JCB Dieselmax Mechanical Engine Repair Service Manual

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This service manual PDF download for the JCB Dieselmax Mechanical Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section 4 - Systems Description
Section 5 - Fault Finding
Section 6 - Test Procedures
Section 7 - Fuel System
Section 8 - Cooling System
Section 9 - Lubrication System
Section 10 - Electrical System
Section 11 - Induction and Exhaust System
Section 12 - Base Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9806/3000-05
Total Pages : 438


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9806-3000
JCB Dieselmax Mechanical Engine

Section 1 - General Information
General Information
Introduction
About this Manual
Using the Service Manual
Section Numbering
Left Side, Right Side
Units of Measurement
Machine Related Data
Acronyms and Abbreviations
Identifying the Engine
Engine Identification Plate
Typical Engine Identification Number
Component Labels
Engine Component Identification
Independent Power Unit Component Identification
Technical Data
Basic Engine Data - 444 Engine
Basic Engine Data - 448 Engine
Engine Block & Bedplate Data
Cylinder Head Data
Inlet and Exhaust Valve Data
Rocker Levers, Rocker Shaft and Tappets Data
Pistons and Connecting Rods Data
Crankshaft Data
Camshaft Data
Fuel System Data
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B20 Biodiesel
Warranty
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Lubrication System Data
Cooling System Data
Electrical Equipment Data
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
'Torque Stop' Hose System
Torque + Angle Explanation
Torque + Angle Tightening Procedure
Engine Torque Figures
Lubricants and Capacities
Engine Lubricating Oil
Recommended Oils
Engine Oil Capacity
Coolant Mixtures
Service Aids
Sealing, Retaining and Care Compounds
Service Tools
General Engine Tools
Specialist Engine Tools
Service Tool Drawings
892/01146 - Core Plug Fitting Tool
892/01147 - Crankshaft Turning Tool
892/01148 - Timing Pin
892/01149 - Sump Sealant Template
892/01150 - Oil Sump Location Dowel
892/01151 - Injector Sleeve Removal Tool
892/01152 - Valve Stem Seal Fitting Tool
892/01154 - FIP Cover Removal Tool
892/01155 - FIP Gear Removal Tool
892/01157 - Crankshaft Front Seal Fitting Tool
892/01156 - Crankshaft Rear Seal Fitting Tool
892/01158 - Crankshaft Rear Seal Alignment Tool
892/01159 - Injector Seal Fitting Tool
892/01168 - Dummy Injector
892/01169 - Top Dead Centre (TDC) Setting Tool
Engine Mounting Frame
Service Parts and Repair Kits
Engine Repair Parts and Kits Identification
Engine Lifting
Lifting Information
Operating Procedures
Starting the Engine
Pre-Start Notes
Start Procedure
Engine Checks After Start-up
Engine Running-in Procedure
Stopping the Engine

Section 2 - Care and Safety
Care and Safety
Safety Notices
Introduction
Safety Checklist
General Safety
Operating Safety
Maintenance Safety

Section 3 - Maintenance
Maintenance
Routine Maintenance
Introduction
Cleaning the Engine
High Pressure Cleaning
Lubricants - Health and Safety
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid - Oil
Eyes
Swallowing
Skin
Spillage
Fires
Service Schedules
How to Use the Service Schedules
Calendar Equivalents
Service Schedule Applications
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Engine Cooling System
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive (FEAD) Belt
Front End Accessory Belt (FEAD) Inspection
Front End Accessory Belt (FEAD) Replacement
Engine Fuel System
Draining the Water Separator and Fuel Filter
Changing the Filter Element
Changing the Water Separator Pre- Filter
Bleeding the Fuel System
Air Intake System
Air Cleaners
Engine Breather
Cleaning the Engine Breather Gauze
Valve Clearances and Adjustment
Before Adjustment
Adjustment
After Adjustment
Engine Lifting Information

Section 4 - Systems Description
Systems Description
Engine Overview
Component Identification
External
Internal
Basic Description
The Four Stroke Cycle
Camshaft and Valve Operation
The Four Cylinder Cycle - JCB Dieselmax Engine
Firing Order
Timing Gears
Timing
Valve Train
Front End Accessory Drive (FEAD) Belt System
Lubrication System
Basic Description
Oil Pump
Oil Cooler and Filter
Oil Cooler Matrix
Oil Filter
Camshaft Lubrication
Crankshaft Lubrication
Rocker Assembly Lubrication
Piston Cooling and Small End Bearing Lubrication
Fuel System
Basic Description
Pre-Filter/Water Separator, Lift Pump and Fuel Filter
Pre Filter/Water Separator
Lift Pump
State A - Pumping
State B - Lifting
Fuel Filter
Fuel Injection Pump - Injection Cycle
State A - Charging
State B - Injecting
Fuel Injector Pump - Governor
State A - Increasing Engine Speed
State B - Decreasing Engine Speed
Features of the DP210/DP310 Fuel Injection Pump
Cold Start Advance - Shown at A
Hydraulic Light Load Advance
Variable Fuelling - Shown at B
Latch Valve
ESOS - Electric Shut Off Solenoid
Turbo Boost Control (Turbocharged engines only)
Features of the DB4 Fuel Injection Pump
Cold Start Advance
Hydraulic Light Load Advance
ESOS - Electric Shut Off Solenoid
Droop Control
Electronic Governing
Injectors and Combustion
Injectors
Combustion
Induction, Exhaust and Breather Systems
Induction and Exhaust Systems
Naturally Aspirated
Turbocharged
Intercooled
Exhaust Gas Recirculation (EGR)
Engine Breather
SA, SB, SC Engines
SD, SF Engines
Cooling System
Description
Thermostat
State A - `Closed' - Engine Cooled
State B - `Open' - Engine Hot
Injectors
Coolant Pump
Electrical System
Electrical Circuit Schematic
Electrical Components

Section 5 - Fault Finding
Fault Finding
Fault Finding
Introduction
Fault Finding Charts
A Charts - Engine
B Charts - Fuel
C Charts - Lubricating Oil
D Charts - Coolant

Section 6 - Test Procedures
Test Procedures
Introduction
Test Procedures Introduction
Testing
Lift Pump Operation
Pressure Test Procedures
Measuring the Inlet Restriction
Fuel Injection Pump Delivery
Engine Compression
Engine Oil Pressure
High Lubrication Oil Pressure
Low Lubrication Oil Pressure
Thermostat
Air System and Turbocharger
Air Filters
Air Intake Connections
Exhaust Manifold Leaks (Turbocharged Engines)
Turbocharger Checks
Wastegate Operational Check
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid - Electrolyte
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test

Section 7 - Fuel System
Fuel System
Fuel Filter
Removal and Replacement
Fuel Lines
Identification
Removal and Replacement
High Pressure Fuel Lines
Before disconnecting or removing fuel lines
Removal
Replacement
After replacing fuel lines:
Low Pressure Fuel Lines
Before disconnecting or removing fuel lines:
Removal
Replacement
After replacing fuel lines:
Fuel Bleed-off Lines (Low Pressure)
Before disconnecting or removing fuel lines:
Removal
Replacement
After replacing the fuel lines:
Fuel Lift Pump
Removal and Replacement
Removal
Replacement
Fuel Injection Pump
Removal and Replacement
Component Identification - DP 210/310
Component Identification - DB4
Before Removing:
Removal
Replacement
After Replacing
Droop Adjustment (DB4 Pump Only)
Fuel Injectors (Atomisers)
Removal and Replacement
Removal
Before removing
Removal
Replacement
After Replacing
Bleeding Air From The System
Bleeding Air From The System

Section 8 - Cooling System
Cooling System
Drive Belt - Coolant Pump
Front End Accessory Drive Belt (FEAD)
Removal and Replacement
Thermostat
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Coolant Inlet Assembly
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Coolant Pump
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Lubricating Oil Cooler
Removal and Replacement

Section 9 - Lubrication System
Lubrication System
Oil Filter Head
Removal and Replacement
Oil Pan (Sump)
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Oil Pump
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Lubricating Oil Cooler and Filter Head
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly

Section 10 - Electrical System
Electrical System
Starter Motor
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Dismantling and Assembly
Alternator
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Dismantling and Assembly
Electric Shut-Off Solenoid (ESOS)
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Cold Start Advance Solenoid
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Engine Cold Start Switch
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Engine Oil Pressure Switch
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Coolant Temperature Sender Unit
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing

Section 11 - Induction and Exhaust System
Induction and Exhaust System
Turbocharger
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Dismantling and Assembly
Dismantling
Assembly
Exhaust Manifold
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Inlet Manifold
Removal and Replacement
Before Removing
Removal
Inspection
Replacement

Section 12 - Base Engine
Base Engine
Cylinder Head
Rocker Cover
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Dismantling and Assembly
CCV Diaphragm Valve
Dismantling
Assembly
CCV Gauze Filters
Dismantling
Assembly
Rocker Assembly
Removal and Replacement
Before Removing
Removal
Before Replacing
Replacement
After Replacing
Dismantling, Inspection and Assembly
Before Dismantling
Dismantling
Inspection
Assembly
After Assembly
Valve Clearances
Adjustment
Before Adjustment
Adjustment
After Adjustment
Cylinder Head Assembly
Removal and Replacement
Before Removing
Removal
Inspection
Before Replacing
Replacement
Valves, Valve Springs and Stem Seals
Removal and Replacement
Before Removing
Removal
Inspection
Before Replacing
Replacement
After Replacing
Front End Accessory Drive Belt System (FEAD)
Tensioner
Removal and Replacement
Before Removing
Removal
Replacement
Flywheel and Housing
Flywheel
Removal and Replacement
Before Removing
Removal
Replacement
Flywheel Gear Ring
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Flywheel Housing
Removal and Replacement
Before Removing
Removal
Before Replacing
Replacement
After Replacing
Timing Case and Drive Gears Assembly
Drive Gear - Fuel Injection Pump
Removal and Replacement
Before Removing
Removal
Replacement
Drive Gear - Crankshaft
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Drive Gear - High Duty P.T.O. Idler
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Drive Gear - Camshaft
Removal and Replacement
Camshaft and Tappets
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Timing Case - Rear
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Pistons and Connecting Rods
Big End Bearing
Removal, Inspection and Assembly
Before Removing
Removal
Inspection
Replacement
After Replacing
Piston and Connecting Rod Assembly
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Piston and Connecting Rod Assembly
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Crankshaft Assembly
Crankshaft Pulley
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Rear Oil Seal
Removal and Replacement
Before Removing
Removal
Replacement - Thick Hub (24mm)
Replacement - Thin Hub (15mm)
After Replacing
Front Oil Seal
Removal and Replacement
Before Removing
Removal
Replacement
After Replacing
Crankshaft
Removal and Replacement
Before Removing
Removal, Bedplate
Removal, Crankshaft
Inspection
Before Replacing
Replacement, Crankshaft
Replacement, Bedplate
After Replacing

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