Section 1

Section 1
General Information
Service Manual - JCB Dieselmax Tier 3 SE Engine
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
Publication No.
9806/3030-02
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
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1-0 9806/3030-02 1-0

Contents Page No.

Introduction
About this Manual .................................................................................... 1 - 1
Using the Service Manual .................................................................. 1 - 1
Section Numbering ............................................................................. 1 - 1
Left Side, Right Side ........................................................................... 1 - 1
Units of Measurement ........................................................................ 1 - 1
Machine Related Data ........................................................................ 1 - 2
Cleanliness Requirements
Effects of Contamination ......................................................................... 1-3
Common Rail Fuel Injection System .................................................. 1-3
Maintenance Environment, Common Rail Fuel Injection ......................... 1-4
Cleaning the Engine ................................................................................ 1-6
Further Cleaning Procedures, Common Rail Fuel Injection ............... 1-7
Terms and Definitions

Acronyms and Abbreviations ................................................................... 1 - 8
Technical Data
Fuel ......................................................................................................... 1 - 9
Acceptable and Unacceptable Fuels .................................................. 1 - 9
Fuel Types ........................................................................................ 1 - 11
Usage and Effects of Fuels .............................................................. 1 - 12
Sulphur Content ............................................................................... 1 - 13
Effects of Fuel Contaminates ........................................................... 1 - 14
Basic Engine Data ................................................................................. 1 - 15
Engine Block & Bedplate Data .............................................................. 1 - 16
Cylinder Head Data ............................................................................... 1 - 17
Inlet and Exhaust Valve Data ................................................................ 1 - 18
Rocker Levers, Rocker Shaft and Tappets Data ................................... 1 - 19
Pistons and Connecting Rods Data ....................................................... 1 - 20
Crankshaft Data ..................................................................................... 1 - 21
Camshaft Data ....................................................................................... 1 - 22
Fuel System Data .................................................................................. 1 - 23
Lubrication System Data ....................................................................... 1 - 24
Cooling System Data ............................................................................. 1 - 25
Electrical Equipment Data ..................................................................... 1 - 26
Switches and Sensors ...................................................................... 1 - 26
Identifying the Engine

Engine Identification Plate ..................................................................... 1 - 29
Typical Engine Identification Number ............................................... 1 - 29
Component Labels ........................................................................... 1 - 29
Engine Component Identification ........................................................... 1 - 30
External ............................................................................................ 1 - 30
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ................................... 1 - 38
Introduction ....................................................................................... 1 - 38
Bolts and Screws .............................................................................. 1 - 38
Hydraulic Connections ........................................................................... 1 - 42
'O' Ring Face Seal System ............................................................... 1 - 42
'Torque Stop' Hose System .............................................................. 1 - 45
Torque + Angle Explanation .................................................................. 1 - 46
Torque + Angle Tightening Procedure ................................................... 1 - 47
1-i 1-i
Contents
Contents Page No.

Engine Torque Figures .......................................................................... 1 - 48
Lubricants and Capacities

Engine Lubricating Oil ........................................................................... 1 - 62
Recommended Oils .......................................................................... 1 - 62
Engine Oil Capacity .......................................................................... 1 - 62
Coolant .................................................................................................. 1 - 63
Coolant Mixtures .................................................................................... 1 - 64
Coolant Mixtures .............................................................................. 1 - 64
Service Aids
Sealing, Retaining and Care Compounds ............................................. 1 - 65
Service Tools
General Engine Tools ............................................................................ 1 - 66
Specialist Engine Tools .......................................................................... 1 - 68
Service Tool Drawings ........................................................................... 1 - 74
892/01146 - Core Plug Fitting Tool ................................................... 1 - 74
892/01147 - Crankshaft Turning Tool ............................................... 1 - 75
892/01148 - Timing Pin ..................................................................... 1 - 76
892/01149 - Sump Sealant Template ............................................... 1 - 77
892/01150 - Oil Sump Location Dowel ............................................. 1 - 78
892/01151 - Injector Sleeve Removal Tool ....................................... 1 - 79
892/01152 - Valve Stem Seal Fitting Tool ......................................... 1 - 80
892/01154 - FIP Cover Removal Tool .............................................. 1 - 81
892/01155 - FIP Gear Removal Tool ................................................ 1 - 82
892/01157 - Crankshaft Front Seal Fitting Tool ................................ 1 - 83
892/01156 - Crankshaft Rear Seal Fitting Tool ................................. 1 - 84
892/01158 - Crankshaft Rear Seal Alignment Tool ........................... 1 - 85
892/01159 - Injector Seal Fitting Tool ............................................... 1 - 85
892/01168 - Dummy Injector ............................................................ 1 - 86
Engine Mounting Frame ................................................................... 1 - 87
Service Parts and Repair Kits

Engine Repair Parts and Kits Identification ........................................... 1 - 88
Engine Lifting
Lifting Information ................................................................................ 1 - 101
Operating Procedures
Starting the Engine .............................................................................. 1 - 102
Pre-Start Notes ............................................................................... 1 - 102
Start Procedure .............................................................................. 1 - 103
Engine Checks After Start-up ......................................................... 1 - 104
Engine Running-in Procedure ........................................................ 1 - 105
Stopping the Engine ....................................................................... 1 - 106
Storage and Preservation

Storage ................................................................................................ 1 - 108
Preservation ........................................................................................ 1 - 109
Capping Engine Openings ............................................................. 1 - 109
Hot Test Description ....................................................................... 1 - 110
1 - ii 1 - ii
Introduction
About this Manual
Using the Service Manual 5 Fault Finding ...etc.
This publication is designed for the benefit of JCB Left Side, Right Side
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department. References to the `left' side and the `right' side of the
engine are when viewed from the flywheel end of the
These personnel should have a sound knowledge of engine, as shown at 1A.
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
engines.
Renewal of oil seals, gaskets, etc., and any component

showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid, engine oil and
ingress of dirt. Finally, please remember above all else
SAFETY MUST COME FIRST!
The manufacturer's policy is one of continuous

improvement. The right to change the specification of the
engine without notice is reserved. No responsibility will be
accepted for discrepancies which may occur between the
specifications of the engine and the descriptions contained
in this publication.
Section Numbering
The manual is compiled in sections, the first three are
numbered and contain information as follows:
1 General Information includes torque settings and

service tools.
2 Care & Safety includes warnings and cautions

pertinent to aspects of workshop procedures etc.
3 Routine Maintenanceincludes service schedules

and recommended lubricants. Fig 1.
The remaining sections deal with Descriptions, Fault Units of Measurement

Finding, Dismantling, Overhaul etc. of specific
components, for example: In this manual, the S.I. system of units is used. For
example, liquid capacities are given in litres. The imperial
4 Systems Descriptions units follow in parenthesis () e.g. 28 litres (6 UK gal).
1-1 9806/3030-02 1-1

Introduction
About this Manual
Machine Related Data

The JCB Dieselmax Engine can be fitted to a variety of
constructions and agricultural machines. The scope of this
publication is limited to the engine, but references to a
typical machine installation will be made. Tasks and
information specific to a machine installation will be listed
in the relevant machine Service Manual, for example
engine removal and replacement procedures.
1-2 9806/3030-02 1-2

Effects of Contamination
When carrying out service procedures on the engine The main filter is rated at 2 micron = 0.002 mm (0.0007874
cleanliness is of paramount importance. in). The pre-filter is rated at 5 micron.
Common Rail Fuel Injection System Listed are a few typical comparisons of micron size:
!MWARNING
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in).
– Human Hair = 70 microns (0.07 mm, 0.00275 in).
The high pressure fuel system is extremely – Grain of Salt = 100 microns (0.1 mm, 0.00394 in).
susceptible to damage if it is contaminated. Always
– The smallest particle visible to the naked eye is 40
clean the engine using the correct procedures before
microns (0.00157in) approximately.
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Whist the requirement for a good level of cleanliness is well

known and common practice, the introduction of high
pressure common rail fuel injection necessitates working
to new levels of cleanliness.
Once inside the system, fuel circuit contaminants greatly

effect the performance and life of the fuel injection
equipment. For example, contaminants in the fuel pump
will develop internal wear to cause internal leakage and
hence lower discharges. Use of poor quality fuels and poor
maintenance could also lead to contaminants entering the
fuel injectors. There is a possibility of catastrophic Fig 2.
equipment failure if debris should prevent the injectors
from fully closing. The main contaminants can be classified The main filter and pre-filter must be changed in
as follows: accordance with the applicable service schedule and
procedures. The water in fuel sensor must be maitained to
– Solid Particles - sand, fibres, metallic particles, ensure correct operation at all times.
welding scale, sealing materials and wear particles
etc. The potential for engine damage due to fuel contamination
– Liquid - usually water and incompatible oils and is much greater when using common rail injection
greases. technology than with mechanical injection systems. This is
because common rail requires components with smaller
– Gases - Air, sulphur dioxide etc. which can create
manufacturing tolerances, especially the fuel injectors. In
corrosive compounds if dissolved in the fluid.
addition, common rail operates at much higher fuel
pressures, over five times that of mechanical systems.
These contaminants can appear during manufacture,
assembly, operation and maintenance.
Similar pressures are used by commercial water jet cutting
machines to cut metal. Fortunately clean diesel fuel has
It is critical that the machine is thoroughly cleaned prior to
lubricating qualities that prevents erosion of components
completing any maintenance work. K Cleaning the
but it is obvious that contaminated fuel will cause serious
Engine ( T 1-6).
damage at such high pressures.
1-3 9806/3030-02 1-3

Maintenance Environment, Common Rail Fuel Injection
!MWARNING Site - open to weather. This repair site is not an

acceptable location. Only in extremely extenuating
The high pressure fuel system is extremely circumstances should a machine be repaired on an open
susceptible to damage if it is contaminated. Always site prepared using the guidelines below.
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel Action
system can cause catastrophic failure of the engine. Clean the engine K Cleaning the Engine ( T 1-6). If the
machine is on hard standing, clean away the material
washed from the engine.
Depending on circumstances engine maintenance may be
Place suitable clean boards on the ground around the
required in various working environments. Obviously
machine.
procedures are best carried out in a dedicated workshop
equipped with a suitable clean room, but in practice this is Erect clean plastic sheeting to shelter the engine from
not always possible. wind and rain.
Wear a new disposable environmental type suit when
Maintenance procedures requiring removal or working on the fuel system. If the suit becomes
replacement of fuel system components, particuarly high contaminated with mud, move away from the engine and
pressure components, require special precautions to make change into a new suit.
the working environment suitable, reducing the risk of
Use clean latex gloves (non-powdered).
contamination to an absolute minimum.
Before you start work make sure that all the required
Use the following guidelines to make sure you reduce the replacement parts and tools are on site. Make sure that
chances of fuel system contamination when working in the replacement parts are still sealed inside their
different environments: packaging.
Cap all exposed ports and orifices immediately. Do not
leave them open.
High pressure fuel pipes MUST BE RENEWED if any
pipe joint is loosened or disconnected. DO NOT re-use
the original pipe.
1-4 9806/3030-02 1-4

Site - closed to weather from above. Least acceptable Vehicle Maintenance Workshop. Unless the workshop
conditions, if possible move the machine to a more has a dedicated `sealable clean room' work bay,
suitable environment. precautions must still be taken.
Action Action
Clean the engine K Cleaning the Engine ( T 1-6). Clean the engine K Cleaning the Engine ( T 1-6).
Clean the floor of all material washed from the engine. Clean the engine in the dedicated area and then move it
Place suitable clean boards on the ground around the to the workshop.
machine. Clean the floor area around the machine.
Erect clean plastic sheeting to shelter the engine from the Erect clean plastic sheeting to shelter the engine from
wind and the possibility of debris such as dirt and dust any wind and the possibility of debris such as dirt and
falling from above. dust falling from above.
Wear a new disposable environmental type suit when Ensure that workshop doors to the outside are kept
working on the fuel system. If it becomes contaminated closed. A gust of wind through an open door will easily
with mud, move away from the engine and change into a blow sand particles into the air.
new suit. Make sure your work wear is clean, non-flocking and lint
Use clean latex gloves (non-powdered). free. If in doubt wear a new disposable environmental
Before you start work make sure that all the required type suit.
replacement parts and tools are on site. Make sure that Use clean latex gloves (non-powdered).
the replacement parts are still sealed inside their Before you start work make sure that all the required
packaging. replacement parts and tools are on site. Make sure that
Cap all exposed ports and orifices immediately. Do not the replacement parts are still sealed inside their
leave them open. packaging.
High pressure fuel pipes MUST BE RENEWED if any Cap all exposed ports and orifices immediately. Do not
pipe joint is loosened or disconnected. DO NOT re-use leave them open.
the original pipe. High pressure fuel pipes MUST BE RENEWED if any
pipe joint is loosened or disconnected. DO NOT re-use
the original pipe.
1-5 9806/3030-02 1-5

Cleaning the Engine
Cleaning the Engine
!MWARNING 7 Apply an approved cleaning and degreasing agent

with a brush. Obey the manufacturers instructions.
Clean the engine before you start engine maintenance.
Obey the correct procedures. Contamination of the 8 Use a pressure washer to remove the soft dirt and oil.
fuel system will cause damage and possible failure of
the engine. Important: DO NOT aim the water jet directly at oil seals
ENG-8-5_2 or electrical and electronic components such as the engine
electronic control unit (ECU), alternator or fuel injectors.
Before carrying out any service procedures that require
components to be removed, the engine must be properly Important: DO NOT place the jet nozzle closer than
cleaned. 600mm (24 in) to any part of the engine.
Cleaning must be carried out either in the area of 9 When the pressure washing is complete move the
components to be removed or, in the case of major work, machine away from the wash area, or alternatively,
or work on the fuel system, the whole engine and clean away the material washed from the machine.
surrounding machine must be cleaned.
10 Before working on specific areas of the engine use a
Important: Stop the engine and allow it to cool for at least compressed air jet to dry off any moisture. When the
one hour. DO NOT attempt to clean any part of the engine area is dry use a soft clean brush to remove any sand
while it is running. or grit particles that remain.
1 Make sure that the electrical system is isolated. 11 When removing components be aware of any dirt or
debris that may be exposed. Cover any open ports
2 Make sure that all electrical connectors are correctly and clean away the deposits before proceeding.
coupled. If connectors are open fit the correct caps or
seal with water proof tape. K Further Cleaning Procedures, Common Rail Fuel
Injection ( T 1-7)
3 Cover the alternator with a plastic bag to prevent
water ingress.
4 Seal the engine air intake, exhaust and breather

system.
5 Make sure that the oil filler caps and dipstick are
correctly installed.
6 Use a low pressure water jet and brush to soak off

caked mud or dirt.
!MCAUTION
The engine or certain components could be damaged
by high pressure washing systems; special
precautions must be taken if the engine is to be
washed using a high pressure system.
Ensure that the alternator, starter motor and any other

electrical components are shielded and not directly
cleaned by the high pressure cleaning system.
ENG-3-3
1-6 9806/3030-02 1-6

Cleaning the Engine
Further Cleaning Procedures, Common

Rail Fuel Injection
!MWARNING
Clean the engine before you start engine maintenance.
Obey the correct procedures. Contamination of the
fuel system will cause damage and possible failure of
the engine.
ENG-8-5_2
Important: Additional cleaning must be carried out prior to

working on the high pressure fuel system. It is extremely
important the high pressure fuel components and the
adjacent parts of the engine are meticulously cleaned
before any components are removed. K Effects of
Contamination ( T 1-3).
1 Clean the engine as described in Cleaning the

Engine. K Cleaning the Engine ( T 1-6).
2 Remove hoses, electrical harnesses and ancillaries

to improve access and expose any remaining trapped
dirt close to the relevant high pressure components.
3 Wash away any remaining dirt or debris and then dry

the area using a compressed air jet. When the area is
dry use a soft clean brush to remove sand or grit
particles that remain.
Important: Before starting work on the high pressure fuel

system make sure that the working environment is
suitable. K Maintenance Environment, Common Rail
Fuel Injection ( T 1-4)
1-7 9806/3030-02 1-7

Terms and Definitions

Acronyms and Abbreviations
Some of the following acronyms and abbreviations are mm Millimetre

used in this service manual. The remainder are used in the
automotive industry and are repeated for reference only. MPH Miles per Hour
NA Naturally Aspirated
°C Celsius N/A Not Applicable/Not Available
°F Fahrenheit Nm Newton Metre
A/R As Required NSP Non Serviced Part
API American Petroleum Institute O/D Outside Diameter
BBDC Before Bottom Dead Centre OEM Original Equipment Manufacturer
BDC Bottom Dead Centre PPM Parts per Million
BSFC Brake Specific Fuel Consumption PSI Pounds per square Inch
BTDC Before Top Dead Centre PTO Power Take Off
CCV Crankcase Vent PWM Pulse Width Modulation
CID Cubic inch Displacement RH Right Hand
cST Centistokes RME Rapeseed Methyl Ester
ECM Electronic Control Module RPM Revolutions per Minute
ECS Emission Control System SAE Society of Automotive Engineers
ECU Electronic Control Unit SME Sunflower Methyl Ester
EPA Environmental Protection Agency SOME Soyabean Methyl Ester
CAN Controller Area Network STD Standard
DLA Diagnostic Link Adapter TBA To be Advised
FAME Fatty Acid Methyl Esters TC Turbocharged
FEAD Front End Accessory Drive TCA Turbocharged Aftercooled
FIE Fuel Injection Equipment TDC Top Dead Centre
Hg Mercury TI Technical Information
HP Horse Power TMAP Temperature and Mass Air Pressure
HPV High Pressure Valve TPS Throttle Position Sensor
I/D Inside Diameter VOME Vegetable Oil Methyl Esters
IMV Inlet Metering Valve
kg Kilogram
KPH Kilometres per hour
Kw Kilowatt
LH Left Hand
ltr Litre
MIL Malfunction Indicator lamp
1-8 9806/3030-02 1-8

Technical Data
Fuel
Technical Data
Fuel
Acceptable and Unacceptable Fuels

Important: No warranty liability whatsoever will be
accepted for failure of fuel injection equipment where the
failure is attributed to the quality and grade of the fuel used.
Fuel Specification Applicable Engines Service Requirements

EN590 Diesel fuel types - Auto/C0/C1/C2/ All Dieselmax engines. Obey the usual routine
C3/C4 maintenence schedules and
BS2869 Class A2 procedures
ASTM D975-91 Class 2, US DF1, US DF2,

US DFA
JIS K2204 (1992) Grades 1, 2, 3 and Special
Grade 3
ASTM D975-91 Class 1DA All Dieselmax engines. Engines Obey the usual routine
MIL T38219 XF63 operated with these fuels may have maintenence schedules and
a reduced service life procedures. Fuel additives are
NATO F63 recommended for use with low
French EN590 (RME5) with 5% maximum sulphur fuels
K Additives ( T 1-10)
AVTURFSII, NATO F34, JP8, MIL T83133, All Dieselmax engines. Engines Obey the usual routine
DERD 2463, DEF STAN 91-87 operated with these fuels will have maintenence schedules and
AVCAT FSII, NATO F44, JP5, MIL T5624, a reduced service life procedures. Fuel additives MUST
DERD 2452, AVTOR be used K Additives ( T 1-10)
NATO F35, JET A1, DEF STAN 91-91,

DERD 2494, JP7
AVCAT, NATO F43 (obsolete), JP5 without
additives
JET A (ASTM D1655)
ASTM D3699 Kerosene
B20 Biodiesel - RME content blended with Dieselmax engines manufactured YOU MUST obey special routine
mineral derived diesel (20% maximum) - from 2007 on ONLY(1) maintenance schedules and
ASTM D6751, DIN 51606, ISO 14214 procedures. K Service
Requirements for use of B20
Biodiesel ( T 1-10)
AVTAG (obsolete) These fuels are NOT ACCEPTABLE
AVTAG FSII (obsolete), NATO F40, JP4, with or without additives. Engines
DERD 2454 MUST NOT be operated with these
fuels
JET B (ASTM D1655)
BS MA100
JIS K2203 No.2
Unmodified vegetable oils
(1) The year of manufacture is part of the engine serial number. Refer to Identifying the Engine.
1-9 9806/3030-02 1-9

Technical Data
Fuel
Additives serial number and factory filled with CH4 oil) - this is
not approved with other manufacturers.
The additives listed below are advertised as being suitable – Use heater kits in low ambient temperature territories.
for bringing the lubricity levels of kerosene/low sulphur
– The biodiesel must meet the following standards:
fuels up to those of diesel fuels. They must be used as
ASTM D6751, DIN 51606, ISO 14214
specified by your fuel supplier who will understand the
concentration level necessary.
Note: If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB
– Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%),
currently), use the internet as a source for the kits.
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels.
Note: If performance related issues are to be reported to
– Lubrizol 539N. Dosage (on Swedish low sulphur fuel) JCB Service, and the engine has been run on biodiesel,
250 ppm. then the fuel system must be filled with standard diesel (at
– Paradyne 7505 (from Infineum). Dosage 500 ppm least 2 x tank fills) to EN590 specification and relevant stall
(0.05%). speeds recorded prior to making the report.
Note: These products are given as examples only. The Warranty

information is derived from the manufacturers data. The
products are not recommended or endorsed by JCB. JCB have shown a commitment to support the enviroment
by approving the use of biodiesel blended fuels.
Service Requirements for use of B20 Biodiesel
Using a B20 blend of biodiesel requires caution and
– The engine oil must be a grade CH4 as minimum additional servicing of the engine is required. K Service
specification. Requirements for use of B20 Biodiesel ( T 1-10)
– Do not leave unused B20 biodiesel in the fuel tank for
Failure to follow the additional recommended service
extended periods (top up each day).
requirements may lead to a warranty claim being declined.
– Make sure that 1 in 5 fuel tank fills use standard diesel
to EN590 specification, this will help to prevent Failures resulting by the incorrect use of biodiesels or
`gumming'. other fuel additives are not defects of the JCB Dieselmax
– Make sure regular oil sampling is completed (look for engine workmanship and therefore will not be supported
excessive unburnt fuel content, water or wear by JCB Warranty.
particles.
– Change the engine oil and filter more frequently (as a
minimum half the recommended intervals), or as
indicated by oil sampling.
– Change the fuel filters more frequently (as a minimum
half the recommended intervals), or if there are
engine performance related issues.
– Make sure the fuel is stored correctly, care must be
taken to make sure no water enters the machine fuel
tank (or the storage tank). Water will encourage mico-
bacterial growth.
– Make sure that the fuel pre-filter is drained DAILY (not
every week as currently advised).
– Only JCB ENGINES built after Jan. 2007 are
applicable (i.e. engines with 07 on the end of their
1 - 10 9806/3030-02 1 - 10
Technical Data
Fuel
Fuel Types
Note: The information that follows does not indicate types
of fuel that are acceptable or unacceptable. K Acceptable
and Unacceptable Fuels ( T 1-9).
Any fuel purchased for operation of the JCB Dieselmax

engine must be purchased from reputable oil producers/
outlets and stored in accordance with the manufacturers
recommendations. K Effects of Fuel
Contaminates ( T 1-14)
1 Diesel - mineral derived, hydrocarbon fuels to

European standard EN590 or equivalent.
2 Low Sulphur Diesel - mineral derived, hydrocarbon

fuels to EN590 or equivalent. This fuel has totally
replaced automotive (road use) diesel in the
European Union since October 1996 and has sulphur
limited to a maximum of 0.05% by weight.
3 Ultra Low Sulphur Diesel - Reformulated mineral

derived, hydrocarbon fuels to EN590 or equivalent.
Now widely available in the UK, mainland Europe and
some parts of the USA. Sulphur limited to a maximum
of 0.005% by weight or lower. K Sulphur
Content ( T 1-13)
4 Vegetable Oil -unmodified. Certain pure vegetable

oils (sunflower oil, rapeseed oil etc.)
5 Biodiesel - chemically modified vegetable oil. By

chemically modifying vegetable oils, methyl esters of
that oil are produced. These are collectively known as
"Fatty Acid Methyl Esters" (FAME) or "Vegetable Oil
Methyl Esters" (VOME).
Note: Refer also to additional information. K Usage and

Effects of Fuels ( T 1-12).
1 - 11 9806/3030-02 1 - 11
Technical Data
Fuel
Usage and Effects of Fuels stability, viscosity and cetane number than those
produced from unmodified vegetable oils, but it is
Note: The information that follows does not indicate types recognised that there are potential problems
of fuel that are acceptable or unacceptable. K Acceptable associated with the finished fuel characteristics.
and Unacceptable Fuels ( T 1-9). These oils are less stable than mineral oil derived
fuels when stored and they will readily degrade
1 Low Sulphur Diesel producing fatty acids, methanol and water, none of
which are desirable in the FIE. These effects are
In its basic form because of the process of reducing known to be accelerated when the fuel is stored in the
sulphur by removal of sulphur containing compounds presence of air and water together.
(which contribute to mechanical lubrication) an
increase in the wear rate of the fuel injection An extract `common statement' from the FIE
equipment could occur. In view of this, the major fuel manufactures specifies that "The fuel injection
producers add suitable lubricity improvers to enable equipment manufacturers can accept no liability
the FIE to run satisfactorily, with no acceleration in whatsoever for failure attributable to operating their
wear rate. They must ensure that the lubricity products with fuels for which the products were not
improvers do not themselves create residual deposits designed, and no warranties or representations are
that could block the fuel system e.g. filter, injectors made as to the possible effects of running these
etc. products with such fuels".
In addition to the lubrication effect there can also be a The three most common Fame types are RME -
further reduction in the aromatic content of the fuel Rapeseed methyl ester (preferred crop in Europe),
which can lead to shrinking/cracking of traditionally SME - Soyabean methyl ester (preferred crop in
nitrile rubber seals throughout the fuel injection USA). Less common FAME's can be derived from
equipment that has previously been exposed to animal fats (e.g. modified beef extracts) and
higher sulphur level fuels. The major fuel producers reclaimed cooking oils.
tend to maintain the total aromatic content to an
acceptable level (15% by volume). 5 B20 Biodiesel
2 Ultra Low Sulphur Diesel Biodiesel refers to pure fuel before it is blended with
diesel fuel K Chemically Modified Vegetable Oils
Also known as `city diesel'. Available throughout the (FAME/VOME) ( T 1-12). When biodiesel is blended
UK and some parts of Europe since March 1999. This with diesel fuel it is referred to as B5, B20 etc, where
fuel has a maximum sulphur content of 0.005% by the number indicates the percentage of biodiesel in
weight and a further reduction in the natural lubricity the fuel, for example B5 contains 5% biodiesel.
and aromatic content than experienced with low
sulphur diesel. Major oil producers will add lubrication Biodiesel has different characteristics than mineral
improvers and also maintain the total aromatic based fuels in that it is able to mix with water and
content to an acceptable level. therefore will have a high water retention capacity -
this could lead to seals swelling, fuel system
3 Unmodified Vegetable Oils corrosion and seal damage.
Burned in diesel engines neat or used as an extender Biodiesels will `cloud' at higher temperatures than
to mineral derived fuel. When these are subjected to mineral based fuels. To explain Cloud Point - the
heat in the fuel injection system they form sticky lowest temperature at which fluid can flow and
deposits that can be found inside the fuel pump and a performs its functions is referred to as Pour Point.
hard lacquer in the injectors where exposure to even Just prior to reaching its Pour Point the diesel fluid
higher temperatures takes place. becomes `cloudy' due to crystallization of waxy
constituents - this is know as Cloud Point. Using
4 Chemically Modified Vegetable Oils (FAME/VOME) diesel at temperature below its cloud point can result
These fuels have been derived from a wide range of

vegetable oils and animal fats, resulting in better
1 - 12 9806/3030-02 1 - 12
Technical Data
Fuel
in filter clogging. To prevent this happening pre- Sulphur Content
heating will be required.
High sulphur content can cause engine wear. (High
Using B20 biodiesel can result in unburnt fuels sulphur fuel is not normally found in North America,
accumulating in the engine oil, ultimately this can Europe or Australia.) If you have to use high sulphur fuel
affect the engine oil efficiency and lead to engine you must change the engine oil more frequently. K Table
damage (with standard diesel any unburnt fuel 1. Sulphur Content ( T 1-13).
evaporates off the lubricating oil).Biodiesels must be
stored to exclude water absorption and oxidation. Low sulphur fuels must have the appropriate fuel lubricity
additives, these lubricity improvers must not create
The natural properties of biodiesel make it a good residual deposits that block the fuel system, e.g. injectors,
medium for micro bacterial growth, these microbes filters etc. Contact your fuel Supplier.
can cause fuel system corrosion and early fuel filter
blocking. It will be necessary to consult and seek
advice from your fuel supplier, the effectiveness of !MCAUTION
conventional antibacterial additives when used in A combination of water and sulphur will have a
biodiesel is still being investigated in the fuel corrosive chemical effect on fuel injection equipment.
industry.A high percentage biodiesel mixture (>20%) It is essential that water is eradicated from the fuel
can lead to fuel gelling and filter blocking in low system when high sulphur fuels are used.
temperature operation, it may also effect the power
ENG-3-2
and performance of the engine.
Table 1. Sulphur Content
To minimise the risk of engine damage when using a
Percentage of sulphur in Oil Change Interval
B20 mix, there are additional service requirements.
the fuel (%)
K Service Requirements for use of B20
Biodiesel ( T 1-10) Less than 0.5 Normal
0.5 to 1.0 0.75 of normal
If the recommended actions are not taken there may
More than 1.0 0.50 of normal
be the following consequences:- low temperature
filter clogging- injectors lacquering / sticking-
deterioration of seals and rubber hoses- corrosion of
metal parts in the fuel system- engine performance
problemsThese risks will be increased if the fuel has
been poorly stored, that is deteriorated through
oxidation and / or water absorption.
1 - 13 9806/3030-02 1 - 13
Technical Data
Fuel
Effects of Fuel Contaminates

The effect of dirt, water and other contaminants in diesel
can be disastrous for injection equipment:
– Dirt - A severely damaging contaminant. Finely

machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to the
abrasive nature of dirt particles - increased wear will
almost inevitably lead to greater leakage, uneven
running and poor fuel delivery.
– Water - water can enter fuel through poor storage or
careless handling, and will almost inevitably
condense in fuel tanks. The smallest amounts of
water can result in effects that are just as disastrous
to the fuel injection pump as dirt, causing rapid wear,
corrosion and in severe cases, even seizure. It is
vitally important that water is prevented from reaching
the fuel injection equipment. The filter/water trap must
be drained regularly.
– Wax - Wax is precipitated from diesel when the
ambient temperature falls below that of the fuel's
cloud point, causing a restriction in fuel flow resulting
in rough engine running. Special winter fuels may be
available for engine operation at temperatures below
0°C (32°F). These fuels have a lower viscosity and
limit wax formation.
1 - 14 9806/3030-02 1 - 14
Technical Data
Basic Engine Data
Basic Engine Data
Engine Variants:
- SE Turbocharged with Intercooler
Emission compliance US-EPA Tier 3, EU Stage IIIA
Rated speed 2200 rpm
Weight (Dry):
- SE 457 kg (1007 lb)(1)
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
- SE 17.1 : 1
Engine Compression see Note (2)
Direction of rotation (viewed from front {crankshaft pulley} end) Clockwise
Valves 4 per cylinder
Valve clearances measured at the tappet end of the rockers
(measured cold):
- Inlet 0.15 to 0.20 mm (0.006 to 0.008 in)
- Exhaust 0.43 to 0.50 mm (0.017 to 0.020 in)
(3)
Lubricating oil pressure 4.3 bar (62lb in2)
Combustion system Common rail direct Injection
High pressure fuel pump Rotary mechanical, high pressure with electronically
controlled fuel metering
(1) Dry wieght. No cooling fan drive.

(2) Compression variance between each cylinder should be no greater than 3.5 bar (50 lb in2)
(3) Engine at normal operating temperature and maximum revs.
1 - 15 9806/3030-02 1 - 15
Technical Data
Engine Block & Bedplate Data
Engine Block & Bedplate Data
Cylinder bore (1) 103.000-103.020 mm (4.055-4.046 in)

Main bearing bolts torque (2)
- first stage 50 Nm (37 lbf ft)

- second stage 115 Nm ( 85 lbf ft)
- final stage turn a further 180°
Surface finish for cylinder head joint Rz < 15m; Rmax < 20m
Diameter of first oversize bore 103.500-03.520 mm (4.074-4.076 in)
Diameter of second oversize bore 104.00-104.020 mm (4.094- 4.952 in)
Main bearing bore (without bearings)
- numbers 1 to 4 92.000-92.020 mm (3.622-3.623 in)
- number 5 105.000-105.020 mm (4.134-4.135 in)
Main bearing bore (with bearings)
- numbers 1 to 4 88.047-88.090 mm (3.466-3.468 in)
- number 5 100.047-100.090 mm (3.939-3.941 in)
Camshaft bore
- numbers 1 to 4 60.040-60.070 mm (2.364-2.365 in)
- number 5 (bush) 60.290-60.32 mm (2.374-2.375 in)
Permissible wave profile wt<10m (2.5 distance)
(1) Nominal diameter to be measured 63mm below head face.

(2) Torque information MUST be used in conjunction with recommended procedures contained in this manual. Failure to
use the appropriate and correct removal, replacement, dismantle and assembly procedures may result in an engine
failure in service. Refer also to the procedures for the correct bolt tightening sequence.
1 - 16 9806/3030-02 1 - 16
Technical Data
Cylinder Head Data
Cylinder Head Data
Cylinder head distortion (maximum permissible)

- end to end 0.05 mm (0.002 in)
- side to side 0.03 mm (0.0012 in)
Valve recess depth
- Inlet 0.85 mm (0.033 in)
- Exhaust 0.85 mm (0.033 in)
Valve seat angle
- inlet 120 ° (inclusive)
- exhaust 90 ° (inclusive)
(1)
Cylinder head bolts torque
- first stage 40 Nm (30 lbf ft)
- second stage 75 Nm (56 lbf ft)
- third stage repeat 75Nm
- fourth stage torque angle + 90 °
- final stage torque angle + 180°
Surface finish for cylinder head joint Rz < 15m; Rmax < 20m
Permissible wave profile wt < 10m 2.5 distance
(1) Torque information MUST be used in conjunction with recommended procedures contained in this manual. Failure to
use the appropriate and correct removal, replacement, dismantle and assembly procedures may result in an engine
failure in service. Refer also to the procedures for the correct bolt tightening sequence.
1 - 17 9806/3030-02 1 - 17
Technical Data
Inlet and Exhaust Valve Data
Inlet and Exhaust Valve Data
Max lift inlet 9.64 mm @ 101° atdc

Max lift exhaust 9.84 mm @ 115° btdc
Inlet opens (top of ramp) 6° btdc
Inlet closes 28° abdc
Exhaust opens 41° bbdc
Exhaust closes 9° atdc
Valve stem diameter
- inlet 6.928-6.943mm (0.2727-0.2733 in)
- exhaust 6.918-6.933mm (0.2724-0.2729 in)
Valve spring free length 40.18mm (1.581 in)
Valve guide bore diameter
- min 6.958mm (0.2739 in)
- max 6.968mm (0.2743 in)
Valve face angle
- inlet 60.5 °
- exhaust 45.17 °
Valve length 131.9-132.4 mm (5.193-5.213 in)
Valve sealing stem seal with sealing washer
Valve head depth (below cylinder head surface)
- inlet 0.89 to 1.39mm (0.035 to 0.055 in)
- exhaust 0.95 to 1.45mm (0.037 to 0.057 in)
Valve rim thickness 2.98-3.38 mm (0.117-0.133 in)
1 - 18 9806/3030-02 1 - 18
Technical Data
Rocker Levers, Rocker Shaft and Tappets Data
Rocker Levers, Rocker Shaft and Tappets Data
Valve tip clearances measured at the tip of the rockers

(measured cold):
- Inlet 0.19 to 0.27 mm (0.007 to 0.011 in)
Valve clearances measured at the tappet end of the
rockers (measured cold):
- Inlet 0.15 to 0.20 mm (0.006 to 0.008 in)
Rocker lever bore diameter
- min 26.046mm (1.025 in)
- max 26.129mm (1.029 in)
Rocker shaft diameter
- min 26.00mm (1.0236 in)
- max 26.021mm (1.0244 in)
Tappets stem diameter
- min 19.987mm (0.787 in)
- max 19.975mm (0.786 in)
Tappet bore diameter
- min 20.00mm (0.7874 in)
- max 20.021mm (0.7882 in)
Tappet height (maximum) 55.25mm (0.0218 in)
1 - 19 9806/3030-02 1 - 19
Technical Data
Pistons and Connecting Rods Data
Pistons and Connecting Rods Data
Gudgeon pin bore diameter

- min 40.008mm (0.015751 in)
- max 40.013mm (0.015753 in)
Piston ring clearance
- top ring half keystone ring
- middle ring 0.11 to 0.07mm (0.0043 to 0.0027 in)
- bottom (oil) ring 0.09 to 0.05mm (0.0035 to 0.0019 in)
Piston ring gap
- top ring 0.3 to 0.5mm (0.118 to 0.019 in)
- bottom (oil) ring 0.25 to 0.50 mm (0.0098 to 0.0196 in)
Piston height above cylinder block (cold) 0.0375 to 0.3385 mm (0.0014 to 0.013 in)
Piston groove width
- top ring 3.108 to 3.133mm (0.122 to 0.123 in)
- bottom (oil) ring 4.04 to 4.06mm (0.1590 to 0.1598 in)
Connecting rod type (1) Split fracture
Connecting rod bore diameter 77.00 to 77.01mm (3.0314 to 3.0318 in)
Connecting rod side clearance
- min 0.05mm (0.0019 in)
- max 0.40mm (0.0157 in)
Big end bearings:
- width 32.5 to 33.00 mm (1.279 to 1.299 in)
- thickness (at centre) 1.990 to 1.981mm (0.0783 to 0.0779 in)
Small end bearings:
- inside diameter 40.034 to 40.020mm (1.5761 to 1.5755 in)
(1) Split fracture type connecting rods MUST NOT be dot punched, or etched in any way during disassembly - refer to
relevant service procedures.
1 - 20 9806/3030-02 1 - 20
Technical Data
Crankshaft Data
Crankshaft Data
Main bearing journal diameter (x4)

- min 87.98 mm (3.460 in)
- max 88.00 mm (3.464 in)
Main rear bearing journal diameter (x 1)
- min 99.98 mm (3.936 in)
- max 100.00 mm (3.937 in)
Connecting rod bearing journal diameter
- min 72.98 mm (2.873 in)
- max 73.00 mm (0.2755 in)
Maximum wear and ovality on journals TBA mm

Crankshaft induction hardness 55 HRc min on surface
Thrust washer width
- min 2.44 mm (0.096 in)
- max 2.50 mm (0.787 in)
Crankshaft end float
- min 0.05 mm (0.002 in)
- max 0.28 mm (0.011 in)
1 - 21 9806/3030-02 1 - 21
Technical Data
Camshaft Data
Camshaft Data
Camshaft journal diameter

- 4 off 59.99 to 59.97mm (2.362 to 2.361 in)
- 1 off 60.25 to 60.22mm (2.372 to 2.370 in)
Camshaft lobe wear limits
Inlet 7.385-7.435mm (0.291-0.293 in)
Exhaust 7.545-7.595mm (0.297-0.299 in)
Camshaft bush diameter 60.32 to 60.29mm (2.375 to 2.374 in)
Camshaft Gear (1) 104 teeth
(1) The camshaft gear is not available as a separate service item. The gear must be heated onto the camshaft in the
correct timed position. Specialist fixtures are used during the production process to achieve the correct timing.
1 - 22 9806/3030-02 1 - 22
Technical Data
Fuel System Data
Fuel System Data
High Pressure Pump Type Delphi

Direction of rotation from drive end Anti-clockwise
Fuel Lift Pump Type Electrically operated
Fuel filter restriction - maximum pressure drop 0.65 bar (9.0 lb/in2)
Fuel return restriction - maximum 0.22 bar (3.0 lb/in2)
Injector information Electronically controlled solenoid actuated injectors. Each
injector is marked with a unique calibration code.
1 - 23 9806/3030-02 1 - 23
Technical Data
Lubrication System Data
Lubrication System Data
Filter type Screw-on canister (with drain facility)

Pressure to open by-pass valve 1.6 bar (23 lb/in2)
Oil pressure relief valve setting 4.5 bar (65 lb/in2)
Oil pressure switch setting 0.6 bar falling (9 lb/in2)
Oil pump (1) Integral unit with relief valve
(1) The oil pump is a non-serviceable part.
1 - 24 9806/3030-02 1 - 24
Technical Data
Cooling System Data
Cooling System Data
Radiator cap pressure setting 1 bar (14.5 lb/in2)

Thermostat Wax element with by-pass blanking
Thermostat operating temperature:
- nominal temperature 88°C (190°F)
- start to open temperature 86 - 90°C (187 - 194°F)
- full open temperature 102°C (216°F)
- travel (fully open) 9mm (0.354 in.)
Fan belt type Front end accessory drive (FEAD)
Fan belt (FEAD) adjustment Automatic belt tensioner
Fan belt (FEAD) type Multigroove belt
Coolant Temperature Switch/Sender range see *** 'Electrical Equipment Data' on page 26 ***
Water pump (1) Bolt on, belt driven unit
(1) The water pump is a non-serviceable part.
1 - 25 9806/3030-02 1 - 25
Technical Data
Electrical Equipment Data
Alternator
Make Iskra - AAK
Rating
- option 1 14V, 95Amp
- option 2 28V, 55Amp
Cooling Internal Fan
W-terminal For engine speed indication
Alternator speed 2.8 x engine speed
Starter Motor (1)

Make Iskra - AZF 45
Rating
- option 1 12V, 4.2kW
- option 2 24V, 4.2kW
Operating range -30 to +120°C (-22 to 248°F)
Number of pinion teeth 11
(1) Never operate the starter motor longer than 20 seconds. Allow at least 2 minutes for cooling and battery recovery
before operating again. Overheating caused by excessive operation will seriously damage the starter motor.
Switches and Sensors
Flywheel position sensor

- type Inductive coil
Camshaft position sensor

- type Inductive coil
1 - 26 9806/3030-02 1 - 26
Technical Data
Coolant Temperature Sender

- type Temperature dependent resistance
- tightening torque 22 Nm max (16 lb ft)
- thread diameter M12 x 1.5
- Temperature v resistance table
Temperature °C (°F) Resistance - Ohms +/- %
25 (77) 2062 5.7
50 (122) 833 4.3
100 (212) 187 2.0
110 (230) 144 2.4
Inlet Manifold Air Pressure and Temperature Sensor

(TMAP)
- fixing screw tightening torque 3.3 Nm (2.4 lb ft)
- fixing screw thread diameter M5
- supply voltage 5V
Temperature Sensor
- type temperature dependent resistor
- temperature v resistance table
Temperature °C (°F) resistance - Ohms +/- %
5 (41) 4707 4.66
10 (50) 3791 4.55
15 (59) 3075 4.44
20 (68) 2510 4.33
25 (77) 2062 4.22
30 (86) 1715 4.12
Pressure Sensor
- type Piezo - resistive
- atmospheric pressure v voltage
atmospheric pressure mbar output voltage V +/- V
980 +/- 25 1.84 0.05
Knock sensor
- type Piezo crystal
- fixing screw tightening torque (max) 24 Nm (17.5 lbf ft)
- fixing screw thread diameter M8
1 - 27 9806/3030-02 1 - 27
Technical Data
Throttle position sensor (TPS) (1)

- type Two channel ratiometric voltage output sensor
- supply voltage 5V
- rotational range 0 -75 degrees
- output range linear output voltage over the rotational range
(1) The throttle position sensor is not supplied as part of the engine assembly. The technical data given is compatible with
the specification required.
Rail pressure sensor

- type The rail pressure sensor is integral with the common rail.
High pressure rail fuel valve

- type The rail high pressure fuel valve is integral with the common
rail.
Fuel temperature sensor

- type The fuel temperature sensor is integral with the high pressure
fuel pump.
Oil pressure switch

- set pressure 0.6 bar falling (9 lb/in2)
- switch mode Normally closed
- max pressure 27.5 bar (398 lb/in2)
- max working pressure 13.8 bar (200 lb/in2)
- tightening torque 16 Nm max (12 lb ft)
- thread diameter M10 x 1.5
1 - 28 9806/3030-02 1 - 28

Engine Identification Plate
Typical Engine Identification Number

E
Engine data labels 3A are located on the cylinder block at
position 3C and rocker cover 3D (if fitted). The data label
contains important engine information and includes the
engine identification number 3E.
A typical engine identification number is explained as

follows: D
SA 320/40001 U 00001 04 B
1 2 3 4 5
1 Engine Type
S = 4.4 litre series
A = naturally aspirated
C B
B = turbocharged
Fig 3. Engine
C = turbocharged and intercooled
Component Labels
E = electronic common rail fuel injection
In addition to the engine labels, some of the machine
2 Engine part number engine components will also have a label attached, or a
part number etched into the casting, these include:
3 Country of manufacture
– the starter motor
U = United Kingdom – the alternator
– the high pressure fuel pump
4 Engine serial number
– engine bedplate
5 Year of manufacture – engine block
– cylinder head
The last three parts of the engine identification number are
stamped on the cylinder block at position 3B as follows: – turbo charger
In some instances, it may be necessary to quote the

U 00001 04 information on these labels, for instance if there is a parts
query, or a warranty claim. Make a note of these numbers.
1 - 29 9806/3030-02 1 - 29
Engine Component Identification
External
The following identifies the main components of a typical
engine assembly visible from the exterior. Some variants
may differ in detail.
30
2 31
2 32
2
2
18
3 27
1 9
26 23
10
23
15
4
13
19
14
29
28
25
21 17
24
22
12
33
16 7
6 20
Fig 4. Engine - As viewed on the left hand side
K Table 2. ( T 1-31)
1 - 30 9806/3030-02 1 - 30
Table 2. Engine - As viewed on the left hand side
K Fig 4. ( T 1-30).
1 Rocker cover 16 Lubrication oil dip stick
2 Fuel injectors and high pressure fuel pipes 17 Low duty PTO (blanking cover if no device is fitted)
3 Lubrication oil filler cap 18 Fuel injection common rail
4 Timing gear case 19 Low pressure fuel line (to tank)
5 Flywheel housing 20 Oil drain plug (sump)
6 Bed plate 21 Oil pressure switch
7 Lubrication oil pan (sump) 22 Oil filter housing drain plug
8 23 Knock sensor (2)
9 Air Inlet manifold 24 Cam shaft position sensor (mounted on the side of the
engine block)
10 High pressure fuel pump 25 Flywheel position sensor
11 26 Fuel pressure dump valve
12 Fuel filter 27 Fuel pressure sensor
13 Lubrication oil filler cap 28 Inlet metering valve (IMV)
14 Lubrication oil filter 29 Fuel temperature sensor
15 Lubrication oil cooler housing 30 Inlet air temperature and pressure sensor (TMAP)
31 Tappet covers (4)
32 High pressure fuel pipe - rail feed
33 Engine electronic control unit (ECU)
1 - 31 9806/3030-02 1 - 31
Fig 5. Engine - As viewed on the right hand side
K Table 3. ( T 1-33)
1 - 32 9806/3030-02 1 - 32
Table 3. Engine - As viewed on the right hand side
K Fig 5. ( T 1-32)
1 Rocker cover 14 Coolant pump housing (cylinder block)
2 Crankcase ventilation filter assembly 15 Coolant inlet/radiator hose connector
3 Cylinder block 16 Heavy duty PTO (blanking cover if no device is fitted)
4 Timing gear case 17 Starter motor assembly
5 Flywheel housing 18 Turbocharger oil drain line
6 Bed plate 19 Turbocharger oil feed line
7 Lubrication oil pan (sump) 20 Oil drain plug (sump)
9 Turbocharger 21 Crank case filter vent to atmosphere
11 Exhaust manifold 22 Crank case filter oil drain hose
12 Alternator and pulley assembly 23 Crank case filter inlet hose
1 - 33 9806/3030-02 1 - 33
Fig 6. Engine - As viewed on the crankshaft pulley (front) end
K Table 4. ( T 1-35)
1 - 34 9806/3030-02 1 - 34
Table 4. Engine - As viewed on the crankshaft pulley (front) end
K Fig 6. ( T 1-34)
1 Rocker cover 10 Coolant pump and drive pulley assembly
2 Cylinder head 11 Inlet manifold induction heater (if fitted)
3 Cylinder block 12 Alternator and drive pulley assembly
4 Bed plate 13 Cab heater water hose connector
5 Lubrication oil pan (sump) 14 Coolant temperature sensor
6 Crankshaft pulley 15 Coolant thermostat housing/radiator hose connector
9 Drive belt tensioner and pulley
1 - 35 9806/3030-02 1 - 35
Fig 7. Engine - As viewed on the flywheel (rear) end
K Table 5. ( T 1-37)
1 - 36 9806/3030-02 1 - 36
Table 5. Engine - As viewed on the flywheel (rear) end
K Fig 7. ( T 1-36)
1 Rocker cover 7 Crankcase ventilation filter inlet hose
2 Cylinder head 8 Crankcase pressure relief valve
3 Flywheel 9 Engine electrical harness
4 High pressure fuel pump drive gear cover 10 Crankshaft position target disc
5 Flywheel housing 11 Crankshaft position sensor
6 Crank case ventilation chamber
1 - 37 9806/3030-02 1 - 37
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Torque Settings
T11-002
Introduction Bolts and Screws

Some external fasteners on JCB machines are Use the following torque setting tables only where no
manufactured using an improved type of corrosion torque setting is specified in the text.
resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow Plating used on Note: Dacromet fasteners are lubricated as part of the
earlier machines. plating process, do not lubricate.
The two types of fasteners can be readily identified by Torque settings are given for the following conditions:
colour and part number suffix. K Table 6. Fastener Types
( T 1-38). Condition 1
Table 6. Fastener Types – Un-lubricated fasteners

Fastener Colour Part No. Suffix – Zinc fasteners
Type
– Yellow plated fasteners
Zinc and Golden finish 'Z' (e.g. 1315/3712Z)
Yellow Condition 2
Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)
– Zinc flake (Dacromet) fasteners
Note: As the Dacromet fasteners have a lower torque – Lubricated zinc and yellow plated fasteners
setting than the Zinc and Yellow fasteners, the torque – Where there is a natural lubrication. For example,
figures used must be relevant to the type of fastener. cast iron components
Note: A Dacromet bolt should not be used in conjunction Verbus Ripp Bolts
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. For the
same reason, a Dacromet nut should not be used with a
Zinc or Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Fig 8.
Note: Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could occur. Torque settings for these bolts are determined by the
Dacromet bolts are only used for external applications. application. Refer to the relevant procedure for the
They are not used in applications such as gearbox or required settings.
engine joint seams or internal applications.
1 - 38 9806/3030-02 1 - 38
Torque Settings
Table 7. Torque Settings - UNF Grade 'S' Fasteners
Bolt Size Hexagon (A/F) Condition 1 Condition 2
in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft
1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4
5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7
3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5
7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0
1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9
9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9
5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5
3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9
7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9
1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9
1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0
1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3
Table 8. Torque Settings - Metric Grade 8.8 Fasteners

ISO Metric
Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8
M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6
M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2
M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7
M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6
M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7
M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5
M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0
M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9
M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4
1 - 39 9806/3030-02 1 - 39
Torque Settings
Table 9. Metric Grade 10.9 Fasteners
ISO Metric
M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4
M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2
M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1
M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2
M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7
M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0
M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2
M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6
M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1
M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2
Table 10. Metric Grade 12.9 Fasteners

ISO Metric
M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5
M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1
M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5
M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1
M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2
M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4
M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7
M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0
M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1
M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7
1 - 40 9806/3030-02 1 - 40
Torque Settings
Table 11. Torque Settings - Rivet Nut Bolts/Screws
Bolt Size
ISO Metric
Thread mm Nm kgf m lbf ft
M3 3 1.2 0.1 0.9
M4 4 3.0 0.3 2.0
M5 5 6.0 0.6 4.5
M6 6 10.0 1.0 7.5
M8 8 24.0 2.5 18.0
M10 10 48.0 4.9 35.5
M12 12 82.0 8.4 60.5
Table 12. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
Bolt Size
ISO Metric
Thread Nm kgf m lbf ft
M3 2.0 0.2 1.5
M4 6.0 0.6 4.5
M5 11.0 1.1 8.0
M6 19.0 1.9 14.0
M8 46.0 4.7 34.0
M10 91.0 9.3 67.0
M12 159.0 16.2 117.0
M16 395.0 40.0 292.0
M18 550.0 56.0 406.0
M20 770.0 79.0 568.0
M24 1332.0 136.0 983.0
1 - 41 9806/3030-02 1 - 41
Torque Settings
Hydraulic Connections
T11-003
'O' Ring Face Seal System

Adaptors Screwed into Valve Blocks
Adaptor screwed into valve blocks, seal onto an 'O' ring

which is compressed into a 45° seat machined into the
face of the tapped port.
Table 13. Torque Settings - BSP Adaptors

BSP Adaptor Hexagon (A/F)
Size
in. mm Nm kgf m lbf ft
1/4 19.0 18.0 1.8 13.0
3/8 22.0 31.0 3.2 23.0
1/2 27.0 49.0 5.0 36.0
5/8 30.0 60.0 6.1 44.0
3/4 32.0 81.0 8.2 60.0
1 38.0 129.0 13.1 95.0
1 1/4 50.0 206.0 21.0 152.0
Table 14. Torque Settings - SAE Connections

SAE Tube SAE Port Hexagon (A/F)
Size Thread Size mm Nm kgf m lbf ft
4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5
6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0
8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0
10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0
12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0
16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0
20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0
1 - 42 9806/3030-02 1 - 42
Torque Settings
Hoses Screwed into Adaptors
Fig 9.
Hoses 9-B screwed into adaptors 9-A seal onto an Ò' ring Note: Dimension 9-D will vary depending upon the torque
9-C which is compressed into a 45° seat machined into the applied.
face of the adaptor port.
Table 15. BSP Hose - Torque Settings

BSP Hose Size Hexagon (A/F)
1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8
1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8
1 - 43 9806/3030-02 1 - 43
Torque Settings
Adaptors into Component Connections with Bonded Washers
Table 16. BSP Adaptors with Bonded Washers - Torque Settings

BSP Size
in. Nm kgf m lbf ft
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0
1 - 44 9806/3030-02 1 - 44
Torque Settings
'Torque Stop' Hose System
Fig 10.
`Torque Stop' Hoses 10-B screwed into adaptors 10-A 'Torque Stop' Hoses have an additional shoulder 10-D,
seal onto an 'O' ring 10-C which is compressed into a 45° which acts as a physical stop.
seat machined in the face of the adaptor port. To prevent
the 'O' ring being damages as a result of over tightening, Note: Minimum dimension 10-E fixed by shoulder 10-D.
Table 17. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0
1 - 45 9806/3030-02 1 - 45
Torque Settings
Torque + Angle Explanation
Torque + Angle Explanation
Insufficient preload of a bolted joint can cause major

problems, such as cylinder head warp, leaking gasket
joints etc. There are several methods of achieving an
accurate preload of a bolted joint, the two main methods
used on the JCB 444 engine are:
1) Torque Control Tightening
2) Angle Control Tightening
1 Torque Control Tightening
Using a torque meter to control the torque is the most

popular means of controlling preload, and in the
majority of instances this method is adequate. It
should be noted that with this process, the majority of
the torque is used to overcome friction, therefore
slight variations in the frictional conditions can lead to
large changes in the bolt preload.
2 Angle Control Tightening
Where a more precise preload is required, the `torque

+ angle' tightening method is used. The bolt is
tightened to a predetermined torque (this may be
done in stages), and then as a final sequence, the bolt
is tightened to a predetermined angle - this method of
tightening the bolts results in a smaller variation in the
final preload.
It is critical that the predetermined tightening angle is

accurately achieved, failure to tighten accurately to
the specified angle could result in the bolt preload
being incorrect - this will lead to eventual failures. It is
good practice to replace all bolts that have been
tightened using the torque + angle procedure.
1 - 46 9806/3030-02 1 - 46
Torque Settings
Torque + Angle Tightening Procedure
Torque + Angle Tightening Procedure
The following example explains the recommended torque

+ angle procedure. A torque angle gauge should be used
for accuracy, but as a visual check, the bolts can be match
marked as described below.
A
1 Tighten the bolt to the specified torque (specified
torque values will be detailed in the relevant
sections).
0
2 Mark a line across the centre of the bolt, and a second

line on the part to be clamped - the two lines should
be aligned, as shown at A.
3 Mark a third line at the specified torque angle - in this

instance the additional torque angle is 90°. This line
must be marked the specified angle in a clockwise
direction (to further tighten the bolt), as shown at B.
B
4 In some instances, angle torque tightening can be
specified in two stages, for instance in this example,
the first angle quoted is 90° (shown at B), and then a
second angle of 180°. The additional 180° angle is
from the LAST tightened position - as shown at C.
5 Tighten the bolt so that the line on the bolt aligns with
the angle(s) marked on the item to be clamped - +90
remember, to ensure complete accuracy an angle
gauge should be used.
+180
Fig 11.
1 - 47 9806/3030-02 1 - 47
Torque Settings
Engine Torque Figures
This section details all the torque figures to be used on the Item
JCB 444 Engine. Some of the torques MUST be used in
conjunction with the recommended procedures contained K Table 37. Thermostat Housing Bolts ( T 1-56)
in this manual, for instance if the torques need to be K Table 45. Turbo Charger to Exhaust Manifold Nuts
applied in a specific sequence. For convenience, the list ( T 1-59)
below is arranged in alphabetical order to help you quickly K Table 39. Water Heater Outlet Connector ( T 1-57)
locate the item.
K Table 38. Water Inlet Connector Bolts ( T 1-56)
Item K Table 40. Water Pump Bolts ( T 1-57)
K Table 20. Bedplate Bolts ( T 1-49) K Table 41. Water Temperature Sender/Switch
( T 1-58)
K Table 18. Cylinder Head Bolts ( T 1-49)
K Table 42. Exhaust Manifold Bolts ( T 1-58)
K Table 29. Fan Belt Tensioner Bolts ( T 1-53)
K Table 27. Flywheel Housing Bolts ( T 1-52)
K Table 26. Flywheel Hub to Crank Bolts ( T 1-52)
K Table 47. Flywheel to Crankshaft Hub Bolts
( T 1-60)
K Table 48. Front Pulley to Crankshaft Bolts ( T 1-60)
K Table 36. Fuel Injection Pump Cap ( T 1-55)
K Table 21. High Pressure Fuel Pump Retaining Nuts
( T 1-50)
K Table 22. Gear Case to Cylinder Bolts ( T 1-50)
K Table 44. High Pressure Fuel Pipes ( T 1-59)
K Table 24. Idler Blanking Plug ( T 1-51)
K Table 25. Idler Gear Hub Assembly Bolts ( T 1-52)
K Table 31. Injection Pump Gear Nut ( T 1-54)
K Table 33. Injector Clamp Bolts ( T 1-54)
K Table 19. Injector Sleeve ( T 1-49)
K Table 43. Inlet Manifold Bolts ( T 1-58)
K Table 49. Lifting Bracket Bolts ( T 1-60)
K Table 35. Oil Cooler To Cylinder Block ( T 1-55)
K Table 23. Oil Pump Bolts ( T 1-51)
K Table 30. Oil Sump Retaining Bolts ( T 1-53)
K Table 28. Piston Conrod End Cap Bolts ( T 1-53)
K Table 46. Power Take Off (PTO) Pump Bolts
( T 1-59)
K Table 34. Rocker Cover Bolts ( T 1-55)
K Table 32. Rocker Shaft Bolts ( T 1-54)
K Table 50. Starter Motor Bolts ( T 1-61)
1 - 48 9806/3030-02 1 - 48
Torque Settings
Table 18. Cylinder Head Bolts
Item Nm lbf ft Angle
Cylinder head to block bolts(1) x 12
- first stage torque 40 30 -
- second stage torque 75 56 -
- third stage torque 75 56 -
- fourth stage torque - - + 90°
- final stage torque - - + 180°
(1)
Note : Torque information MUST be used in conjunction with
recommended procedures contained in this manual.
Fig 12.
Table 19. Injector Sleeve

Injector Sleeve 36-42 27-31 -
Fig 13.
Table 20. Bedplate Bolts

Bedplate to block(1)
Bolts A - initial snug torque 50 37 -
Bolts B 24 18 -
Bolts A - second stage 115 85 -
Bolts A - final stage angle torque - - + 180°
(1)
A
B
Fig 14.
1 - 49 9806/3030-02 1 - 49
Torque Settings
Table 21. High Pressure Fuel Pump Retaining Nuts
High pressure fuel pump retaining nuts A 22-26 16-19 - A
Table 22. Gear Case to Cylinder Bolts

Gear case to cylinder block bolts 31-35 23-26 -
Fig 15.
1 - 50 9806/3030-02 1 - 50
Torque Settings
Table 23. Oil Pump Bolts
Oil pump bolts 22-26 16-19 -
Fig 16.
Table 24. Idler Blanking Plug

Idler blanking plug 17-19 13-14 -
Fig 17.
1 - 51 9806/3030-02 1 - 51
Torque Settings
Table 25. Idler Gear Hub Assembly Bolts
Idler gear hub assembly bolts 60-70 44-52 -
Fig 18.
Table 26. Flywheel Hub to Crank Bolts

Flywheel hub to crank gear bolts 43-51 32-38 -
Fig 19.
Table 27. Flywheel Housing Bolts

Flywheel housing to gearcase bolts
- M10 bolts (x 6) 43-51 32-38 -
- M8 bolts (x 12) 22-26 16-19 -
Fig 20.
1 - 52 9806/3030-02 1 - 52
Torque Settings
Table 28. Piston Conrod End Cap Bolts
Piston conrod end cap bolts(1)
- third stage angle torque + 90°
Note(1): Torque information MUST be used in conjunction with

Fig 21.
Table 29. Fan Belt Tensioner Bolts

Fan belt tensioner retaining bolts 22-26 16-19 -
Fig 22.
Table 30. Oil Sump Retaining Bolts

Oil sump retaining bolts A 22-26 16-19 - B
Oil sump plug B 40-60 30-44 -
Fig 23.
1 - 53 9806/3030-02 1 - 53
Torque Settings
Table 31. Injection Pump Gear Nut
Injection pump gear retaining nut A (1) 65 48 -
A
Note(1): Torque information MUST be used in conjunction with

Fig 24.
Table 32. Rocker Shaft Bolts

Rocker shaft to cylinder head bolts A 22-26 16-19 -
A
Note: The valve lash adjusting screw B must have a minimum turning
torque of 12Nm. If the turning torque is less than 12Nm, then a new B
adjusting screw must be fitted.
Fig 25.
Table 33. Injector Clamp Bolts

Injector clamp bolts 22-26 16-19 -
Fig 26.
1 - 54 9806/3030-02 1 - 54
Torque Settings
Table 34. Rocker Cover Bolts
Rocker cover retaining bolts 20-24 16-19 -
Fig 27.
Table 35. Oil Cooler To Cylinder Block

Oil cooler housing to cylinder block bolts A 22-26 16-19 -
B
Oil cooler matrix to oil cooler housing bolts 21-25 15-18 -
B
A
Oil filter drain plug C 35-40 26-29 -
Fig 28.
Table 36. Fuel Injection Pump Cap

FIP tamper-proof cap 65-75 48-56 -
Fig 29.
1 - 55 9806/3030-02 1 - 55
Torque Settings
Table 37. Thermostat Housing Bolts
Thermostat housing retaining bolts 22-26 16-19 -
Fig 30.
Table 38. Water Inlet Connector Bolts

Water inlet connector retaining bolts 22-26 16-19 -
Fig 31.
1 - 56 9806/3030-02 1 - 56
Torque Settings
Table 39. Water Heater Outlet Connector
Water heater outlet connector 25-30 19-22 -
Fig 32.
Table 40. Water Pump Bolts

Water pump retaining bolts 22-26 16-19 -
Fig 33.
1 - 57 9806/3030-02 1 - 57
Torque Settings
Table 41. Water Temperature Sender/Switch
Water temperature sender/switch 16 12 -
Fig 34.
Table 42. Exhaust Manifold Bolts

Exhaust manifold retaining bolts
- first stage 25 19 -
- final stage angle torque + 90°
Fig 35.
Table 43. Inlet Manifold Bolts

Inlet manifold retaining bolts 22-26 16-19 -
Fig 36.
1 - 58 9806/3030-02 1 - 58
Torque Settings
Table 44. High Pressure Fuel Pipes
High pressure fuel pipes 25-29 19-22 -
Table 45. Turbo Charger to Exhaust Manifold Nuts

Turbo charger to exhaust manifold 22-26 16-19 -
retaining nuts
Table 46. Power Take Off (PTO) Pump Bolts

Power take off (PTO) pump bolts
- SAE À' - M10 bolts 43-51 32-38 -
- SAE `B' - M12 bolts 73-89 54-66 -
Fig 37.
1 - 59 9806/3030-02 1 - 59
Torque Settings
Table 47. Flywheel to Crankshaft Hub Bolts
Flywheel to crankshaft hub retaining
bolts(1)
- final stage angle torque - - + 120°
(1)
Fig 38.
Table 48. Front Pulley to Crankshaft Bolts

Front pulley to crankshaft retaining bolts(1)
- final stage angle torque - - + 180°
(1)
Fig 39.
Table 49. Lifting Bracket Bolts

Lifting bracket retaining bolts 43-51 32-38 -
Fig 40.
1 - 60 9806/3030-02 1 - 60
Torque Settings
Table 50. Starter Motor Bolts
Starter motor retaining bolts 43-51 32-38 -
Fig 41.
1 - 61 9806/3030-02 1 - 61

Engine Lubricating Oil
New engines DO NOT require a running-in period. The Engine Oil Capacity
engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting Choose the grade of oil to suit the temperature range as
in excessive oil consumption, could occur if the engine is detailed. K Table 51. ( T 1-62). The engine oil capacity,
gently run-in. Under no circumstances should the engine including filter and clean sump is 11.5 litres MIN and 14
be allowed to idle for extended periods; (e.g. warming up litres MAX mark on the dipstick.
without load).
Table 53.
A minimum API CH-4 grade oil must be used. Superior Item Capacity litres (UK Gal)
grade oils may be more appropriate for heavy duty
applications (such as sustained high loads and operation Minimum Maximum
at elevated temperatures). Engine 11.5 (2.5) 14 (3.0)
The choice of lubricant viscosity should be made based on

the lowest ambient temperature at which the machine will
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 51. ( T 1-62).
Important: When selecting the oil viscosity grade make

sure the oil conforms with or exceeds the recommended
specification. K Recommended Oils ( T 1-62).
Table 51.
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 52.
Engine Oil Specification
JCB Extreme ACEA E5/B3/A3, API CH-4/SJ
Performance
1 - 62 9806/3030-02 1 - 62
Coolant
Coolant
Engine Coolant JCB High Performance Antifreeze(1)

and Inhibitor/Water & Summer
Coolant/Water. K Coolant
Mixtures ( T 1-64)
Specification ASTM D6210(2)
(1) If an alternative 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.
(2) Do not use anti-freeze that does not conform to this
standard.
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 or in

accordance with the vehicle service documentation, which
ever comes first. 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.
Important: The coolant must contain the correct corrosion

inhibitor. Serious damage to the cooling system can occur
if corrosion inhibitor is not used.
1 - 63 9806/3030-02 1 - 63
Coolant Mixtures
Coolant Mixtures
Coolant Mixtures – Ensure that the antifreeze complies with International

T3-009_3
Specification ASTM D6210.
Check the strength of the coolant mixture at least once a – Always read and understand the manufacturer's
year, preferably at the start of the cold period. instructions.
– Ensure that a corrosion inhibitor is included. Serious
Replace the coolant mixture according to the intervals damage to the cooling system can occur if corrosion
shown in the machine's Service Schedule. inhibitors are not used.
– Ensure that the antifreeze is ethylene glycol based
!MWARNING and does not use Organic Acid Technology (OAT).
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1
You must dilute full strength antifreeze with clean water

before use. Use clean water of no more than a moderate
hardness (pH value 8.5). If this cannot be obtained, use
de-ionized water. For further information advice on water
hardness, contact your local water authority.
The correct concentration of antifreeze protects the engine

against frost damage in winter and provides year round
protection against corrosion.
The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
50% Concentration (Standard)

Protects against damage down to -40 °C (-39 °F)
60% Concentration (Extreme Conditions Only)

Protects against damage down to -56 °C (-68 °F)
Important: Do not exceed a 60% concentration, as the

freezing protection provided reduces beyond this point.
If you use any other brand of antifreeze:
1 - 64 9806/3030-02 1 - 64
Service Aids
Sealing, Retaining and Care Compounds
Part Number Description and Application

4102/3800 RTV silicone sealant - oil pan to bedplate
320/00831 Anaerobic sealant - bedplate to block
Anaerobic sealant - gear case to block
Anaerobic sealant - flywheel housing to gear case
320/00829 Rubber lubricant Gel - injector Sleeve O-ring
Rubber lubricant Gel - rear crankshaft oil seal
Rubber lubricant Gel - front crankshaft oil seal
320/00812 Anaerobic Adhesive - all core plugs
4102/3500 Anaerobic retaining adhesive - injector sleeve threads
4104/1557 Cleaner and degreaser - for degreasing components prior to use of anaerobic sealant.
4104/2900 Degreaser
4104/3200 Gasket remover
1 - 65 9806/3030-02 1 - 65
Service Tools
General Engine Tools
The following `general' service tools are recommended to

perform safe and correct engine repair procedures.
When applicable, the JCB part number will be shown

immediately below the tool title.
If there is no part number, the tool is not available from JCB

Service. In this instance, the tool can be purchased from
any good tool store.
Fig 44. Dial Test Indicator

Use in a number of applications where it is necessary to
measure accurate dimensions.
Fig 42. Piston Ring Expander Tool
Use to install piston rings on to the piston. Ensures the
rings are fitted without damage or distortion.
Fig 43. Piston Ring Compressor Tool

Fig 45. Valve Spring Compressor Tool
Use to compress the piston rings in preparation for fitting
the piston assembly into the cylinder bore. Use to install and remove valve spring collets.
1 - 66 9806/3030-02 1 - 66
Service Tools
General Engine Tools
Fig 46. Star Drive (Torx®) Heavy Duty Set 764250
Use to loosen and tighten all star drive fasteners. Use in

Fig 49. Torque + Angle Tool
conjunction with a good quality, calibrated torque
wrench. Use to accurately torque bolts. The torque + angle
method is used extensively on the JCB 444 Engine.
C040200
Fig 47. 892/00292 Oil Filter Wrench Fig 50. Star Drive (Torx®) Heavy Duty Socket Bit (T40
size)
Use to install or remove spin-on filter canister.
Use to loosen and tighten the coolant pump retaining
bolts.Use in conjunction with a good quality, calibrated
torque wrench.
Fig 48. 892/00041 Bore De-Glazing Tool

De-glazing tool for cylinder bores (to assist bedding-in of
new piston rings).
1 - 67 9806/3030-02 1 - 67
Service Tools
Specialist Engine Tools
The following `specialist' service tools are required to

perform safe and correct engine repair procedures.
The tools can be ordered using the tool part number

detailed.
For reference, a copy of the tool drawings is included in

section 10. If the tools are to be made locally, the correct
grade of material must be used.
762500
Fig 53. 892/01148 Timing Pin (Crankshaft)

Use to correctly align the crankshaft at top dead centre
(TDC).
762480
Fig 51. 892/01146 Cylinder Block Core Plug Fitting

Tool
Use to correctly fit cylinder block core plugs. Tool
includes handle and different size cups to suit various
size core plugs. 762500
Fig 54. 892/01148 Timing Pin (Camshaft)

Use to align the camshaft in the correct timed position
when removing/fitting the fuel injection pump.
762490
Fig 52. 892/01147 Crankshaft Turning Tool

Use to manually turn the crankshaft, for instance when 762510
setting top dead centre (TDC). 4 x mounting holes to suit
crankshaft pulley. Fig 55. 892/01149 Template For Application Of Oil
Sump Sealant
Use to ensure correct sealant application.
Note: Correct positioning of the sealant is critical to
prevent leaks.
1 - 68 9806/3030-02 1 - 68
Service Tools
762550
762520 Fig 59. 892/01154 Fuel Injection Pump, Tool For

Removing The Tamper-proof Cover
Fig 56. 892/01150 Oil Sump Location Dowels (2 off
required) Use to gain access to the FIP gear retaining locknut. The
tool is used to remove the tamper proof cover.
Use to correctly align the sump, prevent sump movement
during fitting.
Note: Correct positioning of the sump is critical to ensure
a good joint and prevent leaks.
762560
762530
Fig 60. 892/01155 Fuel Injection Pump Gear Removal
Tool
Use to remove the gear from the fuel injection pump
Fig 57. 892/01151 Injector Sleeve Fitting/Removing
shaft.
Tool
Use to fit and remove the injector sleeves. The sleeves
are pre-fitted on cylinder head assemblies.
763470
Fig 61. 892/01157 Crankshaft Front Oil Seal Fitting

762540 Tool
Fig 58. 892/01152 Valve Stem Seals Fitting Tool Use to correctly fit the crankshaft front oil seal.
Use to ensure positive engagement of the valve stem
seals.
1 - 69 9806/3030-02 1 - 69
Service Tools
Use to safely lift and lower the engine, lifting brackets are
purposed designed.
763480
Fig 62. 892/01156 Crankshaft Rear Oil Seal Fitting

Tool
Use to correctly fit the crankshaft rear oil seal. 762610
Fig 65. 892/01159 Rocker Cover Injector Seals Fitting

Tool
Use to correctly set and fit the rocker cover injector seals.
763490
Fig 63. 892/01158 Crankshaft Rear Oil Seal Alignment

Tool
Use to position the crankshaft rear oil seal before using
fitting tool 892/01156. This tool must be used to position
the seal, otherwise the lip of the seal may be ìnverted'
during the fitting process - leading to potential oil leak.
762620
Fig 66. 892/01168 Dummy Injector

Use in place of the injector to check engine compression.
End drilled and tapped 1/8-28BSP to accept universal
adaptor fitting.
Fig 64. 892/01160 (x 2) Lifting Brackets
1 - 70 9806/3030-02 1 - 70
Service Tools
768310
Fig 67. 892/01173 Sealant Applicator

Use to apply the anaerobic and silicone sealant evenly
and correctly.
Note: For reference use the following sealant bead
sizes: 1.5 mm bead for anaerobic sealant, 4.0 mm bead
for silicone sealant .
Fig 69. 892/01176 Template For Application Of Gear

Case To Engine Block Anaerobic Sealant
ensure joint integrity.
Fig 68. 892/01175 Template For Application Of

Bedplate To Engine Block Anaerobic Sealant
Fig 70. 892/01176 Template For Application Of

Flywheel Housing To Gear Case Anaerobic Sealant
1 - 71 9806/3030-02 1 - 71
Service Tools
Fig 73. 892/01264 Injector Removal Tool

Enables easy removal of injectors. Locates on the
injector in place of the retainer clamp.
C041200
Fig 71. Engine Mounting Frame

For use with a suitable engine stand. Manufacture
locally. K Service Tool Drawings ( T 1-74)
Fig 74. 892/01266 Sensor Kit

Enables the engineer to test the engine sensors by a
process of substitution. Kit contains:
Part No. Qty Description
320/04555 1 Coolant temperature sensor
320/04046 1 Oil pressure switch
320/05558 1 Temperature and mass air pressure
sensor (TMAP)
320/09524 1 Camshaft position sensor
Fig 72. 892/01248 Valve Clearance Service Kit 320/09514 1 Knock sensor
Use to measure and adjust valve clearances without 320/09570 1 Crankshaft position sensor
removal of the rocker cover. 320/09565 1 Sensor clamp plate
1 - 72 9806/3030-02 1 - 72
Service Tools
Fig 75. 892/01248 Injector Leak Off Test Kit

Use to confirm a defective injector.
A396950-C1
Fig 76. 993/70111 Torque Wrench
Fig 77. 892/01267 Spanner

Use to remove and replace high pressure fuel lines. Use
with 993/70111 torque wrench.
1 - 73 9806/3030-02 1 - 73
Service Tools
Service Tool Drawings
892/01146 - Core Plug Fitting Tool
Fig 78.
1 - 74 9806/3030-02 1 - 74
Service Tools
892/01147 - Crankshaft Turning Tool
Fig 79.
1 - 75 9806/3030-02 1 - 75
Service Tools
892/01148 - Timing Pin
MATERIAL: 10.0 DIA SILVER STEEL

FINISH: CHEMICAL BLACK
Fig 80.
1 - 76 9806/3030-02 1 - 76
Service Tools
892/01149 - Sump Sealant Template
354.5
410.5
399.5
60.5
55.5
418.5
33.5
37.5
423.5
97.5
9.9
460.5
363
0
3
358.5
341
333.5
304
291.5
R3
6
229.5
223
R67
179.2 R64
170
154.8 164
R5
.5
25˚ R19 111
104.5
25˚
9.5
R1
1.5
R2
33.8 37
7.5
0
R5
17.5 0
DI
A
9
396.5
MATERIAL: CARDBOARD
46
(DIMENSIONS IN MM)
39
407.5
Fig 81.
1 - 77 9806/3030-02 1 - 77
Service Tools
892/01150 - Oil Sump Location Dowel
MATERIAL: BS970: 1991 709M40T (EN19T)

FINISH: CHEMICAL BLACK
Fig 82.
1 - 78 9806/3030-02 1 - 78
Service Tools
892/01151 - Injector Sleeve Removal Tool
Fig 83.
1 - 79 9806/3030-02 1 - 79
Service Tools
892/01152 - Valve Stem Seal Fitting Tool
Fig 84.
1 - 80 9806/3030-02 1 - 80
Service Tools
892/01154 - FIP Cover Removal Tool
Fig 85.
1 - 81 9806/3030-02 1 - 81
Service Tools
892/01155 - FIP Gear Removal Tool
Fig 86.
1 - 82 9806/3030-02 1 - 82
Service Tools
892/01157 - Crankshaft Front Seal Fitting Tool
Fig 87.
1 - 83 9806/3030-02 1 - 83
Service Tools
892/01156 - Crankshaft Rear Seal Fitting Tool
Fig 88.
1 - 84 9806/3030-02 1 - 84
Service Tools
892/01158 - Crankshaft Rear Seal Alignment Tool
Fig 89.
892/01159 - Injector Seal Fitting Tool
Fig 90.
1 - 85 9806/3030-02 1 - 85
Service Tools
892/01168 - Dummy Injector
Fig 91.
1 - 86 9806/3030-02 1 - 86
Service Tools
Engine Mounting Frame
347.2
12 169.2 138
112
5 51.1
20 H7 thru Plate 10 33
25
194
161
32
61.2
127
497 82.5
25.4
17 on
127 PCD
263 10
12
109
R20
148.6 109
124
C040100
Fig 92.
1 - 87 9806/3030-02 1 - 87

Engine Repair Parts and Kits Identification
K Engine Repair Parts and Kits Identification ( T 1-88)

Item Page
detail the repair parts and kits available from JCB Service.
When applicable, the removal and replacement, or Rocker Cover Gasket Kit K ( T 1-88)
dismantling and assembly procedures contained in this Crankshaft Assembly Kit K ( T 1-89)
manual will make a reference to the parts and kits on these
Piston Kit (TC) K ( T 1-89)
pages.
Piston Kit (TCA) K ( T 1-90)
For instance, Rocker Cover - Removal and Top Gasket Kit (TC/TCA) K ( T 1-91)
Replacement - Section 12 details the rocker cover
removal and replacement procedure. On this page, there Bottom Gasket Kit K ( T 1-92)
is a sub-heading termed `Service Parts', listed under this Oil Pan (sump) Sealant Kit K ( T 1-92)
heading are items available as replacement parts. The Cylinder Head Ki t(TC) K ( T 1-93)
items are identified exactly as listed in the following pages,
eg, item 1 - Rocker Cover Gasket Kit, item 1.1 - Rocker Cylinder Head Kit (TCA) K ( T 1-93)
Cover Gasket, etc. Cylinder Head Gasket Kit (+0.25) K ( T 1-94)
Cylinder Head Gasket Kit (+0.50) K ( T 1-94)
The kits are identified for your reference, when applicable
a complete kit can be ordered, or the individual parts. Refer Main Bearing Kit (Std) K ( T 1-95)
to the engine parts catalogue for the relevent part Thrust Washer Kit (Std) K ( T 1-95)
numbers.
Big End Bearing Kit (Std) K ( T 1-96)
For convenience, the kit titles and page cross references Engine Overhaul Kit (TC) K ( T 1-97)
are identified as follows. Engine Overhaul Kit (TCA) K ( T 1-98)
Starter Motor Kit K ( T 1-99)
Alternator Kit K ( T 1-100)
Item Description Qty

1 Rocker cover gasket kit 1
1.1 Rocker cover seal 1
1
1.3
1.2 Injector seal 4
1.3 Injector cap 4 1.4
1.4 Fuel pipe cap 8

1.5 O-ring leak-off rail 4
1.6 O-ring oil filler cap 1
1.5 1.2 1.1
1.6
Fig 93.
1 - 88 9806/3030-02 1 - 88

2 Crankshaft assy kit 1
2.1 Crankshaft - machining 1
2
2.2 Crankshaft gear assy - HCR 1
2.3 Hub - flywheel 1 2.5
2.4 Zero leak plug 1

2.5 Screw 1
14 Main bearing kit std 1
15 Thrust washer kit std 1 2.3
2.2
14
15
2.4
Fig 94.

4 Piston kit TC 1 4.2
4.1 Piston assy TC (NSP) 1
4
4.2 Piston ring kit std 1
4.3 Retainer - piston pin 1
4.3
4.1
Fig 95.
1 - 89 9806/3030-02 1 - 89

5 Piston kit TCA 1
5.1 Piston assy TCA (NSP) 1
5 5.2
5.2 Piston ring kit std 1

5.3 Retainer - piston pin 1
5.3
5.1
Fig 96.
1 - 90 9806/3030-02 1 - 90

7 Top gasket kit TC/TCA 1 1.6
7.1 Gasket / heat-shield 1
7
1.5
7.2 Gasket t/c to manifold 1 1.3
7.3 Copper washer 4 6.2

7.4 O-ring 1
7.5 Sealing washer - oil drain 1
1.1 Rocker cover seal 1 6.15
1.2 Injector seal 4 6.1
6.16
1.3 Injector cap 4
1.5 O-ring leak-off rail 4 1.1
1.2
1.6 O-ring - filler cap 1 7.2
6.1 Cylinder head gasket 1 6.6
7.3
6.2 Valve stem seal 16
6.10
6.3 Thermostat hsg c-seal 1 6.4
6.4 Gasket inlet manifold 1
7.5
6.6 Intake heater gasket 1 7.4 6.3
6.7 6.9
6.7 Cooler cover gasket 1
6.8 Gasket - water inlet pipe 1 6.8
6.9 Washer - fuel injector 4

6.10 Seal - fuel injector 4 6.11
7.1
6.11 O-ring - plugs, oil cooler housing 2
6.12
6.12 O-ring - oil cooler matrix 2 6.14
6.14 Bonded seal - oil pressure sender, 1
6.15 Bonded seal - temperature sender 1 Fig 97.
switch
6.16 Bonded seal - water outlet 1
connector
1 - 91 9806/3030-02 1 - 91

8 Bottom gasket kit 1 8.8
8.1 Water pump gasket 1
8 8.7
8.9
8.2 Oil seal front 1 8.10
8.5
8.3 Oil seal rear 1
8.4 Oil pan sealant 1
8.5 Sealant template oil pan 1
8.6 Sealant 1
8.7 Oil drain plug o-ring 2
8.8 Gasket t/c oil drain 1
8.9 O-ring 1 8.2 8.4
8.10 Seal FIP 1 8.13
8.11 O-ring 1
8.12 O-ring 1
8.12
8.13 Seal - oil pick up 1 8.3
8.11
8.6
8.1
Fig 98.

9.0 Oil pan sealant kit 1
8.4 Oil pan sealant 1
9 8.4
8.7
8.5 Sealant template oil pan 1 8.13
8.5
8.7 O-ring - drain plug 1
8.13 Seal - oil pick up 1
Fig 99.
1 - 92 9806/3030-02 1 - 92

10 Cylinder head Kit NA/TC 1
10.1 Cylinder Head Machining(1) 1
10
10.3
10.2 GA Valves Inlet 8 10.2
10.3 GA Valves Exhaust 8
Fig 100.
(1) Refer to Technical Data, Section 1, for machining information and tolerances.

11 Cylinder head Kit TCA 1
11.1 Cylinder Head Machining(1) 1
11
10.3
10.2 GA Valves Inlet 8 10.2
10.3 GA Valves Exhaust 8
Fig 101.
(1) Refer to Technical Data, Section 1, for machining information and tolerances.
1 - 93 9806/3030-02 1 - 93

12 Cylinder head gasket kit +0.25 1
12.1 Cylinder head gasket +0.25 1
12
12.1
Fig 102.

13 Cylinder head gasket kit +0.50 1
13.1 Cylinder head gasket +0.50 1
13
13.1
Fig 103.
1 - 94 9806/3030-02 1 - 94

14 Main bearing kit std 1 14.3
14.1 Bearing - Main Upper std (1) 4

14 14.1
14.1
14.2 Bearing - Main Lower std (1) 4 14.1
14.3 Bearing - Main Upper Rear std(1) 1
14.1
14.4 Bearing - Main Lower Rear std (1) 1
14.4
14.2
14.2
14.2
14.2
Fig 104.
(1) Items not available separately, part of kit item 14.

15 Thrust washer kit std 1
15.1 Bearing - Main Thrust Washer 2
15
15.1
Fig 105.
1 - 95 9806/3030-02 1 - 95

16 Big-end bearing kit std 1
16.1 Bearing - Big-end std 8
16
16.1
Fig 106.
1 - 96 9806/3030-02 1 - 96

18 Engine overhaul kit TC std 1
17.1 Bolt - M8 x 57 Con. Rod 8
18
4 Piston kit TC 4
6 Top gasket kit 1
4
8 Bottom gasket kit 1
17.1
Fig 107.
1 - 97 9806/3030-02 1 - 97

19 Engine overhaul kit TCA std 1
17.1 Bolt - M8 x 57 Con. Rod 8
19
5 Piston kit TCA 4
6 Top gasket kit 1
5
8 Bottom gasket kit 1
17.1
Fig 108.
1 - 98 9806/3030-02 1 - 98

50 Starter motor kit 1
50.1 Starter solenoid 1
50
50.2 Sundry parts kit (bolts, o-ring) 1 50.1
50.3 Brush holder assembly 1

50.4 Brush kit 1
50.2
50.3
50.4
Fig 109.
1 - 99 9806/3030-02 1 - 99

60 Alternator kit 1
60.1 Thru bolt kit 1
60
60.2 Pulley 1
60.3 Nut and spacer 1 60.1
60.4 Regulator and brush box assembly 1
60.2
60.4
60.3
Fig 110.
1 - 100 9806/3030-02 1 - 100

Engine Lifting
Lifting Information
Refer to the Technical Data section for the various engine

weights.
B
The lifting equipment used must be an approved type and
capable of lifting the engine safely. The recommended
lifting equipment is shown at 111-B.
Never attempt to manually lift heavy components such as

the cylinder head, crankshaft etc on your own. Always use
lifting equipment, or obtain the help of an assistant.
Inspect the lifting brackets 111-A for signs of damage. The

brackets must be correctly torqued to the engine block, the
correct torque figure for the bracket retaining bolts is 43-
51Nm. A
Make sure the lifting equipment does not damage any of
the engine dressing and the rocker cover.
A
Fig 111.
1 - 101 9806/3030-02 1 - 101

Starting the Engine
Pre-Start Notes
!MWARNING
On turbo-charged machines, do not keep the
accelerator pedal fully depressed when the engine has
started. Do not race the engine until the oil pressure
low light has gone out. Racing the engine too soon
could damage the turbo-charger due to insufficient
lubrication.
16-2-4-1
Several factors will influence the starting performance of

the engine, these include:
– The ambient temperatures

– The condition of the battery
– The viscosity of the engine oil
– The condition of the starter motor
The engine does not require any cold starting aids for
temperatures down to -18°C.
If the engine is operating in temperatures below -18°C,

then a pre-heater is available. The heater fits in the inlet
manifold as shown, and is linked into the machine's
electrical system.
In severe cold climate conditions, a block heater can be

installed.
Make sure that all the necessary machine pre-start checks Fig 112.
have been completed, these will include:
– engine oil level

– engine coolant level
– battery connections
– fuel tank has sufficient fuel
– fuel pre-filters drained
– the machine is safe and ready to start
1 - 102 9806/3030-02 1 - 102

Starting the Engine
Start Procedure
1 Make sure that all machine controls are in the
`neutral' position.
2 If a pre-heater is fitted, turn the starter key A to the to

the pre-heat position II. If applicable to your
equipment, the warning light on the instrument cluster
will extinguish when pre-heat is complete.
!MCAUTION
Do not operate the starter motor for more than 20
seconds at one time. Let the starter motor cool for at
least 2 minutes.
0124
3 Turn the starter key to the starter engage position III

and hold it there until the engine starts. Do not
operate the starter for more than 20 seconds.
Note: If the engine does not start at the first attempt, return
the key to the off (O) position and allow the starter to cool
for a few minutes and then repeat steps 2 and 3.
4 As soon as the engine starts, release the key which

will return to the run position.
5 K Engine Checks After Start-up ( T 1-104).
Fig 113.
1 - 103 9806/3030-02 1 - 103

Starting the Engine
Engine Checks After Start-up - white - abnormal
!MWARNING 6 Check for any lubricating oil leakage, particularly

around joints and connectors.
On turbo-charged machines, do not keep the
accelerator pedal fully depressed when the engine has
started. Do not race the engine until the oil pressure
!MWARNING
low light has gone out. Racing the engine too soon Fluid Under Pressure
could damage the turbo-charger due to insufficient Fine jets of fluid at high pressure can penetrate the
lubrication. skin. Keep face and hands well clear of fluid under
16-2-4-1 pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
!MWARNING the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Stop the engine and investigate the cause if any of the INT-3-1-10_2
following conditions occur:
1 The warning lights fail to go off when the engine

!MWARNING
has been started. Fuel oil is highly inflammable. Stop the engine
immediately if a fuel leak is suspected. Completely
2 The alarm is still sounding when the engine has wipe off any spilt fuel which could cause a fire.
been started. 8-3-4-3_1
3 The warning lights illuminate and the alarm 7 Check the fuel circuit for leakage, including fuel lines,
sounds when the engine is running. fuel filter(s) and high pressure pump. Stop the engine
immediately if a fuel leak is suspected.
16-2-4-2
Important: DO NOT attempt to tighten high pressure fuel
Check the following items after the engine has been line connections. DO NOT attempt to repair high pressure
started. fuel lines. If the fuel lines are damaged or leaking they
must be replaced by a qualified engineer.
1 Make sure that all the engine instrumentation warning
lights have extinguished. 8 Check the coolant system for signs of leakage,
particularly around the radiator and hose
2 Do not over accelerate the engine until the òil connections.
pressure low' warning light has extinguished.
3 If any warning indicator fails to extinguish, or if they

illuminate while the engine is running, make the
machine safe, stop the engine and investigate the
cause.
4 Listen for engine noise, any abnormal noise must be

investigated to determine the cause.
5 Check the exhaust smoke colour, generally after the

engine has reached operating temperature, the
exhaust colour should be as detailed:
- colourless or light blue - normal

- black - abnormal
1 - 104 9806/3030-02 1 - 104

Starting the Engine
Engine Running-in Procedure

New engines DO NOT require a running-in period. The
engine/machine should be used in a normal work cycle
immediately. 10 15 10 15
RPM x 100 RPM x 100
5 20 5 20
Glazing of the piston cylinder bores, resulting in excessive
oil consumption, could occur if engine duty is too light from 0 25 0 25
new.
Under no circumstances should the engine be allowed to

idle for extended periods; (e.g. warming up without load).
The recommended grade of engine oil must be used.

K Engine Lubricating Oil ( T 1-62).
Superior grade oils may be more appropriate for heavy

duty applications (such as sustained high loads and
operation at elevated temperatures).
Fig 114.
1 - 105 9806/3030-02 1 - 105

Starting the Engine
Stopping the Engine

1 Make sure that all machine controls are in the
`neutral' position.
!MCAUTION
Allow turbocharged engines to run at approximately
1000 rpm and reduced load for 2 to 3 minutes before
shut down. This will allow the turbocharger to cool.
Failure to follow this procedure could result in
turbocharger damage.
ENG-1-6
2 It is recommended that turbocharged engines are run

at 1000 RPM (approximately) and reduced load for 2
- 3 minutes before shut down. This will allow the
turbocharger to cool and return to idle speed while
engine oil pressure is still available for lubrication.
3 Turn the starter key to the OFF (O) position, as shown

at A.
Fig 115.
1 - 106 9806/3030-02 1 - 106

Starting the Engine
Page left intentionally blank
1 - 107 9806/3030-02 1 - 107


Storage
Engines should be stored in original shipping packaging.

Damaged or disturbed packaging should be made
weatherproof immediately.
If an engine is shipped `with oil', it should be stored in the

correct (upright) position.
If an engine is shipped `dry of oil', after 6 months it should

be filled with oil to the correct level and `re-inhibited'.
K Hot Test Description ( T 1-110).
All floor stock engines should be stored under cover in dry

conditions and not subjeced to extreme variations in
temperature or humidity.
1 - 108 9806/3030-02 1 - 108

Preservation
Preservation
Capping Engine Openings

All openings on the engine must be suitably capped to
prevent ingress of water and contamination by foreign
particles.K Fig 116. ( T 1-109)
4 5
3
7 6
10
12
11
8 9
2
Fig 116.
Item Description 7 Heater port cap
1 Top hose cap 8 Dipstick plug
2 Bottom hose cap 9 ECU machine harness connector cap
3 Turbocharger intake cap 10 Fuel spill back line cap
4 Turbocharger compressor outlet cap 11 Low duty PTO (if fitted) cap
5 Turbocharger exhaust outlet cap 12 Heavy duty PTO (if fitted) cap
6 Inlet manifold cap
1 - 109 9806/3030-02 1 - 109

Preservation
Hot Test Description

All engines despatched from JCB Power Systems will
have been subjected to a hot test (checking items such as
oil pressure, engines speeds, torque values etc) and
therefore the interior surfaces will have beeen coated with
engine oil.
!MWARNING
When using cleaning agents, solvents or other
chemicals, you must adhere to the manufacturer's
instructions and safety precautions.
GEN-1-9
All coolant galleries are coated with CRODAFLUID PA75

corrosion inhibitor.
Stored engines will require re-inhibiting every 6 months,

this will include hot testing the engine using a dynometer.
The hot test profile is:
Stage Mode Speed Torque Time

(rpm) (Nm) (secs)
1 Speed/Torque 830 0 50
1 - 110 9806/3030-02 1 - 110

Section 1 - General Information

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1-0 9806/3030-02 1-0

Contents Page No.

Terms and Definitions

Identifying the Engine

Contents Page No.

Lubricants and Capacities

Service Parts and Repair Kits

Storage and Preservation

Using the Service Manual 5 Fault Finding ...etc.

Renewal of oil seals, gaskets, etc., and any component

The manufacturer's policy is one of continuous

1 General Information includes torque settings and

2 Care & Safety includes warnings and cautions

3 Routine Maintenanceincludes service schedules

The remaining sections deal with Descriptions, Fault Units of Measurement

1-1 9806/3030-02 1-1

Machine Related Data

1-2 9806/3030-02 1-2

Whist the requirement for a good level of cleanliness is well

Once inside the system, fuel circuit contaminants greatly

1-3 9806/3030-02 1-3

Maintenance Environment, Common Rail Fuel Injection

!MWARNING Site - open to weather. This repair site is not an

1-4 9806/3030-02 1-4

1-5 9806/3030-02 1-5

Cleaning the Engine

!MWARNING 7 Apply an approved cleaning and degreasing agent

4 Seal the engine air intake, exhaust and breather

6 Use a low pressure water jet and brush to soak off

Ensure that the alternator, starter motor and any other

1-6 9806/3030-02 1-6

Further Cleaning Procedures, Common

Important: Additional cleaning must be carried out prior to

1 Clean the engine as described in Cleaning the

2 Remove hoses, electrical harnesses and ancillaries

3 Wash away any remaining dirt or debris and then dry

Important: Before starting work on the high pressure fuel

1-7 9806/3030-02 1-7

Terms and Definitions

Some of the following acronyms and abbreviations are mm Millimetre

1-8 9806/3030-02 1-8

Acceptable and Unacceptable Fuels

Fuel Specification Applicable Engines Service Requirements

ASTM D975-91 Class 2, US DF1, US DF2,

NATO F35, JET A1, DEF STAN 91-91,

1-9 9806/3030-02 1-9

Note: These products are given as examples only. The Warranty

Any fuel purchased for operation of the JCB Dieselmax

1 Diesel - mineral derived, hydrocarbon fuels to

2 Low Sulphur Diesel - mineral derived, hydrocarbon

3 Ultra Low Sulphur Diesel - Reformulated mineral

4 Vegetable Oil -unmodified. Certain pure vegetable

5 Biodiesel - chemically modified vegetable oil. By

Note: Refer also to additional information. K Usage and

These fuels have been derived from a wide range of

Effects of Fuel Contaminates

– Dirt - A severely damaging contaminant. Finely

Basic Engine Data