This workshop repair service manual PDF download for the JCB Dieselmax Tier 3 SE 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 - Routine 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 13 - Electronic Data Systems
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9806/3030-01
Total Pages : 520
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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9806-3030-01
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
Cleanliness Requirements
Effects of Contamination
Common Rail Fuel Injection System
Maintenance Environment, Common Rail Fuel Injection
Cleaning the Engine
Further Cleaning Procedures, Common Rail Fuel Injection
Terms and Definitions
Acronyms and Abbreviations
Technical Data
Fuel
Acceptable and Unacceptable Fuels
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Basic Engine Data
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
Lubrication System Data
Cooling System Data
Electrical Equipment Data
Switches and Sensors
Identifying the Engine
Engine Identification Plate
Typical Engine Identification Number
Component Labels
Engine Component Identification
External
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'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
Coolant Mixtures
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
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
Storage and Preservation
Storage
Preservation
Capping Engine Openings
Hot Test Description
Section 2 - Care and Safety
Care and Safety
Safety Notices
Introduction
Safety Checklist
Common Rail (Tier 3) Specific
General Safety
Operating Safety
Maintenance Safety
Section 3 - Routine Maintenance
Routine Maintenance
Routine Maintenance
Introduction
Maintenance Procedures
Cleaning the Engine
Lubricants - Health and Safety
Hygiene
Storage
Waste Disposal
First Aid - Oil
Spillage
Fires
Service Schedules
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Engine Cooling System
Coolant Mixtures
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive (FEAD) Belt
Engine Fuel System
Fuel
Draining the Water Separator and Fuel Filter
Changing the Filter Element
Changing the Water Seperator Pre- Filter
Bleeding the Fuel System
Air Intake System
Engine Crankcase Ventilation
Changing the Filter Element
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
Common Rail Fuel Injection
Compared to Mechanical Direct injection Systems
Component Location and Identification
Basic Operation
Pre-Filter/Water Separator, Lift Pump and Fuel Filter
High Pressure Fuel Pump Assembly
Injectors and Combustion
Engine Electronic Control System
Pulse Width Modulation (PWM)
Induction, Exhaust and Breather Systems
Induction and Exhaust Systems
Turbocharged
Intercooled
Exhaust Gas Recirculation (EGR)
Engine Breather
Cooling System
Description
Thermostat
State A - `Closed' - Engine Cold
State B - `Open' - Engine Hot
Injectors
Coolant Pump
Electrical System
Electrical Circuit Schematics
Starting and Charging
Engine Electronic Control Unit - Fuel Injection Control
Engine Electronic Control Unit - Machine Electrical Interface
Section 5 - Fault Finding
Fault Finding
Fault Finding
Introduction
Electronic Fault Codes
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
Flow Test Procedures
Fuel Injectors
Diagnostics Tests
Leak Off Test
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
Turbocharger Checks
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
Low Pressure Fuel Lines
Injector Bleed-off Lines (Low Pressure)
Rail Bleed-off Line (Low Pressure)
Common Rail Assembly
Removal and Replacement
Before Removal
Removal
Replacement
Fuel Lift Pump
Removal and Replacement
High Pressure Fuel Pump
Removal and Replacement
Component Identification
Before Removing:
Removal
Replacement
After Replacing
Fuel Injectors (Atomisers)
Removal and Replacement
Removal
Replacement
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
Coolant Temperature Sender Unit
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
Engine Oil Pressure Switch
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Camshaft Position Sensor
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Knock Sensor
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Crankshaft Position Sensor
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Temperature and Air Pressure Sensor (TMAP)
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Engine Electronic Control Unit (ECU)
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
Section 11 - Induction and Exhaust System
Induction and Exhaust System
Turbocharger
Removal and Replacement
Before Removing
Removal
Inspection
Replacement
After Replacing
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
Dismantling and Assembly
Rocker Assembly
Removal and Replacement
Dismantling, Inspection and Assembly
Valve Clearances
Remove the Tappet Covers
Set the Engine
Measure and Adjust the Valve Clearances
Assemble the Tappet Covers
Cylinder Head Assembly
Removal and Replacement
Valves, Valve Springs and Stem Seals
Removal and Replacement
Front End Accessory Drive Belt System (FEAD)
Tensioner
Removal and Replacement
Flywheel and Housing
Flywheel
Removal and Replacement
Flywheel Gear Ring
Removal and Replacement
Flywheel Housing
Removal and Replacement
Timing Case and Drive Gears Assembly
Drive Gear - High Pressure Fuel Pump
Removal and Replacement
Drive Gear - Crankshaft
Removal and Replacement
Drive Gear - High Duty P.T.O. Idler
Removal and Replacement
Drive Gear - Camshaft
Removal and Replcement
Camshaft and Tappets
Removal and Replacement
Timing Case - Rear
Removal and Replacement
Pistons and Connecting Rods
Big End Bearing
Removal, Inspection and Assembly
Piston and Connecting Rod Assembly
Removal and Replacement
Piston and Connecting Rod Assembly
Dismantling, Inspection and Assembly
Crankshaft Assembly
Crankshaft Pulley
Removal and Replacement
Rear Oil Seal
Removal and Replacement
Front Oil Seal
Removal and Replacement
Crankshaft
Removal and Replacement
Section 13 - Electronic Data Systems
Electronic Data Systems
Network Systems
Descripton
What is the Network System?
CANbus Communications System
Electronic Fault Codes
Fault Code Displays
CAN Enabled Display
CANbus Connected Computer
MIL Display
Engine ECU Fault Codes
Servicemaster
Why Use Servicemaster?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECUs
Summary
What is Servicemaster?
Introduction
CANbus Communications System
Servicemaster Structure
How to Set Up Servicemaster
Install Servicemaster
Start Servicemaster
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Servicemaster to the Machine CANbus
Servicemaster Tools
Engine ECU
JCB 4.4L Tier 3 Diagnostics Tool - User Guide
Vehicle Setup Data Tool - User Guide
Engine ECU Flashloader Tool - User Guide
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