JCB Dieselmax 672 Mechanical Engine Operator Manual 9831-2550-2

Description

• Model List:
  • Dieselmax 672 Mechanical Engine

• 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. Diesel Fuel Quality ………………………………………………………………………..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 …………………………………………………………………………..25
• 26. Pre-Start Notes ……………………………………………………………………………25
• 27. Start Procedure …………………………………………………………………………..25
• 28. Engine Checks After Start-up ………………………………………………………..27
• 29. Engine Running-in Procedure ……………………………………………………….28
• 30. Stopping the Engine …………………………………………………………………….29
• 31. Lubricants and Capacities
• 32. Engine Lubricating Oil ………………………………………………………………………31
• 33. Recommended Oils ……………………………………………………………………..31
• 34. Engine Oil Capacity ……………………………………………………………………..31
• 35. Coolant Mixtures ………………………………………………………………………………32
• 36. Coolant Mixtures …………………………………………………………………………32
• 37. Coolant ………………………………………………………………………………………33
• 38. Fuel ……………………………………………………………………………………………….34
• 39. Acceptable and Unacceptable Fuels ………………………………………………34
• 40. Usage and Effects of Fuels …………………………………………………………..37
• 41. Effects of Fuel Contaminates ………………………………………………………..38
• 42. Routine Maintenance
• 43. Introduction ……………………………………………………………………………………..39
• 44. Maintenance Procedures ……………………………………………………………..39
• 45. Cleaning the Engine …………………………………………………………………………40
• 46. Lubricants – Health and Safety …………………………………………………………..41
• 47. Hygiene ……………………………………………………………………………………..41
• 48. Storage ………………………………………………………………………………………41
• 49. Waste Disposal ……………………………………………………………………………41
• 50. First Aid – Oil ……………………………………………………………………………….41
• 51. Spillage ………………………………………………………………………………………42
• 52. Fires ………………………………………………………………………………………….42
• 53. Service Schedules ……………………………………………………………………………43
• 54. Engine Oil and Filter …………………………………………………………………………46
• 55. Checking the Oil Level …………………………………………………………………46
• 56. Changing the Oil and Filter ……………………………………………………………47
• 57. Engine Cooling System …………………………………………………………………….49
• 58. Coolant Mixtures …………………………………………………………………………49
• 59. Checking the Coolant Level ………………………………………………………….49
• 60. Changing the Coolant …………………………………………………………………..50
• 61. Front End Accessory Drive (FEAD) Belt …………………………………………51
• 62. Engine Fuel System …………………………………………………………………………52
• 63. Fuel …………………………………………………………………………………………..52
• 64. Draining the Water Separator and Fuel Filter …………………………………..53
• 65. Changing the Filter Element ………………………………………………………….54
• 66. Changing the Water Separator Pre- Filter ……………………………………….55
• 67. Bleeding the Fuel System …………………………………………………………….56
• 68. Air Intake System …………………………………………………………………………….57
• 69. Engine Crankcase Ventilation …………………………………………………………….58
• 70. Changing the Filter Element ………………………………………………………….58
• 71. Lifting Information …………………………………………………………………………….60
• 72. Fault Finding
• 73. Introduction ……………………………………………………………………………………..61
• 74. Fault Finding Charts …………………………………………………………………….62
• 75. A Charts – Engine …………………………………………………………………………….63
• 76. B Charts – Fuel ………………………………………………………………………………..78
• 77. C Charts – Lubricating Oil ………………………………………………………………….80
• 78. D Charts – Coolant ……………………………………………………………………………83
• 79. Storage and Preservation
• 80. Storage …………………………………………………………………………………………..87
• 81. Preservation ……………………………………………………………………………………88
• 82. Capping Engine Openings ……………………………………………………………88
• 83. Hot Test Description …………………………………………………………………….90
• 84. Technical Data
• 85. Basic Engine Data (Dieselmax 672) ……………………………………………………91
• 86. Engine Block and Bedplate Data (Dieselmax 672) …………………………………..92
• 87. Cylinder Head Data (Dieselmax 672) ………………………………………………….93
• 88. Inlet and Exhaust Valve Data (Dieselmax 672) …………………………………….94
• 89. Rocker Levers, Rocker Shaft and Tappets Data (Dieselmax 672) …………..95
• 90. Pistons and Connecting Rods Data (Dieselmax 672) ……………………………96
• 91. Crankshaft Data (Dieselmax 672) ………………………………………………………97
• 92. Camshaft Data (Dieselmax 672) ………………………………………………………..98
• 93. Fuel System Data (Dieselmax 672) …………………………………………………….99
• 94. Lubrication System Data (Dieselmax 672) …………………………………………100
• 95. Cooling System Data (Dieselmax 672) ………………………………………………101
• 96. Electrical Equipment Data (Dieselmax 672) ……………………………………….102
• 97. Switches and Sensors ………………………………………………………………..102
• 98. Torque + Angle Explanation …………………………………………………………….104
• 99. Torque + Angle Tightening Procedure ……………………………………………….105
• 100. JCB Service
• 101. Warranty ……………………………………………………………………………………….107
• 102. JCB Technical Service …………………………………………………………………….108