This service manual provides instructions for maintaining and servicing Loadall rough terrain variable reach trucks. It contains 3 sections:
1. The foreword stresses the importance of reading and understanding the manual before operating equipment and treating it as part of the machine.
2. The contents section lists the chapters covering various machine systems like the engine, brakes, hydraulics and electrical systems.
3. The engine section provides procedures for cleaning, checking, removing and installing engines as well as storing engines. It emphasizes safety, using the correct tools and cleaning to prevent contamination.
The document summarizes the design of a transformer with an input voltage of 220V and output voltage of 110V with an apparent power of 100VA. It describes calculating the core area, turns per volt, primary and secondary windings based on standard formulas. Materials needed include a former, core, copper wire and have a total cost of 560 BDT. The transformer was tested and the results were not described further.
This document provides an overview of basic electrical concepts and principles including AC/DC circuits, voltage, current, resistance, and Ohm's law. It also discusses power in electrical circuits including real, reactive, and apparent power as well as power factor. Additional topics covered include single and three-phase power systems, transformers including types and connections, and electrical devices and symbols used in control circuits. Control circuits are described including AND, OR, and combined logic operations. The document concludes with discussing reading electrical drawings and a workshop practical example.
Why do Transformers Fail?
�The electrical windings and the magnetic core in a transformer are subject to a number of different forces during operation, for example:
�Expansion and contraction due to thermal cycling
�Vibration
�Local heating due to magnetic flux
�Impact forces due to through-fault current
�Excessive heating due to overloading or inadequate cooling
This document provides an overview of the electrical department, power system, and maintenance practices at MGCC. It discusses the department organization, roles and responsibilities. It describes the power system including sources of power, substations, switchgear, and distribution. It also outlines the various types of electrical equipment used including motors, transformers, variable speed drives, and UPS systems. The document discusses maintenance activities such as planning, condition monitoring, and statutory compliance. It provides details on maintenance of key electrical assets and defines different types of maintenance.
Transformers play an important role in the distribution of electricity-Understanding how transformers are used to alter the voltage of a supply is very important, as they form an important part of all electrical appliances, mobile phone, TV, radio, you just name it. In this slideshare however you will meet basic calculations and hints on how to solve them.
By Ivan Ukiwah
This document contains examples and problems related to linear DC machines. It discusses machine parameters like voltage, resistance, magnetic flux density. It asks questions about machine operation under different load conditions, calculating speed, power, efficiency. Questions include determining initial force and current, steady state speed with and without load, and effect of changing magnetic field strength or load force direction. The document is working through examples and problems to understand linear DC motor and generator operation.
Lecture 1a Selection of Motor Rating.pptxVarsha506533
The document discusses factors to consider when selecting an electric motor's power rating, including thermal modeling to ensure efficient heat dissipation, motor duty classes, and determining ratings based on operating conditions. Proper sizing is important for reliability and productivity, and ratings indicate permissible current and voltage to safely run the motor within insulation temperature limits.
Transformer vector group_test_conditionsSARAVANAN A
The document provides test conditions for various transformer vector groups including YNyn0, YNyn6, Dd0, Dd6, YNd1, YNd11, Dyn11, and Dyn1. For each vector group, 3 measurement conditions are listed that involve measuring voltages between different transformer terminals when voltage is applied to the HV side. The conditions are designed such that satisfying all 3 confirms the vector group by establishing the phase shift between the primary and secondary windings.
The document summarizes the design of a transformer with an input voltage of 220V and output voltage of 110V with an apparent power of 100VA. It describes calculating the core area, turns per volt, primary and secondary windings based on standard formulas. Materials needed include a former, core, copper wire and have a total cost of 560 BDT. The transformer was tested and the results were not described further.
This document provides an overview of basic electrical concepts and principles including AC/DC circuits, voltage, current, resistance, and Ohm's law. It also discusses power in electrical circuits including real, reactive, and apparent power as well as power factor. Additional topics covered include single and three-phase power systems, transformers including types and connections, and electrical devices and symbols used in control circuits. Control circuits are described including AND, OR, and combined logic operations. The document concludes with discussing reading electrical drawings and a workshop practical example.
Why do Transformers Fail?
�The electrical windings and the magnetic core in a transformer are subject to a number of different forces during operation, for example:
�Expansion and contraction due to thermal cycling
�Vibration
�Local heating due to magnetic flux
�Impact forces due to through-fault current
�Excessive heating due to overloading or inadequate cooling
This document provides an overview of the electrical department, power system, and maintenance practices at MGCC. It discusses the department organization, roles and responsibilities. It describes the power system including sources of power, substations, switchgear, and distribution. It also outlines the various types of electrical equipment used including motors, transformers, variable speed drives, and UPS systems. The document discusses maintenance activities such as planning, condition monitoring, and statutory compliance. It provides details on maintenance of key electrical assets and defines different types of maintenance.
Transformers play an important role in the distribution of electricity-Understanding how transformers are used to alter the voltage of a supply is very important, as they form an important part of all electrical appliances, mobile phone, TV, radio, you just name it. In this slideshare however you will meet basic calculations and hints on how to solve them.
By Ivan Ukiwah
This document contains examples and problems related to linear DC machines. It discusses machine parameters like voltage, resistance, magnetic flux density. It asks questions about machine operation under different load conditions, calculating speed, power, efficiency. Questions include determining initial force and current, steady state speed with and without load, and effect of changing magnetic field strength or load force direction. The document is working through examples and problems to understand linear DC motor and generator operation.
Lecture 1a Selection of Motor Rating.pptxVarsha506533
The document discusses factors to consider when selecting an electric motor's power rating, including thermal modeling to ensure efficient heat dissipation, motor duty classes, and determining ratings based on operating conditions. Proper sizing is important for reliability and productivity, and ratings indicate permissible current and voltage to safely run the motor within insulation temperature limits.
Transformer vector group_test_conditionsSARAVANAN A
The document provides test conditions for various transformer vector groups including YNyn0, YNyn6, Dd0, Dd6, YNd1, YNd11, Dyn11, and Dyn1. For each vector group, 3 measurement conditions are listed that involve measuring voltages between different transformer terminals when voltage is applied to the HV side. The conditions are designed such that satisfying all 3 confirms the vector group by establishing the phase shift between the primary and secondary windings.
Power Factor: what it is, how to measure it and how to improve it to reduce u...Pulse Energy
Low power factor is expensive and inefficient. Energy utility companies often charge additional fees to large commercial, institutional, and industrial clients when their power factor drops below 0.95. Understanding power factor and knowing how to measure it and improve it generates significant energy savings for very little cost.
Mike Wrinch, P. Eng. presented an informative 45 minute webinar on understanding, measuring, and improving power factor to reduce energy bills in buildings and facilities. Mike’s presentation included:
* An explanation of power factor and how it affects energy bills and electric systems' distribution capacity
* An overview of the hardware and software needed to measure the power factor in buildings
* Solutions to improve a building’s power factor
Transformers are an essential part of the electricity network: they convert electrical energy from one voltage level to another. This course is introducing the subject of transformers. The intention of the whole series is to promote lifecycle thinking when procuring transformers. Therefore, the focus will be on energy performance, reliability, asset management
Operation and maintenance of transformerKapil Singh
The document provides information on operation and maintenance of distribution transformers. It defines transformers and describes their working principle of mutual electromagnetic induction. It then discusses transformation ratios, the purposes of transformers, their advantages, types, parts, insulation, testing, and maintenance procedures. Key points covered include daily, quarterly and yearly maintenance checks, oil testing parameters, and common transformer tests like ratio, no load, short circuit and insulation tests.
The document provides an overview of variable frequency drive (VFD) basics, including:
- The main components of a VFD are the converter section, which converts AC to DC, the DC bus section, which stores the DC voltage, and the inverter section, which converts the DC back to variable frequency AC to control motor speed.
- Pulse width modulation (PWM) is used to vary the width of output voltage pulses to adjust motor speed and torque.
- A VFD allows controlling motor torque at all speeds to meet application needs, unlike direct AC connection which is limited to a fixed speed-torque curve.
- Proper sizing and installation of input and output components like contactors
This document provides an overview of power factor, including basics, causes of low power factor, disadvantages, correction methods, and advantages of correction. It defines power factor as the ratio of true power to apparent power. Induction motors, transformers, and other inductive loads cause low power factors. Correcting power factor reduces equipment sizes and losses, improves voltage regulation, and avoids penalties under power factor tariffs. Static capacitors and synchronous condensers are common correction methods.
How is power transformer protected??? This provides a basic understanding of power transformer. Furthermore, the protective relay application on power transformer is included.
Electromechanical relays are used to separate AC and DC circuits and interface between electronic control circuits and power circuits. They use an electromagnet to open and close contacts to allow current to pass through or be blocked. Relays have advantages like low cost and contact life but also limitations like wear over time. Common applications include solenoid control and automotive uses. Relays provide a reliable way to integrate power and control circuits.
This document summarizes the construction and operating principles of an induction-type energy meter. The meter uses two coils - a current coil and a pressure coil - to produce rotating magnetic fields that interact with eddy currents in a disc, causing the disc to rotate. The number of revolutions of the disc corresponds to the amount of energy passing through the meter. A recording mechanism connected via gears registers the energy consumed in kilowatt-hours.
Power cable selection, cable selection Methodology wessam alaslmi
Cable installation and Selection Methodology according to IEC code supported with an example of how to do so.
Explain what practical environment requires when establishing a new facility requires electricity.
explain the purpose of the selected cable.
explain when to use the cable carrier types.
explain how to carry out calculations of such thing.
Project on Transformer Design | Electrical Machine DesignJikrul Sayeed
Transformer Design | Core Design | Full Design | EE 3220 Electrical Machine Design
EE-3220
Core Design
Window Dimensions
Yoke Design
Overall Dimensions of Frame
Low Voltage Winding
High Voltage Winding
Resistance
Leakage Reactance
Regulation
Losses
Core Loss
Efficiency
No Load Current
Tank
Project on Transformer Design
the ratio of the actual electrical power dissipated by an AC circuit to the product of the r.m.s. values of current and voltage. The difference between the two is caused by reactance in the circuit and represents power that does no useful work.
This document discusses motor protection principles and thermal modeling for motor protection relays. Some key points:
- Motors account for a large portion of electricity usage and failures can be costly. Thermal stress is a major cause of failures.
- A motor protection relay uses a thermal model to monitor the thermal capacity used based on operating conditions like load, ambient temperature, voltage, and current balance. It can trip for overload based on reaching 100% thermal capacity.
- The thermal model considers motor states like running, starting, and overloaded. It uses thermal limit curves, an overload curve, cooling time constants, and a hot to cold stall time ratio in its calculations. Current unbalance is also accounted for through a bias factor.
The SIPROTEC 4 7UM62 protection relays can do more than just protect. They also offer numerous additional functions. Be it earth faults, short-circuits, overloads, overvoltage, overfrequency or underfrequency asynchronous conditions, protection relays assure continued operation of power stations. The SIPROTEC 4 7UM62 protection relay is a compact unit which has been specially developed and designed for the protection of small, medium-sized and large generators.
1. The document discusses different types of transformers used in power plants including power transformers, service transformers, and measuring transformers.
2. It describes key components of transformers like the core, windings, cooling systems, and protections devices. Transformer connections, vector groups, and voltage classifications are also covered.
3. Various transformers used in thermal power plants are discussed including generator transformers, station transformers, unit auxiliary transformers, and those used for distribution within the plant.
This document contains questions and answers related to electrical engineering topics. Some key points addressed include:
- Electric traction uses electric power for transportation systems like railways and trams. DC motors are commonly used.
- Electronic chokes are needed to start a 40W tube light with 230V AC/DC without other components like a coil.
- Pu (per unit) is used in power system diagrams to normalize component ratings to a common base value for comparison.
- In thermal power stations, steam is generated by burning coal in a boiler and used to power a turbine coupled to an electric generator.
1) Voltage collapse is a major cause of recent blackouts due to increased reliance on remote generation and lack of transmission expansion. As transmission lines trip, reactive power losses increase, reducing voltage.
2) Generators provide reactive power (VARs) to support system voltage through their automatic voltage regulators (AVRs). During low voltage events, AVRs and generator protection systems may not be able to maintain stable operation.
3) Undervoltage load shedding is used to prevent total system collapse by automatically removing certain loads if voltage drops below a threshold for a set time period. This helps restore the balance between generation and load.
AC drives control the speed of AC motors by adjusting the frequency and voltage of the incoming AC power. A typical AC drive system includes an operator control, drive controller, and AC motor. The drive controller uses a variable voltage inverter to convert fixed voltage/frequency into adjustable voltage/frequency. The inverter includes a rectifier, intermediate circuit, inverter, and control circuit. The control circuit generates pulses to turn the inverter switches on and off, controlling the output frequency and voltage supplied to the motor. Modern drives such as pulse width modulation and flux vector drives provide improved dynamic response over traditional variable voltage inverter drives.
The document discusses motor protection and motor control centers. It provides details on sizing conductors that supply single and multiple motors, sizing overload protection devices based on motor nameplate ratings, and protecting motors from short circuits and ground faults. It also describes the components, construction, and wiring classifications of motor control centers, which are used to control and provide protection for motors and connecting cables.
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.
Jcb 535 v140 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 maintain proper valve timing and sealing.
Power Factor: what it is, how to measure it and how to improve it to reduce u...Pulse Energy
Low power factor is expensive and inefficient. Energy utility companies often charge additional fees to large commercial, institutional, and industrial clients when their power factor drops below 0.95. Understanding power factor and knowing how to measure it and improve it generates significant energy savings for very little cost.
Mike Wrinch, P. Eng. presented an informative 45 minute webinar on understanding, measuring, and improving power factor to reduce energy bills in buildings and facilities. Mike’s presentation included:
* An explanation of power factor and how it affects energy bills and electric systems' distribution capacity
* An overview of the hardware and software needed to measure the power factor in buildings
* Solutions to improve a building’s power factor
Transformers are an essential part of the electricity network: they convert electrical energy from one voltage level to another. This course is introducing the subject of transformers. The intention of the whole series is to promote lifecycle thinking when procuring transformers. Therefore, the focus will be on energy performance, reliability, asset management
Operation and maintenance of transformerKapil Singh
The document provides information on operation and maintenance of distribution transformers. It defines transformers and describes their working principle of mutual electromagnetic induction. It then discusses transformation ratios, the purposes of transformers, their advantages, types, parts, insulation, testing, and maintenance procedures. Key points covered include daily, quarterly and yearly maintenance checks, oil testing parameters, and common transformer tests like ratio, no load, short circuit and insulation tests.
The document provides an overview of variable frequency drive (VFD) basics, including:
- The main components of a VFD are the converter section, which converts AC to DC, the DC bus section, which stores the DC voltage, and the inverter section, which converts the DC back to variable frequency AC to control motor speed.
- Pulse width modulation (PWM) is used to vary the width of output voltage pulses to adjust motor speed and torque.
- A VFD allows controlling motor torque at all speeds to meet application needs, unlike direct AC connection which is limited to a fixed speed-torque curve.
- Proper sizing and installation of input and output components like contactors
This document provides an overview of power factor, including basics, causes of low power factor, disadvantages, correction methods, and advantages of correction. It defines power factor as the ratio of true power to apparent power. Induction motors, transformers, and other inductive loads cause low power factors. Correcting power factor reduces equipment sizes and losses, improves voltage regulation, and avoids penalties under power factor tariffs. Static capacitors and synchronous condensers are common correction methods.
How is power transformer protected??? This provides a basic understanding of power transformer. Furthermore, the protective relay application on power transformer is included.
Electromechanical relays are used to separate AC and DC circuits and interface between electronic control circuits and power circuits. They use an electromagnet to open and close contacts to allow current to pass through or be blocked. Relays have advantages like low cost and contact life but also limitations like wear over time. Common applications include solenoid control and automotive uses. Relays provide a reliable way to integrate power and control circuits.
This document summarizes the construction and operating principles of an induction-type energy meter. The meter uses two coils - a current coil and a pressure coil - to produce rotating magnetic fields that interact with eddy currents in a disc, causing the disc to rotate. The number of revolutions of the disc corresponds to the amount of energy passing through the meter. A recording mechanism connected via gears registers the energy consumed in kilowatt-hours.
Power cable selection, cable selection Methodology wessam alaslmi
Cable installation and Selection Methodology according to IEC code supported with an example of how to do so.
Explain what practical environment requires when establishing a new facility requires electricity.
explain the purpose of the selected cable.
explain when to use the cable carrier types.
explain how to carry out calculations of such thing.
Project on Transformer Design | Electrical Machine DesignJikrul Sayeed
Transformer Design | Core Design | Full Design | EE 3220 Electrical Machine Design
EE-3220
Core Design
Window Dimensions
Yoke Design
Overall Dimensions of Frame
Low Voltage Winding
High Voltage Winding
Resistance
Leakage Reactance
Regulation
Losses
Core Loss
Efficiency
No Load Current
Tank
Project on Transformer Design
the ratio of the actual electrical power dissipated by an AC circuit to the product of the r.m.s. values of current and voltage. The difference between the two is caused by reactance in the circuit and represents power that does no useful work.
This document discusses motor protection principles and thermal modeling for motor protection relays. Some key points:
- Motors account for a large portion of electricity usage and failures can be costly. Thermal stress is a major cause of failures.
- A motor protection relay uses a thermal model to monitor the thermal capacity used based on operating conditions like load, ambient temperature, voltage, and current balance. It can trip for overload based on reaching 100% thermal capacity.
- The thermal model considers motor states like running, starting, and overloaded. It uses thermal limit curves, an overload curve, cooling time constants, and a hot to cold stall time ratio in its calculations. Current unbalance is also accounted for through a bias factor.
The SIPROTEC 4 7UM62 protection relays can do more than just protect. They also offer numerous additional functions. Be it earth faults, short-circuits, overloads, overvoltage, overfrequency or underfrequency asynchronous conditions, protection relays assure continued operation of power stations. The SIPROTEC 4 7UM62 protection relay is a compact unit which has been specially developed and designed for the protection of small, medium-sized and large generators.
1. The document discusses different types of transformers used in power plants including power transformers, service transformers, and measuring transformers.
2. It describes key components of transformers like the core, windings, cooling systems, and protections devices. Transformer connections, vector groups, and voltage classifications are also covered.
3. Various transformers used in thermal power plants are discussed including generator transformers, station transformers, unit auxiliary transformers, and those used for distribution within the plant.
This document contains questions and answers related to electrical engineering topics. Some key points addressed include:
- Electric traction uses electric power for transportation systems like railways and trams. DC motors are commonly used.
- Electronic chokes are needed to start a 40W tube light with 230V AC/DC without other components like a coil.
- Pu (per unit) is used in power system diagrams to normalize component ratings to a common base value for comparison.
- In thermal power stations, steam is generated by burning coal in a boiler and used to power a turbine coupled to an electric generator.
1) Voltage collapse is a major cause of recent blackouts due to increased reliance on remote generation and lack of transmission expansion. As transmission lines trip, reactive power losses increase, reducing voltage.
2) Generators provide reactive power (VARs) to support system voltage through their automatic voltage regulators (AVRs). During low voltage events, AVRs and generator protection systems may not be able to maintain stable operation.
3) Undervoltage load shedding is used to prevent total system collapse by automatically removing certain loads if voltage drops below a threshold for a set time period. This helps restore the balance between generation and load.
AC drives control the speed of AC motors by adjusting the frequency and voltage of the incoming AC power. A typical AC drive system includes an operator control, drive controller, and AC motor. The drive controller uses a variable voltage inverter to convert fixed voltage/frequency into adjustable voltage/frequency. The inverter includes a rectifier, intermediate circuit, inverter, and control circuit. The control circuit generates pulses to turn the inverter switches on and off, controlling the output frequency and voltage supplied to the motor. Modern drives such as pulse width modulation and flux vector drives provide improved dynamic response over traditional variable voltage inverter drives.
The document discusses motor protection and motor control centers. It provides details on sizing conductors that supply single and multiple motors, sizing overload protection devices based on motor nameplate ratings, and protecting motors from short circuits and ground faults. It also describes the components, construction, and wiring classifications of motor control centers, which are used to control and provide protection for motors and connecting cables.
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.
Jcb 535 v140 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 maintain proper valve timing and sealing.
Jcb 535 v125 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 maintain proper valve timing and sealing.
Jcb 535 95 telescopic handler service repair manual sn from 2902000 onwardsdufjsjekkkemm
This service manual provides instructions for maintaining and servicing Loadall rough terrain variable reach trucks. It contains 3 sections:
1. The foreword stresses the importance of reading and understanding the manual before operating equipment.
2. The contents section lists the chapters covering various machine systems like the engine, brakes, hydraulics and electrical systems.
3. The engine section provides procedures for cleaning, checking, removing and installing engines, as well as storing engines. It emphasizes safety, identifies necessary tools, and lists steps to disconnect and reconnect engine components.
Jcb 533 105 telescopic handler service repair manual from 2902000dufjsjekkkemm
This document provides information on servicing the engine valves for a JCB loadall vehicle. It includes technical specifications for the inlet and exhaust valves, diagrams identifying the valve components, descriptions of how the valve train operates, and procedures for adjusting and removing/installing valves. Safety precautions are outlined and torque specifications are provided.
Jcb 531 70 telescopic handler service repair manual sn from 2902000 onwardsdufjsjekkkemm
This service manual provides instructions for maintaining and servicing Loadall rough terrain variable reach trucks. It contains 3 sections:
1. The foreword stresses the importance of reading and understanding the manual before operating equipment.
2. The contents section lists the chapters covering various machine systems like the engine, brakes, hydraulics and electrical systems.
3. The engine section provides procedures for cleaning, checking, removing and installing engines, as well as storing engines. It emphasizes safety, identifies important components and tools, and outlines steps to take before and after work.
Jcb 512 26 telescopic handler service repair manual (sn from 2902000 onwards)dufjsjekkkemm
This service manual provides instructions for servicing and repairing Loadall rough terrain variable reach trucks. It contains sections covering the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, brakes, steering, driveline, hydraulics, and electrical systems. The engine section provides detailed procedures for servicing components like the rocker assembly, tappets, camshaft, oil sump, timing gears, and more. Instructions include removal and installation steps, torque specifications, and safety warnings.
Jcb 510 55 telescopic handler service repair manual (sn 2902000 and up)dufjsjekkkemm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. Section 15 covers the engine, including removing and installing the bedplate. The bedplate acts as the main strength component of the engine, maintaining alignment and supporting internal components. Detailed instructions are provided on cleaning, applying sealant, installing bearing shells and bolts, and torquing to specification. Safety cautions are included to only remove heavy components like the bedplate using lifting devices and obtaining the correct service parts.
Jcb 510 44 telescopic handler service repair manual (sn 2902000 and up)dufjsjekkkemm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 508-66, 509-45, 510-44, and 510-55. It contains original instructions from the manufacturer and covers maintenance and repair of the machine, engine, attachments, and various systems. Technicians must carefully follow the instructions in the manual to safely operate and maintain the equipment.
Jcb 509 45 telescopic handler service repair manual (sn 2902000 and up)dufjsjekkkemm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks models 508-66, 509-45, 510-44, and 510-55. It contains original instructions from the manufacturer and covers maintenance for the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, brake, steering, driveline, hydraulic, and electrical systems. Safety warnings are provided and the manual instructs technicians to fully understand procedures before working on the equipment.
Jcb 509 23 telescopic handler service repair manual (sn from 2902000 onwards)dufjsjekkkemm
This service manual provides instructions for servicing and repairing Loadall rough terrain variable reach trucks. It contains sections covering the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, brakes, steering, driveline, hydraulics, and electrical systems. The engine section provides detailed procedures for servicing engine components like the rocker assembly, tappets, camshaft, oil sump, timing gears, and more. Instructions include removal and installation steps, torque specifications, and safety warnings.
Jcb 508 66 telescopic handler service repair manual (sn 2902000 and up)dufjsjekkkemm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks models 508-66, 509-45, 510-44, and 510-55. It contains original instructions from the manufacturer and covers maintenance of the machine, attachments, body, operator station, engine, fuel system, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. Users are warned to study the manual before operating or maintaining the machine.
Jcb 506 23 telescopic handler service repair manual (sn from 2902000 onwards)dufjsjekkkemm
This service manual provides instructions for servicing and repairing Loadall rough terrain variable reach trucks. It contains sections covering the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, brakes, steering, driveline, hydraulics, and electrical systems. The engine section provides detailed procedures for servicing engine components like the rocker assembly, tappets, camshaft, oil sump, timing gears, and more. Instructions include removal and installation steps, torque specifications, and safety warnings.
New holland t8.350 pst tier 4 b tractor service repair manual [zjre04001 ]dufjsjekkkemm
This service manual provides information for servicing New Holland T8 series tractors, including the T8.320, T8.350, T8.380, T8.410, and their SmartTrax variants. The manual covers systems such as the engine, transmission, axles, hydraulics, electrical systems, and more. Safety precautions are provided to ensure personal safety during maintenance.
New holland t8.350 cvt tier 4 b tractor service repair manual [zjre04001 ]3dufjsjekkkemm
This document is a service manual for New Holland T8 series tractors with continuously variable transmissions produced from 2018 onwards. It contains information on engine systems, power coupling, transmission, drivetrains, hydraulics, electrical systems, and other components. The manual is intended to be used by qualified service technicians and dealership personnel for maintenance and repair purposes. Safety precautions are provided throughout to prevent injury to technicians during service work.
New holland t8.350 cvt tier 4 b tractor service repair manual [zjre04001 ]2dufjsjekkkemm
This document is a service manual for New Holland T8 series tractors with continuously variable transmissions produced from 2018 onward. It contains information on maintenance and repair for the engine, transmission, axles, brakes, hydraulics, steering, wheels, and tracks of the tractors. The manual is organized by vehicle systems with over 10 chapters covering topics such as the engine, power coupling, transmission, hydraulics, steering, and more. Each chapter contains sections on specific components.
New holland t8.350 cvt tier 4 b tractor service repair manual [zjre04001 ]1dufjsjekkkemm
This document is a service manual for New Holland T8 series tractors with continuously variable transmissions produced from 2018 onward. It contains information on maintenance and repair for the engine, transmission, axles, brakes, hydraulics, steering, wheels, and tracks of the tractors. The manual is organized by system with over 10 main sections covering topics such as the engine, power coupling, transmission, front and rear axles, brakes, hydraulics and hitches.
New holland t8.350 cvt tier 4 b tractor service repair manual [zjre04001 ]dufjsjekkkemm
This document is a service manual for New Holland T8 series tractors with continuously variable transmissions produced from 2018 onwards. It contains information on engine systems, power coupling, transmission, drivetrains, hydraulics, electrical systems, and other components. The manual is intended to be used by qualified service technicians and dealership personnel for maintenance and repair purposes. Safety precautions are provided throughout to prevent injury to technicians during service work.
New holland t8.320 pst tier 4 b tractor service repair manual [zjre04001 ]3dufjsjekkkemm
This service manual provides information for servicing New Holland T8 series tractors, including the T8.320, T8.350, T8.380, T8.410, and their SmartTrax variants. The manual covers systems such as the engine, transmission, axles, hydraulics, electrical systems, and more. Safety precautions are provided to ensure personal safety during maintenance.
New holland t8.320 pst tier 4 b tractor service repair manual [zjre04001 ]2dufjsjekkkemm
This service manual provides information for servicing New Holland T8 series tractors, including the T8.320, T8.350, T8.380, T8.410, and their SmartTrax variants. The manual covers systems such as the engine, transmission, axles, hydraulics, electrical systems, and more. Safety precautions are provided to ensure personal safety during maintenance.
Expanding Access to Affordable At-Home EV Charging by Vanessa WarheitForth
Vanessa Warheit, Co-Founder of EV Charging for All, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
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.
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!
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!
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
2. 15 - Engine
00 - Engine
00 - General
15 - 27 9813/9050-1 15 - 27
Drain and Fill
Refer to: PIL 15-21-00.
Clean
Notice: Clean the engine before you start engine
maintenance. Obey the correct procedures.
Contamination of the fuel system will cause
damage and possible failure of the engine.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine
is to be washed using a high pressure system.
Make sure that the alternator, starter motor and
any other electrical components are shielded
and not directly cleaned by the high pressure
cleaning system. Do not aim the water jet directly
at bearings, oil seals or the engine air induction
system.
Before carrying out any service procedures that
require components to be removed, the engine must
be properly cleaned.
Cleaning must be carried out either in the area of
components to be removed or, in the case of major
work, or work on the fuel system, the whole engine
and surrounding machine must be cleaned.
Stop the engine and allow it to cool for at least one
hour. DO NOT attempt to clean any part of the engine
while it is running.
1. Make sure that the electrical system is isolated.
2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
Length/Dimension/Distance: 600mm
3. 15 - Engine
00 - Engine
00 - General
15 - 28 9813/9050-1 15 - 28
9. When the pressure washing is complete move
the machine away from the wash area, or
alternatively, clean away the material washed
from the machine.
10. Before working on specific areas of the engine
use a compressed air jet to dry off any moisture.
When the area is dry use a soft clean brush to
remove any sand or grit particles that remain.
11. When removing components be aware of any
dirt or debris that may be exposed. Cover any
open ports and clean away the deposits before
proceeding.
Additional cleaning must be carried out prior to
working on the high pressure fuel system. Refer to:
PIL 18-00-00.
Check (Condition)
Start the engine and check for:
• Excessive smoke
• Excessive vibration
• Excessive noise
• Overheating
• Performance
• Unusual smells.
4. 15 - Engine
00 - Engine
00 - General
15 - 29 9813/9050-1 15 - 29
Check (Leaks)
Before you start the machine, do a check for oil leaks:
1. Make the machine safe.
2. Get access to the engine compartment (if
applicable)
3. Check the engine and the area below for oil
leaks.
4. Close the engine cover (if applicable).
5. If necessary, contact your JCB dealer.
Check (Pressure)
Special Tools
Description Part No. Qty.
Pressure Gauge (0-70
Bar)
892/00346 1
This test is used to diagnose suspected poor
compression in one or more of the engine cylinders.
Use ServiceMaster to control the test.
Engine Oil Pressure
Use the following procedures to measure the engine
oil pressure. Several factors can influence the engine
oil pressure, the following conditions are assumed:
• The correct engine oil has been used. Refer to:
PIL 15-21-00.
• The engine oil level is correct. Refer to: PIL
75-03-03.
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Get access to the engine.
3. Disconnect the electrical connector to the oil
pressure switch, remove the switch from the oil
cooler housing.
4. Install a suitable adaptor into the vacant pressure
switch port (M10 x 1.5mm thread) and a pressure
test gauge. Make sure that the gauge has a
sealing washer as shown.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
5. 15 - Engine
00 - Engine
00 - General
15 - 30 9813/9050-1 15 - 30
Figure 133.
A
B
A Oil pressure switch
B Sealing washer
5. Start the engine and allow a few seconds to
gain oil pressure, increase the engine revs to
the rated speed. Record the pressure gauge
reading. Check that the pressure is within the
specified tolerance.
Refer to: PIL 15-00-00.
6. Remove the pressure gauge and install the
pressure switch.
High Lubrication Oil Pressure
High oil pressure will be evident when starting in cold
conditions. Typically the pressure will be 1 to 2 bar
and higher in cold operation, the pressure should
drop when the engine reaches normal operating
temperature.
If the pressure remains high when operating
temperature is achieved, check the oil level, if this is
correct, suspect the oil pressure relief valve is at fault.
Low Lubrication Oil Pressure
Several factors can be the cause of low lubricating
oil pressure:
• Low oil level - typically evident as a loss of
pressure when operating on uneven ground or
on a gradient.
• Blocked oil filter - a blocked filter will show as a
gradual loss of pressure.
• Blocked suction strainer (pick-up pipe) -
typically evident as low pressure on start up,
if the blockage frees itself in the sump, the
pressure will pick up to normal.
• Coolant in the oil - coolant in the lubricating oil
will show as a milky discolouration of the oil and
an increase in oil level. Check for damaged core
plugs, lubricating oil cooler, cylinder head and/
or gasket.
• Fuel in the oil - fuel in the oil will result in thin'
black lubricating oil, the oil will also have a
diesel fuel smell. Check the fuel injection pump
(FIP) shaft seal, piston ring wear, lift pump
diaphragm damage or injector leakage if fuel is
evident in the oil.
• Damaged oil pump - oil pressure will be high at
low oil temperature but fall when oil becomes
hotter.
6. 15 - Engine
00 - Engine
00 - General
15 - 31 9813/9050-1 15 - 31
Remove and Install
Special Tools
Description Part No. Qty.
Fuel Injector equipment
Cap Kit (430 Engine)
320/B9321 1
Lifting Brackets (430
Engine)
320/B9421 1
Engine Lifting Spreader
Bar
892/01382 1
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
The lifting equipment used must be an approved
type and capable of lifting the engine safely. The
recommended lifting equipment is shown. Use a
spreader bar when lifting the engine. Never attempt
to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
an assistant. Inspect the lifting brackets for signs
of damage. The brackets must be correctly torqued
to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
rocker cover.
Component Identification
The following component identification is for a typical
engine installation. There will be some component
differences depending on the machine variant.
Before attempting to remove the engine ensure that
all the necessary components have either been
removed, or safely disconnected from the engine.
Figure 134.
N
H
M
G
B
AA
A
J
PQ
Figure 135.
FF
E
D
R
A
A
7. 15 - Engine
00 - Engine
00 - General
15 - 32 9813/9050-1 15 - 32
Figure 136.
L
S
K
C
A Engine mounting bolts
B Front lifting bracket - front
C Lifting bracket fixing bolts
D Fuel pipe - return to tank
E Fuel pipe - feed from lift pump
F Electrical connector - ECM (Engine Control
Module)
G Electrical connections - alternator
H Hose connection - cab heater
J Electrical connections - starter motor
K Rear lifting bracket
L Gearbox/hydraulic pump to engine mounting
bolts
M Top coolant hose
N Bottom coolant hose
P Air inlet hose
Q Turbocharger outlet hose
R Charge air inlet hose
S Exhaust pipe
Before Removal
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Position the machine on firm level ground. Make
the machine safe.
Refer to: PIL 01-03.
3. Discharge the hydraulic pressure.
4. Get access to the engine.
Remove
1. Disconnect and remove the battery.
2. Drain the engine oil.
Refer to: PIL 15-21-00.
3. Drain the engine coolant.
Refer to: PIL 21-00-00.
4. Remove the cooling pack.
5. Disconnect the air inlet hose.
6. Disconnect the turbocharger outlet hose.
7. Disconnect the charge air hose.
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine
block connectors. Release the hose clips and
disconnect the hoses.
10. Disconnect the top coolant hose.
11. Disconnect the bottom coolant hose.
12. Disconnect the wiring connections from the
starter motor.
Refer to: PIL 15-75-00.
13. Disconnect the wiring connections from the
alternator.
Refer to: PIL 15-72-00.
14. Disconnect the fuel supply and return pipes.
Plug all the open ports and hoses to prevent
contamination.
Special Tool: Fuel Injector equipment Cap Kit
(430 Engine) (Qty.: 1)
15. Disconnect the electrical harness at the ECM
machine side connector. Important: Do not touch
the connector pins on the ECM or harness
connectors. Cover the connectors to prevent
contamination.
16. Make sure that all relevant harnesses and hoses
are unclipped from the engine and tied out of the
way.
17. If necessary, drain the hydraulic tank. Disconnect
and plug the hydraulic suction and delivery lines
at the transmission pump and gear pump. Label
the hoses to aid installation.
18. Remove the gearbox/hydraulic pump to engine
retaining bolts and pull the gearbox/hydraulic
pump clear of the engine.
8. 15 - Engine
00 - Engine
00 - General
15 - 33 9813/9050-1 15 - 33
18.1. Make sure that the torque converter stays
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Special Tool: Lifting Brackets (430 Engine) (Qty.:
1)
Special Tool: Engine Lifting Spreader Bar (Qty.:
1)
20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
21. Raise the engine and lift it clear of the machine.
22. Lower the engine into a suitable stand that is
capable of supporting the weight of the engine.
Figure 137.
T
U
A
A
A Lifting brackets
T Lifting equipment
U Spreader bar
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. It is vitally important that the torque converter
is installed at the gearbox and engine flywheel
correctly. Failure to locate the torque converter
correctly will result in damage to the gearbox oil
pump on engine start up.
9. 15 - Engine
00 - Engine
00 - General
15 - 34 9813/9050-1 15 - 34
3. Fill the cooling system.
Refer to: PIL 21-00-00.
3.1. When you fill the cooling system make
sure you use the correct water/antifreeze
mixture. A 50% mixture should be
maintained even if frost protection is not
required.
Refer to: PIL 75-09-03.
4. Fill and check the hydraulic fluid level.
5. Fill and check the engine oil level. Make sure the
correct oil is used.
Refer to: PIL 75-03-03.
6. Check the hydraulic, fuel and cooling systems for
leaks.
7. Check the operation of all drive and hydraulic
services.
10. 15 - Engine
00 - Engine
00 - General
15 - 35 9813/9050-1 15 - 35
Store and Recommission
Engines should be stored in the original shipping
packaging. Damaged or disturbed packaging should
be made weatherproof immediately.
If an engine is shipped with oil, it should be stored in
the correct (upright) position.
If an engine is shipped dry of oil, after 6 months it
should be filled with oil to the correct level and re-
inhibited, refer to hot test description.
All floor stock engines should be stored under cover
in dry conditions and not subjected to extreme
variations in temperature or humidity.
If an engine is to be placed into storage, all external
signs of surface coating damage or corrosion should
be cleaned and re-coated. Electrical connectors and
components should be coated with a protective
spray.
Capping Engine Openings
All openings on the engine must be suitably capped
to prevent ingress of water and contamination by
foreign particles.
11. 15 - Engine
00 - Engine
00 - General
15 - 36 9813/9050-1 15 - 36
Figure 138.
B
A
D
C
E
F
A ECM (Engine Control Module) machine harness
connector cap
B Machine harness interconnect connector cap
C Fuel pipe – return to tank cap D Fuel pipe – feed from lift pump cap
E Coolant circuit bleed pipe cap F Air intake cap
12. 15 - Engine
00 - Engine
00 - General
15 - 37 9813/9050-1 15 - 37
Figure 139.
G
H
J
K
L
M
G Turbocharger intake cap H Coolant top hose cap
J Turbocharger compressor outlet cap K Coolant bottom hose cap
L Cab heater feed and return spigots M Heavy duty PTO (Power Take-Off)
13. 15 - Engine
00 - Engine
00 - General
15 - 38 9813/9050-1 15 - 38
Figure 140.
N
N Turbocharger exhaust outlet (tape over)
12 Month Revalidation Procedure
1. Pre-inspection:
1.1. Inspect packaging for signs of damage.
1.2. Inspect the caps for signs of damage.
1.3. Inspect openings for signs of water or dirt
ingress.
1.4. Inspect the engine for signs of external
corrosion.
1.5. Inspect the engine for signs of fluid leaks.
2. From storage:
2.1. Remove the air intake caps.
2.2. Make sure the engine oil level is correct.
2.3. Using a suitable power supply at the correct
voltage, crank the engine over for the
specified time period.
Duration: 20s
2.4. During cranking, check that the oil pressure
switch opens using a multimeter. The switch
is closed when there is no or low oil
pressure and opens when oil pressure
reaches a set point. After three separate
cranking periods, If the oil pressure switch
does not open (indicating no, or low oil
pressure), contact your JCB engine dealer.
2.5. Recap all engine openings.
2.6. Coat any exposed bare metal with a
suitable product.
2.7. Electrical connectors and components
should be coated with a protective spray if
exposed.
2.8. Cover in weatherproof packaging.
2.9. Place in storage, under cover on level
ground or shelving.
2.10. Record details of work as required.
2.11. Do not expose to extremes of temperature
or humidity.
Notice: Do not operate the starter motor for more
than 20s at one time. Let the starter motor cool for
at least 2min.
Table 59. Oil Pressure Switch Set Points
Oil pressure switch
closed
>0.6bar (8.7psi)
Oil pressure switch open <0.6bar (8.7psi)
OEM Commissioning Check on Engine
Installation After More Than 12 Months
1. Flush the coolant system with proprietary
flushing solution.
2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
3. Hot test engine according to the hot test profile.
Refer to Table 60.
4. Drain engine oil and replace engine oil filter.
5. Refill with the correct oil and inhibit the cooling
system using the correct product.
6. Record details of work as required.
Hot Test Description
WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
the manufacturer's instructions and safety
precautions.
All engines despatched from JCB will have been
subjected to a hot test (checking items such as oil
pressure, engines speeds, torque values etc.) and
therefore the interior surfaces will have been coated
with engine oil.
All coolant galleries are coated with CRODAFLUID
PA75 corrosion inhibitor.
Stored engines will require re-inhibiting every 12
months, this will include hot testing the engine using
a dynamometer. The hot test profile is:
Table 60. Hot Test Profile
Stage Mode Speed
(rpm)
Torque
(Nm)
Time
(secs)
1 Speed/
Torque
830 0 50
2 Speed/
Torque
1300 50 60
14. 15 - Engine
06 - Cylinder Head
00 - General
15 - 47 9813/9050-1 15 - 47
Component Identification
Figure 142.
A
B
C
A Cylinder head bolts
B Cylinder head
C Cylinder head gasket
15. 15 - Engine
06 - Cylinder Head
00 - General
15 - 48 9813/9050-1 15 - 48
Remove and Install
Special Tools
Description Part No. Qty.
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
Before Removal
This procedure requires service parts. Make sure
you have obtained the correct parts before you start.
Refer to the Parts Catalogue.
1. Make the machine safe.
Refer to: PIL 01-03.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Drain the coolant.
Refer to: PIL 21-00-00.
5. Remove the engine wiring harness.
6. Remove the ECM (Engine Control Module).
Refer to: PIL 33-45-06.
7. Remove the thermostat.
Refer to: PIL 21-12-00.
8. Disconnect the CCV (Crankcase Ventilation)
pipes.
Refer to: PIL 15-28-00.
9. Remove the fuel injector cover.
Refer to: PIL 18-18-04.
10. Remove the high pressure fuel pipes.
Refer to: PIL 18-96-03.
11. Remove the injector leak-off, leak-off pipe to fuel
filter, and return to tank low pressure fuel pipes.
Refer to: PIL 18-96-06.
12. Remove the fuel injectors.
Refer to: PIL 18-18-03.
13. Remove the fuel rail.
Refer to: PIL 18-18-12.
14. Remove the EGR (Exhaust Gas Recirculation)
system.
Refer to: PIL 18-27-00.
15. Remove the exhaust manifold pressure sensor
assembly.
Refer to: PIL 15-84-16.
16. Remove the exhaust manifold and turbocharger
assembly.
Refer to: PIL 18-24-04.
17. Remove the glow plugs.
Refer to: PIL 15-80-00.
18. Disconnect the charge air inlet hose.
19. Remove the rocker cover.
Refer to: PIL 15-42-06.
20. Remove the rocker assembly.
Refer to: PIL 15-42-00.
16. 15 - Engine
06 - Cylinder Head
00 - General
15 - 49 9813/9050-1 15 - 49
Figure 143.
12
1
2 3
45
6
9
10 7
8
0° +90 °
Y
11
12
X13
1-10 Cylinder head fixing bolts (x10) 11 Cylinder head
12 Location dowels (x2) 13 Cylinder head gasket
X Cylinder head gasket identification holes Y Matchmarks
21. Remove the push rods. Make a note of the
order to make sure that they are installed in their
original positions.
Remove
1. Progressively remove the cylinder head bolts in
reverse order, starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts.
2. Carefully lift the cylinder head from the
crankcase. If necessary use a soft face hammer.
DO NOT use a lever to separate the cylinder
head from the crankcase. Discard the head
gasket.
3. Using a suitable cleaning agent, carefully remove
all traces of the head gasket material from the
cylinder head and crankcase mating faces.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4. Check the cylinder head and crankcase mating
faces for signs of damage and distortion.
Refer to: PIL 15-06-00.
Before Install
1. Obtain the correct new cylinder head bolts. The
original bolts MUST NOT be re-used.
17. 15 - Engine
06 - Cylinder Head
00 - General
15 - 50 9813/9050-1 15 - 50
2. Obtain the correct replacement head gasket.
Note the number of cylinder head gasket
identification holes.
3. Make sure that all items are clean and free from
damage and corrosion.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in three stages, use the
torque and angle method.
Refer to: PIL 72-00-00.
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-10) to the 1st stage pre-torque.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
4.2. Tighten the bolts, starting with the middle
pair and working outwards (in sequence 1-
10) to the 2nd stage pre-torque.
4.3. Repeat the 2nd stage pre-torque. Refer to
step 4.2.
4.4. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-10) to
the final stage torque. As a visual check,
matchmark the bolts to the cylinder head
before you start. When the bolts have
been angle tightened, the matchmarks will
appear as shown at Y. Refer to Figure 143.
Table 63. Torque Table
Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
1-10 (Final Stage) 90°
18. 15 - Engine
12 - Crankshaft
00 - General
15 - 61 9813/9050-1 15 - 61
Check (Condition)
1. Measure the crankshaft journal diameters to
confirm they are within service limits.
Refer to: PIL 15-12-00.
Figure 147.
B
A
C
A Crankcase
B Crankshaft
C Crankshaft position sensor target wheel
2. Check the main bearing surfaces for damage and
excessive wear.
Figure 148.
D
D Main bearing shells
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oilways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling saddle jets are
clear. If the saddle jets cannot be cleared, replace
the saddle jets.
Figure 149.
E
E Saddle jets
19. 15 - Engine
12 - Crankshaft
00 - General
15 - 62 9813/9050-1 15 - 62
Remove and Install
Special Tools
Description Part No. Qty.
Template for Sealant
Bedplate to Crankcase
(430 Engine)
320/02333 1
Crankshaft Turning Tool
(Major Repair) (430
Engine)
320/A3170 1
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to the Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Drain the engine oil.
Refer to: PIL 15-21-00.
4. Remove the engine.
Refer to: PIL 15-00-00.
5. Remove the fuel filter.
Refer to: PIL 18-09-03.
6. Remove the drive belt.
Refer to: PIL 15-18-03.
7. Remove the crankshaft pulley.
Refer to: PIL 15-12-12.
8. Remove the front crankshaft oil seal.
Refer to: PIL 15-12-06.
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
10. Remove the dipstick.
11. Remove the dipstick tube.
Refer to: PIL 15-45-09.
12. Remove the bolts (x2) and disconnect the
turbocharger oil drain pipe.
13. Remove the oil sump.
Refer to: PIL 15-45-00.
14. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now.
Refer to: PIL 15-06-00.
15. Remove the starter motor.
Refer to: PIL 15-75-00.
16. Remove the flywheel.
Refer to: PIL 15-54-00.
17. Remove the rear crankshaft oil seal.
Refer to: PIL 15-12-09.
18. Remove the flywheel housing.
Refer to: PIL 15-54-03.
19. Remove the oil pump.
Refer to: PIL 15-60-00.
20. Remove the bolt securing the fuel hose to the
bedplate.
Figure 150.
E
E Fuel pipe retaining bolt
21. Remove the main bearing caps.
Refer to: PIL 15-12-03.
22. Set the engine to TDC (Top Dead Centre).
20. 15 - Engine
12 - Crankshaft
00 - General
15 - 63 9813/9050-1 15 - 63
Special Tool: Crankshaft Turning Tool (Major
Repair) (430 Engine) (Qty.: 1)
Remove
1. Remove the bedplate peripheral bolts.
Figure 151.
OO
O
OO
2 3 710 6
1 4 89 5
O
O
N
P
O
1-10 Main bearing bolts (x10) N Bedplate
O Bedplate peripheral bolts (x12) P O-ring
2. Progressively remove the main bearing bolts in
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate.
Figure 152.
R
R
N
N Bedplate
R Lifting bolts (obtain locally)
4. Remove the bedplate.
21. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
22. 15 - Engine
12 - Crankshaft
00 - General
15 - 64 9813/9050-1 15 - 64
5. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
6. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
Figure 153.
A
B
A Thrust washers
B Crankshaft
C Rear main bearing
7. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
8. Carefully lift out the bearing shells.
Figure 154.
D
D Main bearing shells
9. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put labels on the shells to make sure that they
are installed in their original positions during
assembly.
10. Inspect the crankshaft and main bearings for
damage and excessive wear.
Refer to: PIL 15-12-00.
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
23. 15 - Engine
12 - Crankshaft
00 - General
15 - 65 9813/9050-1 15 - 65
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the upper bearing shells as follows:
Figure 155.
D
Y
G
D Main bearing shells
G Bearing location tab
Y Oil-way holes
3.1. Use a suitable degreasing agent to make
sure that the surfaces of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
3.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
3.3. Make sure that the oil-way holes in the
bearing saddles align with the holes in the
bearing shell. If the holes are even partially
misaligned the piston cooling oil jet will be
restricted, causing the engine to fail.
3.4. Lubricate the upper bearing shells with
clean engine oil.
4. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged. Make sure that the
connecting rods are located onto the crankshaft
journals.
4.1. Make sure that the connecting rods are
located onto the crankshaft journals.
4.2. Make sure that the crankshaft is installed
so that the engine timing is correct. The
single mark on the crankshaft drive gear
must locate between the two marks on the
camshaft drive gear.
Figure 156.
L
M
J
K
J Camshaft drive gear timing marks
K Crankshaft drive gear timing mark
L Camshaft drive gear
M Crankshaft drive gear
5. Install the thrust washers as follows:
24. 15 - Engine
12 - Crankshaft
00 - General
15 - 66 9813/9050-1 15 - 66
Figure 157.
C
A
A
H
B
A Thrust washer
B Crankshaft
C Rear main bearing
H Oil slot - thrust washers
5.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
5.2. Make sure that they are installed in the
correct positions, with the two oil slots
facing outwards from the bearing saddle.
5.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
5.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged.
6. Check that the crankshaft end float is within
service limits.
Refer to: PIL 15-12-00.
7. Install the four lifting bolts to the bedplate as
shown.
8. Lubricate the lower bearing shells with clean
engine oil. If the bearings have been removed,
make sure that the location tab engages in the
slot as shown.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
9. The sealant template is used on the crankcase,
NOT the bedplate.
Special Tool: Template for Sealant Bedplate to
Crankcase (430 Engine) (Qty.: 1)
10. Locate the location tabs on the template using
a location dowel and a fixing bolt. Use the
templates as a guide apply a bead of sealant
around the crankcase/bedplate mating face as
shown to the dimension specified.
Length/Dimension/Distance: 1.5mm