JCB 45Z-1, 48Z-1, 51R-1 COMPACT EXCAVATOR Service Repair Manual Instant Download

1
Foreword
SERVICE MANUAL COMPACT EXCAVATOR 45Z-1,
48Z-1, 51R-1 EN - 9813/6400 - ISSUE 2
- 07/2018 This manual contains original
instructions, verified by the manufacturer (or
their authorized representative). Copyright
2018 Â 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. www.jcb.com
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine
you do not understand.
Treat the Operator's Manual as part of the
machine. Keep it clean and in good condition.
Replace the Operator's Manual immediately if it
is lost, damaged or becomes unreadable.
Contents 01 - Machine 03 - Attachments, Couplings
and Load Handling 06 - Body and Framework 09 -
Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC) 15 - Engine
18 - Fuel and Exhaust System 21 - Cooling
System 27 - Driveline 30 - Hydraulic System 33 -
Electrical System 72 - Fasteners and Fixings 75
- Consumable Products 78 - After Sales
2
18 - Fuel and Exhaust System 24 - Exhaust 00 -
General
00 - General
Introduction
Introduction .....................................
............... 18-77 Health and Safety
..........................................
18-78 Component Identification ...................
............ 18-79 Check (Condition)
.......................................... 18-81
The exhaust system is used to guide exhaust gases
away from the controlled combustion inside the
engine by means of an exhaust pipe. Depending on
the machine design, the exhaust gas may flow
through the following components

• Cylinder head and exhaust manifold.
• Turbocharger to increase the engine power (if
  installed).
• A catalytic converter or EGR (Exhaust Gas
  Recirculation) system to reduce air pollution (if
  installed).
• SCR (Selective Catalytic Reduction) (if
  installed). In SCR system exhaust gases pass
  through the DEF (Diesel Exhaust Fluid) injection
  chamber to lower the NOx (Nitrogen Oxide)
  concentration in the exhaust gases.
• A silencer or muffler to reduce noise (if
  installed).
• The exhaust pipe carries the toxic and noxious
  gases away from the users of the machine. Note
  machines or generators that work indoors can
  quickly fill an enclosed space with carbon
  monoxide or other poisonous exhaust gases if
  they are not properly vented to the outdoors.

9813/6400-2
18 - 77
3
18 - Fuel and Exhaust System 24 - Exhaust 00 -
General
Health and Safety Exhaust Gases Machine exhaust
gases can harm and possibly kill you or
bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, install
an exhaust extractor. If you begin to feel
drowsy, stop the machine at once and get into
fresh air. Sparks Explosions and fire can be
caused by sparks from the exhaust or the
electrical system. Do not use the machine in
closed areas where there is flammable material,
vapour or dust. Hazardous Atmospheres This
machine is designed for use in normal out door
atmospheric conditions. It must not be used in
an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or
dust, without first consulting your JCB
dealer. Hot Components Touching hot surfaces can
burn skin. The engine and machine components
will be hot after the unit has been running.
Allow the engine and components to cool before
servicing the unit. WARNING! The engine has
exposed rotating parts. Switch off the engine
before working in the engine compartment. Do not
use the machine with the engine cover open.
9813/6400-2
18 - 77
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5
18 - Fuel and Exhaust System 24 - Exhaust 00 -
General
Component Identification Table 117. Intake and
exhaust circuit
Air in intake.
Gas in recycle.
Gas in exhaust.
Figure 460. Typical circuit
5
2
1
10
11
F B
6
4
8
C
7
D E
3
1 Air in intake from air filter 3 Air in inter
cooler flow 5 Air in intake manifold flow 7 Air
in cylinder intake 10 Gas in outlet towards
catalyst B Exhaust manifold
2 Air in compression 4 Air cooling 6 Air in head
intake 8 Gas in cylinder outlet 11 Gas in
oxidation C Upper crankcase
6
18 - Fuel and Exhaust System 24 - Exhaust 00 -
General
D Lower crankcase F Catalyst
E Oil sump
Figure 461. Typical circuit G
9
6
11
15
A
12
14 13
6 Air in head intake 9 Gas in head outlet
11 Gas in oxidation 12 Gas in recycle towards EGR valve
13 Gas in EGR valve outlet 14 Gas cooling (in EGR cooler)
15 Exhaust gas recirculation into intake manifold A Intake manifold
G Radiator
7
18 - Fuel and Exhaust System 24 - Exhaust 00 -
General

• Check (Condition)
• Excessive smoke from the exhaust stack combined
  with a complaint of low power could be as a
  result of
• Dirt or dust (unfiltered air) ingested directly
  into the engine, resulting in damage to the
  cylinder bores, there will also be a possible
  increase in oil consumption.
• Air leaks from the air hose connections.
• Exhaust manifold leaks.

8
18 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
03 - Inlet Manifold
Introduction
Introduction .....................................
............... 18-82 Check (Condition)
..........................................
18-83 Remove and Install .........................
.............. 18-83
On compression ignition (diesel) engines, the
inlet manifold (also called the intake manifold)
is the part of the air intake system that
distributes air for combustion to the cylinders
via each inlet port in the cylinder head. The
design of the manifold is important to make sure
that air is distributed as evenly as possible
under all engine speed and load conditions.
9
18 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
Check (Condition)
Remove and Install

1. Check the manifold mating faces for signs of
   damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
   defect.

NOTE The illustrations shown are for a 4
cylinder engine however, the 3 cylinder engine
also has a similar configuration.
Before Removal

1. This procedure requires service parts. Make sure
   you have obtained the correct service parts
   before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
   the engine has been running, let it cool before
   you start the service work.
3. Remove the EGR (Exhaust Gas Recirculation)
   cooler.
4. Remove the TMAP (Temperature Manifold Air
   Pressure) sensor.

Remove Front Intake Manifold 1. Remove the screw
to loosen the clamp that secures the coolant
hose between the oil cooler and water
pump. Figure 462.
E
C
A B

• D
• Front Intake manifold
• Screw
• Clamp
• Coolant hose
• Water pump
• Remove the screws to open the front intake
  manifold.
• Remove the two gaskets and the separation plate
  from the front intake manifold.

10
18 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
Figure 463.
Figure 465.
H
L
M
A
P
Q
G
N

• F
• A Front intake manifold
• Gasket (x2)
• Separation plate

• L Screw M Clamp N Screw
• Rear intake manifold
• Gasket
• Put protective covers on the open ports of the
  cylinder head.
• Inspect the intake manifolds for any damage.
  Replace if damaged.
• Refer to PIL 18-24-03.

Rear Intake Manifold
1. Remove the screw that attaches the holder to
the rear intake manifold. Figure 464.
Install Rear Intake Manifold
J

1. Remove the protective cover from the open ports
   of the cylinder head.
2. Install the intake manifold mounting studs to
   align the holes on the cylinder head with the
   rear intake manifold.
3. Put the rear intake manifold and the gasket in
   position against the cylinder head.
4. Install the screws to attach the rear intake
   manifold to the cylinder head.

• K
• Screw
• Holder
• Remove the screws to loosen the clamp of the
  high pressure fuel pipe.
• Remove the screws that attach the rear intake
  manifold to the cylinder head.
• Remove the rear intake manifold with its gasket.

11
18 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
Figure 466.
4. Put the screws into the front intake
manifold. Figure 468.
R
R
Q
P
G
G
H
F
R
N

• A
• A Front intake manifold
• Gasket
• Separation plate
• R Mounting stud
• 5. Make sure that you leave the holes shown open
  for the EGRcooler and the coolant hose clamp.
• Figure 469.

• N Screw
• Rear intake manifold
• Gasket
• Mounting stud
• Tighten the screws to the correct torque value.
• Install the screws to attach the holder to the
  rear intake manifold.
• Tighten the screws to the correct torque value.
• Install the screws to attach the clamp of the
  high pressure fuel pipe.
• Figure 467.
• M
• L

S
S
J

• S Screw holes for EGR cooler and coolant hose
  clamp
• Tighten the screws to the correct torque value.
• Install the screw on the clamp that secures the
  hose between the oil cooler and water pump.
• Figure 470.

K
J Screw K Holder L Screw M Clamp 9. Tighten
the screws to the correct torque value.
E
C
A
Front Intake Manifold

1. Put the two gaskets and the separation sheet in
   position on the intake manifold mounting studs.
2. Make sure you install the separation plate
   between the two gaskets.
3. Put the front intake manifold in position against
   the mounting studs.

B
D

1. Front Intake manifold
2. Screw
3. Clamp
4. Coolant hose
5. Water pump

12
18 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold

• After Installation
• Install the TMAP sensor.
• Install the EGR cooler.
• Table 118. Torque Values

Item Nm
F 23
J 6
L 6
N 23
13
18 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
04 - Outlet Manifold
Introduction
Introduction .....................................
............... 18-87 Component Identification
............................... 18-88 Check
(Condition) ......................................
.... 18-89 Remove and Install ....................
................... 18-90
The exhaust outlet manifold collects the exhaust
gases from the multiple cylinders and delivers it
to the turbocharger or the exhaust pipe.
14
18 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
Component Identification The exhaust manifold
collects the exhaust gases from the multiple
cylinders and deliver it to the exhaust
pipe. Figure 471.
C
B
A
A Outlet manifold C Manifold gasket
B Fixing bolts
15
18 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold

• Check (Condition)
• Check the manifold mating faces for signs of
  damage and distortion.
• Check the manifold casting for signs of cracks.
• Renew the manifold if there are any signs of
  defect.
• Visually inspect for leaks at the exhaust
  manifold. Make sure all gaskets are in good
  condition, replace as required.

16
18 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
Remove and Install
NOTE The illustrations shown are for a 4
cylinder engine however, the 3 cylinder engine
also have a similar configuration.

1. Remove the nuts that attach the exhaust manifold
   to the cylinder head. Discard the nuts.
2. Remove the exhaust manifold and its metal
   gaskets.
3. Discard the gaskets.
4. Put protective head openings contamination.

Remove

1. Make sure that the engine is safe to work on. If
   the engine has been running, let it cool before
   you start the service work.
2. Get access to the exhaust manifold.
3. Remove the turbocharger.

covers on the and manifolds to
cylinder prevent
Figure 472.
C
B
A
A Exhaust manifold C Gasket (x5)
B Self locking nut (x10)
17
18 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold

• Install
• Important Replace the metal gaskets between the
  manifold and the cylinder head every time they
  are removed.
• Remove the protective covers from the cylinder
  head and manifolds.
• Make sure that the contact surfaces of the
  cylinder head and manifolds are clean.
• Put the metal gaskets on the cylinder head studs.
• Put the exhaust manifold on the studs.
• Apply Loctite 242 on the studs.
• Install the self locking nuts to secure the
  exhaust manifold.
• Tighten the nuts to the correct torque value.
• Install the turbocharger.
• Table 119. Torque Values

Item Nm
B 25
18
18 - Fuel and Exhaust System 24 - Exhaust 18 -
Catalyst
18 - Catalyst
Introduction
Introduction .....................................
............... 18-92 Component Identification
............................... 18-93 Operation
..................................................
..... 18-94 Check (Condition) ....................
...................... 18-95 Remove and Install
....................................... 18-95
The catalytic converter also called a catalyst is
a vehicle emissions control device that converts
toxic pollutants in exhaust gas to less toxic
pollutants by catalyzing a reaction (oxidation
or reduction).
19
18 - Fuel and Exhaust System 24 - Exhaust 18 -
Catalyst
Component Identification
Figure 473.
A B
C
D
A Turbine housing with Wastegate valve C Gasket
B Catalyst support flange D Catalyst
20
18 - Fuel and Exhaust System 24 - Exhaust 18 -
Catalyst
Operation
The catalytic converter consists of a monolith
honeycomb substrate coated with platinum group
metal catalyst. This honeycomb structure is then
covered in a stainless steel container.
catalyst, several exhaust pollutants are
converted into harmless substances.
The diesel oxidation catalyst is designed to
oxidize carbon monoxide, gas phase hydrocarbons,
and the Soluble Organic Fraction (SOF) of diesel
particulate matter to CO2 and H2O
The honeycomb structure with many small parallel
channels presents a high catalytic contact area
to exhaust gases. As the hot gases contact the
Figure 474.
Diesel exhaust contains sufficient amounts of
oxygen, necessary for the above chemical
reactions. The concentration of O2 in the
exhaust gases from diesel engine varies between
3 17 , depending on the engine load. The
catalyst activity increases with temperature. A
minimum exhaust temperature of about 200 C is
necessary for the catalyst to "light off". At
higher temperatures, conversions depend on the
catalyst size and design and can be higher than
90 . The catalytic oxidation of SOF results in
reduction of diesel particulate matter emission.
The particulate matter conversion efficiency can
range widely, depending on the SOF contents of
the particulates and sulphur level in the fuel.
21
18 - Fuel and Exhaust System 24 - Exhaust 18 -
Catalyst
Check (Condition)
Remove and Install
A catalyst converter may reach the end of its
life prematurely if on the receiving end of a
badly performing engine. Catalytic converters
are free from moving components and require
little to no maintenance. Therefore, what wears
out or damages a catalytic converter is external
and not an issue caused by the unit itself.
Remove

• Make sure that the engine is safe to work on. If
  the engine has been running, let it cool before
  you start the service work.
• The catalyst can be hot even after the engine has
  cooled. Make sure that the catalytic converter
  is fully cooled even if the engine has cooled.
• Remove the nuts and bolt that attach the catalyst
  to the front exhaust pipe.
• Figure 475.

What damages a catalytic converter can vary, but
here's a few examples

• Out-of-tune engine - Catalytic converters are
  designed to work when the engine is running
  optimally. This could be due to incorrect fuel
  mixture, incorrect engine timing etc. Including
  potential damage to the catalytic converter,
  such issues may cause damage to the engine
  itself.
• Excessive fuel - If your vehicle is using
  excessive fuel, it won't get burnt and make your
  machine go faster. It's simply unused and re-
  routed through the exhaust. As a result, this
  unused fuel will enter the catalytic converter.
  The converters operate at high temperatures and
  can ignite the fuel as it enters, this renders
  the catalytic converter at super-hot
  temperatures, even causing it to melt down.
• Oil - Oil entering the exhaust will ultimately
  travel though the catalytic converter, clogging
  the internals of the catalytic converter and
  preventing it from working efficiently. This can
  cause excessive heat to accumulate within the
  converter and other engine components.
• Physical damage - The catalytic converter being
  located where it is, can receive damage from
  road debris such as rocks. Although the
  catalytic converter is protected, a strike from
  a heavy piece of debris may damage the internals.

B E
A
D
G
B E
C
F
Important

• Strap
• Nut (x3)
• Gasket
• Front exhaust pipe
• Bolt
• Catalyst
• Mounting bracket
• Remove the gasket between the catalyst and the
  front exhaust pipe.
• Loosen the strap of the catalyst from the
  catalyst mounting bracket.
• Remove the nuts that attach the catalyst to the
  turbocharger support flange.

• Use only the specified fuel. Low S.A.P.S.
  technology (fuel with low Sulphate, Phosphorous,
  Sulphur content) keeps catalyst in working
  conditions. The presence of sulfate, phosphorus
  and sulfur ashes causes with time the catalyst
  clogging and its consequent inefficiency.
• Do not run the engine at idle for more than 10
  min.

22
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18 - Fuel and Exhaust System 24 - Exhaust 18 -
Catalyst
Figure 476.
Table 120. Torque Values
Item Nm
A 10
B 24
H 24

• K
• J
• F H
• F Catalyst H Nut (x3) J Gasket
• K Turbocharger support flange
• Remove the gasket between the catalyst and the
  support flange.
• Release the strap completely from the catalyst.
• Carefully remove the catalyst from the engine
  with a soft mallet.
• Remove the thermal blanket from the catalyst.
• Install
• Make sure that the catalyst is clean and not
  damaged.
• Make sure you always use new gaskets.
• Put the thermal blanket on the catalyst.
• Put the catalyst in position against the mounting
  bracket.
• Attach the strap. Do not tighten it at this
  stage.
• Put the gasket on the support flange studs.
• Put the catalyst mounting flange on the
  turbocharger support flange.

18 - 96
9813/6400-2
18 - 96
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