JCB BASIC ENGINE TRAINING MANUAL 1

                    

                                                                                                                                                                                      

                                                              Training  Manual 

                                                                                                                                                                                      

                    

                    

                                                          

                                                          

                                                         JCB ECO MAX ENGINE 

                                                          

                                          BASIC ENGINE TRAINING MANUAL 

                           

                    

                                                                   

                    

                    

                    

                    

                                              (ONLY FOR TRAINING PURPOSE)

                                                                                                                                                         

                                                               CONTENTS 

            1. JCB ENGINE VARIENTS…..……………………………01 - 01 

            2. TECHNICAL DATA………………………………………..02 - 03 

            3. ENGINE MAINTENANCE SCHEDULE…………….04 - 04 

            4. SYSTEM FUNCTION…………………………………....05 - 17 

            5. FUEL INJECTION PUMP REMOVAL AND  

             REFITMENT ………………………….……………..….….18 - 24 

            6. VALVE CLEARANCES.…………………………….…...25 - 27  

            7. LUBRICATNT AND CAPACITIES…………….……..28 - 29 

            8. CRANKING TEST…...……………………………..…….30 - 31 

            9. INSTRUMENT PANEL INDICATORS……………...32 - 32 

          

                                                                  

                                                                                                                   

                                                   Basic description of Engine.  

          

          

         JCB Engine Variants 

          

         4.4 Lts Engine 

           •  Called as the JCB 444 Engine 

           •  4 Cylinder, 4.4 Lts Engine 

           •  Bore Diameter 103 mm 

           •  Stroke Length 132 mm 

           •  HP – 84 to 160 HP 

           •  Powers - range of BHL (Except the 3DX), WLS, 

              Compactors, Tracked Excavators 

               

         4.8 Lts Engine 

           •  Called as the JCB 448 Engine 

           •  4 Cylinder, 4.8 Lts Engine 

           •  Bore Diameter 106 mm 

           •  Stroke Length 136 mm 

           •  HP – Only 76 HP 

           •  Powers only the 3DX 

         Training Manual – JCB Eco Max Mechanical Engine.     Page 1 

          

                                                               Technical Data

                                                               Basic Engine Data

                                  Technical Data

                               Basic Engine Data - 448

            Engine Variants:

               - DG                                                                                         Naturally Aspirated

               - DD                                                                                         Turbocharged

               - DF                                                                                         Turbocharged with Intercooler

            Emission compliance                                                                        Tier 3/Stage3A/Bharat Stage 3

            Rated speed                       2200 rpm

            Weight (Dry):

               - DG                                                                                         472 kg (1040 lb)

                -DD                                             `                                           477 kg (1052 lb)

               - DF                                                                                         477 kg (1052 lb)

            Number of cylinders               4

            Nominal bore size                                                                             106 mm (4.173 in)

            Stroke                                                                                               136 mm (5.316 in)

            Cylinder arrangement              In line

            Combustion Cycle                  4-stroke

            Firing order                      1-3-4-2

            Displacement                                                                                    4.80 litres

            Compression ratio

               - DG                                                                                         18.6 : 1

               - DD                                                                                         18.3 : 1

               - DF                                                                                         17.5 : 1

            Engine Compression                see Note (1)

            Direction of rotation (viewed from front {crankshaft pulley} end)Clockwise

            Valves                            4 per cylinder

            Valve tip clearances (measured cold):

               - Inlet                        0.19 to 0.27 mm (0.007 to 0.011 in)

               - Exhaust                      0.56 to 0.64 mm (0.022 to 0.025in)

            Lubricating oil pressure (2)      4.6 bar (67lb in2)

            Combustion system                 Direct Injection

            Fuel injection pump               Rotary Mechanical

           (1)Compression variance between each cylinder should be no greater than 3.5 bar (50 lb in2)

           (2)Engine at normal operating temperature and maximum revs.

                                                               Technical Data

                                                               Basic Engine Data

                                  Technical Data

                               Basic Engine Data - 444

            Engine Variants:

               - SG                                                                                         Naturally Aspirated

               - SD                                                                                         Turbocharged

               - SF                                                                                         Turbocharged with Intercooler

            Emission compliance                                                                        Tier 3/Stage3A/Bharat Stage 3

            Rated speed                       2200 rpm

            Weight (Dry):

               - SG                                                                                         472 kg (1040 lb)

                -SD                                             `                                           477 kg (1052 lb)

               - SF                                                                                          477 kg (1052 lb)

            Number of cylinders               4

            Nominal bore size                                                                             103 mm (4.055 in)

            Stroke                                                                                               132 mm (5.16 in)

            Cylinder arrangement              In line

            Combustion Cycle                  4-stroke

            Firing order                      1-3-4-2

            Displacement                                                                                    4.40 litres

            Compression ratio

               - SG                                                                                         18.6 : 1

               - SD                                                                                         18.3 : 1

               - SF                                                                                         17.5 : 1

            Engine Compression                see Note (1)

            Direction of rotation (viewed from front {crankshaft pulley} end)Clockwise

            Valves                            4 per cylinder

            Valve tip clearances (measured cold):

               - Inlet                        0.19 to 0.27 mm (0.007 to 0.011 in)

               - Exhaust                      0.56 to 0.64 mm (0.022 to 0.025in)

            Lubricating oil pressure (2)      4.6 bar (67lb in2)

            Combustion system                 Direct Injection

            Fuel injection pump               Rotary Mechanical

           (1)Compression variance between each cylinder should be no greater than 3.5 bar (50 lb in2)

           (2)Engine at normal operating temperature and maximum revs.

                                                                                ENGINE MAINTENANCE SCHEDULE 

                                                        Basic description of Engine. 

        

       Engine Maintenance Schedule 

                                                   

        

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

        Basic Description of Engine:- 

            The JCB Eco max engine is a 4 cylinder diesel engine in which the fuel is ignited by compression ignition (C.I.). The 

        engine operates on a four stroke cycle. 

            The Four Stroke Cycle: 

            Induction 

             As the piston travels down the cylinder it draws filtered air at atmospheric pressure and ambient 

        temperature through an air filter and inlet valves into the cylinder. 

                  

             Compression 

             When the piston reaches the bottom of its stroke the inlet valves close. The piston then starts to rise up the 

        cylinder compressing the air trapped in the cylinder. This causes the temperature and pressure of the air to rise. Fuel 

        is injected into the cylinder when the piston is near to top dead centre. 

                  

              Power 

              The piston continues to rise after the start of fuel injection causing a further increase in pressure and 

         temperature. The temperature rises to a point at which the fuel/air mixture ignites. A cylinder is said to be `firing' when 

         the fuel/air mixture ignites. This combustion causes a very rapid rise in both temperature and pressure. The high 

         pressure generated propels the piston downward turning the crankshaft and producing energy.  

        Training Manual – JCB Eco Max Mechanical Engine. Page 5 

         

                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

                 

            Exhaust  

         


Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored in the flywheel forces the piston up the cylinder expelling the exhaust gases. In a running engine these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice. 

                   

                                               

             

         

                                                SYSTEM FUNCTIONS 

                                               Basic description of Engine. 

         

            The engine is started by electric starter motor. The motor turns the engine via a pinion and teeth on the engine 

        flywheel. When the engine runs the crankshaft drives the camshaft via gears. The camshaft opens and closes the inlet and 

        exhausts valves and via pushes rods in time with the four stroke cycle. The engine has 16 valves, 2 inlet and 2 exhaust valves for 

        each cylinder. 

            The crankshaft also drives a mechanical fuel injection pump via gears. The pump injects fuel via injectors, or atomisers 

        into each cylinder in time with the four stroke cycle. Fuel is pumped from a fuel tank to the injection pump by means of a lift 

        pump driven by cam lobes on the camshaft. 

             Air is drawn into the engine via inlet manifold and exhaust gasses exit via exhaust manifold. On turbocharged engines 

        an exhaust driven turbocharger pressurises air at the inlet manifold. 

             A mechanical lubrication oil pump is driven by the crankshaft via gears. The pump pressurises and circulates oil for 

        engine lubrication and cooling purposes. A drive belt again driven by the crankshaft drives a coolant circulation pump, 

        alternator, radiator cooling fan and other ancillaries such as an air conditioning compressor. 

            Camshaft and Valve Operation: 

            As the crankshaft rotates the camshaft also rotates, driven by a gear on the crankshaft. The inlet and exhaust valves 

        are opened by lobes on the camshaft in time with the cycle. The diagrams show the position of the camshaft at each part of the 

        four stroke cycle. It can be seen that for a complete cycle the camshaft revolves once. Since the crankshaft revolves twice 

        during the cycle it follows that the camshaft is driven at half crankshaft (engine) speed. 

            Four Cylinder Cycle 

            With the crankshaft positioned as shown the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons 

        in numbers 2 and 3 cylinders are at bottom dead centre. 

            Cylinder Number 1 - The piston is at the top of its Compression stroke and is about to start its Power stroke -Valve 

        Operation Inlet and exhaust valves closed  

            Cylinder Number 2 - The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke - Valve 

        Operation Inlet valves closed exhaust valves about to open 

              Cylinder Number 3 - The piston is at the bottom of its Induction stroke and is about to start its Compression stroke. 

        Valve Operation Exhaust valves closed, inlet valves about to close  

             Cylinder Number 4 - The piston is at the top of its Exhaust stroke and is about to start its Induction stroke. Valve 

        Operation Exhaust valves about to close, inlet valves about to open 

            Firing Order  

            A cylinder is said to be `firing' when the fuel/air mixture ignites and the piston is about to start its power stroke. 

            It is important to note that number 1 cylinder is `firing' and about to start its Power stroke. Rotating the crankshaft a 

        further 360 degrees would position the pistons as described but the engine would be at a different stage in its four stroke cycle, 

        with number 1 cylinder about to start its Induction stroke.  

            The stages in the four stroke cycle for each cylinder are as follows: 

             

       

         

                                                 SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

                                 

            Timing Gears 

            The timing gears are located inside a casing at the flywheel end of the engine. 

            The engine must be `timed' so that the camshaft operates the valves and the fuel injection pump injects the fuel at 

        the correct times relative to the crankshaft position. Valve timing is achieved by ensuring that the camshaft drive gear B is 

        meshed to the crankshaft gear A at their correct angular positions, for more information about valve timing. Timing of the fuel 

        injection pump is not dependent on drive gear meshing. The pump drive shaft is supplied locked at the correct angular position 

        relative to crankshaft/camshaft position. With the crank and camshaft positioned correctly (using temporary locking pins), the 

        pump is fitted to drive gear and its drive shaft unlocked. 

                                   

            All the gears are driven via the crankshaft gear. 

            Camshaft gear - The camshaft is driven at half crankshaft speed. 

            Fuel injection pump gear - The fuel injection pump is driven via compound gear fitted to the camshaft. The pump 

        rotates at half crankshaft speed. 

        Training Manual – JCB Eco Max Mechanical Engine. Page 8 

         

                                                                                                                   SYSTEM FUNCTIONS 

                                                  Basic description of Engine.  

          

             Oil pump gear -The lubrication oil pump is driven directly by the crankshaft gear.  

             Heavy Duty PTO Gear (if fitted). The PTO is driven by the crankshaft gear via idler gear (if fitted). The PTO is driven 

         by the camshaft gear. 

             Valve Train 

             The valve train system opens and closes the valves with correct timing in relation to the piston movements. 

             The camshaft drive gear is driven by the crankshaft gear at half the speed of the crankshaft. Camshaft lobes, two for 

         each cylinder, (operating exhaust and inlet valves) actuate the valve tappets. 

              Each push rod has one end in a valve tappet and the other end under a rocker arm, or as applicable. Adjusting screw 

         has a ball shaped end that locates in the push rod. 

              The adjusting screw is used for setting the valve clearance.  

             When the camshaft rotates the cam lobes act on the tappets. The push rods act on the rockers which pivot on shaft, 

         depressing two valves at once via the bridge piece. 

              The screw is self locking in the rocker by means of a tapered thread. Wave washers act like springs to keep the 

         rockers in their correct positions along the shaft and prevent them contacting one another. The rockers incorporate a swivel tip, 

         ensuring alignment with the bridge piece. This prevents excessive wear. 

              Each valve has a compression spring. The function of the spring is to close the valve and at the same time return the 

         rocker arm and push rod ensuring that the tappets follow the camshaft lobes. The spring is located on the valve stem by a 

                             retainer and split collets.  

                                 The valves extend through the cylinder head. There are no sleeves or 

                             valve guides in the cylinder head. The valves are made from a special metal to 

                             provide a long service life. Damaged or worn valves cannot be lapped or re-

                             ground and must be replaced with new ones. Each valve stem has an oil seal. 

                                  Valve seat inserts are pressed into the cylinder head. The seat inserts 

                             are also made from a special metal to provide for a long service life. Damaged or 

                             worn seat inserts can be removed and replaced with new ones. 

                                  

                                  

                                  

             Lubrication System 

             Basic Description 

             The lubrication system distributes oil around the engine by a system of galleries and drillings in the cylinder block and 

         cylinder head. The oil lubricates and seals the moving parts of the engine, reducing friction and wear. In addition the oil plays an 

         Training Manual – JCB Eco Max Mechanical Engine.   Page 9 

          

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

        important role in cooling the engine by carrying heat from the engine to the cooler. A piston cooling jet sprays oil onto the 

        underside of the pistons to keep them cool. 

            Oil is drawn from the oil pan (sump) by the integral oil pump via the strainer. The strainer prevents any large particles 

        of debris passing through, which may damage the pump. 

             The oil passes from the outlet side of the pump through a relief valve which limits the maximum oil pressure by 

        venting oil back to the inlet side of the pump. 

             From the pump the oil passes through the cooler and filter. After cooling and filtering, oil passes into the main oil 

        gallery. An oil pressure switch senses oil pressure. From the main gallery oil is delivered, via drillings, to the crankshaft main 

        bearings, rocker assembly, and camshaft and timing gears. Note that drilling is through the cylinder block and cylinder head. 

             When the high pressure oil has passed through the bearings it reverts to sump pressure and `splash' lubricates 

        internal components such as rocker tips, cam lobes and timing gear teeth. Gravity drains the oil via galleries in the cylinder head 

        and block, back into the oil pan (sump). A drain slot allows oil to drain from the timing case back to the oil pan. 

            1. Oil pan (sump)  

            2. Suction strainer  

            3. Oil pump 4 Oil cooler 

            5. Filter                    

            6 .Camshaft - high pressure oil feed                                                

            7. Crankshaft main bearings - high pressure oil feed  

            8 .Rocker assembly - high pressure oil feed  

            9. PTO idler gear bearing/timing case - high pressure oil feed  

            10. External high pressure oil feed connection (engine block) - Turbo charger (if fitted)  

            11. Main high pressure oil feed gallery (engine block) 

        Training Manual – JCB Eco Max Mechanical Engine. Page 10 

         

                                                                                                                   SYSTEM FUNCTIONS 

                                                   Basic description of Engine.  

          

               

              Color Key - Lub Lines 

              Green Oil at sump pressure  

              Red Oil at high pressure  

              Pink Oil at lower pressure but higher than sump pressure 

              Fuel System  

              Basic Description 

              The fuel system is central to the performance and efficiency of the engine distributing an accurate amount of fuel to 

         each cylinder at exactly the right time. 

               Fuel is drawn from the tank by engine driven lift pump via the water trap. The trap separates any water in the fuel 

         before if passes through the lift pump.  

              Fuel is pressurised at low pressure by the lift pump and passes through a fuel filter on its way to the inlet on the fuel 

         injection pump. Effective filtration and decontamination of the fuel is essential. The injection pump can be damaged beyond 

         repair by contaminated fuel. 

               The fuel injection pump is of a rotary type and is driven by the engine. The pump delivers fuel at high pressure to the 

         fuel injectors. The high pressure fuel is delivered in `pulses' timed at the correct point in the combustion cycle for each cylinder.  

              When the fuel injectors receive a pulse of fuel at high pressure they inject atomised fuel into the combustion 

         chamber.  

              When the pressure of the fuel at the injector’s falls, the injector snaps shut and any trapped fuel bleeds back to the 

         fuel tanks via the bleed off fuel lines.  

              Some fuel flows through the pump at all times to provide internal lubrication and cooling. This fuel bleeds back to 

         tank via the bleed-off fuel lines. 

         Training Manual – JCB Eco Max Mechanical Engine.    Page 11 

          

                                                                                                                   SYSTEM FUNCTIONS 

                                                Basic description of Engine.  

          

                                                   

             1 Fuel tank 

              2 Water trap (sedimenter)  

             3 Lift pump  

             4 Fuel filter  

             5 Fuel injection pump (FIP) (DP210 pump shown)  

             6 Fuel injectors (atomisers) 

             Colour Key - Fuel Lines 

             Green -Suction  

             Yellow -Low pressure  

             Red -High pressure  

             Orange -Bleed-off (return to tank) 

              

              

             Cooling System 

         Training Manual – JCB Eco Max Mechanical Engine. Page 12 

          

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

            Description 

            During the working cycle of the engine a great deal of heat is generated. It is important that the engine is kept at its 

        normal operating temperature to achieve maximum efficiency. It is the function of the cooling system to allow the engine to 

        reach this temperature quickly and then maintain it. 

            Coolant pump, driven via a pulley and front end accessory drive belt, draws coolant from the pump cavity. 

             Coolant is pumped through the outlet gallery to the oil cooler cavity in the left-hand side of the cylinder block. As the 

        coolant flows past the oil cooler matrix heat is exchanged from the oil to the coolant. This enables the oil to function as a 

        coolant as well as a lubricant. See Lubrication System.  

            The coolant leaves the oil cooler cavity and passes into the main cylinder block gallery. The gallery is connected to the 

        cylinder water jackets. Coolant flows around and up the jackets and then passes into the cylinder head via link galleries. Coolant 

        circulates around the cylinder head where it conducts heat away from the combustion chambers and also the fuel injector tips. 

        The coolant then passes to the thermostat housing. 

            When the engine is below normal operating temperature the thermostat is closed, preventing coolant flowing to the 

        machine radiator via the top hose connection port. Instead coolant is directed through by-pass gallery back to the pump cavity  

        and is again drawn into the pump. 

             When the engine is at operating temperature the thermostat opens, closing the by-pass gallery to the pump and 

        opening the top hose connection port to the machine radiator. Coolant passes through the radiator matrix and is cooled. The 

        coolant flows back to the engine via bottom hose connection port and is again drawn into the pump.  

            A coolant temperature gauge and warning light sender unit is fitted at port. 

             A cab heater hose can be fitted at port. This enables coolant to circulate through a heater matrix when the 

        thermostat is open or closed, ensuring fast heater warm up. 

             A cold start switch is fitted at port. When the coolant is cold the switch closes and energises a cold start solenoid on 

        the fuel injection pump, enabling a cold start mode. 

            1 Coolant pump      9 Thermostat housing - cylinder head  

            2 Drive belt - coolant pump     10 Thermostat - cylinder head  

            3 Pump cavity - cylinder block   11 Top hose connection port - cylinder head  

            4 Pump outlet gallery - cylinder block    12 By-pass gallery - cylinder head and block  

            5 Oil cooler cavity - cylinder block   13 Bottom hose connection port - cylinder block  

             6 .Coolant gallery - cylinder block   14. Port - Coolant temperature sender and switch unit  

             7. Cylinder cooling jackets - cylinder block  15. Port - Cab heater hose connection  

             8. Link galleries - cylinder block to head   16. Port - Cold start switch - cylinder block 

        Training Manual – JCB Eco Max Mechanical Engine. Page 13 

         

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

                                           

            Induction and Exhaust Systems 

            The induction system ensures the required volume of air enters the engine to provide efficient combustion of the fuel 

        in the cylinders. There are 3 types of induction system to suite different engine applications: 

             – Naturally aspirated 

             – Turbocharged  

            – Turbocharged and inter-cooled 

             

            Naturally Aspirated 

             Air is drawn into the engine via the air filter 36-1. The air at atmospheric pressure flows from the air filter to 

        the inlet manifold, from where it is pulled into the cylinder during the induction cycle. Exhaust gases leave the engine 

        via exhaust manifold. 

        Training Manual – JCB Eco Max Mechanical Engine. Page 14 

         

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

                                 

            Component Identification 

            1 .Air filter  

            2 .Inlet manifold  

            3 .Exhaust manifold 

            Turbocharged 

            A turbocharger is bolted to the outlet port of the exhaust manifold. 

             The turbocharger uses energy from the exhaust gases to drive a turbine which in turn drives the compressor via a 

        common shaft. Air is drawn through the air filter into the compressor side of the turbocharger. The compressor forces 

        pressurised air into the cylinders via the cross-over pipe and inlet manifold. The extra volume of air allows more fuel to be 

        injected increasing the engine power output. 

             The air is compressed to a minimum pressure of 1 bar (14.5 lb/in2) depending upon engine speed and load. The 

        turbocharger spins at up to 1000,000 rpm and reaches temperatures approaching 700 ºC (1292 ºF); it is essential, therefore, 

        that a good supply of oil reaches it at all times. The oil not only lubricates the turbocharger but also carries away excess heat. 

        External oil feed pipe connected to a port on the cylinder block supplies oil to the turbocharger bearing. Oil returns to the 

        engine oil pan via external drain pipe. Integral oil seals prevent oil escaping to the compressor and turbine ends of the 

        turbocharger.  

            The pressure generated by the compressor is known as `boost pressure' The boost pressure is controlled by the 

        wastegate assembly. Boost pressure acts on a pneumatic actuator. The actuator is linked to the wastegate valve via operating 

        linkage. When the boost pressure reaches a pre-set value the wastegate opens allowing exhaust gas to bypass the turbine, thus 

        reducing the speed of the compressor. At higher engine speeds the wastegate is continually opening and closing a small 

        amount, maintaining a constant boost pressure. 

        Training Manual – JCB Eco Max Mechanical Engine. Page 15 

         

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

                                 

            Component Identification 

            1 Turbocharger     2 Exhaust manifold  

            3 Turbine       4 Compressor  

            5 Air filter    6 Cross-over pipe  

            7 Inlet manifold 

            Intercooled  

            Turbocharged engines can be configured for inter-cooling. As the air is compressed by the turbocharger it also heats 

        up and becomes less dense, reducing the combustion efficiency. By passing the compressed air through a heat exchanger or 

        `inter-cooler' it is cooled before reaching the engine. The inter-cooler most commonly takes the form of an air blast matrix but 

        can be a water cooled matrix. 

                          

             

             

            Exhaust Gas Recirculation (EGR) 

        Training Manual – JCB Eco Max Mechanical Engine. Page 16 

         

                                                                                                                  SYSTEM FUNCTIONS 

                                               Basic description of Engine.  

         

            The JCB Dieselmax Engine (Mechanical Tier 3) features an internal Exhaust Gas Recirculation (EGR) system. This 

        enables a small amount of exhaust gas to be introduced into the induction air for combustion. 

             The system reduces nitrogen oxide (NOx) emissions.  

            A small amount of exhaust gas is introduced into the inlet manifold by using the camshaft to open the inlet valves 

        during the exhaust stroke. The valves are opened only for a short period and at low lift. 

             To achieve this, each of the camshaft inlet lobes A is provided with a second lobe portion B which has a very small 

        height measurement over and above its basic curve. This is additional to the main inlet valve opening ramp C.  

            EGR tends to reduce the amount of fuel burned in the power stroke. This is evident by the increase in particulate 

        emissions that corresponds to an increase in EGR.  

            Particulate matter (mainly carbon) that is not burned in the power stroke is wasted energy. This increase in 

        particulate emissions maybe perceived as excessive black smoke although it is perfectly normal. 

                                    

        Training Manual – JCB Eco Max Mechanical Engine. Page 17 

         

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

       Fuel Injection Pump - Removal and Fitment 

       Component Identification 

       1 Fuel injection pump 

       2 Pump fixing nuts 

       3 Injection pump gear cover 

       4 Injection pump lock bolt 

       5 Keyhole washer 

       6 Cold start advance solenoid 

       7 Electric shut-off solenoid (ESOS) 

       8 Fuel line connector (inlet) 

       9 Fuel bleed-off connector 

       10 Turbo boost vacuum pipe (if fitted)     

               

       11 Drive shaft nut 

       12 Drive gear 

       15 Throttle lever 

       Training Manual – JCB Eco Max Mechanical Engine. Page 18 

        

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

       16 Lift Pump    

                                    

       Service Tools 

       Item   Description 

           A    Timing pin – crankshaft 

           C     Crankshaft turning tool 

           D    Top dead centre setting  tool 

           E     Gear removal tool 

                       comprises: 

            F     Reaction cap / Blind Nut 

           G     Tool body 

           H     Special bolt 

           J      ‘C’ shaped ring spanner 

         13     Blanking plug (access for      

                     crankshaft locking pin) 

       Training Manual – JCB Eco Max Mechanical Engine. Page 19 

        

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

                                                   

        

                                               

       Before removing: 

         a)   Ensure that the engine cannot be started. 

         b)   Release the fuel line couplings at the inlet connection 8 and bleed-off connection 9 on the 

          pump. Remove the high pressure fuel lines.                                                              

         c)  Release the fuel line couplings at the fuel lift pump connections 18 and disconnect the throttle 

          cable. 

       IMPORTANT NOTE: DO NOT attempt to remove the fuel injection pump until both the engine and pump 

       are mechanically locked in the correct position - refer to the procedures  below.  

       Training Manual – JCB Eco Max Mechanical Engine. Page 20 

        

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

       The pump will need the timing reset by a fuel injection equipment specialist if it is not locked in the 

       correct position prior to removal. 

       Removal 

         1)  Uncouple the electrical connectors at the shut-off solenoid (ESOS) 7 and cold advance solenoid 

          6. 

         2)  Turbocharged Engines Only: Disconnect the boost control vacuum pipe 10 at the diaphragm on 

          the injection pump. 

         3)  Remove the taper blanking plug 13. 

         4)  Set number 1 piston to top dead center (on its  compression stroke): 

         5)  Remove the fuel lift pump.  

         6)  Install the TDC setting tool D, use one of the lift pump retaining bolts 17 to hold the tool in 

          position. 

         7)   Make sure that the top hole locates centrally over the lift pump actuating pin 19. 

                            

         8)  Use rotation tool B and turn the crankshaft until timing   pin A engages in the crankshaft timing 

          hole. Check that the lift pump actuating pin is protruding from the face of the setting tool, if not 

          complete steps 4.4 and 4.5.             

         9)  Remove the timing pin A. 

         10) Rotate the crank pulley 360° and refit the timing pin A 

       Training Manual – JCB Eco Max Mechanical Engine. Page 21 

        

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

                                 

        

       Note: The timing pin MUST be engaged in the crankshaft 

       timing hole. It is possible that the pin may appear to ‘engage’ 

       but it is in fact between the crankshaft webbing.  

       Always check the pin has engaged correctly by trying to move the crankshaft clockwise and anti-

       clockwise. If you can not turn the crankshaft in both directions, the pins will be engaged. 

         11) Remove fuel injection pump gear cover 3. 

         12) Undo and remove the drive shaft nut 11. 

         13)  Loosen lock bolt 4 on the fuel injection pump so that the special keyhole washer 5 can be slid 

          across to its   locking position (as shown at Y). Screw the lock bolt in and torque tighten. The 

          washer 5 should be loose. 

       Training Manual – JCB Eco Max Mechanical Engine. Page 22 

        

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

                                                

        

         14) Undo and remove the nuts 2. Use special spanner J to undo the nut close to the  cylinder block. 

          Be sure to remove all 3 nuts.                                      

         15) Fit reaction cap F (service tool) over the pump shaft. Screw service tool G to the   housing. Using 

          a suitable ratchet drive and socket screw in bolt H (service tool) until resistance is felt. 

         16) The injection pump drive gear 12 is located on a taper on the pump drive shaft. To  remove the 

          pump the taper lock must be ‘broken’. Support the fuel injection     pump.  Tap the end of bolt H 

          with a soft faced hammer. When the taper ‘breaks’ there will be an audible sound. 

                Note: The pump drive gear connects to the injection pump drive shaft by means of  taper lock 

       alone. There is no mechanical locking key. 

         17)  Withdraw the pump from the flywheel housing. Remove service tools H, G and F.   IMPORTANT 

          NOTE: DO NOT remove the engine locking pin A. Make sure that no one attempts to turn the 

          engine.                                                                       

                  IMPORTANT NOTE: DO NOT loosen the fuel injection pump lock bolt 4. 

        

       Replacement / Fitment 

       Service procedures on the fuel injection pump can only be carried out by specialist personnel with the 

       relevant training and equipment. Before replacing an injection pump with a new one, or one that has 

       been serviced, make sure that the drive shaft is locked, with bolt 4 tightened with keyhole washer 5 in 

       the correct position. Make sure that the engine is still locked in the correct position. 

         1)  Make sure that taper surfaces on the injection pump drive shaft and gear 12 are clean and free 

          from oil. 

       Training Manual – JCB Eco Max Mechanical Engine. Page 23 

        

                                  FUEL INJECTION PUMP REMOVAL AND FITMENT 

                                       Basic description of Engine. 

        

         2)  Make sure that the oil seal is correctly located on the injection pump mounting face. Locate the 

          pump onto the mounting studs. Locate the drive gear 12 over the pump drive shaft. 

         3)  Fit and torque tighten the nuts 2 to 24 Nm (17.7 lbf ft). Use special spanner H to tighten the nut 

          close to the cylinder block. 

         4)  Fit and torque tighten the pump gear nut 11 to the 1st stage pre torque.  

               Note: If the washer is supplied with a replacement pump, DO NOT FIT THE WASHER. Secure the gear 

       with the nut 11 only. 

         5)  Loosen lock bolt 4 until the keyhole washer 5 can be slid under the bolt (as shown at X). Then 

          torque tighten bolt 4. The washer 5 should be locked. 

         6)  Torque tighten pump gear nut 11 to final stage. 

         7)  Fit the gear cover 3 using service tool. Make sure its sealing ‘O’ ring is correctly fitted. Torque 

          tighten the gear cover. 

         8)  Remove the engine lock pin A and refit the blanking plug B. 

         9)  Couple the electrical connectors at the shut-off solenoid(ESOS) 7 and cold advance solenoid 6. 

         10) Turbocharged Engines Only: Reconnect the boost control vacuum pipe 10 at the diaphragm on 

          the injection pump. 

       After replacing: 

         1)  Replace the rocker cover on Cylinder Head . 

         2)  Reconnect the fuel line couplings at the inlet connection 8 and bleed-off connection 9 on the 

          pump. Fit the high pressure fuel lines. 

         3)  Remove the TDC setting tool and replace the fuel lift pump. 

         4)  Reconnect the throttle cable. 

         5)  Bleed the fuel system. 

         6)  Start the engine and check for fuel leaks. 

        

       Training Manual – JCB Eco Max Mechanical Engine. Page 24 

        

                                                                                                                  VALVE CLEARANCES 

                                           Basic description of Engine.  

         

        Valve Clearances – Adjustment 

        Component  Identification

                                             

        1 Rockers 

        2 Bridge pieces 

        3 Tappet adjusters 

        I - Inlet valves 

        E - Exhaust valves 

        Training Manual – JCB Eco Max Mechanical Engine. Page 25 

         

                                                                                                                   VALVE CLEARANCES 

                                                 Basic description of Engine.  

          

         Tappet Clearances (Engine cold) 

         Item                                 mm                   inch 

         Inlet valves              0.19 - 0.27      0.007 - 0.010 

         Exhaust valves        0.56 - 0.64      0.022 - 0.026 

         Adjustment sequence table: 

         STEP   Set –up Cylinder No. Check / Adjust 

                (Dancing Position) Cylinder No. 

           A          4             1 

           B          2             3

                                      

           C          1             4 

           D          3             2 

          

         Before adjustment: 

           1)  Ensure that the engine is safe to work on. If the engine has been running, make sure the engine 

             has cooled sufficiently before you start. 

           2)  Disconnect and remove the fuel lines from the injectors. 

           3)  Remove the rocker cover. 

           4)  Ensure that all items are clean and free from damage and corrosion. 

         Adjustment 

         The valve clearances should be checked/adjusted in a set sequence as given in the adjacent table. 

         The preferred method to measure the clearance is to use a dial test indicator (DTI) T1 mounted on a 

         magnetic base. Note that the DTI must be positioned to contact the machined surface of the rocker on 

         Training Manual – JCB Eco Max Mechanical Engine.  Page 26 

          

                                                                                                                  VALVE CLEARANCES 

                                           Basic description of Engine.  

         

        the centre line X. If a DTI is not available, feeler gauges can be used to measure the clearance Y between 

        the bridge piece and the rocker insert as shown. 

          1)  Using a socket and wrench, move the rocker 1 to open the valves against the force of the 

           springs. 

          2)  Slowly relax the force on the rocker until you feel the exact position at which the valves shut. 

           Measure the valve clearance from this point. 

        Step A - Rotate the crankshaft in the normal direction of rotation (clockwise when viewed from the front 

        of the engine) to ‘set-up’ the valves of No.4 cylinder so that the point is reached where the exhaust 

        valve is closing while the inlet valve is just starting to open. This is the point where the two 

        rockers are moving past one another in opposite directions. 

        With No.4 cylinder in this position, measure the clearance of No.1 cylinder inlet and exhaust valves, and 

        adjust them if necessary. See Tappet Clearances. 

        Step B - Further rotate the crankshaft to ‘set-up’ the valves of No.2 cylinder as above, then measure the 

        clearance of No.3 cylinder valves.  

        Complete steps c and d in sequence for the remaining cylinders. 

        Note: Take care to keep the rocker at right angles to the rocker shaft when making measurements,  

        otherwise incorrect values will be obtained. Always use a socket or ring spanner to turn the tappet 

        adjusters 3, DO NOT use an open ended spanner. 

        After adjustment: 

          1)  Replace the rocker cover. 

          2)  Reconnect the fuel lines to the injectors. 

         

        Training Manual – JCB Eco Max Mechanical Engine. Page 27 

         

                                                                                                   Lubricants and Capacities

                                                   Lubricants and Capacities

                                                               Engine Lubricating Oil

                      New engines DO NOT require a running-in period. The 

                      engine/machine should be used in a normal work cycle          (1)  Not suitable for generator set applications.

                      immediately, glazing of the piston cylinder bores, resulting 

                      in excessive oil consumption, could occur if the engine is    Engine Oil Capacity

                      gently run-in. Under no circumstances should the engine 

                      be allowed to idle for extended periods; (e.g. warming up     Choose the grade of oil to suit the temperature range as 

                      without load).                                                detailed. K Table 54.  ( T 1-55). The engine oil capacity, 

                      A minimum API CF4 grade oil must be used. Superior            including filter and clean sump is 12 litres MIN and 15 litres 

                      grade  oils  may  be  more  appropriate  for  heavy  duty     MAX mark on the dipstick.

                      applications (such as sustained high loads and operation                              Table 56. 

                      at elevated temperatures).                                     Item             Capacity litres (UK Gal)

                      The choice of lubricant viscosity should be made based on                       Minimum             Maximum

                      the lowest ambient temperature at which the machine will       Engine           12 (2.6)            15 (3.3)

                      be  started  and  the  maximum  ambient  temperature  at 

                      which it will operate.

                      The  following  table  provides  guidance  as  to  the 

                      temperature  range  that  can  be  accommodated  by 

                      standard  oil  viscosities  and  can  be  used  to  select  an 

                      appropriate grade. K Table 54.  ( T 1-55).

                                             Table 54. 

                      Oil Viscosity Minimum               Maximum

                                    Temperature °C (°F)   Temperature °C (°F)

                      SAE 0W30       - 40 (-40)            + 30 (86)

                      SAE 0W20       - 40 (-40)            + 10 (50)

                      SAE 5W20       - 30 (-22)            + 10 (50)

                      SAE 5W40       - 30 (-22)            + 40 (104)

                      SAE 10W30  - 20 (-4)                 + 40 (104)

                      SAE 15W40  - 15 (-5)                 + 50 (122)

                      Recommended Oils

                                             Table 55. 

                      Engine Oil              Specification

                      JCB High                                             (1)

                                              ACEA E2:B2:A2, API CF4/SG

                      Performance(1)

                      JCB Extreme             ACEA E5/B3/A3, API CH-4/SJ

                      Performance

                                                                           

                    Training Manual - JCB Eco Max Mechanical Engine.                                                                Page 28

   

                                                              

                                                                       Lubricants and Capacities

                                                                                    Coolant Mixtures

                                              Coolant Mixtures

                            !MWARNING

               Antifreeze can be harmful. Obey the manufacturer's 

               instructions  when  handling  full  strength  or  diluted 

               antifreeze.

               7-3-4-4_1

               The protection provided by JCB Four Seasons Antifreeze 

               and Summer Coolant is shown below. If any other anti-

               freeze is used, refer to the manufacturer's instructions and 

               ensure that a corrosion inhibitor is included. DO NOT use 

               solutions of more than 60% or less than 50% or damage to 

               the cooling system will occur.

               55% Solution - Maintains circulation down to -36 deg C (-

               33 deg F), protects against damage down to -41 deg C (-

               42 deg F)

               The strength of the anti-freeze solution must be checked at 

               least once a year, preferably at the beginning of the cold 

               period. It is an advantage to leave the anti-freeze in all the 

               year  round  as  it  gives  continued  protection  against 

               corrosion. Always renew the anti-freeze every two years. A 

               50%  anti-freeze  mixture  must  be  used  even  if  frost 

               protection  is  not  needed.  This  gives  protection  against 

               corrosion and raises the coolant's boiling point.

               It  should  be  noted  that  serious  damage to the  cooling 

               system can occur if corrosion inhibitors are not used.

                                                 

            Training Manual - JCB Eco Max Mechanical Engine.                            PagePage 02 29

                                                                                                                  CRANKING TEST 

                                            Basic description of Engine.  

         

         

        Cranking test  

        The cranking test described below needs to be conducted before and after doing any oil and filter 

        change on all JCB engines. Proceed to carry out the service based on the outcome of cranking test.  

          1)  Start the engine and bring to normal operating temperature which takes about 15 minutes.  

          2)  Disconnect the ESOS electrical connector on the fuel injection pump.  

          3)  Crank the engine for 15 seconds with the ESOS disconnected. Record the time taken by the 

            engine low oil pressure warning light in the dashboard to go out. The engine low oil pressure 

            light in the dash board should go out in a maximum of 15 seconds.   

                                                  

          4)  If the engine oil pressure warning light goes out in less than 15 seconds, reconnect the ESOS and 

            proceed with the engine service. Ensure the operator fully comprehends the importance of the 

            low engine oil pressure warning light and the water in fuel warning light.  

          5)  In the rare event that the oil pressure light does not go out in 15 seconds of cranking, stop 

            cranking and wait for 30 seconds. 

          6)  Crank again for 15 seconds. Again if the oil pressure light does not go out in 15 seconds, abort 

            the engine service. Do not proceed with the oil and filter change.  

        Training Manual – JCB Eco Max Mechanical Engine. Page 30 

         

                                                                                                                  CRANKING TEST 

                                            Basic description of Engine.  

         

         

                                          

         

                                         

        Training Manual – JCB Eco Max Mechanical Engine. Page 31 

         

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  INSTRUMENT PANEL  

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                       Basic description of Engine.  

                                                                                                                                                        

                                                                                                                                                        

                                                                                                                                                       Instrument Panel indicators: 

                                                                                                                                                       Engine Oil Pressure Low  

                                                                                                                                                        

                                                                                                                                                                                                                                                             

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   

                                                                                                                                                       Audible / Visual.  

                                                                                                                                                        

                                                                                                                                                       Operates if the engine oil pressure is below normal. 

                                                                                                                                                       The light should go out when the engine is started. 

                                                                                                                                                        

                                                                                                                                                        High Engine Coolant Temperature 

                                                                                                                                                         

                                                                                                                                                                                                                                                                        

                                                                                                                                                         

                                                                                                                                                        Red light & audible alarm. Lights if the engine temperature is above normal. 

                                                                                                                                                         

                                                                                                                                                          Air Filter Choke  

Red light and audible alarm if the air filter is chocked.Water In Fuel  Signal comes on when the water level in Pre filter beyond permissible level. 

                                                                                                                                                           

                                                               

                                                                                      

https://join-adf.ly/17520243                                               https://join-adf.ly/17520243