The document provides instructions for removing and installing a cylinder head from an engine. It begins by listing safety precautions and required tools and consumables. The removal process involves progressively removing cylinder head bolts, lifting the cylinder head off, and cleaning the mating surfaces. Installation is the reversal of removal. Torque values for the cylinder head bolts and checking mating surfaces are also outlined.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upfujsjefskekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, torque specifications, and other technical details needed for repair and maintenance.
Jcb 550 80 telescopic handler service repair manual sn 2336575 and upfujsjefskekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems like the engine, brakes, hydraulics and electrical systems. The document provides removal and installation instructions, specifications, and safety information to correctly service and maintain the machines.
Jcb 531 70 telescopic handler service repair manual sn 2336575 and upfusoelskemfm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 531 70 telescopic handler service repair manual sn 2336575 and upudfjjdfjkksekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, technical specifications, and safety information.
Jcb 541 70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Procedures are provided for maintenance, removal and installation of parts, and repair. Safety warnings are included throughout regarding working on and operating the machines.
Jcb 531 t70 telescopic handler service repair manual sn 2336575 and upufjjsjekkdemd
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upfujsjefskekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, torque specifications, and other technical details needed for repair and maintenance.
Jcb 550 80 telescopic handler service repair manual sn 2336575 and upfujsjefskekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems like the engine, brakes, hydraulics and electrical systems. The document provides removal and installation instructions, specifications, and safety information to correctly service and maintain the machines.
Jcb 531 70 telescopic handler service repair manual sn 2336575 and upfusoelskemfm
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Jcb 531 70 telescopic handler service repair manual sn 2336575 and upudfjjdfjkksekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, technical specifications, and safety information.
Jcb 541 70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Procedures are provided for maintenance, removal and installation of parts, and repair. Safety warnings are included throughout regarding working on and operating the machines.
Jcb 531 t70 telescopic handler service repair manual sn 2336575 and upufjjsjekkdemd
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upkmf8sueddkk
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 535 t95 telescopic handler service repair manual sn 2336575 and upfusoelskemfm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 541 70 telescopic handler service repair manual sn 2336575 and upfhsejkdkme
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 531 t70 telescopic handler service repair manual sn 2336575 and upyhhjjkfkseme
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 541 t70 telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, specifications, and safety information.
Jcb 533 105 telescopic handler service repair manual sn 2336575 and upudfjjdfjkksekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, torque specifications, and other technical details needed for repair and maintenance.
Jcb 535 95 telescopic handler service repair manual sn 2336575 and upfujjsekleio
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, technical specifications, and safety information.
Jcb 531 t70 telescopic handler service repair manual sn 2336575 and upfujjsekleio
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, torque specifications, and other technical details needed for repair and maintenance.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upufujjsejfkkemme
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 550 80 telescopic handler service repair manual sn 2336575 and upjfjkskrtekfmsmem
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfujsefkxswksemm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems including the engine, fuel system, cooling system, brakes, hydraulics, electrical system and more. Safety warnings are provided throughout advising technicians to study the manual before working on machines.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfhsejkdkme
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. The manual provides removal and installation instructions, torque specifications, and other technical details needed for repair and maintenance.
Jcb 526 56 telescopic handler service repair manual sn 2336575 and upfjkskekxsdcmdmme
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 526 56 telescopic handler service repair manual sn 2336575 and upudjjfkkskemm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 541 70 telescopic handler service repair manual sn 2336575 and upjfjkskrtekfmsmem
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 526 56 telescopic handler service repair manual sn 2336575 and upfujsefkskekmm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 531 70 telescopic handler service repair manual sn 2336575 and upyhhjjkfkseme
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
New holland td5020 tractor service repair manualfusjefjskekemm
This document is a service manual for TD series tractor models TD5010 through TD5050. It contains sections covering general information, the engine, clutch, gearbox, transmission, brakes, hydraulics, steering, axles, auxiliary equipment, electrical systems, and the cab. Each section provides specifications, diagrams, troubleshooting information, removal and installation instructions, and repair procedures for the various systems on the tractors. Safety warnings are provided at the beginning noting that only qualified technicians should perform repairs using the proper tools and following the instructions carefully.
New holland t6030 tractor service repair manualfusjefjskekemm
The document is a service manual that provides technical specifications, diagrams, and repair instructions for the hydraulic, pneumatic, electrical, and electronic systems of tractor models T6010 through T6070. It includes sections on the primary and secondary hydraulic power systems, hydraulic command system, electrical power system, electronic systems, and fault codes. The primary hydraulic power system section provides detailed information on fixed displacement pumps, variable displacement pumps, and charge pumps including specifications, diagrams of hydraulic circuits, operating descriptions, and exploded parts views.
New holland t4050 supersteer tractor service repair manualfusjefjskekemm
This document is a service manual for T4020, T4030, T4040, and T4050 tractor models. It contains sections on general guidelines, the engine, clutch, transmissions, drive lines, front and rear mechanical transmissions, power take-off, brakes, hydraulic systems, steering, axle and wheels, cab air conditioning, electrical system, platform/cab/bodywork, and technical support. Each section provides specifications, diagrams, removal and installation instructions, disassembly and assembly procedures, adjustments, and fault finding information.
New holland t4050 deluxe tractor service repair manualfusjefjskekemm
This document is a service manual for T4020, T4030, T4040, and T4050 tractor models. It contains sections on general guidelines, the engine, clutch, transmissions, drive lines, mechanical transmissions, power take-off, brakes, hydraulics, steering, axles and wheels, air conditioning, electrical systems, and the platform/bodywork. Each section provides specifications, diagrams, removal and installation instructions, and troubleshooting information for repair and maintenance of components.
New holland t8.380 powershift transmission (pst) tractor service repair manualfusjefjskekemm
Plug or cap all ports and lines.
RAIL13TR04235AA 13
14. Remove the two bolts (1) securing the oil cooler
mounting bracket.
RAIL13TR04236AA 14
47794972 10/11/2014
10.1 [10.001] / 6
Engine - Engine and crankcase
15. Disconnect the wiring harness connectors (1) from the
engine.
RAIL13TR04238AA 15
16. Disconnect the fuel lines (1) from the fuel filter head.
Plug or cap the lines and ports.
RAIL13TR04239AA 16
17. Remove the two bolts (1) securing the
New holland t8.350 tractor service repair manual (pin zfre03123 and above)fusjefjskekemm
This service manual provides information for servicing the engines, transmissions, axles, hydraulic systems, and other components of T8 tractor models 320, 350, 380, and 410, including SmartTrax versions, with Powershift transmissions. The manual covers removal and installation procedures, specifications, and troubleshooting information to aid technicians in repairing and maintaining these agricultural tractors.
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2. 15 - Engine
00 - Engine
00 - General
15 - 32 9813/8950-2 15 - 32
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. Get access to the engine.
Remove
1. Disconnect and remove the battery. Refer to (PIL
33-03).
2. Drain the engine oil. Refer to (PIL 15-21).
3. Drain the engine coolant, remove the cooling
pack. Refer to (PIL 21-03).
4. Discharge the hydraulic pressure. Refer to (PIL
30-00).
5. Drain the hydraulic tank. Disconnect and plug
the hydraulic suction and delivery lines at the
transmission pump and gear pump. Label the
hoses to ensure correct reassembly. Refer to
(PIL 30-00).
6. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to ensure correct reassembly.
7. Disconnect the exhaust system.
8. Label the cab heater hoses at the engine block
connectors. Release the hose clips and remove
the hoses.
9. Disconnect the wiring connections from the
starter motor. Refer to (PIL 15-75).
10. Disconnect the wiring connections from the
alternator. Refer to (PIL 15-72).
11. Disconnect the wiring connections from the
engine sensors and actuators. Refer to (PIL
15-84).
12. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
13. Disconnect the electrical harness at the engine
harness.
14. Uncouple the electrical harness at the
ECM (Engine Control Module) machine side
connector. Important: Do not touch the connector
pins on the ECM or harness connectors. Cover
the connectors to prevent contamination.
15. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
16. Disconnect and plug the hoses at the hydraulic
pump.
17. Disconnect the wiring to the hydraulic pump.
18. Remove the gearbox to engine retaining bolts,
pull the transmission and converter clear of
the engine, make sure that the converter stays
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Special Tool: Lifting Bracket Front (Qty.: 1)
Special Tool: Lifting Bracket Rear (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. Withdraw the engine in a level attitude until the
hydraulic pump is clear of the chassis. Raise the
engine to lift it clear of the machine.
22. Lower the engine into a suitable stand that is
capable of supporting the weight of the engine.
3. 15 - Engine
00 - Engine
00 - General
15 - 33 9813/8950-2 15 - 33
Figure 135.
A
B
A
C
A Lifting bracket mounting bolts
B Lifting equipment
C Spreader bar
Install
1. Replacement is a reversal of the removal
procedure. Note the following:
2. Important: It is vitally important that the torque
converter is installed at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil
pump on engine start up.
3. Fill the cooling system with the correct mix of
coolant fluid. Refer to (PIL 21-00).
4. Fill and Check the hydraulic fluid level. Refer to
(PIL 30-00).
5. Fill and Check the engine oil level. Make sure the
correct oil is used. Refer to (PIL 75-03).
6. On completion, check the hydraulic and cooling
system for leakage and levels.
7. Check the function of the drive and loader
services.
Table 35. Torque Values
Item Nm
A 47
4. 15 - Engine
00 - Engine
00 - General
15 - 34 9813/8950-2 15 - 34
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.
Some engine configurations may differ in detail to the
illustrations shown. Make sure you identify and cap
all openings.
Figure 136. Typical engine
5
3
4
16
13
11
9
15
8
1
6
14
7
10 2
12
17
5. 15 - Engine
00 - Engine
00 - General
15 - 35 9813/8950-2 15 - 35
1 Top hose cap 2 Bottom hose cap
3 Turbocharger intake cap 4 Turbocharger compressor outlet cap
5 Turbocharger exhaust outlet cap 6 Inlet manifold cap
7 Dipstick plug 8 ECM (Engine Control Module) machine
harness connector cap
9 Fuel spill back line cap 10 Low duty PTO (Power Take-Off) (if installed)
cap
11 Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots
13 Coolant circuit de-gas spigot 14 CCV canister outlet on the closed loop
breathing circuit (55kW)
15 Low pressure fuel filter inlet spigot (engines
with fuel filter attached)
16 SCR (Selective Catalytic Reduction) coolant
feed spigot (if installed)
17 Fuel pump low pressure inlet spigot (engines
with no fuel filter attached)
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.
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 20
second 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 20 s at one time. Let the starter motor cool for
at least 2 min.
Table 36. Oil Pressure Switch Set Points
Oil pressure switch
closed
> 0.6 bar ( 8.7 psi)
Oil pressure switch open < 0.6 bar ( 8.7 psi)
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 37.
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:
7. 15 - Engine
03 - Crankcase
00 - General
15 - 39 9813/8950-2 15 - 39
00 - General
Introduction .................................................... 15-39
Technical Data ............................................... 15-40
Introduction
The crankcase is the housing for the crankshaft.
The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and
connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 137.
B
A
A Crankcase
B Crankshaft
8. 15 - Engine
03 - Crankcase
00 - General
15 - 40 9813/8950-2 15 - 40
Technical Data
Table 38. Crankcase and Bedplate Data
4.4 L 4.8 L
Cylinder bore
(1)
103 –103.02 mm 106 –106.02 mm
Main bearing bolts torque
(2)
First stage 50 N·m 50 N·m
Second stage 115 N·m 115 N·m
Final stage Turn a further 180 ° Turn a further 180 °
Surface finish for cylinder head
joint
(3)
Rz < 15 m, Rmax < 20 Rz < 15 m, Rmax < 20
Diameter of first oversize bore 103.5 –103.52 mm 106.5 –106.52 mm
Diameter of second oversize bore 104 –104.02 mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92 –92.02 mm 92 –92.02 mm
Number 5 105 –105.02 mm 105 –105.02 mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047 –88.09 mm 88.047 –88.09 mm
Number 5 100.047 –100.09 mm 100.047 –100.09 mm
Camshaft bore
Numbers 1 to 4 60.04 –60.07 mm 60.04 –60.07 mm
Number 5 (bush) 60.29 –60.32 mm 60.29 –60.32 mm
Permissible wave profile wt < 10 m (2.5 distance) wt < 10 m (2.5 distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
9. 15 - Engine
06 - Cylinder Head
00 - General
15 - 46 9813/8950-2 15 - 46
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 0.4 L
Before Removal
1. This procedure requires service parts. Make sure
you have obtained the correct 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 thermostat, refer to (PIL 21-12).
5. Remove the fuel pipes, refer to (PIL 18-96).
6. Remove the rocker cover, refer to (PIL 15-42).
7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
10. 15 - Engine
06 - Cylinder Head
00 - General
15 - 47 9813/8950-2 15 - 47
Figure 139.
16
12841591317
210 61418 73 11
15
19
22
21
20
0° +90° +180°
Y
X
1-18 Cylinder head fixing bolts (x18) 19 Cylinder head
20 Crankcase 21 Location dowels (x2)
22 Cylinder head gasket
11. 15 - Engine
06 - Cylinder Head
00 - General
15 - 48 9813/8950-2 15 - 48
Remove
1. Progressively remove the cylinder head bolts in
reverse order, starting at bolt 18. Note that 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
Technical Data (PIL 15-06).
Before Assembly
1. Obtain the correct new cylinder head bolts. Note
that the original bolts MUST NOT be re-used.
2. Obtain the correct replacement head gasket.
Note the number of identification holes as shown
at X.
3. Make sure that all items are clean and free from
damage and corrosion.
Assemble
The cylinder head bolts are tightened using a torque
and angle method, refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
1. Replacement is the reversal of the removal
procedure.
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 five stages, use the
torque and angle method, refer to Fasteners and
Fixings, General, Introduction (PIL 72-00).
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-18) to the 1st stage pre-torque.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
4.2. Then, further tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1- 18) to the 2nd stage pre-
torque.
4.3. Then, re-tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1-18) to the 3rd stage pre-torque.
4.4. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-18) to the
4th stage pre-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.
4.5. Finally, angle tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1- 18) for the final stage torque.
Table 40.
Description Torque Value
Cylinder head to
crankcase bolts 1-18
- first stage torque 40 N·m
- second stage torque 75 N·m
- third stage torque 75 N·m
- fourth stage torque 90 °
- final stage torque 180 °
12. 15 - Engine
09 - Bedplate
00 - General
15 - 51 9813/8950-2 15 - 51
00 - General
Introduction .................................................... 15-51
Remove and Install ....................................... 15-52
Introduction
The bedplate acts as the main strength component
of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 140.
1
2
1 Bedplate
2 Crankcase
13. 15 - Engine
09 - Bedplate
00 - General
15 - 52 9813/8950-2 15 - 52
Remove and Install
Special Tools
Description Part No. Qty.
Template for Sealant
Bedplate to Crankcase
(4 Cyl)
892/12356 1
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4 L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO (Power Take-Off)
device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
15. 15 - Engine
09 - Bedplate
00 - General
15 - 54 9813/8950-2 15 - 54
Remove
1. Remove the bedplate peripheral bolts.
2. Progressively remove the main bearing bolts in
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate.
4. Remove and discard the O-ring.
5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
Figure 142.
18
18
18
18
18
T6
T6
T6
18
12
T6
P3
13
11
A (T5)
V
YY P2
51
9
4
8
3
7
62
10
T4
T4
W
P2
B (T5)
Y Y P2
X
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)
12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
16. 15 - Engine
09 - Bedplate
00 - General
15 - 55 9813/8950-2 15 - 55
T4 Guide pins (x2 obtain locally) T5 Sealant template
T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
17. 15 - Engine
09 - Bedplate
00 - General
15 - 56 9813/8950-2 15 - 56
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Anaerobic sealant will not start to cure
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and tightened to the correct
torque value within 5 minutes (with a maximum
permissible time of 15 minutes).
Important: BEFORE installing the bedplate: DO NOT
rotate the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of the
crankcase.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown.
4. Install the four lifting bolts T6 to the bedplate as
shown.
5. Install a new O-ring at the bedplate.
6. Use a suitable degreasing agent to clean both
sides of the lower bearing shells. Assemble the
lower bearing shells into the bedplate. Lubricate
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
7. Note: The sealant template T5 is used on
the crankcase, NOT the bedplate. The sealant
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1)
8. Locate the holes in the templates A and B using
four fixing bolts at positions Y. Use the templates
as a guide apply beads of sealant P2 around the
crankcase/bedplate mating face as shown to the
dimension specified.
Length/Dimension/Distance: 1.5 mm
9. Remove the four fixing bolts at positions Y.
Remove the templates A and B, make sure
you do not smudge the sealant. Discard the
templates.
10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
beads as shown at X.
11. Make sure that the location guide pins T4 are in
position in the crankcase. Assemble the bedplate
to the crankcase use the alignment guide pins.
12. Note: The bedplate is heavy. Two people will
be required to lift and rotate the bedplate safely
on to the crankcase. Install new main bearing
bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 1st stage pre-
torque.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
13. Install the bedplate peripheral bolts. Tighten the
bolts to the correct torque value.
14. After installation and tightening the bedplate
peripheral bolts, further tighten the main bearing
bolts in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 2nd stage
pre-torque.
15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
(in sequence 1-10) for the final stage torque. Use
the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
Important: If the parts have not been tightened to the
correct torque value within the maximum 15 minute
time period, then the parts must be separated,
thoroughly cleaned and fresh sealant applied.
After Installation
1. Check that the crankshaft can be freely rotated
by hand. Remove the bedplate lifting bolts T6.
2. Carry out the procedures listed, Before removal
in reverse order.
Table 41. Torque Table
Item Torque Value
1-10 (1st Stage) 50 N·m
1-10 (2nd Stage) 115 N·m
19. 15 - Engine
12 - Crankshaft
00 - General
15 - 62 9813/8950-2 15 - 62
Operation
Lubrication
Oil is fed from the main gallery via five drillings, one
to each of the main bearings. A groove around the
diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 144.
1 Main gallery 2 Drillings (x5)
3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
20. 15 - Engine
12 - Crankshaft
00 - General
15 - 63 9813/8950-2 15 - 63
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 145.
A
A Main bearing shells
2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 146.
B
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
Figure 147.
D
C
C J-jets
D Fixing screws
21. 15 - Engine
12 - Crankshaft
00 - General
15 - 64 9813/8950-2 15 - 64
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4 L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
25. Remove the bedplate, refer to (PIL 15-09).
Remove
1. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
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23. 15 - Engine
12 - Crankshaft
00 - General
15 - 65 9813/8950-2 15 - 65
Figure 148.
C
B
A
A
A Thrust Washers B Crankshaft
C Rear main bearing
2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
4. Carefully lift out the bearing shells.
Figure 149.
D
D Main bearing shells
5. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
then install cooling J jets as follows:
24. 15 - Engine
12 - Crankshaft
00 - General
15 - 66 9813/8950-2 15 - 66
Figure 150.
F
E
E J jets (x4)
F Fixing screws
3.1. Insert the cooling jets into the crankcase.
3.2. Note: There are different types of cooling
jets installed depending on the engine
application. The jets are colour coded.
3.3. Be sure to install the correct jets. Refer to
the relevant parts catalogue for the correct
cooling jet identification.
3.4. Tighten the retaining screws to the correct
torque value.
4. Install the upper bearing shells as follows:
Figure 151.
D
G
D Main bearing shells
G Bearing location tab
4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
4.3. Important: Make sure that the oil-way holes
in the bearing saddles align with the holes
in the bearing shell. If the holes are even
partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
25. 15 - Engine
12 - Crankshaft
00 - General
15 - 67 9813/8950-2 15 - 67
Figure 152.
C
B
A
A
A
H
A Thrust washers B Crankshaft
C Rear main bearing H Oil slot - thrust washers
6.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).
Table 43. Torque Values
Item Nm
F 24