JCB 48Z-1, 51R-1 COMPACT EXCAVATOR Tier 3 Perkins Engine Service Repair Manual Instant Download

1
Foreword
SERVICE MANUAL COMPACT EXCAVATOR 48Z-1,
51R-1 EN - 9813/6200 - ISSUE 1 - 0
/2016 This manual contains original
instructions, verified by the manufacturer (or
their authorized representative). Copyright
2016 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 and Options
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
15 - Engine 06 - Cylinder Head 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-27 Technical Data
...............................................
15-28 Check (Condition) ..........................
................ 15-28 Calibrate
..................................................
...... 15-29 Remove and Install
....................................... 15-30
The cylinder head is located above the cylinders
on top of the crankcase. It closes in the top of
the cylinder, forming the combustion chamber.
This joint is sealed by a cylinder head gasket.
The cylinder head also provides the space for the
passages that feed air and fuel to the cylinder
and allow the exhaust to escape. The cylinder
head is also used to mount the valves (PIL 15-30)
and fuel injectors (PIL 18-18).
15 - 27
3
15 - Engine 06 - Cylinder Head 00 - General
Technical Data
Check (Condition)

• Make the machine safe. Refer to (PIL 01-03).
• Get access to the engine. Refer to (PIL 06-06).
• Remove the cylinder head bolts in the reverse
  numerical order. This will prevent distortion of
  the cylinder head. Refer to Figure 72.
• Figure 72.
• 12 4 5 13

Table 38. Cylinder head gasket
Piston height below top face of crankcase Gasket Thickness
0.35mm to 0.5mm 1.2mm
0.5mm to 0.6mm 1.3mm
Table 39. Distortion of the cylinder head
Description Data
Distortion of the cylinder head 00.05mm
Maximum service limit 0.12mm
Maximum limit for re- grinding the cylinder head 0.15mm
9
1
8
17
16
7
10
2
18
15

• 11 3 6 14
• Remove the cylinder head from the engine.
• Clean the cylinder head thoroughly.
• Make sure that the contact surface of the
  cylinder head and the contact surface of the
  crankcase are clean, smooth and flat.
• Inspect the bottom surface of the cylinder head
  for pitting, corrosion and cracks.
• Inspect the area around the valve seats and the
  holes for the fuel injectors.
• Put the cylinder head on a suitable support.
• Figure 73.
• A

• B
• Cylinder head
• Support
• 10. Use a straight edge and a feeler gauge to
  check the six positions for distortion. Refer to
  Figure 74.

15 - 28
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5
15 - Engine 06 - Cylinder Head 00 - General
Calibrate
Figure 74.

• The dowel pins in the crankcase hold the
  cylinder head gasket in the correct position
  when the cylinder head is installed. Refer to
  Figure 75.
• The stamped marking on the cylinder head gasket
  must face upward. This makes sure that the
  cylinder head gasket is installed correctly.
  Refer to Figure 75.
• Figure 75.
• A
• B
• C

1
4
3
6
5
2

• Dowel pins
• Gasket
• Stamped marking
• Before you tighten the bolts, apply clean engine
  oil on the threads of the bolts. The bolts must
  be tightened to the torque of 101Nm in the
  specified numerical sequence only. Refer to
  Figure 76.
• Figure 76.
• 12 4 5 13

9
1
8
17
16
7
10
2
18
15

• 11 3 6 14
• Use a straight edge and a feeler gauge to check
  the six positions for distortion. Refer to
  Figure 77.
• Figure 77.
• 1

4
3
6
5
2
6
15 - Engine 06 - Cylinder Head 00 - General
Remove and Install CAUTION This component is
heavy. It must only be removed or handled using a
suitable lifting method and device.

• If you grind the cylinder head, check the valve
  depth below the cylinder head face. Refer to
  (PIL 15-30).

• Remove
• Make the machine safe. Refer to (PIL 01-03).
• 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.
• Remove the exhaust manifold. Refer to (PIL
  18-24).
• Remove the fuel filter. Refer to (PIL 18-09).
• Remove the fuel injectors. Refer to (PIL 18-18).
• Remove the glow plugs. Refer to (PIL 15-80).
• Remove the rocker shaft and the push rods. Refer
  to (PIL 15-42).
• Remove the cooling pump. Refer to (PIL 21-09).
• Drain the cooling system. Refer to (PIL 21-00).
• Gradually loosen the bolts in reverse numerical
  order. This will prevent distortion of the
  cylinder head. Refer to Figure 78.
• Figure 78.
• 12 4 5 13

17
9
1
8
16
10
2
7
18
15

• 11 3 6 14
• Remove the bolts from the cylinder head.
• Carefully lift the cylinder head off the
  crankcase with a suitable lifting device.
• Make sure of the following
• Do not use a lever to separate the cylinder head
  from the crankcase.
• Take care not to damage the machined surfaces of
  the cylinder head.
• Avoid contamination of the cylinder bores with
  coolant or with debris.
• Place the cylinder head on a surface that will
  not scratch the face of the cylinder head.
• Remove the cylinder head gasket. Retain the old
  gasket to help identification.

7
15 - Engine 06 - Cylinder Head 00 - General

• Make a note of the position of the dowels. Do not
  remove the dowels unless they are damaged.
• If necessary, remove the thermostat from the
  cylinder head. Refer to (PIL 21-12).
• Figure 79.
• A

1. Make sure that the new gasket is of the same
   thickness as the old gasket.
2. Align the gasket with the guide bolt and the
   dowels. Install the gasket onto the crankcase.
3. Lift the cylinder head with a suitable lifting
   device.
4. Align the cylinder head with the guide bolts on
   the crankcase. Install the cylinder head onto
   the crankcase.

1. Make sure that the cylinder head is correctly
   positioned on the dowels.
2. Remove the guide bolts.
3. Install the bolts to the cylinder head.
4. Tighten the bolts to the correct torque value in
   the specified numerical sequence only. Refer to
   Figure 78.
5. If removed, install the thermostat to the
   cylinder head. Refer to (PIL 21-12).
6. Install the cooling pump. Refer to (PIL 21-09).
7. Install the rocker shaft and the push rods. Refer
   to (PIL 15-42).
8. Install the glow plugs. Refer to (PIL 15-80).

B

1. Bolt
2. Cylinder head

Figure 80.
D
C
18. Install the fuel injectors. Refer to (PIL
18-18).
D

1. Install the fuel filter. Refer to (PIL 18-09).
2. Install the exhaust manifold. Refer to (PIL
   18-24).

C
Table 40. Torque Values
Item Description Nm
A Bolt 100

• Dowel
• Guide bolt (M11 by 100mm)
• Install
• Clean the mating surfaces of the cylinder head
  and the crankcase.
• Make sure that no debris enters the cylinder
  bores, the coolant passages, or the lubricant
  passages.
• Inspect the mating surface of the cylinder head
  for distortion. If the mating surface of the
  cylinder head is distorted beyond the maximum
  permitted limits, replace the cylinder head.
• Inspect dowels for damage. If necessary, replace
  the dowels in the crankcase.
• Install the guide bolts to the crankcase.

8
15 - Engine 09 - Bedplate 00 - General
00 - General Introduction The bedplate acts as
the main strength component of the engine. it
maintains the correct alignment and supports the
weight of the internal components. Figure 81. 1
2

1. Bedplate
2. Crankcase

15 - 33
15 - 33
9
15 - Engine 12 - Crankshaft 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-35 Technical Data
...............................................
15-36 Component Identification ...................
............ 15-36 Check (Condition)
..........................................
15-37 Remove and Install .........................
.............. 15-37
The crankshaft is housed inside the crankcase. It
is connected to the piston via a connecting rod,
they form a simple mechanism that converts
reciprocating motion into rotating motion. Refer
to Engine- General, Operation, The Four Stroke
Cycle (PIL 15-00).
15 - 35
10
15 - Engine 12 - Crankshaft 00 - General
Technical Data
Component Identification
Figure 84.
Table 41.
Description Data Data
Description Standard Service limit
Thrust washer thickness 2.953mm 0.5mm
Crankshaft end play 0.10.3mm 0.5mm

• Make sure that the oil grooves of all of the
  thrust washers are toward the crankshaft.
• Figure 82.

B
B
A
D
A

1. Crankcase
2. Crankshaft

• C
• Crankshaft
• Main bearing holder bolt
• Thrust washer
• Top thrust washer
• If the crankshaft end play exceeds the service
  limit, check the thrust washers for wear.
• Figure 83.
• F
• E

• A
• A Crankshaft
• Allen head screw
• Retaining bolt
• Table 42. Torque Values

Item Description Nm
B Main bearing holder bolt 52
E Allen head screw 27
F Retaining bolt 52
15 - 36
11
15 - Engine 12 - Crankshaft 00 - General
Remove and Install CAUTION This component is
heavy. It must only be removed or handled using a
suitable lifting method and device.
Check (Condition)

1. Check the main bearing surfaces for damage and
   excessive wear.
2. Measure the crankshaft diameters to confirm they
   are within service limits. Refer to
   Crankshaft- Technical Data (PIL 15-12).
3. Check that the oilway cross drillings in the
   crankshaft are clear and free from debris.
   Blocked or restricted oilways will cause oil
   starvation at the big end bearings.

Remove

1. Remove the engine oil relief valve. Refer to (PIL
   15-60).
2. Remove the crankshaft rear seal. Refer to (PIL
   15-12).
3. Remove the engine oil pump and the suction pipe.
   Refer to (PIL 15-60).
4. Remove the pistons and the connecting rods.
   Refer to (PIL 15-36).
5. Mount the engine in a suitable stand with the
   rear end facing upwards.
6. Remove the bolts from the crankcase.
7. Remove the Allen screws from the crankcase.
8. Attach a suitable lifting device to the
   crankshaft assembly.
9. Carefully lift the crankshaft assembly from the
   crankcase.

1. If necessary, gently tap the nose of the
   crankshaft with a soft faced hammer.
2. Install the nut for the crankshaft pulley to
   protect the nose of the crankshaft. Do not
   scratch the finished surfaces of the crankshaft.

15 - 37
12
15 - Engine 12 - Crankshaft 00 - General
Figure 85.

• Tighten the bolts and the screws to the correct
  torque value.
• Check the crankshaft end play.
• Push the crankshaft towards the front of the
  engine.
• Install a DTI (Dial Test Indicator) to the
  crankcase and the rear face of the crankshaft.
• Push the crankshaft toward the rear of the
  engine.
• Measure the crankshaft end play with the DTI.
• Make sure that the end play does not
  exceed the maximum permissible crankshaft end
  play. Refer to Crankshaft - Technical Data -
  (PIL 15-12).
• Table 43. Torque Values

C
D
B
A
Item Description Nm
C Bolt 52
D Allen screw 27

• Crankshaft
• Crankcase
• Bolt
• Allen screw
• Figure 86.
• E

A
B

• A Crankshaft
• B Crankcase
• E Lifting device
• Install
• Installation is the opposite of the removal
  procedure. Additionally do the following steps.
• Before installation make sure that all the
  components are clean and free from damage.

15 - 38
13
15 - Engine 12 - Crankshaft 03 - Main Bearing
03 - Main Bearing
Introduction
Introduction .....................................
............... 15-39 Check (Condition)
..........................................
15-40 Remove and Install .........................
.............. 15-41
In a piston engine, the main bearings are the
bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting
rods from dislodging the crankshaft, instead
forcing the crank to convert the reciprocating
movement into rotation. Figure 87.
A

• B
• Main bearing
• Main bearing bolts

15 - 39
14
15 - Engine 12 - Crankshaft 03 - Main Bearing
Check (Condition)
Figure 88.
Check the condition of the main bearings by
measuring the clearance between the two bearing
halves.
If the crankshaft journals and the bores for the
crankcase and connecting rods were measured, no
further checks are necessary. If the bearing
clearance measurement is necessary, the use of
the plastic gauge is an acceptable method. The
plastic gauge is less accurate on journals with
small diameters if the clearances are less than
0.1mm. When you use the plastic gauge make a note
of the following
A
B

• Make sure that the backs of the bearings and the
  bores are clean and dry.
• Make sure that the bearing locking tabs are
  properly seated in the tab grooves.
• The crankshaft must be free of oil at the contact
  points of the plastic gauge.

• Plastic gauge
• Bearing
• Measure the width of plastic gauge while the
  plastic gauge is in the bearing cap or on the
  crankshaft journal.
• Remove all of plastic gauges before you install
  the bearing cap.

Table 44. Plastic Gauges
Colour code Dimensions
Green 0.0250.076mm
Red 0.0510.152mm
Blue 0.1020.229mm
Yellow 0.230.51mm

• Measurement Procedure
• Put the plastic gauge on the crown of the bearing
  that is in the cap.
• Do not allow the plastic gauge to extend over the
  edge of the bearing.
• Use the correct torque-turn specifications in
  order to install the bearing cap.
• Do not use an impact wrench. Be careful not to
  dislodge the bearing when the cap is installed.
• Do not turn the crankshaft when the plastic gauge
  is installed.
• Carefully remove the cap, but do not remove the
  plastic gauge.

15 - 40
15
15 - Engine 12 - Crankshaft 03 - Main Bearing
Remove and Install
Remove

1. Remove the upper main bearing and the lower main
   bearing from the upper main bearing cap and the
   lower main bearing cap respectively.
2. Keep the main bearings with the respective
   bearing caps.
3. Do not remove the dowels from the main bearing
   caps.
4. Remove the front bearing with the driver tool.

1. Remove the crankshaft. Refer to (PIL 15-12).
2. Make sure that the bearing caps are marked for
   orientation and the correct position.
3. Remove the bolt and the upper main bearing cap
   from the lower main bearing cap.
4. Remove the thrust washer1 and the thrust washer2.

Figure 89.
A
A
B
C
D
B
E
F
F
G
G
H
A Bolt C Thrust washer1 E Lower main bearing G
Thrust washer2
B Upper main bearing cap D Upper main bearing F
Lower main bearing cap H Dowel
15 - 41
16
15 - Engine 12 - Crankshaft 03 - Main Bearing
Figure 90. K L

• Install the thrust washer1 and thrust washer2
• Make sure that the thrust washers are aligned
  correctly and the oil grooves are facing the
  crankshaft.
• Install the bolt and tighten to the correct
  torque value.
• Install the front bearing with the driver tool as
  follows
• Make sure that the oil supply hole is aligned
  with the oil gallery in the crankcase.
• Make sure that the joint is facing upwards.
• Make sure that the chamfer faces towards the
  crankcase.
• Install the crankshaft. Refer to (PIL 15-12).

J
M
J
N

1. Front bearing
2. Joint
3. Chamfer
4. Oil supply hole
5. Driver tool

• Install
• Clean the crankshaft thoroughly. Check the
  condition of the crankshaft. Refer to (PIL
  15-12).
• Clean all the bearings and thrust washers.
  Inspect all the components for wear or damage.
• Install the upper main bearing to the upper main
  bearing cap.
• Make sure that the locating tab for the upper
  main bearing is seated in the slot in the upper
  main bearing cap.
• The upper bearing has a groove.
• Install the lower main bearing to the lower main
  bearing cap.
• Make sure that the locating tab for the lower
  main bearing is seated in the slot in the lower
  main bearing cap.
• The lower bearing is a plain bearing that has
  oil holes.
• Lubricate the main bearings with clean engine
  oil.
• Keep the upper and the lower main bearing cap in
  position on the crankshaft.
• Make sure that the bearing caps are installed in
  the correct location and orientation. The
  locating tabs for the upper and the lower
  bearings should be on the same side of the
  engine.
• Make sure that the dowels are in the correct
  position. This is to make sure that the two
  halves of the main bearing caps are aligned.

15 - 42
17
15 - Engine 12 - Crankshaft 06 - Front Oil Seal
06 - Front Oil Seal Remove and Install Special
Tools
Alternative Removal Procedure

1. Remove the crankshaft pulley. Refer to (PIL
   15-12).
2. Remove the timing gear front case. Refer to (PIL
   15-51).
3. Press the front oil seal with a suitable mandrel
   and remove it from the front case.
4. Support the front case to prevent damage to the
   front case.

Description Part No. Qty.
Slide Hammer Kit 993/68100 1
Remove

• Make the machine safe. Refer to (PIL 01-03).
• Remove the crankshaft pulley. Refer to (PIL
  15-12).
• Do not damage the crankshaft during the
  removal process of the crankshaft front oil
  seal.
• Drill the front oil seal with a specified sized
  drill bit.
• Dimension 4mm
• Figure 91.

Install

• Make sure that the bore in the front case and the
  nose of the crankshaft are clean and free from
  damage.
• Lubricate the lip of the new crankshaft front
  seal with clean engine oil.
• Position the front oil seal in the bore of the
  front case.
• Make sure that the lip of the front oil seal that
  is spring loaded is facing toward the inside of
  the front case and that it is square with the
  bore of the case for the front oil seal.
• Install the front oil seal to the front case.
• Figure 92.

A
A
B
C
B
D

• Front case
• Front oil seal
• Slide hammer
• Make sure that the main lip is used to remove
  the front oil seal.
• Do not damage the edge of the housing for the
  front oil seal.
• Remove the front oil seal with a slide hammer.
  Special Tool Slide Hammer Kit (Qty. 1)
• Alternate the position of the slide hammer puller
  from one hole to another hole. This will allow
  you to evenly remove the front oil seal from the
  front case.

• A Front case
• B Front oil seal
• D Soft hammer
• If necessary, hit the front oil seal with a soft
  hammer.
• If removed, install the timing gear front case.
  Refer to (PIL 15-51).
• Install the crankshaft pulley. Refer to (PIL
  15-12).

15 - 43
18
15 - Engine 12 - Crankshaft 09 - Rear Oil Seal
09 - Rear Oil Seal

• or a damaged seal surface by installing a wear
  sleeve. Refer to (PIL 15-12).
• Apply clean engine lubricating oil to the flange
  of the crankshaft around the running surface of
  the rear oil seal.
• Align the new rear oil seal with the flange of
  the crankshaft.
• Carefully install the rear oil seal onto the
  crankshaft flange.
• Apply a continuous bead of Silicone Adhesive to
  the rear face of the crankcase around the edge
  of the rear oil seal and the plug.
• Consumable Clear Silicone Sealant
• Align the flywheel housing and the back plate to
  the dowels.
• Install the flywheel housing and the back plate.
  Refer to (PIL 15-54).

Remove and Install Consumables
Description Part No. Size
Clear Silicone Sealant 4102/0901 0.31L
Remove

• Make the machine safe. Refer to (PIL 01-03).
• Remove the flywheel. Refer to (PIL 15-54).
• Remove the bolt.
• Remove the flywheel housing and the back plate
  from the crankcase. Refer to (PIL 15-54).
• Remove and discard the rear oil seal.
• Figure 93.
• G

• Install the bolt to the crankcase.
• Tighten the bolt to the correct torque value.
• Install the flywheel. Refer to (PIL 15-54).
• Table 45. Torque Values

A
B
D
Item Description Nm
C Bolt 25
F
E
C

• Rear oil seal
• Back plate
• Bolt
• Dowel
• Crankcase
• Crankshaft flange
• Silicone Adhesive
• Install
• Make sure that the mating surface of the
  crankcase, back plate and the flywheel housing
  are clean and free from damage.
• Inspect the dowels. If the dowels are damaged,
  replace them.
• Make sure that the crankshaft flange is clean
  and free from damage. It is possible to reclaim
  a crankshaft flange that has a worn seal surface

15 - 44
19
15 - Engine 12 - Crankshaft 12 - Pulley
12 - Pulley Remove and Install
Figure 95.
A
B
Remove

• Make the machine safe. Refer to (PIL 01-03).
• Remove the engine drive belt. Refer to (PIL
  15-18).
• Loosen the nut. Do not remove the nut at this
  time.
• Install the puller on the pulley with the bolt
  (x3).
• Figure 94.

C
D

1. Woodruff key
2. Pulley
3. Nut
4. Crankshaft

B
Install

• Make sure that all the components are clean and
  free from damage.
• Replace any components that are damaged.
• Make sure that the taper of the crankshaft and
  the bore of the crankshaft pulley are clean and
  dry.
• Install the woodruff key to the crankshaft.
• Install the pulley to the crankshaft.
• Lubricate the nut with clean engine oil and
  install it.
• Tighten the nut to the correct torque value.
• Install the engine drive belt. Refer to (PIL
  15-18).
• Table 46. Torque Values

E
F

• B Pulley
• Puller
• Bolt (x3)
• Pull out the pulley from the crankshaft with the
  puller.
• Remove the bolt (x3) and the puller from the
  pulley.
• Remove the loosened nut.
• Remove the pulley from the crankshaft.
• Remove the woodruff key from the crankshaft.

Item Description Nm
C Nut 304
15 - 45
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15 - Engine 12 - Crankshaft 24 - Wear Sleeve
24 - Wear Sleeve Remove and Install
Figure 97.
A
C
The wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. The wear
sleeves are not original equipment.
C
Remove

• Make the machine safe. Refer to (PIL 01-03).
• Remove the rear oil seal. Refer to (PIL 15-12).
• Mark a deep score line across the crankshaft
  wear sleeve with a sharp tool.
• Take care not to damage the crankshaft.
• Figure 96.

• A Wear sleeve
• C Liquid gasket
• Apply a bead of liquid gasket at the specified
  distance from the flange end of the crankshaft
  wear sleeve.
• Distance 5mm
• Align the wear sleeve with the crankshaft.
• Position the installation tool that is provided
  with the wear sleeve over the crankshaft.
• Drive the wear sleeve on the crankshaft with a
  slide hammer.
• Make sure that the distance from the edge of the
  wear sleeve to the rear face of the crankshaft
  is the same as specified. Refer to Figure 98.
• Distance 2.5 0.1mm
• Figure 98.

A
B

• Wear sleeve
• Crankshaft
• Insert a thin blade between the wear sleeve and
  the crankshaft below the scored line. The
  crankshaft wear sleeve will separate along the
  line.
• Remove and discard the wear sleeve from the
  crankshaft.

A
B
D
E

• Install
• Make sure that the crankshaft is thoroughly clean
  and dry. Remove any areas of raised damage.
• Apply a small continuous bead of liquid gasket
  to the inner surface of the wear sleeve at the
  specified position. Refer to Figure 97.

• Wear sleeve
• Crankshaft
• Installation tool
• Distance from the edge of the wear sleeve to the
  rear face of the crankshaft (2.5 0.1mm)
• Remove the installation tool.
• Make sure that the wear sleeve has no rough
  edges.

10. Install the new rear oil seal. Refer to (PIL
15-12).
15 - 46
9813/6200-1
15 - 46
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