine. It describes how to remove and install these components, noting identification marks, cleaning, lubrication steps, and proper tool usage. Removal involves disassembling the engine down to the cylinder block, while installation requires reassembling components in the reverse order. Precautions are provided to prevent damage during disassembly and assembly.
Caterpillar cat 973 c track loader (prefix ldx) service repair manual (ldx000...fjsjfkskefmem
This document provides instructions for servicing the air conditioning and heating system and turbocharger on a 973C track loader with a C9 engine. It describes safety precautions when working on the refrigerant system and notes to keep all parts clean. Steps are outlined for removing and installing the turbocharger and exhaust manifold.
Caterpillar cat d5 b track tractor (prefix 46x) service repair manual (46x000...fjsjfkskefmem
This service repair manual provides instructions for repairing D5B track tractors with 3306 engines. It describes removing and installing various engine components like the front housing, valve mechanism cover, and gear group in the front of the engine. The procedures provide details on required tools, cleaning parts, applying sealants, and proper torque specifications for reinstallation.
Caterpillar cat 951 c track loader (prefix 86j) service repair manual (86j040...fjsjfkskefmem
- The document provides instructions for disassembling and assembling starting motors for Caterpillar track loaders and excavators.
- It describes removing over a dozen parts from the starting motor housing, including the rear housing, brushes, field winding coils, and pinion drive components.
- Cleaning and inspection steps are included to check all parts for wear and damage before reassembling the starting motor.
Caterpillar cat d4 htsk iii track skidder (prefix 7pk) service repair manual ...fjsjfkskefmem
This document provides instructions for servicing the cylinder head assembly of a Caterpillar 3304 engine. It describes removing and installing the cylinder head assembly in 31 steps, including draining coolant, removing bolts and various components, loosening belts, and installing push rods and valves. It also describes separately removing and installing the spacer plate and valve lifters. The overall document provides detailed disassembly and reassembly instructions for servicing the cylinder head.
Caterpillar cat 951 c track loader (prefix 86j) service repair manual (86j019...fjsjfkskefmem
The document provides instructions for disassembling three types of starting motors used in Caterpillar track loaders and excavators:
1. The disassembly process involves removing 19 main components like the solenoid, rear housing, brushes, pinion drive housing, and field winding coil.
2. Tools needed include retaining ring pliers and a driver. Detailed steps explain how to remove each part, with illustrations showing the component locations.
3. Technicians should mark parts for reassembly, clean components with mineral spirits, and inspect all parts for wear and damage after disassembly.
Caterpillar cat 420 e backhoe loader (prefix djl) service repair manual (djl0...fjsjfkskefmem
The document provides instructions for removing and installing the front drive shaft on a Caterpillar 420E backhoe loader. It describes:
1) Using a hydraulic jack to support the drive shaft guard and remove bolts to lower the guard.
2) Removing bolts to detach the front drive shaft.
3) Installing the drive shaft and tightening new bolts to the specified torque.
4) Raising the guard back into position and installing new bolts.
Caterpillar cat d4 htsk ii track skidder (prefix 8zf) service repair manual (...fjsjfkskefmem
This document provides instructions for servicing components of a D4HTSK II Track Skidder, including removing and installing the cylinder head assembly. The key steps are to drain coolant, remove manifolds, covers and other attached components. Then remove bolts holding the cylinder head and lift it off using tooling and a hoist. Reinstallation involves installing spacers, bolts, push rods and rocker assembly with lubricant before tightening bolts on the cylinder head.
Caterpillar cat 420 e backhoe loader (prefix dan) service repair manual (dan0...fjsjfkskefmem
The document provides instructions for removing and installing the lift cylinder and lift arms on a 420E backhoe loader. Key steps include:
1. Release hydraulic pressure and remove hoses from the lift cylinder before removing it from the lift arms.
2. Use retaining ring pliers and a lifting device to detach the cylinder, then remove it.
3. To remove the lift arms, first remove the tilt cylinder, bucket, and lift cylinder. Then use pliers to remove pins and bearings from the arms before lifting them off.
4. Installation follows the reverse of removal, taking care to clean parts and apply retaining compounds before reattaching cylinders and bearings.
Caterpillar cat 951 c track loader (prefix 69h) service repair manual (69h036...fjsjfkskefmem
This document provides instructions for servicing a 951B/C track loader. It discusses general instructions for disassembly and assembly including safety, cleanliness, removal and installation of parts, cleaning and handling of parts, and use of service tools. It provides details on pressing parts, bolt torque, a torque-turn-tighten procedure, using torque wrench extensions, and torque multipliers.
Caterpillar cat 416 f backhoe loader (prefix lwt) service repair manual (lwt0...fjsjfkskefmem
The document provides instructions for removing and disassembling components related to the rocker shaft and cylinder head on a Caterpillar 416F backhoe loader engine. The procedures include removing the rocker shaft assembly, pushrods, glow plugs, exhaust manifold, fuel injectors and other components. The cylinder head is then removed by gradually loosening setscrews and lifting the head off using a lifting device.
Caterpillar cat 951 b track loader (prefix 86j) service repair manual (86j025...fjsjfkskefmem
The document provides instructions for disassembling three types of starting motors used on Caterpillar equipment:
1) Remove components like the solenoid, rear housing, brushes, and pinion drive housing to access the internal parts.
2) Mark components for correct reassembly and remove retaining rings, pins, and seals.
3) Extract the armature, field winding coil, and pole shoes from the motor housing.
4) Inspect all parts for wear and clean as needed before reassembly.
Caterpillar cat 422 e backhoe loader (prefix maw) service repair manual (maw0...fjsjfkskefmem
This service repair manual provides instructions for repairing and replacing components of the fuel system for a 422E Backhoe Loader powered by a C4.4 engine, including:
- Removing and installing the fuel priming pump and fuel filter base.
- Removing and installing the fuel injection lines.
- Removing the fuel injection nozzles.
- Installing the fuel injection nozzles.
- Removing the Delphi DP210 fuel injection pump.
The document provides detailed step-by-step instructions and illustrations for completing each repair or replacement, with notes about required tools and safety precautions. Removal and installation procedures for each component are presented separately.
Caterpillar cat 416 e backhoe loader (prefix sha) service repair manual (sha0...fjsjfkskefmem
The document provides instructions for removing and disassembling the transmission of a 416E backhoe loader. The removal process involves draining fluids, disconnecting wiring harnesses and hydraulic lines, and removing mounting hardware. The transmission is then lifted out of the machine. Disassembly separates the transmission into its major components like the torque converter, pump group, and valve groups through removal of mounting bolts and seals.
Caterpillar cat 416 d backhoe loader (prefix cxp) service repair manual (cxp0...fjsjfkskefmem
This document provides instructions to disconnect and separate the engine, torque converter, and transmission from a 416D backhoe loader. It outlines 41 steps to disconnect wiring harnesses, hoses, bolts and other components. The engine and transmission assembly weighs 680 kg and must be lifted and supported by tools during separation from the vehicle. Once separated, the transmission weighs 227 kg on its own.
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!
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.
Caterpillar cat d4 e track tractor (prefix 2cb) service repair manual (2cb000...fjsjfkskefmem
This document provides instructions for removing and disassembling the fuel injection pump housing and governor from a Caterpillar D4E track-type tractor powered by a 3304 engine. The removal procedure involves disconnecting fuel lines and other components, then using lifting equipment to remove the housing. The disassembly process describes removing various parts like covers, lifters, bearings, and the camshaft from the housing. The assembly section outlines installing bearings, the camshaft, washer and other parts back into the housing.
Caterpillar cat e70 b excavator (prefix 5tg) service repair manual (5tg00001 ...fjsjfkskefmem
This document provides service information for the travel drive and motor of an E70B excavator model. It includes three pages of specifications and diagrams of the excavator's components. The bulk of the document describes the functional construction and operating principles of the travel drive and motor system. It explains how the swash plate motor, counter-balance valve, parking brake, and reduction gears work together to convert hydraulic pressure into rotational force to power the tracks and control travel speed.
The document provides instructions for properly installing Duo-Cone seals. It describes the components of a Duo-Cone seal and the assembly process. Critical steps include cleaning and inspecting the seal ring, rubber toric, and housing to ensure they are free of contamination or damage before installation. The seal ring and toric must be aligned and installed within specified tolerances to prevent leaks.
Caterpillar cat d6 r track tractor (prefix 7gr) service repair manual (7gr000...fjsjfkskefmem
This document provides instructions for removing and installing a bulldozer blade on a D6R track-type tractor. It lists the required tools and safety precautions. The removal process involves disconnecting hydraulic hoses, removing caps and bolts from the lift cylinders and stabilizer link, and using tooling to support the push arms. Reinstallation is the reverse of the removal process.
Caterpillar cat 3054 c industrial engine (prefix 334) service repair manual (...fjsjfkskefmem
- The document provides installation instructions for a fuel injection pump on a 3054C industrial engine.
- It describes 11 steps for installing the pump, including installing seals, bolts, gears, tubes and ensuring proper timing.
- Proper installation of the spacer and tightening of bolts is emphasized to prevent contact with the pump shaft.
Caterpillar cat d5 htsk ii track skidder (prefix 7eg) service repair manual (...fjsjfkskefmem
This document provides instructions for servicing the valves, valve guides, valve seat inserts, water directors, pistons, and connecting rods of a D5H Track-Type Skidder Series II engine. It describes how to remove and install these components, noting identification marks, cleaning, lubrication steps, and proper tool usage. Removal involves disassembling the engine down to the cylinder block, while installation requires reassembling components in the reverse order. Precautions are provided to prevent damage during disassembly and assembly.
Caterpillar cat 973 c track loader (prefix ldx) service repair manual (ldx000...fjsjfkskefmem
This document provides instructions for servicing the air conditioning and heating system and turbocharger on a 973C track loader with a C9 engine. It describes safety precautions when working on the refrigerant system and notes to keep all parts clean. Steps are outlined for removing and installing the turbocharger and exhaust manifold.
Caterpillar cat d5 b track tractor (prefix 46x) service repair manual (46x000...fjsjfkskefmem
This service repair manual provides instructions for repairing D5B track tractors with 3306 engines. It describes removing and installing various engine components like the front housing, valve mechanism cover, and gear group in the front of the engine. The procedures provide details on required tools, cleaning parts, applying sealants, and proper torque specifications for reinstallation.
Caterpillar cat 951 c track loader (prefix 86j) service repair manual (86j040...fjsjfkskefmem
- The document provides instructions for disassembling and assembling starting motors for Caterpillar track loaders and excavators.
- It describes removing over a dozen parts from the starting motor housing, including the rear housing, brushes, field winding coils, and pinion drive components.
- Cleaning and inspection steps are included to check all parts for wear and damage before reassembling the starting motor.
Caterpillar cat d4 htsk iii track skidder (prefix 7pk) service repair manual ...fjsjfkskefmem
This document provides instructions for servicing the cylinder head assembly of a Caterpillar 3304 engine. It describes removing and installing the cylinder head assembly in 31 steps, including draining coolant, removing bolts and various components, loosening belts, and installing push rods and valves. It also describes separately removing and installing the spacer plate and valve lifters. The overall document provides detailed disassembly and reassembly instructions for servicing the cylinder head.
Caterpillar cat 951 c track loader (prefix 86j) service repair manual (86j019...fjsjfkskefmem
The document provides instructions for disassembling three types of starting motors used in Caterpillar track loaders and excavators:
1. The disassembly process involves removing 19 main components like the solenoid, rear housing, brushes, pinion drive housing, and field winding coil.
2. Tools needed include retaining ring pliers and a driver. Detailed steps explain how to remove each part, with illustrations showing the component locations.
3. Technicians should mark parts for reassembly, clean components with mineral spirits, and inspect all parts for wear and damage after disassembly.
Caterpillar cat 420 e backhoe loader (prefix djl) service repair manual (djl0...fjsjfkskefmem
The document provides instructions for removing and installing the front drive shaft on a Caterpillar 420E backhoe loader. It describes:
1) Using a hydraulic jack to support the drive shaft guard and remove bolts to lower the guard.
2) Removing bolts to detach the front drive shaft.
3) Installing the drive shaft and tightening new bolts to the specified torque.
4) Raising the guard back into position and installing new bolts.
Caterpillar cat d4 htsk ii track skidder (prefix 8zf) service repair manual (...fjsjfkskefmem
This document provides instructions for servicing components of a D4HTSK II Track Skidder, including removing and installing the cylinder head assembly. The key steps are to drain coolant, remove manifolds, covers and other attached components. Then remove bolts holding the cylinder head and lift it off using tooling and a hoist. Reinstallation involves installing spacers, bolts, push rods and rocker assembly with lubricant before tightening bolts on the cylinder head.
Caterpillar cat 420 e backhoe loader (prefix dan) service repair manual (dan0...fjsjfkskefmem
The document provides instructions for removing and installing the lift cylinder and lift arms on a 420E backhoe loader. Key steps include:
1. Release hydraulic pressure and remove hoses from the lift cylinder before removing it from the lift arms.
2. Use retaining ring pliers and a lifting device to detach the cylinder, then remove it.
3. To remove the lift arms, first remove the tilt cylinder, bucket, and lift cylinder. Then use pliers to remove pins and bearings from the arms before lifting them off.
4. Installation follows the reverse of removal, taking care to clean parts and apply retaining compounds before reattaching cylinders and bearings.
Caterpillar cat 951 c track loader (prefix 69h) service repair manual (69h036...fjsjfkskefmem
This document provides instructions for servicing a 951B/C track loader. It discusses general instructions for disassembly and assembly including safety, cleanliness, removal and installation of parts, cleaning and handling of parts, and use of service tools. It provides details on pressing parts, bolt torque, a torque-turn-tighten procedure, using torque wrench extensions, and torque multipliers.
Caterpillar cat 416 f backhoe loader (prefix lwt) service repair manual (lwt0...fjsjfkskefmem
The document provides instructions for removing and disassembling components related to the rocker shaft and cylinder head on a Caterpillar 416F backhoe loader engine. The procedures include removing the rocker shaft assembly, pushrods, glow plugs, exhaust manifold, fuel injectors and other components. The cylinder head is then removed by gradually loosening setscrews and lifting the head off using a lifting device.
Caterpillar cat 951 b track loader (prefix 86j) service repair manual (86j025...fjsjfkskefmem
The document provides instructions for disassembling three types of starting motors used on Caterpillar equipment:
1) Remove components like the solenoid, rear housing, brushes, and pinion drive housing to access the internal parts.
2) Mark components for correct reassembly and remove retaining rings, pins, and seals.
3) Extract the armature, field winding coil, and pole shoes from the motor housing.
4) Inspect all parts for wear and clean as needed before reassembly.
Caterpillar cat 422 e backhoe loader (prefix maw) service repair manual (maw0...fjsjfkskefmem
This service repair manual provides instructions for repairing and replacing components of the fuel system for a 422E Backhoe Loader powered by a C4.4 engine, including:
- Removing and installing the fuel priming pump and fuel filter base.
- Removing and installing the fuel injection lines.
- Removing the fuel injection nozzles.
- Installing the fuel injection nozzles.
- Removing the Delphi DP210 fuel injection pump.
The document provides detailed step-by-step instructions and illustrations for completing each repair or replacement, with notes about required tools and safety precautions. Removal and installation procedures for each component are presented separately.
Caterpillar cat 416 e backhoe loader (prefix sha) service repair manual (sha0...fjsjfkskefmem
The document provides instructions for removing and disassembling the transmission of a 416E backhoe loader. The removal process involves draining fluids, disconnecting wiring harnesses and hydraulic lines, and removing mounting hardware. The transmission is then lifted out of the machine. Disassembly separates the transmission into its major components like the torque converter, pump group, and valve groups through removal of mounting bolts and seals.
Caterpillar cat 416 d backhoe loader (prefix cxp) service repair manual (cxp0...fjsjfkskefmem
This document provides instructions to disconnect and separate the engine, torque converter, and transmission from a 416D backhoe loader. It outlines 41 steps to disconnect wiring harnesses, hoses, bolts and other components. The engine and transmission assembly weighs 680 kg and must be lifted and supported by tools during separation from the vehicle. Once separated, the transmission weighs 227 kg on its own.
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!
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.
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.
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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.
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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.