service repair manual

1. SERVICE MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
525-60
EN - 9813/3900 - ISSUE 3 - 02/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

2. 15 - Engine
00 - Engine
00 - General
15 - 3 9813/3900-3 15 - 3
00 - General
Introduction ...................................................... 15-3
Health and Safety ........................................... 15-5
Technical Data ................................................. 15-6
Component Identification ................................. 15-7
Operation ....................................................... 15-10
Diagram ......................................................... 15-14
Fault-Finding .................................................. 15-15
Drain and Fill ................................................. 15-18
Clean ............................................................. 15-19
Check (Pressure) .......................................... 15-20
Remove and Install ....................................... 15-20
Store and Recommission .............................. 15-22
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.
Replacement of oil seals, gaskets, etc., and any
component that show signs of wear or damage, is
expected as a matter of course.
It is expected that components will be cleaned and
lubricated where required, 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 Kohler KDI engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition
(C.I.). The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The
starter motor turns the engine via a pinion and teeth
on the engine flywheel.
When the engine runs the crankshaft drives the
camshaft though the gears. The camshaft opens and
closes the inlet and exhaust valves and through push
rods in time with the four stroke cycle. The engine
has 16 valves, 2 inlet and 2 exhaust valves for each
cylinder.
The crankshaft also drives a mechanical high
pressure fuel pump via gears. The pump is part of the
electronically controlled common rail fuel injection
system.
Air is drawn into the engine through the inlet
manifold and exhaust gases exit through the exhaust
manifold. The engine uses a variable geometry
turbocharger which pressurises the air at the inlet
manifold.
A mechanical lubrication oil pump is driven by the
crankshaft through gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt again driven by the crankshaft, drives a
coolant circulation pump and alternator.
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.

3. 15 - Engine
00 - Engine
00 - General
15 - 4 9813/3900-3 15 - 4
Figure 135.
H
E
F
G
A
D
C
B
A Crankshaft B Crankshaft gear
C Intermediate gear D Camshaft gear
E Camshaft F Tappet
G Push rod H Valve
Figure 136.
K
C D
A
L
J
B
A Crankshaft
B Crankshaft gear
C Intermediate gear
D Camshaft control gear
J Camshaft phonic wheel
K Intermediate gear pin
L Phonic wheel positioning reference pin on
camshaft
Figure 137.
H
G
N
M
Q
P
G Rocker arm push rod
H Valve
M Articulation control valve
N Valve control bridge
P Hydraulic tappet
Q Rocker arm

4. 15 - Engine
00 - Engine
00 - General
15 - 5 9813/3900-3 15 - 5
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 the maximum is exceeded, 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.

5. 15 - Engine
00 - Engine
00 - General
15 - 6 9813/3900-3 15 - 6
Technical Data
Table 46.
Description
Engine Type KDI 2504 TCR
Emission compliance US-EPA Tier 4 final, EU
Stage IIIB
Max. operating speed 2200 RPM (Revolutions
Per Minute)
Power Output 55kW at 2200 RPM
Weight (Dry) 233kg
Number of cylinders 4
Nominal bore size 88mm
Stroke 102mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.482L
Compression ratio 17: 1
Direction of rotation
(viewed from flywheel
end)
Counterclockwise
Valves 4 per cylinder
Tappets Hydraulic
Lubricating oil pressure
(Dependent on engine
temperature and speed)
1–2.8bar (14.5–40.6psi)
Filter type Screw-on canister
Pressure to open by-
pass valve
2.5 ± 0.5bar
(36.2 ± 7.2psi)
Oil pressure switch set-
ting
0.8 ± 0.1bar
(11.6 ± 1.4psi) falling
Oil pump
(1)
Integral unit with relief
valve
Combustion system Common rail direct In-
jection
High pressure fuel pump High pressure with elec-
tronically controlled fuel
metering
(1) The oil pump is a non-serviceable part

6. 15 - Engine
00 - Engine
00 - General
15 - 7 9813/3900-3 15 - 7
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 138.
DC
E
H
N
P
L
M
G
F
K
J
A
B
A Flywheel housingRefer to: PIL 15-54-03. B FlywheelRefer to: PIL 15-54-00.
C Fuel filterRefer to: PIL 18-09-00. D Fuel filter drain plugRefer to: PIL 18-09-00.
E DipstickRefer to: PIL 15-45-09. F Oil filterRefer to: PIL 15-21-00.
G Oil coolerRefer to: PIL 15-69-00. H PTO (Power Take-Off) cover (If installed)
J High pressure fuel pumpRefer to: PIL
18-18-15.
K Inlet manifoldRefer to: PIL 18-24-03.
L Catalytic converterRefer to: PIL 18-24-18. M EGR (Exhaust Gas Recirculation) valveRefer to:
PIL 18-27-06.
N Engine harness P ECM (Engine Control Module)

7. 15 - Engine
00 - Engine
00 - General
15 - 8 9813/3900-3 15 - 8
Figure 139.
N
M
L
KE
JG
H
F
P
Q
R
C
B
D
A
A ThermostatRefer to: PIL 21-12-00. B Oil filler capRefer to: PIL 15-57-00.
C Cooling pumpRefer to: PIL 21-09-00. D Drive beltRefer to: PIL 15-18-03.
E Crankshaft phonic wheelRefer to: PIL
15-12-15.
F Oil sumpRefer to: PIL 15-45-00.
G Timing gear caseRefer to: PIL 15-51-21. H AlternatorRefer to: PIL 15-72-00.
J Oil sump drain plugRefer to: PIL 15-45-03. K CrankcaseRefer to: PIL 15-03-00.
L BedplateRefer to: PIL 15-09-00. M Crankcase ventilation filterRefer to: PIL
15-27-00.
N Starter motorRefer to: PIL 15-75-00. P Oil pressure sensorRefer to: PIL 15-84-21.
Q Cylinder headRefer to: PIL 15-06-00. R Outlet manifoldRefer to: PIL 18-24-04.

8. 15 - Engine
00 - Engine
00 - General
15 - 9 9813/3900-3 15 - 9
Figure 140.
E
F
G
J
H
B
A
K
C D
A InjectorRefer to: PIL 18-18-03. B Rocker coverRefer to: PIL 15-42-06.
C Turbocharger actuatorRefer to: PIL 18-35-00. D TurbochargerRefer to: PIL 18-35-00.
E Turbocharger linkRefer to: PIL 18-35-00. F Oil filler capRefer to: PIL 15-57-00.
G Low pressure fuel return pipesRefer to: PIL
18-96-06.
H EGR coolerRefer to: PIL 18-27-09.
J High pressure fuel pipesRefer to: PIL
18-96-03.
K Fuel railRefer to: PIL 18-18-12.

9. 15 - Engine
00 - Engine
00 - General
15 - 10 9813/3900-3 15 - 10
Operation
The Four Cylinder Cycle
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.
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.
The stages in the four stroke cycle for each cylinder
are as follows:
Table 47. The Four Stroke Cycle
Cylinder number Piston operation Valve operation
1 The piston is at the top of its Compression 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 Induction 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 Exhaust stroke and
is about to start its Induction stroke.
Valve Operation Exhaust valves
about to close, inlet valves about
to open

10. 15 - Engine
00 - Engine
00 - General
15 - 11 9813/3900-3 15 - 11
Figure 141. Typical Four Cylinder Engine
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

11. 15 - Engine
00 - Engine
00 - General
15 - 12 9813/3900-3 15 - 12
Four Stroke Cycle
Induction
As the piston travels down the cylinder, it draws
filtered air at atmospheric pressure and ambient
temperature through an air filter and 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 TDC (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 downwards 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 142.
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

12. 15 - Engine
00 - Engine
00 - General
15 - 13 9813/3900-3 15 - 13
Figure 143.
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

13. 15 - Engine
00 - Engine
00 - General
15 - 14 9813/3900-3 15 - 14
Diagram
Electrical Operation and Schematics
The schematic diagram shows a typical system.
For machine specific schematics, refer to electrical
system- general, refer to (PIL 33-00).
The schematic is shown with the ignition switch
set to position III and the transmission set to N. A
signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
CAN (Controller Area Network)bus to tell the Engine
ECU that the transmission is in Neutral.
The engine ECU provides power to the engine
compartment fusebox to energise the start relay, the
fuel pump relay, the starter motor and the fuel pump.
Figure 144.
3
4
5
6
7
8
9
10
1
2
-VE+VE
D+
Charge
W
M
-VE+VE
ECUECU
ECUECU
M
B
L
E
H
K
J
G
F
A
D
C
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU

14. 15 - Engine
00 - Engine
00 - General
15 - 18 9813/3900-3 15 - 18
Drain and Fill
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
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.
Engine oil replacement must be completed in
accordance with the service schedules. Failure to
replace the oil replacement at the recommended
interval could cause serious engine failure.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained
with the oil.
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Park the machine on a hard level surface for
accurate measurement of the oil level.
3. Get access to the engine.
4. Place a container of suitable size beneath the
drain plug.
5. Remove the oil filler cap.
Figure 145.
A
B
C
A Oil filler cap
B Drain plug
C O-ring
CAUTION! Oil will gush from the hole when the
drain plug is removed. Keep to one side when
you remove the plug.
6. Remove the oil dipstick.
7. Remove the oil sump drain plug and O-ring from
both sides of the oil sump.
8. Drain the engine oil into an suitable container.
9. Clean and install the drain plug with a new O-
ring. Tighten the plug to the correct torque value.
10. Through one of the filler points, fill the engine with
the recommended oil to the MAX mark on the
dipstick.
Figure 146.
A
A Oil filler cap
Figure 147.
E
F
D
D Dipstick
E Maximum level mark
F Minimum level mark
11. Wipe off any spilt oil, install the filler cap and
make sure it is secure.
12. Operate the engine, until the oil pressure low
warning light has extinguished.
13. Check for oil leakage.
14. When the oil has cooled, check the oil level
again, and if necessary top up with clean engine
oil.

15. 15 - Engine
00 - Engine
00 - General
15 - 19 9813/3900-3 15 - 19
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 connected. If connectors are open
install 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 brush to soak
off 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 the engine electronic
control unit (ECU), alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine.
Distance: 600mm
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, General, Clean.

16. 15 - Engine
00 - Engine
00 - General
15 - 20 9813/3900-3 15 - 20
Check (Pressure)
Special Tools
Description Part No. Qty.
Pressure Gauge (0-40
Bar)
892/00278 1
1. Make the machine safe with the excavator/lift
arm lowered.
Refer to: PIL 01-03-27.
2. Make sure that the engine oil and fuel are at the
correct level.
3. Remove the pressure switch.
Refer to: PIL 15-84-21.
4. Connect a pressure gauge to the pressure switch
fitting.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
Figure 148.
A
5. Start the engine.
6. Monitor the oil pressure with respect to the oil
temperature.
7. The oil pressure should be more than the
specified value.
Pressure: 1.5bar (21.7psi)
8. Stop the engine and allow it to cool.
9. Remove the pressure gauge and install the
pressure switch.
Remove and Install
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.
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.
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 01-03-27.
3. Get access to the engine.
Refer to: PIL 06-06-06.
Remove
1. Disconnect and remove the battery.
Refer to: PIL 33-03-00.
2. Drain the engine oil.
Refer to: PIL 15-00-00.
3. Drain the engine cooling system.
Refer to: PIL 21-00-00.
4. Remove the cooling pack.
5. Discharge the hydraulic pressure.
Refer to: PIL 30-00-00.

17. 15 - Engine
00 - Engine
00 - General
15 - 21 9813/3900-3 15 - 21
6. Drain the hydraulic tank. Disconnect and plug
the hydraulic pipes. Label the hoses to help
installation.
7. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to help installation.
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine
crankcase. Release the hose clips and remove
the hoses.
10. Disconnect the wiring connections from the
starter motor.
Refer to: PIL 15-75-00.
11. Disconnect the wiring connections from the
alternator.
Refer to: PIL 15-72-00.
12. Disconnect the wiring connections from the
engine sensors and actuators.
Refer to: PIL 15-84.
13. 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.
14. Disconnect the electrical harness at the engine
harness.
15. 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.
16. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
17. Disconnect and plug the hoses at the hydraulic
pump.
18. Disconnect the wiring to the hydraulic pump.
19. Attach slings to the engine lifting eyes.
Figure 149.
A
A
B B
A Lifting eye
B Sling
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 it 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.
Install
1. Replacement is a reversal of the removal
procedure. Note the following:
2. Fill the cooling system with the correct mix of
coolant fluid.
Refer to: PIL 75-00-00.
3. Fill and Check the hydraulic fluid level.
Refer to: PIL 30-00-00.
4. Fill and Check the engine oil level.
Refer to: PIL 15-00-00.
5. On completion, check the hydraulic and cooling
system for leakage and levels.
6. Check the function of the drive and hydraulic
services.
Table 70. Torque Values
Item Nm
A 25

18. 15 - Engine
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15 - 22 9813/3900-3 15 - 22
Store and Recommission
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
Engine Storage (up to 6 months)
Before you store the engine make sure that:
• The environment is not humid or exposed to
bad weather.
• The storage place is not near an electrical
panel.
• Prevent storing the engine in direct contact with
the ground.
1. Cover the engine with a proper protective sheet
to prevent it from dampness and atmospheric
contaminants.
Engine Storage (over 6 months)
1. Follows the precautions mentioned in the above
procedure.
2. Fill the engine housing with protective oil up to
the maximum level.
3. Refuel the machine with fuel additives for long
storage.
4. For machines with expansion tank:
4.1. Make sure that the coolant is up to the
maximum level.
5. For machines without expansion tank:
5.1. Fill the coolant until the pipes inside the
radiator are covered by specified distance.
Distance: 5mm
5.2. Do not overfill the radiator, but leave
sufficient space for the fuel to expand.
6. Start the engine and run it at idle speed for the
specified duration.
Duration: 2min
7. Bring the engine to 75% of the maximum rated
speed for the specified duration.
Duration: 5–10min
8. Turn off the engine.
9. Drain the fuel tank completely.
10. Spray engine oil (SAE 10W40) on the exhaust
and intake manifolds.
11. Seal the exhaust and intake ducts to prevent
contamination.
12. Clean the engine.
Refer to: PIL 15-00-00.
13. Apply protective paints on non-painted parts.
14. Loosen the alternator belt.
15. Cover the engine with a proper protective sheet
to prevent it from dampness and atmospheric
contaminants.
Engine Starting After Storage
1. Remove the protective sheet.
2. Use a cloth soaked in degreasing fluid to remove
the protective treatment from the external parts.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
3. Inject lubricating oil (not more than 2cm³) into the
intake ducts.
4. Adjust the alternator belt tension.
Refer to: PIL 15-18-00.
5. Refuel the machine.
6. Make sure that the oil and the coolant are up to
the maximum level.
7. Start the engine and run it at idle speed for the
specified duration.
Duration: 2min
8. Bring the engine to 75% of the maximum rated
speed for the specified duration.
Duration: 5–10min
9. Stop the engine.
10. While the oil is still hot, drain the protective oil in
a suitable container.
11. Put new oil up to the maximum level.
12. Replace the filters (air, oil, fuel).
13. Drain the cooling circuit completely and put new
coolant up to the maximum level.
Important: Over time, lubricants and filters lose their
properties, so it is important to consider whether they
need replacing, also based on the criteria mentioned
in the maintenance schedules.
If the engine is not to be used for an extended period,
the protective treatment procedure must be repeated
within 730d of the previous one.

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20. 15 - Engine
03 - Crankcase
00 - General
15 - 25 9813/3900-3 15 - 25
00 - General
Introduction .................................................... 15-25
Technical Data ............................................... 15-26
Clean ............................................................. 15-27
Calibrate ........................................................ 15-28
Remove and Install ....................................... 15-29
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 150.
B
A
A Crankcase
B Crankshaft

21. 15 - Engine
03 - Crankcase
00 - General
15 - 26 9813/3900-3 15 - 26
Technical Data
Table 71. Crankcase and Bedplate Data
Main bearing bolts
torque
(1)
First stage 40N·m
Second stage 70N·m
Third stage 120N·m
Peripheral bolts
Fourth stage 20N·m
Fifth stage 35N·m
(1) Torque information must be used in conjunction
with 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.
Table 72. Cylinder bore Data
Dimensional Class
(1)
Cylinder Diameter
(1)
Piston Diameter
(1)
Clearance
(1)
STD 88.003mm
(3.4647in)-88.017mm
(3.4652in)
87.943mm
(3.4623in)-87.957mm
(3.4628in)
R+0.1 88.103mm
(3.4686in)-88.117mm
(3.4691in)
88.043mm
(3.4663in)-88.057mm
(3.4668in)
+0.5 88.503mm
(3.4843in)-88.517mm
(3.4849in)
88.443mm
(3.4820in)-88.457mm
(3.4826im)
+1 89.003mm
(3.5041in)-89.017mm
(3.5046in)
88.943mm
( 3.5017in)-88.957mm
(3.5022in)
0.046mm
( 0.0018in)-0.074mm
(0.0029in)
(1) This table shows the reference values and their classification applicable for new engines only.

22. 15 - Engine
03 - Crankcase
00 - General
15 - 27 9813/3900-3 15 - 27
Clean
Oil pipes
Important: Make sure you keep a safe distance from
all of the open ports.
1. Remove all the plugs.
2. Put a pipe cleaner in all the open ports to clean
the oil pipes,as shown.
3. Use a compressed air line to remove any
remaining oil.
4. Install all the plugs with Loctite.
Figure 151.
A
A
B
A
A
A Plug B Oil pipe