JCB Ecomax Engine T4I (68-129KW), T4 (55KW) Operator Manual 9821-2950

Description

• Model List:
  • Ecomax Engine T4I (68-129KW), T4 (55KW)

• 1. Contents Page No.
• 2. i i
• 3. Care and Safety
• 4. Important Information …………………………………………………………………………1
• 5. The Operator Manual …………………………………………………………………….1
• 6. Safety Warnings ……………………………………………………………………………1
• 7. Safety Yours and Others …………………………………………………………………….2
• 8. Checklists …………………………………………………………………………………………3
• 9. Common Rail (Tier 4) Specific …………………………………………………………3
• 10. General Safety ……………………………………………………………………………..5
• 11. Introduction …………………………………………………………………………………..6
• 12. Operating Safety …………………………………………………………………………..6
• 13. Maintenance Safety ……………………………………………………………………….7
• 14. General Information
• 15. Introduction ……………………………………………………………………………………..13
• 16. Product Compliance …………………………………………………………………….13
• 17. Using this Manual ………………………………………………………………………..13
• 18. Left Side, Right Side …………………………………………………………………….13
• 19. Units of Measurement ………………………………………………………………….13
• 20. Machine – Equipment Related Data ………………………………………………..13
• 21. Acronyms and Abbreviations …………………………………………………………14
• 22. Identifying the Engine
• 23. Engine Identification Plate …………………………………………………………………17
• 24. Typical Engine Identification Number ……………………………………………..17
• 25. Component Labels ………………………………………………………………………17
• 26. Engine Component Identification ………………………………………………………..20
• 27. External ……………………………………………………………………………………..20
• 28. Independent Power Unit Component Identification …………………………..30
• 29. Operating Procedures
• 30. Starting the Engine …………………………………………………………………………..31
• 31. Pre-Start Notes ……………………………………………………………………………31
• 32. Start Procedure …………………………………………………………………………..32
• 33. Engine Checks After Start-up ………………………………………………………..33
• 34. Engine Running-in Procedure ……………………………………………………….34
• 35. Stopping the Engine …………………………………………………………………….35
• 36. Lubricants and Capacities
• 37. Engine Lubricating Oil ………………………………………………………………………37
• 38. Recommended Oils ……………………………………………………………………..37
• 39. Engine Oil Capacity ……………………………………………………………………..37
• 40. Coolant Mixtures ………………………………………………………………………………38
• 41. Coolant Mixtures …………………………………………………………………………38
• 42. Coolant ………………………………………………………………………………………39
• 43. Fuel ……………………………………………………………………………………………….40
• 44. Fuels ………………………………………………………………………………………….40
• 45. Routine Maintenance
• 46. Introduction ……………………………………………………………………………………..45
• 47. Cleaning the Engine …………………………………………………………………………46
• 48. Lubricants – Health and Safety …………………………………………………………..47
• 49. Hygiene ……………………………………………………………………………………..47
• 50. Storage ………………………………………………………………………………………47
• 51. Waste Disposal ……………………………………………………………………………47
• 52. Handling …………………………………………………………………………………….47
• 53. First Aid – Oil ……………………………………………………………………………….48
• 54. Spillage ………………………………………………………………………………………48
• 55. Fires ………………………………………………………………………………………….48
• 56. Service Schedules ……………………………………………………………………………49
• 57. Engine Oil and Filter …………………………………………………………………………51
• 58. Checking the Oil Level …………………………………………………………………51
• 59. Changing the Oil and Filter ……………………………………………………………52
• 60. Engine Cooling System …………………………………………………………………….54
• 61. Coolant Mixtures …………………………………………………………………………54
• 62. Checking the Coolant Level ………………………………………………………….54
• 63. Changing the Coolant …………………………………………………………………..55
• 64. Front End Accessory Drive (FEAD) Belt …………………………………………56
• 65. Engine Fuel System …………………………………………………………………………57
• 66. Fuel …………………………………………………………………………………………..57
• 67. Draining the Water Separator and Fuel Filter …………………………………..58
• 68. Changing the Filter Element ………………………………………………………….59
• 69. Changing the Water Separator Pre- Filter ……………………………………….60
• 70. Bleeding the Fuel System …………………………………………………………….61
• 71. Air Intake System …………………………………………………………………………….62
• 72. Engine Crankcase Ventilation …………………………………………………………….63
• 73. Changing the Filter Element ………………………………………………………….63
• 74. Valve Clearances ……………………………………………………………………………..66
• 75. Introduction …………………………………………………………………………………66
• 76. Removing the Tappet Covers ………………………………………………………..66
• 77. Setting the Engine ……………………………………………………………………….67
• 78. Measuring and Adjusting the Valve Clearances ……………………………….68
• 79. Assembling the Tappet Covers ………………………………………………………69
• 80. Lifting Information …………………………………………………………………………….70
• 81. Fault Finding
• 82. Introduction ……………………………………………………………………………………..71
• 83. Fault Codes ………………………………………………………………………………..71
• 84. Reduced Torque Mode …………………………………………………………………72
• 85. Limp Home Mode ………………………………………………………………………..72
• 86. Engine Shutdown ………………………………………………………………………..72
• 87. Component Replacement ……………………………………………………………..72
• 88. Fault Finding Charts …………………………………………………………………….73
• 89. Storage and Preservation
• 90. Storage …………………………………………………………………………………………..99
• 91. Preservation ………………………………………………………………………………….100
• 92. Capping Engine Openings ………………………………………………………….100
• 93. Hot Test Description …………………………………………………………………..101
• 94. Technical Data
• 95. Basic Engine Data (444) ………………………………………………………………….103
• 96. Engine Block & Bedplate Data (444) …………………………………………………104
• 97. Cylinder Head Data (444) ………………………………………………………………..105
• 98. Inlet and Exhaust Valve Data (444) …………………………………………………..106
• 99. Rocker Levers, Rocker Shaft and Tappets Data (444) …………………………107
• 100. Pistons and Connecting Rods Data (444) ………………………………………….108
• 101. Crankshaft Data (444) …………………………………………………………………….109
• 102. Camshaft Data (444) ……………………………………………………………………… 110
• 103. Fuel System Data (444) ………………………………………………………………….. 111
• 104. Lubrication System Data (444) ………………………………………………………… 112
• 105. Cooling System Data (444) …………………………………………………………….. 113
• 106. Electrical Equipment Data (444) ………………………………………………………. 114
• 107. Switches and Sensors ……………………………………………………………….. 114
• 108. Basic Engine Data (448) …………………………………………………………………. 117
• 109. Engine Block & Bedplate Data (448) ………………………………………………… 118
• 110. Cylinder Head Data (448) ……………………………………………………………….. 119
• 111. Inlet and Exhaust Valve Data (448) …………………………………………………..120
• 112. Rocker Levers, Rocker Shaft and Tappets Data (448) …………………………121
• 113. Pistons and Connecting Rods Data (448) ………………………………………….122
• 114. Crankshaft Data (448) …………………………………………………………………….123
• 115. Camshaft Data (448) ………………………………………………………………………124
• 116. Fuel System Data (448) …………………………………………………………………..125
• 117. Lubrication System Data (448) …………………………………………………………126
• 118. Cooling System Data (448) ……………………………………………………………..127
• 119. Electrical Equipment Data (448) ……………………………………………………….128
• 120. Switches and Sensors ………………………………………………………………..128
• 121. Torque + Angle Explanation …………………………………………………………….131
• 122. Torque + Angle Tightening Procedure ……………………………………………….132
• 123. Engine Torque Tightening Figures …………………………………………………….133
• 124. JCB Service
• 125. Warranty ……………………………………………………………………………………….141
• 126. JCB Technical Service …………………………………………………………………….142