JCB DieselMax 672 Engine Tier 2, Tier 3-BS3 And Stage Operator Manual 9821-7300

Description

• Model List:
  • DieselMax 672 Engine Tier 2, Tier 3-BS3 And Stage

• 1. Care and Safety
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Safety Yours and Others …………………………………………………………………….2
• 6. Checklists …………………………………………………………………………………………3
• 7. Common Rail Specific ……………………………………………………………………3
• 8. General Safety ……………………………………………………………………………..5
• 9. Introduction …………………………………………………………………………………..6
• 10. Operating Safety …………………………………………………………………………..6
• 11. Maintenance Safety ……………………………………………………………………….7
• 12. General Information
• 13. Introduction ……………………………………………………………………………………..13
• 14. Left Side, Right Side …………………………………………………………………….13
• 15. Units of Measurement ………………………………………………………………….13
• 16. Machine – Equipment Related Data ………………………………………………..13
• 17. Acronyms and Abbreviations …………………………………………………………14
• 18. Identifying the Engine
• 19. Engine Identification Plate …………………………………………………………………15
• 20. Typical Engine Identification Number ……………………………………………..15
• 21. Component Labels ………………………………………………………………………15
• 22. Engine Component Identification ………………………………………………………..17
• 23. External ……………………………………………………………………………………..17
• 24. Operating Procedures
• 25. Starting the Engine …………………………………………………………………………..29
• 26. Pre-Start Notes ……………………………………………………………………………29
• 27. Start Procedure …………………………………………………………………………..29
• 28. Engine Checks After Start-up ………………………………………………………..31
• 29. Engine Running-in Procedure ……………………………………………………….32
• 30. Stopping the Engine …………………………………………………………………….33
• 31. Lubricants and Capacities
• 32. Engine Lubricating Oil ………………………………………………………………………35
• 33. Recommended Oils ……………………………………………………………………..35
• 34. Engine Oil Capacity ……………………………………………………………………..35
• 35. Coolant Mixtures ………………………………………………………………………………36
• 36. Coolant Mixtures …………………………………………………………………………36
• 37. Coolant ………………………………………………………………………………………37
• 38. Fuel ……………………………………………………………………………………………….38
• 39. Acceptable and Unacceptable Fuels ………………………………………………38
• 40. Usage and Effects of Fuels …………………………………………………………..41
• 41. Effects of Fuel Contaminates ………………………………………………………..42
• 42. Routine Maintenance
• 43. Introduction ……………………………………………………………………………………..43
• 44. Maintenance Procedures ……………………………………………………………..43
• 45. Cleaning the Engine …………………………………………………………………………44
• 46. Lubricants – Health and Safety …………………………………………………………..45
• 47. Hygiene ……………………………………………………………………………………..45
• 48. Storage ………………………………………………………………………………………45
• 49. Waste Disposal ……………………………………………………………………………45
• 50. First Aid – Oil ……………………………………………………………………………….45
• 51. Spillage ………………………………………………………………………………………46
• 52. Fires ………………………………………………………………………………………….46
• 53. Service Schedules ……………………………………………………………………………47
• 54. Engine Oil and Filter …………………………………………………………………………50
• 55. Checking the Oil Level …………………………………………………………………50
• 56. Changing the Oil and Filter ……………………………………………………………51
• 57. Engine Cooling System …………………………………………………………………….53
• 58. Coolant Mixtures …………………………………………………………………………53
• 59. Checking the Coolant Level ………………………………………………………….53
• 60. Changing the Coolant …………………………………………………………………..54
• 61. Front End Accessory Drive (FEAD) Belt …………………………………………55
• 62. Engine Fuel System …………………………………………………………………………56
• 63. Fuel …………………………………………………………………………………………..56
• 64. Draining the Water Separator and Fuel Filter …………………………………..57
• 65. Changing the Filter Element ………………………………………………………….58
• 66. Changing the Water Separator Pre- Filter ……………………………………….59
• 67. Bleeding the Fuel System …………………………………………………………….60
• 68. Air Intake System …………………………………………………………………………….61
• 69. Engine Crankcase Ventilation …………………………………………………………….62
• 70. Changing the Filter Element ………………………………………………………….62
• 71. Lifting Information …………………………………………………………………………….64
• 72. Fault Finding
• 73. Introduction ……………………………………………………………………………………..67
• 74. Fault Codes ………………………………………………………………………………..67
• 75. Reduced Torque Mode …………………………………………………………………68
• 76. Limp Home Mode ………………………………………………………………………..68
• 77. Engine Shutdown ………………………………………………………………………..68
• 78. Component Replacement ……………………………………………………………..68
• 79. Fault Finding Charts …………………………………………………………………….69
• 80. Storage and Preservation
• 81. Storage …………………………………………………………………………………………..95
• 82. Preservation ……………………………………………………………………………………96
• 83. Capping Engine Openings ……………………………………………………………96
• 84. Hot Test Description …………………………………………………………………….98
• 85. Technical Data
• 86. Basic Engine Data (Dieselmax 672) ……………………………………………………99
• 87. Engine Block and Bedplate Data (Dieselmax 672) …………………………………100
• 88. Cylinder Head Data (Dieselmax 672) ………………………………………………..101
• 89. Inlet and Exhaust Valve Data (Dieselmax 672) …………………………………..102
• 90. Rocker Levers, Rocker Shaft and Tappets Data (Dieselmax 672) …………103
• 91. Pistons and Connecting Rods Data (Dieselmax 672) ………………………….104
• 92. Crankshaft Data (Dieselmax 672) …………………………………………………….105
• 93. Camshaft Data (Dieselmax 672) ………………………………………………………106
• 94. Fuel System Data (Dieselmax 672) …………………………………………………..107
• 95. Lubrication System Data (Dieselmax 672) …………………………………………108
• 96. Cooling System Data (Dieselmax 672) ………………………………………………109
• 97. Electrical Equipment Data (Dieselmax 672) ………………………………………. 110
• 98. Switches and Sensors ……………………………………………………………….. 110
• 99. Torque + Angle Explanation ……………………………………………………………. 113
• 100. Torque + Angle Tightening Procedure ………………………………………………. 114
• 101. JCB Service
• 102. Warranty ………………………………………………………………………………………. 115
• 103. JCB Technical Service ……………………………………………………………………. 116