This document provides information about servicing JCB wheeled excavators. It contains sections on the machine, attachments, body, operator station, HVAC, engine, fuel/exhaust, cooling, brakes, steering, driveline, hydraulics, and electrical systems. The section on the engine provides details on health and safety, technical data, component identification, operation, maintenance procedures, and storage for the engine. It includes diagrams labeling external and internal engine parts and describes the four-stroke operating cycle.
Jcb t2 t3 elec engine 4 cyl service repair manualujfjjskekkksmem
This service manual section contains information about a JCB T2/3 Elec Engine, including:
- The engine is a 4 cylinder diesel with common rail fuel injection and variable geometry turbocharger.
- It provides identification of major external and internal engine components and their functions.
- Safety precautions are outlined for working on hot components and ensuring proper PPE and procedures.
- Technical specifications of engine variants including displacement, cylinder arrangement, valve clearances and more.
This document is the service manual for MerCruiser #24 GM V-8 305 CID (5.0L) / 350 CID (5.7L) marine engines. The manual contains sections on important information, removal and installation, the engine, electrical systems, fuel systems, cooling systems, exhaust systems, drives, power steering systems and troubleshooting. It provides information and instructions for mechanics to service these MerCruiser engines.
This document provides service information for a GM 4 cylinder 181 cid (3.0L) marine engine. It includes general safety information and outlines the sections contained in the service manual, which cover important information, removal and installation, the engine, electrical, fuel, cooling, exhaust and power steering systems. It describes how to properly use the manual and read parts manuals. It also includes information on engine identification, rotation, testing new engines, and factors that affect boat performance such as the boat bottom, marine fouling, weight distribution and more.
Mercury mercruiser marine engines #28 bravo sterndrives service repair manualjfjskekdhnejd
This document is the service manual for MerCruiser #28 Bravo Sterndrives. It provides information on maintenance, troubleshooting, removal and installation procedures. The manual begins with important safety notices and outlines the document structure. Subsequent sections cover lubrication and maintenance schedules, troubleshooting common issues, and detailed removal and installation instructions for sterndrive components. Torque specifications, lubricants and tools required are also listed throughout.
Komatsu sk510 5 skid steer loader service repair manual (sn 37 df00001 and up)jfjskekdhnejd
This document is a shop manual for the SK510-5 skid-steer loader. It provides information on structure and function, testing and adjusting procedures, disassembly and assembly instructions, and maintenance standards. The manual contains safety precautions that must be followed when servicing equipment. It explains how to properly lift heavy components using hoists or cranes. Standard tightening torques are also provided for bolts, nuts, and other fasteners.
Komatsu ck25 1 skid steer loader service repair manual (sn f00003 and up)jfjskekdhnejd
This document provides an overview and safety instructions for operating a CK25-1 Crawler Skid-Steer Loader. It contains sections on safety, testing and adjusting procedures, removal and installation instructions, maintenance standards, and other technical information. Safety is emphasized, including wearing proper protective equipment and following lockout procedures before performing any repairs or maintenance.
Komatsu d63 e 12 dozer bulldozer service repair manual (sn 2001 and up)jfjskekdhnejd
1) The document is a shop manual that provides instructions for maintenance, repair, and troubleshooting of a Bulldozer model D63E-12 from serial numbers 2001 and up.
2) It consists of several sections that cover specifications, structure and functions, standard values, testing and adjusting procedures, troubleshooting guides, and disassembly/reassembly instructions for components.
3) The sections and subsections are organized by topic and each has a corresponding form number to allow for filing in a binder according to the manual's instructions.
Daewoo doosan de12 tis diesel engine service repair manualjfjskekdhnejd
This maintenance manual provides instructions for maintaining DAEWOO DE series diesel engines, specifically models DE12, DE12T, DE12TI, and DE12TIS. It describes the engine components and specifications. Proper maintenance like checking coolant concentration and fan belt tension are described. Technicians should follow the instructions to prevent issues and keep engines performing optimally for long-term use.
Jcb t2 t3 elec engine 4 cyl service repair manualujfjjskekkksmem
This service manual section contains information about a JCB T2/3 Elec Engine, including:
- The engine is a 4 cylinder diesel with common rail fuel injection and variable geometry turbocharger.
- It provides identification of major external and internal engine components and their functions.
- Safety precautions are outlined for working on hot components and ensuring proper PPE and procedures.
- Technical specifications of engine variants including displacement, cylinder arrangement, valve clearances and more.
This document is the service manual for MerCruiser #24 GM V-8 305 CID (5.0L) / 350 CID (5.7L) marine engines. The manual contains sections on important information, removal and installation, the engine, electrical systems, fuel systems, cooling systems, exhaust systems, drives, power steering systems and troubleshooting. It provides information and instructions for mechanics to service these MerCruiser engines.
This document provides service information for a GM 4 cylinder 181 cid (3.0L) marine engine. It includes general safety information and outlines the sections contained in the service manual, which cover important information, removal and installation, the engine, electrical, fuel, cooling, exhaust and power steering systems. It describes how to properly use the manual and read parts manuals. It also includes information on engine identification, rotation, testing new engines, and factors that affect boat performance such as the boat bottom, marine fouling, weight distribution and more.
Mercury mercruiser marine engines #28 bravo sterndrives service repair manualjfjskekdhnejd
This document is the service manual for MerCruiser #28 Bravo Sterndrives. It provides information on maintenance, troubleshooting, removal and installation procedures. The manual begins with important safety notices and outlines the document structure. Subsequent sections cover lubrication and maintenance schedules, troubleshooting common issues, and detailed removal and installation instructions for sterndrive components. Torque specifications, lubricants and tools required are also listed throughout.
Komatsu sk510 5 skid steer loader service repair manual (sn 37 df00001 and up)jfjskekdhnejd
This document is a shop manual for the SK510-5 skid-steer loader. It provides information on structure and function, testing and adjusting procedures, disassembly and assembly instructions, and maintenance standards. The manual contains safety precautions that must be followed when servicing equipment. It explains how to properly lift heavy components using hoists or cranes. Standard tightening torques are also provided for bolts, nuts, and other fasteners.
Komatsu ck25 1 skid steer loader service repair manual (sn f00003 and up)jfjskekdhnejd
This document provides an overview and safety instructions for operating a CK25-1 Crawler Skid-Steer Loader. It contains sections on safety, testing and adjusting procedures, removal and installation instructions, maintenance standards, and other technical information. Safety is emphasized, including wearing proper protective equipment and following lockout procedures before performing any repairs or maintenance.
Komatsu d63 e 12 dozer bulldozer service repair manual (sn 2001 and up)jfjskekdhnejd
1) The document is a shop manual that provides instructions for maintenance, repair, and troubleshooting of a Bulldozer model D63E-12 from serial numbers 2001 and up.
2) It consists of several sections that cover specifications, structure and functions, standard values, testing and adjusting procedures, troubleshooting guides, and disassembly/reassembly instructions for components.
3) The sections and subsections are organized by topic and each has a corresponding form number to allow for filing in a binder according to the manual's instructions.
Daewoo doosan de12 tis diesel engine service repair manualjfjskekdhnejd
This maintenance manual provides instructions for maintaining DAEWOO DE series diesel engines, specifically models DE12, DE12T, DE12TI, and DE12TIS. It describes the engine components and specifications. Proper maintenance like checking coolant concentration and fan belt tension are described. Technicians should follow the instructions to prevent issues and keep engines performing optimally for long-term use.
Daewoo doosan de12 ti diesel engine service repair manualjfjskekdhnejd
This maintenance manual provides instructions for maintaining DAEWOO DE series diesel engines, models DE12, DE12T, DE12TI, and DE12TIS. It describes the engine components and specifications. Proper maintenance like checking coolant concentration and fan belt tension are important to maintain optimum engine performance and durability. The manual explains maintenance procedures and includes symbols to indicate removal, installation, cleaning, and other service operations.
Daewoo doosan de12 diesel engine service repair manualjfjskekdhnejd
This maintenance manual provides instructions for maintaining Daewoo DE series diesel engines, including the DE12, DE12T, DE12TI, and DE12TIS models. It describes the engine components and specifications. The manual includes symbols to indicate maintenance tasks and safety instructions for preventing environmental damage when disposing of waste. It aims to help customers and distributors properly operate and maintain the engines to retain maximum performance over the long term.
Crown ws2000 series forklift service repair manualjfjskekdhnejd
This document is a service and parts manual for a series of lift trucks. It contains sections on maintenance, lubrication, adjustments, repairs, and inspections for various components of the trucks including the hydraulic system, drive unit, electrical systems, brakes, steering, mast, cylinders, and forks. The manual provides maintenance schedules, diagrams, part numbers, and repair instructions.
Crown wp2300 s series pallet truck service repair manualjfjskekdhnejd
This document provides revisions and additions to the maintenance manual for the WP2300S Series order. Revisions include general corrections and additions to text pages, as well as additions and updates to electrical and hydraulic components used beginning with specific serial numbers. The document outlines revisions made to sections on safety switches, platform controls, diagrams, parameter settings, and troubleshooting guides. It provides an overview of the key changes and updates made to the maintenance instructions and repair information for technicians working on these trucks.
Crown wp2300 series pallet truck service repair manualjfjskekdhnejd
The document provides an overview of maintenance and repair for a WP2300 series truck. It includes sections on lubrication and adjustment, hydraulics, drive unit, electrics, brakes, steering, lifting mechanism, cylinders, electrical diagrams and hydraulic schematics. Safety symbols and notes are defined. The manual is intended for trained service personnel and does not include operating instructions. Replacement parts should reference the truck specification, model, and serial numbers.
Crown wp2000 s series pallet truck service repair manualjfjskekdhnejd
This document is a service manual that provides maintenance and repair instructions for a WP2000S series truck. It contains sections on safety, introduction, lubrication and adjustment, hydraulics, drive unit, electrics, brakes, steering, lifting mechanism, cylinders, and electrical diagrams. The introduction section outlines the purpose and structure of the manual, and notes that replacement parts orders and service training can be obtained through Crown dealers.
This document provides instructions for disassembling a travel motor from an excavator model 326D2 L. The 27 step procedure includes removing the head, brake piston, plates, and friction discs. Special tools are required to remove components like the rotating assembly, bearing races, and retaining rings. Technicians are advised to mark components like the pistons and barrel assembly to ensure correct reassembly.
The document provides instructions for disassembling a travel motor. It begins by having the technician remove the travel motor from the excavator and clean the outside. The technician is then instructed to fasten the motor vertically and mark it for alignment before disassembling. The summary proceeds to list the 27 steps to disassemble the various components of the travel motor, including removing the head, brake piston, barrel assembly, and shaft assembly. Tools required for the disassembly are also provided in a table.
The document provides instructions for disassembling a travel motor from an excavator. It describes 28 steps to fully disassemble the travel motor, removing components like the head assembly, housing assembly, brake piston, springs, seals, and other internal parts. Precautions are provided to watch for spring forces and use lifting devices due to the weight of some components. Detailed illustrations accompany each step for clarity.
Caterpillar cat 325 d mh excavator (prefix rjk) service repair manual (rjk000...jfjskekdhnejd
This document provides instructions for disassembling and assembling the travel motor of a 325D Material Handler excavator. The disassembly process involves removing 28 different components of the travel motor including the head, port plate, springs, brake piston, plates, and seals. The assembly process describes installing these 28 components in reverse order and notes that all seals and gaskets must be replaced and components cleaned before assembly. Precise alignment and installation of components is emphasized to ensure proper function.
Caterpillar cat 325 d mh excavator (prefix c4h) service repair manual (c4h000...jfjskekdhnejd
This document provides instructions to disassemble a final drive on a 325D MH EXCAVATOR. It outlines 31 steps to remove components like the cover, gears, carrier assemblies, housing and seals. Special tools are required and cleanliness is important to prevent dirt from entering during reassembly. The procedure includes notes on alignment marks, weights of parts, and disassembling planetary gears within carrier assemblies.
Caterpillar cat 325 c excavator (prefix s2c) service repair manual (s2c00001 ...jfjskekdhnejd
The document provides instructions for removing and installing inlet and exhaust valves, valve guides, and valve seat inserts on a 3126B engine. It describes the required tools and multi-step procedures for each task, including compressing springs, removing retainers, and tapping guides into place. Safety notices warn of potential injury from parts propelled by springs and ensure clean parts to prevent premature wear.
Caterpillar cat 325 c excavator (prefix dtf) service repair manual (dtf00001 ...jfjskekdhnejd
This document provides instructions for removing and installing various engine components on a 325C excavator including:
1) The alternator, which involves disconnecting cables and removing bolts and nuts.
2) The electric starting motor, which requires removing wires, brackets and bolts.
3) The primary fuel filter and base, which involves disconnecting hoses and removing bolts.
4) The water separator, requiring draining fluid, removing hoses and harness, and replacing the filter element.
Caterpillar cat 325 c excavator (prefix blx) service repair manual (blx00001 ...jfjskekdhnejd
This document provides instructions for removing and installing engine components on a 325C excavator, including:
- Removing and installing inlet and exhaust valves, using specialized tools to compress springs.
- Removing and installing valve guides with driver tools.
- Removing and installing valve seat inserts with an extractor tool.
- Removing the engine oil filter base using a strap wrench. Detailed steps and illustrations are provided for each procedure.
Caterpillar cat 325 c excavator (prefix bla) service repair manual (bla00001 ...jfjskekdhnejd
This document provides instructions for removing and installing various engine components on a Caterpillar 325C excavator, including:
- Removing and installing the flywheel, which requires the use of lifting tools and torque wrenches.
- Removing the crankshaft rear seal using drilling and hammering tools, and removing any wear sleeves.
- Installing the new crankshaft rear seal with a seal installer tool.
- Additional procedures for a crankshaft rear seal carrier, vibration damper, pulley, and flywheel housing that require cleaning surfaces and applying threadlock compounds.
Caterpillar cat 325 c excavator (prefix bkt) service repair manual (bkt00001 ...jfjskekdhnejd
This document provides instructions for removing and installing various components of a 325C excavator engine, including:
- Removing and installing the flywheel, which involves using lifting tools and bolts.
- Removing the crankshaft rear seal, which requires drilling holes and using slide hammers and distorters.
- Installing the crankshaft rear seal using a seal installer.
- Procedures for removing and installing the flywheel housing, vibration damper, and pulley are also provided. Tools are listed and safety notices are included.
Caterpillar cat 325 c excavator (prefix bkh) service repair manual (bkh00001 ...jfjskekdhnejd
The document provides instructions for installing a crankshaft wear sleeve on a 3126B engine if equipped. It describes using distorter rings and a seal distorter to remove an existing wear sleeve by creating creases around it to loosen it from the crankshaft. It also notes that wear sleeves are not factory installed and come with replacement rear seals.
Caterpillar cat 324 e ln excavator (prefix tlf) service repair manual (tlf000...jfjskekdhnejd
This document provides instructions for disassembling and assembling the travel motor of 324E L and 324E LN Excavator models. It lists the required tools and parts and provides step-by-step instructions and illustrations for removing and installing components like the motor head, brake piston, rotating assembly, bearings, seals and other internal parts. Precautions are included to properly handle springs and ensure correct positioning of parts during assembly.
Caterpillar cat 324 e ln excavator (prefix ldg) service repair manual (ldg000...jfjskekdhnejd
1. The document provides step-by-step instructions for disassembling and assembling the travel motor of a 324E LN excavator.
2. It details 27 steps to disassemble components like the head, brake piston, rotating assembly, and seals.
3. The 28 steps for assembly instruct to reinstall these components in reverse order and include lubricating mating surfaces.
Daewoo doosan de12 ti diesel engine service repair manualjfjskekdhnejd
This maintenance manual provides instructions for maintaining DAEWOO DE series diesel engines, models DE12, DE12T, DE12TI, and DE12TIS. It describes the engine components and specifications. Proper maintenance like checking coolant concentration and fan belt tension are important to maintain optimum engine performance and durability. The manual explains maintenance procedures and includes symbols to indicate removal, installation, cleaning, and other service operations.
Daewoo doosan de12 diesel engine service repair manualjfjskekdhnejd
This maintenance manual provides instructions for maintaining Daewoo DE series diesel engines, including the DE12, DE12T, DE12TI, and DE12TIS models. It describes the engine components and specifications. The manual includes symbols to indicate maintenance tasks and safety instructions for preventing environmental damage when disposing of waste. It aims to help customers and distributors properly operate and maintain the engines to retain maximum performance over the long term.
Crown ws2000 series forklift service repair manualjfjskekdhnejd
This document is a service and parts manual for a series of lift trucks. It contains sections on maintenance, lubrication, adjustments, repairs, and inspections for various components of the trucks including the hydraulic system, drive unit, electrical systems, brakes, steering, mast, cylinders, and forks. The manual provides maintenance schedules, diagrams, part numbers, and repair instructions.
Crown wp2300 s series pallet truck service repair manualjfjskekdhnejd
This document provides revisions and additions to the maintenance manual for the WP2300S Series order. Revisions include general corrections and additions to text pages, as well as additions and updates to electrical and hydraulic components used beginning with specific serial numbers. The document outlines revisions made to sections on safety switches, platform controls, diagrams, parameter settings, and troubleshooting guides. It provides an overview of the key changes and updates made to the maintenance instructions and repair information for technicians working on these trucks.
Crown wp2300 series pallet truck service repair manualjfjskekdhnejd
The document provides an overview of maintenance and repair for a WP2300 series truck. It includes sections on lubrication and adjustment, hydraulics, drive unit, electrics, brakes, steering, lifting mechanism, cylinders, electrical diagrams and hydraulic schematics. Safety symbols and notes are defined. The manual is intended for trained service personnel and does not include operating instructions. Replacement parts should reference the truck specification, model, and serial numbers.
Crown wp2000 s series pallet truck service repair manualjfjskekdhnejd
This document is a service manual that provides maintenance and repair instructions for a WP2000S series truck. It contains sections on safety, introduction, lubrication and adjustment, hydraulics, drive unit, electrics, brakes, steering, lifting mechanism, cylinders, and electrical diagrams. The introduction section outlines the purpose and structure of the manual, and notes that replacement parts orders and service training can be obtained through Crown dealers.
This document provides instructions for disassembling a travel motor from an excavator model 326D2 L. The 27 step procedure includes removing the head, brake piston, plates, and friction discs. Special tools are required to remove components like the rotating assembly, bearing races, and retaining rings. Technicians are advised to mark components like the pistons and barrel assembly to ensure correct reassembly.
The document provides instructions for disassembling a travel motor. It begins by having the technician remove the travel motor from the excavator and clean the outside. The technician is then instructed to fasten the motor vertically and mark it for alignment before disassembling. The summary proceeds to list the 27 steps to disassemble the various components of the travel motor, including removing the head, brake piston, barrel assembly, and shaft assembly. Tools required for the disassembly are also provided in a table.
The document provides instructions for disassembling a travel motor from an excavator. It describes 28 steps to fully disassemble the travel motor, removing components like the head assembly, housing assembly, brake piston, springs, seals, and other internal parts. Precautions are provided to watch for spring forces and use lifting devices due to the weight of some components. Detailed illustrations accompany each step for clarity.
Caterpillar cat 325 d mh excavator (prefix rjk) service repair manual (rjk000...jfjskekdhnejd
This document provides instructions for disassembling and assembling the travel motor of a 325D Material Handler excavator. The disassembly process involves removing 28 different components of the travel motor including the head, port plate, springs, brake piston, plates, and seals. The assembly process describes installing these 28 components in reverse order and notes that all seals and gaskets must be replaced and components cleaned before assembly. Precise alignment and installation of components is emphasized to ensure proper function.
Caterpillar cat 325 d mh excavator (prefix c4h) service repair manual (c4h000...jfjskekdhnejd
This document provides instructions to disassemble a final drive on a 325D MH EXCAVATOR. It outlines 31 steps to remove components like the cover, gears, carrier assemblies, housing and seals. Special tools are required and cleanliness is important to prevent dirt from entering during reassembly. The procedure includes notes on alignment marks, weights of parts, and disassembling planetary gears within carrier assemblies.
Caterpillar cat 325 c excavator (prefix s2c) service repair manual (s2c00001 ...jfjskekdhnejd
The document provides instructions for removing and installing inlet and exhaust valves, valve guides, and valve seat inserts on a 3126B engine. It describes the required tools and multi-step procedures for each task, including compressing springs, removing retainers, and tapping guides into place. Safety notices warn of potential injury from parts propelled by springs and ensure clean parts to prevent premature wear.
Caterpillar cat 325 c excavator (prefix dtf) service repair manual (dtf00001 ...jfjskekdhnejd
This document provides instructions for removing and installing various engine components on a 325C excavator including:
1) The alternator, which involves disconnecting cables and removing bolts and nuts.
2) The electric starting motor, which requires removing wires, brackets and bolts.
3) The primary fuel filter and base, which involves disconnecting hoses and removing bolts.
4) The water separator, requiring draining fluid, removing hoses and harness, and replacing the filter element.
Caterpillar cat 325 c excavator (prefix blx) service repair manual (blx00001 ...jfjskekdhnejd
This document provides instructions for removing and installing engine components on a 325C excavator, including:
- Removing and installing inlet and exhaust valves, using specialized tools to compress springs.
- Removing and installing valve guides with driver tools.
- Removing and installing valve seat inserts with an extractor tool.
- Removing the engine oil filter base using a strap wrench. Detailed steps and illustrations are provided for each procedure.
Caterpillar cat 325 c excavator (prefix bla) service repair manual (bla00001 ...jfjskekdhnejd
This document provides instructions for removing and installing various engine components on a Caterpillar 325C excavator, including:
- Removing and installing the flywheel, which requires the use of lifting tools and torque wrenches.
- Removing the crankshaft rear seal using drilling and hammering tools, and removing any wear sleeves.
- Installing the new crankshaft rear seal with a seal installer tool.
- Additional procedures for a crankshaft rear seal carrier, vibration damper, pulley, and flywheel housing that require cleaning surfaces and applying threadlock compounds.
Caterpillar cat 325 c excavator (prefix bkt) service repair manual (bkt00001 ...jfjskekdhnejd
This document provides instructions for removing and installing various components of a 325C excavator engine, including:
- Removing and installing the flywheel, which involves using lifting tools and bolts.
- Removing the crankshaft rear seal, which requires drilling holes and using slide hammers and distorters.
- Installing the crankshaft rear seal using a seal installer.
- Procedures for removing and installing the flywheel housing, vibration damper, and pulley are also provided. Tools are listed and safety notices are included.
Caterpillar cat 325 c excavator (prefix bkh) service repair manual (bkh00001 ...jfjskekdhnejd
The document provides instructions for installing a crankshaft wear sleeve on a 3126B engine if equipped. It describes using distorter rings and a seal distorter to remove an existing wear sleeve by creating creases around it to loosen it from the crankshaft. It also notes that wear sleeves are not factory installed and come with replacement rear seals.
Caterpillar cat 324 e ln excavator (prefix tlf) service repair manual (tlf000...jfjskekdhnejd
This document provides instructions for disassembling and assembling the travel motor of 324E L and 324E LN Excavator models. It lists the required tools and parts and provides step-by-step instructions and illustrations for removing and installing components like the motor head, brake piston, rotating assembly, bearings, seals and other internal parts. Precautions are included to properly handle springs and ensure correct positioning of parts during assembly.
Caterpillar cat 324 e ln excavator (prefix ldg) service repair manual (ldg000...jfjskekdhnejd
1. The document provides step-by-step instructions for disassembling and assembling the travel motor of a 324E LN excavator.
2. It details 27 steps to disassemble components like the head, brake piston, rotating assembly, and seals.
3. The 28 steps for assembly instruct to reinstall these components in reverse order and include lubricating mating surfaces.
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.
Real-time driver monitoring is one of the easiest ways to make fleet management efficient as well as seamless. Connected vehicle solutions such as fleet GPS trackers and associated software help businesses in several ways. Refer to the post below for more details.
car rentals in nassau bahamas | atv rental nassau bahamasjustinwilson0857
At Dash Auto Sales & Car Rentals, we take pride in providing top-notch automotive services to residents and visitors alike in Nassau, Bahamas. Whether you're looking to purchase a vehicle, rent a car for your vacation, or embark on an exciting ATV adventure, we have you covered with our wide range of options and exceptional customer service.
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Charging Fueling & Infrastructure (CFI) Program by Kevin MillerForth
Kevin Miller, Senior Advisor, Business Models of the Joint Office of Energy and Transportation gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
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.
Top-Quality AC Service for Mini Cooper Optimal Cooling PerformanceMotor Haus
Ensure your Mini Cooper stays cool and comfortable with our top-quality AC service. Our expert technicians provide comprehensive maintenance, repairs, and performance optimization, guaranteeing reliable cooling and peak efficiency. Trust us for quick, professional service that keeps your Mini Cooper's air conditioning system in top condition, ensuring a pleasant driving experience year-round.
Charging Fueling & Infrastructure (CFI) Program Resources by Cat PleinForth
Cat Plein, Development & Communications Director of Forth, gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
Charging and Fueling Infrastructure Grant: Round 2 by Brandt HertensteinForth
Brandt Hertenstein, Program Manager of the Electrification Coalition gave this presentation at the Forth and Electrification Coalition CFI Grant Program - Overview and Technical Assistance webinar on June 12, 2024.
2. 15 - Engine
00 - General
00 - General
15 - 3 9813/2650-3 15 - 3
00 - General
Introduction ...................................................... 15-3
Health and Safety ........................................... 15-7
Technical Data ................................................. 15-8
Component Identification ............................... 15-10
Operation ....................................................... 15-14
Drain and Fill ................................................. 15-18
Clean ............................................................. 15-18
Check (Operation) ......................................... 15-19
Check (Pressure) .......................................... 15-20
Remove and Install ....................................... 15-22
Store and Recommission .............................. 15-26
Introduction
This section contains information about the complete
engine assembly. For specific engine technical
information refer to the technical data section.
Make sure that the correct engine service tools,
consumables and torque figures are used when you
perform service procedures.
Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
damage is expected as a matter of course.
It is expected that components will be cleaned and
lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The JCB ecoMax engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The
starter motor turns the engine via a pinion and teeth
on the engine flywheel, refer to (PIL 15-75).
When the engine runs the crankshaft drives the
camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. The engine has 16 valves,
2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a high pressure fuel pump
via gears. The pump is part of the electronically
controlled common rail fuel injection system, refer to
(PIL 18-00).
Air is drawn into the engine, via the inlet manifold
and exhaust gases exit via the exhaust manifold.
The engine uses a VGT (Variable Geometry
Turbocharger) which pressurises the air at the inlet
manifold, refer to (PIL 18-36).
A mechanical lubrication oil pump is driven by
the crankshaft via gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt driven by the crankshaft, drives a
coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
6. 15 - Engine
00 - General
00 - General
15 - 7 9813/2650-3 15 - 7
Health and Safety
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system.Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
7. 15 - Engine
00 - General
00 - General
15 - 8 9813/2650-3 15 - 8
Technical Data
Table 31.
Description SL Engine SH Engine DH Engine
Engine Variants Turbocharged with inter-
cooler
Turbocharged with Inter-
cooler
Turbocharged with Inter-
cooler
Emission compliance US-EPA Tier 4 Final, EU
Stage IV
US-EPA Tier 4i, EU Stage
IIIB
US-EPA Tier 4i, EU Stage
IIIB
Rated speed 2200 RPM (Revolutions
Per Minute)
2200 RPM 2200 RPM (108kW), 2050
RPM (129kW)
Weight (Dry) (Dry weight-No cooling
fan drive) 496kg
(Dry weight-No cooling
fan drive) 496kg
(Dry weight-No cooling
fan drive) 496kg
Number of cylinders 4 4 4
Nominal bore size 103mm 103mm 106mm
Stroke 132mm 132mm 135mm
Cylinder arrangement In line In line In line
Combustion Cycle 4-stroke 4-stroke 4-stroke
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Displacement 4.399L 4.399L 4.765L
Compression ratio 16.7: 1 16.7: 1 16.7: 1
Engine Compression Compression variance
between each cylinder
should be no greater than
3.5bar (50.7psi)
Compression variance
between each cylinder
should be no greater than
3.5bar (50.7psi)
Compression variance
between each cylinder
should be no greater than
3.5bar (50.7psi)
Direction of rotation
(viewed from front {crank-
shaft pulley} end)
Clockwise Clockwise Clockwise
Valves 4 per cylinder 4 per cylinder 4 per cylinder
Valve clearances mea-
sured at the tappet end
of the rockers (measured
cold)
- Inlet 0.23–0.04mm 0.23–0.04mm 0.23–0.04mm
- Exhaust 0.6–0.04mm 0.6–0.04mm 0.6–0.04mm
Lubricating oil pressure
(Dependent on engine
temperature and speed)
1.6–6.5bar (23.2–94.2psi) 1.6–6.5bar (23.2–94.2psi) 1.6–6.5bar (23.2–94.2psi)
Filter type Screw-on canister (with
drain facility)
Screw-on canister (with
drain facility)
Screw-on canister (with
drain facility)
Pressure to open by-pass
valve
- 1.6bar (23.2psi) 1.6bar (23.2psi)
Oil pressure relief valve
setting
6bar (87.0psi) 6bar (87.0psi) 6bar (87.0psi)
Oil pressure switch set-
ting
0.6bar (8.7psi) falling 0.6bar (8.7psi) falling 0.6bar (8.7psi) falling
Oil pump
(1)
Integral unit with relief
valve
Integral unit with relief
valve
Integral unit with relief
valve
8. 15 - Engine
00 - General
00 - General
15 - 9 9813/2650-3 15 - 9
Description SL Engine SH Engine DH Engine
Combustion system Common rail direct Injec-
tion
Common rail direct Injec-
tion
Common rail direct Injec-
tion
High pressure fuel pump High pressure with elec-
tronically controlled fuel
metering
High pressure with elec-
tronically controlled fuel
metering
High pressure with elec-
tronically controlled fuel
metering
(1) The oil pump is a non-serviceable part
9. 15 - Engine
00 - General
00 - General
15 - 10 9813/2650-3 15 - 10
Component Identification
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 94. Left hand Side
4
10
923
8
5
13
19
14
12
20
17
15
622
7
21
18
11
16
1
2
3
1 Rocker cover 2 Fuel injectors and high pressure fuel pipes
3 Lubrication oil filler cap 4 Timing gear case
5 Flywheel housing 6 Bedplate
7 Lubrication oil sump 8 EGR (Exhaust Gas Recirculation) cooler
9 Air inlet manifold 10 High pressure fuel pump
11 Fuel filter 12 Lubrication oil filler cap
13 Lubrication oil filter 14 Lubrication oil cooler housing
11. 15 - Engine
00 - General
00 - General
15 - 12 9813/2650-3 15 - 12
7 Exhaust manifold 8 Alternator
9 Coolant pump housing (crankcase) 10 Coolant inlet/radiator hose connector
11 Heavy duty PTO (blanking cover if no device
is installed)
12 Starter motor assembly
13 Turbocharger oil drain pipe 14 Turbocharger oil feed pipe
15 Oil drain plug (sump) 16 Cab heater connections
Figure 96. Front End
1
2
12
3
4
5
8
10
11
9
6
7
1 Rocker cover 2 Cylinder head
3 Crankcase 4 Bedplate
5 Lubrication oil sump 6 Crankshaft pulley
7 FEAD tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
11 VGT 12 Coolant temperature sensor
12. 15 - Engine
00 - General
00 - General
15 - 13 9813/2650-3 15 - 13
Figure 97. Rear End
1 Rocker cover 2 Cylinder head
3 Flywheel 4 High pressure fuel pump drive gear cover
5 Flywheel housing 6 Engine electrical harness
7 VGT linkage 8 VGT actuator
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
13. 15 - Engine
00 - General
00 - General
15 - 14 9813/2650-3 15 - 14
Operation
The Four Stroke Cycle - 4 Cylinder
Engine
This section describes the cycle sequence, for the 4
cylinder engine.
With the crankshaft positioned as shown, the pistons
in numbers 1 and 4 cylinders are at top dead centre
and pistons in numbers 2 and 3 cylinders are at
bottom dead centre.
It is important to note that number 1 cylinder is firing
and about to start its power stroke. Rotating the
crankshaft a further full rotation would position the
pistons as described but the engine would be at a
different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
The stages in the four stroke cycle for each cylinder
are as follows:
Table 32. The Four Stroke Cycle
Stage number Piston operation Valve operation
1 The piston is at the top of its Com-
pression stroke and is about to
start its Power stroke.
Inlet and exhaust valves closed
2 The piston is at the bottom of its
Power stroke and is about to start
its Exhaust stroke.
Inlet valves closed, exhaust valves
about to open
3 The piston is at the bottom of its In-
duction stroke and is about to start
its Compression stroke.
Exhaust valves closed, inlet valves
about to close
4 The piston is at the top of its Ex-
haust stroke and is about to start
its Induction stroke.
Valve Operation Exhaust valves
about to close, inlet valves about to
open
Firing Order
A cylinder is said to be firing, when the fuel / air
mixture ignites and the piston is about to start its
power stroke.
From the stages described, it can be seen that
number 1 cylinder will be next to fire. Number 3
cylinder is starting its compression stroke and is next
in the cycle, followed by cylinders 4 and 2.
The firing order is therefore; 1, 3, 4, 2.
14. 15 - Engine
00 - General
00 - General
15 - 15 9813/2650-3 15 - 15
Figure 98.
745620
CYL1 CYL2 CYL3 CYL4
A A A A
B
F
C
B
C
B
B
C
C
C B
G
G
H
H
J
J
K
K
C B C B C B
4
5
2
3
A
1
745620
CYL1 Cylinder number 1 CYL2 Cylinder number 2
CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
15. 15 - Engine
00 - General
00 - General
15 - 16 9813/2650-3 15 - 16
Four Stroke Cycle
Induction
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the
inlet valves close. The piston then starts to rise up the
cylinder compressing the air trapped in the cylinder.
This causes the temperature and pressure of the air
to rise. Fuel is injected into the cylinder when the
piston is near to top dead centre.
Power
The piston continues to rise after the start of fuel
injection causing a further increase in pressure and
temperature.
The temperature rises to a point at which the fuel/air
mixture ignites. A cylinder is said to be firing, when
the fuel/air mixture ignites.
This combustion causes a very rapid rise in
both temperature and pressure. The high pressure
generated propels the piston downward turning the
crankshaft and producing energy.
Exhaust
Once the piston has reached the bottom of its travel,
the exhaust valves open and momentum stored
in the flywheel forces the piston up the cylinder
expelling the exhaust gases.
In a running engine these four phases are
continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle of a
four stroke engine, the crankshaft revolves twice.
Figure 99.
3
2
41
B
C
746030
1 Induction stroke
2 Compression stroke
3 Power stroke
4 Exhaust stroke
A Camshaft
B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
BDC Bottom dead centre
TDC TDC (Top Dead Centre)
16. 15 - Engine
00 - General
00 - General
15 - 17 9813/2650-3 15 - 17
Figure 100.
717620
1 2 3 4
A A A A
B C
BC B BC
C
1 Induction stroke 2 Compression stroke
3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
17. 15 - Engine
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15 - 18 9813/2650-3 15 - 18
Drain and Fill
Refer to Engine, Oil Filter, (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 and electronic
components such as ECU (Electronic Control
Unit)'s, alternator or fuel injectors. DO NOT place
the jet nozzle closer than 600mm (24 in) to
any part of the engine or after treatment system
including exhaust sensor ECU (if installed).
18. 15 - Engine
00 - General
00 - General
15 - 19 9813/2650-3 15 - 19
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:
Fuel System - Clean (PIL 18-00).
Check (Operation)
Check the engine speed setting
When the engine is operating normally the engine
speed will be within the values given for different
machine operating modes.
1. Warm the engine water temperature above the
specified value.
Temperature: 50°C (121.9°F)
2. Use the power band mapping graphs and
compare the engine RPM (Revolutions Per
Minute) to the values on the graph. Operate the
throttle knob and check the no load engine rpm
in each power band. Refer to (PIL 18-00).
3. Close the dipper fully and hold the control lever in
the dipper close position. The engine rpm should
be the same as the no load RPM.
19. 15 - Engine
00 - General
00 - General
15 - 20 9813/2650-3 15 - 20
Check (Pressure)
Special Tools
Description Part No. Qty.
Servicemaster
Electronic Test Cable
721/10855 1
Pressure Gauge (0-40
Bar)
892/00278 1
Servicemaster
Electronic Test Kit
Data Link Adaptor
(DLA) Kit
892/01033
892/01174
1*
Digital Hydraulic
Pressure Test Kit
998/11051 1
*Unless otherwise stated, you can use any of the
tools shown.
This test is used to diagnose suspected poor
compression in one or more of the engine cylinders.
Use ServiceMaster to control the test.
Engine Compression Test
1. Connect the Servicemaster tool to the machine,
refer to (PIL 33-57).
Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
Special Tool: Servicemaster Electronic Test
Cable (Qty.: 1)
2. Access the engine compression test and follow
the on screen commands.
3. There is a 5 second delay before the test starts.
4. The test disables the injectors and requests the
tester to crank the engine.
5. Crank the engine for at least 5 seconds, but no
longer than 10 seconds.
6. The engine ECU measures the variation in
engine cranking speed to determine if one
or more cylinders have lower than expected
compression values.
7. Turn off the ignition after the test.
Note: The engine cranking speed must be greater
than 200 rpm for the test to identify suspect cylinders,
ensure the battery condition is suitable to achieve
this test.
Engine Oil Pressure
Use the following procedures to measure the engine
oil pressure. Refer to Oil Sump (PIL 15-45) for a
full explanation of the lubricating oil circuit. Several
factors can influence the engine oil pressure, the
following conditions are assumed:
• The correct engine oil has been used, refer to
Consumable Products, Oil (PIL 75-03).
• The engine oil level is correct, refer to Oil Filter,
Check Level (PIL 15-21).
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 (0-40 Bar) (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1)
20. 15 - Engine
00 - General
00 - General
15 - 21 9813/2650-3 15 - 21
Figure 101.
B
A
A
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, refer to Technical Data (PIL 15-00), for
the recommended circuit pressure.
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 pump 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 refer to (PIL 18-18), 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.
21. 15 - Engine
00 - General
00 - General
15 - 22 9813/2650-3 15 - 22
Remove and Install
Special Tools
Description Part No. Qty.
Lifting Bracket Front 320/09062 1
Lifting Bracket Rear 320/09063 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 102.
16
17
14 15
20
19
21
18
6
7
8
12
11
10
2225
24
23
6 Engine mounting bolts 7 Lifting bracket- front
8 Lifting bracket fixing bolts 10 Fuel line connector- return to tank line
11 Fuel line connector at fuel filter- feed line from
fuel pump
12 Electrical connector- engine ECU machine
side connector (grey)
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24. 15 - Engine
00 - General
00 - General
15 - 24 9813/2650-3 15 - 24
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.
25. 15 - Engine
00 - General
00 - General
15 - 25 9813/2650-3 15 - 25
Figure 103.
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 33. Torque Values
Item Nm
A 47