JCB Dieselmax 444 & 448 Series Engine Complete Workshop Service Repair Manual

Copyright © 2004 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. World Class Customer Support 9806/3000-05 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual JCB Dieselmax Mechanical Engine 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

Section 0 - Service Manual 0-0 0-0 9806/3000-05 Notes:

Copyright © 2004 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. World Class Customer Support 9806/3000-05 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Service Manual - JCB Dieselmax Mechanical Engine 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

Section 1 - General Information 1-0 1-0 9806/3000-05 Notes:

Page No. Contents Section 1 - General Information 1 - i 1 - i Introduction About this Manual .................................................................................... 1 - 1 Using the Service Manual .................................................................. 1 - 1 Section Numbering ............................................................................. 1 - 1 Left Side, Right Side ........................................................................... 1 - 1 Units of Measurement ........................................................................ 1 - 1 Machine Related Data ........................................................................ 1 - 2 Acronyms and Abbreviations ................................................................... 1 - 3 Identifying the Engine Engine Identification Plate ....................................................................... 1 - 4 Typical Engine Identification Number ................................................. 1 - 4 Component Labels ............................................................................. 1 - 5 Engine Component Identification ............................................................. 1 - 6 Independent Power Unit Component Identification ............................... 1 - 10 Technical Data Basic Engine Data - 444 Engine ............................................................ 1 - 11 Basic Engine Data - 448 Engine ............................................................ 1 - 13 Engine Block & Bedplate Data .............................................................. 1 - 14 Cylinder Head Data ............................................................................... 1 - 15 Inlet and Exhaust Valve Data ................................................................ 1 - 16 Rocker Levers, Rocker Shaft and Tappets Data ................................... 1 - 18 Pistons and Connecting Rods Data ....................................................... 1 - 19 Crankshaft Data ..................................................................................... 1 - 20 Camshaft Data ....................................................................................... 1 - 21 Fuel System Data .................................................................................. 1 - 22 Acceptable and Unacceptable Fuels ................................................ 1 - 22 Fuel Types ........................................................................................ 1 - 24 Usage and Effects of Fuels .............................................................. 1 - 25 Sulphur Content ............................................................................... 1 - 26 Effects of Fuel Contaminates ........................................................... 1 - 27 Lubrication System Data ....................................................................... 1 - 28 Cooling System Data ............................................................................. 1 - 29 Electrical Equipment Data ..................................................................... 1 - 30 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ................................... 1 - 32 Introduction ....................................................................................... 1 - 32 Bolts and Screws .............................................................................. 1 - 32 Hydraulic Connections ........................................................................... 1 - 36 'O' Ring Face Seal System ............................................................... 1 - 36 'Torque Stop' Hose System .............................................................. 1 - 39 Torque + Angle Explanation .................................................................. 1 - 40 Torque + Angle Tightening Procedure ................................................... 1 - 41 Engine Torque Figures .......................................................................... 1 - 42 Lubricants and Capacities Engine Lubricating Oil ........................................................................... 1 - 57 Recommended Oils .......................................................................... 1 - 57 Engine Oil Capacity .......................................................................... 1 - 57 Coolant Mixtures .................................................................................... 1 - 58 Service Aids Sealing, Retaining and Care Compounds ............................................. 1 - 59

Section 1 - General Information Contents 1 - ii 1 - ii Page No. Contents Service Tools General Engine Tools ............................................................................ 1 - 60 Specialist Engine Tools .......................................................................... 1 - 62 Service Tool Drawings ........................................................................... 1 - 67 892/01146 - Core Plug Fitting Tool ................................................... 1 - 67 892/01147 - Crankshaft Turning Tool ............................................... 1 - 68 892/01148 - Timing Pin ..................................................................... 1 - 69 892/01149 - Sump Sealant Template ............................................... 1 - 70 892/01150 - Oil Sump Location Dowel ............................................. 1 - 71 892/01151 - Injector Sleeve Removal Tool ....................................... 1 - 72 892/01152 - Valve Stem Seal Fitting Tool ......................................... 1 - 73 892/01154 - FIP Cover Removal Tool .............................................. 1 - 74 892/01155 - FIP Gear Removal Tool ................................................ 1 - 75 892/01157 - Crankshaft Front Seal Fitting Tool ................................ 1 - 76 892/01156 - Crankshaft Rear Seal Fitting Tool ................................. 1 - 77 892/01158 - Crankshaft Rear Seal Alignment Tool ........................... 1 - 78 892/01159 - Injector Seal Fitting Tool ............................................... 1 - 78 892/01168 - Dummy Injector ............................................................ 1 - 79 892/01169 - Top Dead Centre (TDC) Setting Tool ............................ 1 - 80 Engine Mounting Frame ................................................................... 1 - 81 Service Parts and Repair Kits Engine Repair Parts and Kits Identification ........................................... 1 - 82 Engine Lifting Lifting Information .................................................................................. 1 - 98 Operating Procedures Starting the Engine ................................................................................ 1 - 99 Pre-Start Notes ................................................................................. 1 - 99 Start Procedure .............................................................................. 1 - 100 Engine Checks After Start-up ......................................................... 1 - 101 Engine Running-in Procedure ........................................................ 1 - 102 Stopping the Engine ....................................................................... 1 - 103

Section 1 - General Information 1-1 1-1 9806/3000-05 Introduction About this Manual Using the Service Manual This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of engines. 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. Finally, please remember above all else SAFETY MUST COME FIRST! The manufacturer's policy is one of continuous improvement. The right to change the specification of the engine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between the specifications of the engine and the descriptions contained in this publication. Section Numbering The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information includes torque settings and service tools. 2 Care & Safety includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Maintenance includes service schedules and recommended lubricants. The remaining sections deal with Descriptions, Fault Finding, Dismantling, Overhaul etc. of specific components, for example: 4 Systems Descriptions 5 Fault Finding ...etc. Left Side, Right Side References to the `left' side and the `right' side of the engine are when viewed from the flywheel end of the engine, as shown at 1A. Fig 1. Units of Measurement In this manual, the S.I. system of units is used. For example, liquid capacities are given in litres. The imperial units follow in parenthesis () e.g. 28 litres (6 UK gal). A

Section 1 - General Information Introduction About this Manual 1-2 1-2 9806/3000-05 Machine Related Data The JCB Dieselmax Engine can be fitted to a variety of constructions and agricultural machines. The scope of this publication is limited to the engine, but references to a typical machine installation will be made. Tasks and information specific to a machine installation will be listed in the relevant machine Service Manual, for example engine removal and replacement procedures.

Section 1 - General Information Introduction Acronyms and Abbreviations 1-3 1-3 9806/3000-05 Acronyms and Abbreviations Some of the following acronyms and abbreviations are used in this service manual. The remainder are used in the automotive industry and are repeated for reference only. °C Celsius °F Fahrenheit A/R As Required API American Petroleum Institute BBDC Before Bottom Dead Centre BDC Bottom Dead Centre BSFC Brake Specific Fuel Consumption BTDC Before Top Dead Centre CCV Crankcase Vent CID Cubic inch Displacement CSA Cold Start Advance CSAS Cold Start Advance Solenoid cST Centistokes ECM Electronic Control Module ECS Emission Control System EPA Environmental Protection Agency ESOS Electric Shut-Off Solenoid or Engine Shut- Off Solenoid FAME Fatty Acid Methyl Esters FEAD Front End Accessory Drive FIE Fuel Injection Equipment FIP Fuel Injection Pump Hg Mercury HP Horse Power I/D Inside Diameter kg Kilogram KPH Kilometres per hour Kw Kilowatt LH Left Hand ltr Litre mm Millimetre MPH Miles per Hour NA Naturally Aspirated N/A Not Applicable/Not Available Nm Newton Metre NSP Non Serviced Part O/D Outside Diameter OEM Original Equipment Manufacturer PPM Parts per Million PSI Pounds per square Inch PTO Power Take Off RH Right Hand RME Rapeseed Methyl Ester RPM Revolutions per Minute SAE Society of Automotive Engineers SME Sunflower Methyl Ester SOME Soyabean Methyl Ester STD Standard TBA To be Advised TC Turbocharged TCA Turbocharged Aftercooled TDC Top Dead Centre TI Technical Information VOME Vegetable Oil Methyl Esters

Section 1 - General Information 1-4 1-4 9806/3000-05 Identifying the Engine Engine Identification Plate Typical Engine Identification Number Engine data labels 2B are located on the cylinder block and rocker cover (if fitted). The data label contains important engine information and includes the engine identification number. A typical engine identification number is explained as follows: 1 Engine Displacement D = 4.8 litre series S = 4.4 litre series 2 Engine Type Tier 2 Engines A = Naturally Aspirated B = Turbocharged C = Turbocharged with Intercooler Tier 3 Engines D = Turbocharged E = Electronic Common Rail F = Turbocharged with Intercooler 3 Engine part number 4 Country of manufacture U = United Kingdom 5 Engine serial number 6 Year of manufacture 09 = 2009 S A 320/40098 U 00001 04 1 2 3 4 5 6

JCB Dieselmax 444 & 448 Series Engine Complete Workshop Service Repair Manual

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