JCB TLT 30D High Lift, TLT 35D, TLT 35D 4×4 TELETRUK (VARIABLE REACH TRUCK) Service Repair Manual Instant Download (SN 2252520 and up)

1
Foreword
SERVICE MANUAL TELETRUK (VARIABLE REACH
TRUCK) TLT 30D High Lift, TLT 35D, TLT 35D
4x4 EN - 9813/2500 - ISSUE 4 -
08/2017 This manual contains original
instructions, verified by the manufacturer (or
their authorized representative). Copyright
2017 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
Handling 06 - Body and Framework 09 - Operator
Station
and Load
12 -
Heating, Ventilating and Air-
Conditioning (HVAC) 15 - Engine
18 - Fuel and Exhaust System 21 - Cooling
System 24 - Brake System 25 - Steering 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
Calibrate
Remove and Install For Kohler KDI 1903 TCR
........ Page 15-39 For Kohler KDI 2504 TCR
........ Page 15-41
Flatness Check Put the cylinder head on a surface
plate and measure its flatness with a dial
gauge. If the level deviation is greater than
0.10mm (0.004in), the cylinder head must be
machined. The cylinder head should not be
machined more than 0.20mm (0.008in) in
depth. Figure 100.
(For Kohler KDI 1903 TCR) Consumables
Description Part No. Size
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
CAUTION This component is heavy. It must only be
removed or handled using a suitable lifting
method and device.
B
Before Removal

1. This procedure requires service parts. Make sure
   you have obtained the correct 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. Get access to the engine.
4. Remove the thermostat. Refer to PIL 21-12-00.
5. Remove the exhaust manifold. Refer to PIL
   18-24-04.
6. Remove the inlet manifold. Refer to PIL
   18-24-03.
7. Remove the rocker cover. Refer to PIL 15-42-06.
8. Remove the rocker assembly. Refer to PIL
   15-42-00.

A

1. Cylinder head
2. Dial gauge

Remove Make sure that the engine is at ambient
temperature before you remove the cylinder head,
to prevent deformation. 1. Remove the bolts
that attach the cylinder head to the crankcase.
Note that the bolts must not be re-used. Discard
the bolts.
15 - 39
3
15 - Engine 06 - Cylinder Head 00 - General
Figure 101.
Figure 103.
M
B
N
C
A
L

• Piston
• Crankcase
• Measuring points
• Turn the crankshaft to put the piston at TDC
  (Top Dead Centre).
• Put a dial gauge on the crankcase and measure
  the piston protrusion from the crankcase
  surface.
• Do step 3.2 again for all the pistons.
• Record the highest mean value by applying the
  fraction given in Refer to Table 26.
• 4. Make sure that all items are clean and free
  from damage and corrosion.

• Cylinder head
• Bolt
• Eye-bolt
• Carefully lift the cylinder head from the
  crankcase. Only use the eye-bolts installed on
  the cylinder head to move the cylinder head.
• Remove and discard the head gasket.
• Figure 102.

D
Table 26.
Fraction Number of identifica- tion hole
0.030.126mm
0.1270.25mm
0.2510.375mm

• D Head gasket
• Using a suitable cleaning agent, carefully remove
  all traces of the head gasket material from the
  cylinder head and crankcase mating faces.
• Consumable Cleaner/Degreaser - General purpose
  solvent based parts cleaner
• Check the cylinder head and crankcase mating
  faces for signs of damage and distortion.
• Refer to PIL 15-06-00.

Assemble

1. Replacement is the reversal of the removal
   procedure.
2. Position a new head gasket on to the crankcase
   mating face. Make sure that the gasket is
   installed in the correct orientation and
   correctly aligned with the bushings.

Before Assembly

1. Measure the injector projection. Refer to PIL
   18-18-00.
2. Obtain the correct new cylinder head bolts. Note
   that the original bolts must not be re-used.
3. Obtain the correct replacement head gasket. Note
   the number of identification holes as shown in
   Refer to Table 26.

15 - 39
4
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5
15 - Engine 06 - Cylinder Head 00 - General
Figure 104.

• Tighten the bolts in six stages, use the torque
  and angle method.
• Refer to PIL 72-00-00.
• Tighten the bolts, starting with the middle pair
  and working outwards (in sequence 1-10) to the
  1st stage pre-torque.
• Then, further tighten the bolts, starting with
  the middle pair and working outwards (in
  sequence 1-10) to the 2nd stage pre- torque.
• Then, re-tighten the bolts, starting with the
  middle pair and working outwards (in sequence
  1-10) to the 3rd stage pre-torque.
• Use the angle gauge to angle tighten the bolts,
  starting with the middle pair and working
  outwards (in sequence 1-10) to the 4th stage
  pre-torque. As a visual check, match mark the
  bolts to the cylinder head before you start.
  When the bolts have been angle tightened, the
  match marks will appear as shown.
• Figure 107.

Q
D
M
P

• D Head gasket
• M Crankcase
• Centering bushings
• Identification holes
• 3. Lower the cylinder head on to the crankcase.
  Make sure that the cylinder head is correctly
  aligned with the bushings.
• Figure 105.
• A

0 90 90 90
P
P

• Then, further angle tighten the bolts, starting
  with the middle pair and working outwards (in
  sequence 1- 10) to the 5th stage pre-torque.
• Finally, angle tighten the bolts, starting with
  the middle pair and working outwards (in
  sequence 1- 10) for the final stage torque.
• Table 27.

• A Cylinder head
• P Bushings
• Install the new cylinder head bolts.
• Tighten the bolt to the correct torque value.
  Strictly follow the torque sequence shown.
• Figure 106.

Description Torque Value
Cylinder head to crankcase bolts 1-10
- first stage torque 40Nm
- second stage torque 70Nm
- third stage torque 100Nm
- fourth stage torque 90
- fifth stage torque 90
- final stage torque 90
1
3
7
5
8
(For Kohler KDI 2504 TCR) Consumables
Description Part No. Size
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
4
2
6
6
15 - Engine 06 - Cylinder Head 00 - General
CAUTION This component is heavy. It must only be
removed or handled using a suitable lifting
method and device.

• Carefully lift the cylinder head from the
  crankcase. Only use the eye-bolts installed on
  the cylinder head to move the cylinder head.
• Remove and discard the head gasket.
• Figure 109.

Before Removal

1. This procedure requires service parts. Make sure
   you have obtained the correct 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. Get access to the engine.
4. Remove the thermostat. Refer to PIL 21-12-00.
5. Remove the exhaust manifold. Refer to PIL
   18-24-04.
6. Remove the inlet manifold. Refer to PIL
   18-24-03.
7. Remove the rocker cover. Refer to PIL 15-42-06.
8. Remove the rocker assembly. Refer to PIL
   15-42-00.

D

• D Head gasket
• Using a suitable cleaning agent, carefully remove
  all traces of the head gasket material from the
  cylinder head and crankcase mating faces.
• Consumable Cleaner/Degreaser - General purpose
  solvent based parts cleaner
• Check the cylinder head and crankcase mating
  faces for signs of damage and distortion.
• Refer to PIL 15-06-00.

Before Assembly
Remove Make sure that the engine is at ambient
temperature before you remove the cylinder head,
to prevent deformation.

• Measure the injector projection. Refer to PIL
  18-18-00.
• Obtain the correct new cylinder head bolts. Note
  that the original bolts must not be re-used.
• Obtain the correct replacement head gasket. Note
  the number of identification holes as shown in
  Refer to Table 28.
• Figure 110.
• M

1. Remove the bolts that attach the cylinder head
to the crankcase. Note that the bolts must not
be re-used. Discard the bolts. Figure 108.
B
C
A
N
L

1. Cylinder head
2. Bolt
3. Eye-bolt

1. Piston
2. Crankcase
3. Measuring points

7
15 - Engine 06 - Cylinder Head 00 - General

• Turn the crankshaft to put the piston at TDC.
• Put a dial gauge on the crankcase and measure
  the piston protrusion from the crankcase
  surface.
• Do step 3.2 again for all the pistons.
• Record the highest mean value by applying the
  fraction given in Refer to Table 28.
• 4. Make sure that all items are clean and free
  from damage and corrosion.

Figure 112.
A
P
P
Table 28.
Fraction Number of identifica- tion hole
0.030.126mm
0.1270.25mm
0.2510.375mm

• A Cylinder head
• P Bushings
• Install the new cylinder head bolts.
• Tighten the bolt to the correct torque value.
  Strictly follow the torque sequence shown.
• Figure 113.

10
9
3
1
5
7
Assemble

• Replacement is the reversal of the removal
  procedure.
• Position a new head gasket on to the crankcase
  mating face. Make sure that the gasket is
  installed in the correct orientation and
  correctly aligned with the bushings.
• Figure 111.

• 4 2 6 8
• Tighten the bolts in six stages, use the torque
  and angle method.
• Refer to PIL 72-00-00.
• Tighten the bolts, starting with the middle pair
  and working outwards (in sequence 1-10) to the
  1st stage pre-torque.
• Then, further tighten the bolts, starting with
  the middle pair and working outwards (in
  sequence 1-10) to the 2nd stage pre- torque.
• Then, re-tighten the bolts, starting with the
  middle pair and working outwards (in sequence
  1-10) to the 3rd stage pre-torque.
• Use the angle gauge to angle tighten the bolts,
  starting with the middle pair and working
  outwards (in sequence 1-10) to the 4th stage
  pre-torque. As a visual check, match mark the
  bolts to the cylinder head before you start.
  When the bolts have

Q
D
M
P

• D Head gasket
• M Crankcase
• Centering bushings
• Identification holes
• 3. Lower the cylinder head on to the crankcase.
  Make sure that the cylinder head is correctly
  aligned with the bushings.

8
15 - Engine 06 - Cylinder Head 00 - General
been angle tightened, the match marks will
appear as shown. Figure 114.
0 90 90 90

• Then, further angle tighten the bolts, starting
  with the middle pair and working outwards (in
  sequence 1- 10) to the 5th stage pre-torque.
• Finally, angle tighten the bolts, starting with
  the middle pair and working outwards (in
  sequence 1- 10) for the final stage torque.
• Table 29.

Description Torque Value
Cylinder head to crankcase bolts 1-10 Cylinder head to crankcase bolts 1-10
- first stage torque 40Nm
- second stage torque 70Nm
- third stage torque 100Nm
- fourth stage torque 90
- fifth stage torque 90
- final stage torque 90
9
15 - Engine 09 - Bedplate 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-47 Remove and Install
....................................... 15-48
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 115.
1
2

1. Bedplate
2. Crankcase

15 - 47
10
15 - Engine 09 - Bedplate 00 - General

• Remove the timing gear front case. Refer to PIL
  15-51-21.
• Remove the fuel injection pump. Refer to PIL
  18-18-15.
• Remove the fuel injection drive gear. Refer to
  PIL 15-51-00.
• Remove the intermediate drive gear. Refer to
  PIL 15-51-00.
• Remove the high duty PTO (Power Take-Off) device
  (if installed).
• Remove the fuel injectors. Refer to PIL
  18-18-03.
• Remove the rocker cover. Refer to PIL 15-42-06.
• Remove the rocker assembly including the push
  rods.
• Refer to PIL 15-42-00.
• It is not necessary to remove the cylinder head
  assembly to remove the bedplate. If however, the
  cylinder head needs to be removed for other
  reasons (for piston and connecting rod removal
  for example) remove it now.
• Refer to PIL 15-06-00.
• Position the engine upside down in a suitable jig
  or fixture, supported at the front of the
  crankcase.

Remove and Install For Kohler KDI 1903 TCR
........ Page 15-48 For Kohler KDI 2504 TCR
........ Page 15-51
(For Kohler KDI 1903 TCR) Consumables
Description Part No. Size
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
CAUTION This component is heavy. It must only be
removed or handled using a suitable lifting
method and device.
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. Get access to the engine.
4. Remove the drive belt. Refer to PIL 15-18-03.
5. Remove the oil sump. Refer to PIL 15-45-00.
6. Remove the turbocharger (if installed).
7. Remove the exhaust manifold. Refer to PIL
   18-24-04.
8. Remove the starter motor. Refer to PIL
   15-75-00.
9. Remove the flywheel housing. Refer to PIL
   15-54-03.

Remove
1. Remove the main bearing bolts in the sequence
shown. Figure 116.
B

1. Remove the crankshaft rear oil seal flange.
   Refer to PIL 15-12-09.
2. Remove the EGR (Exhaust Gas Recirculation) (if
   installed).
3. Remove the inlet manifold.

A
Refer to PIL 18-24-03. 13. Disconnect and remove
pressure fuel pipes. Refer to PIL 18-96-00.

• Bedplate
• Main bearing bolts (x8)
• 2. Remove the bedplate peripheral bolts in the
  sequence shown.

the high and low
15 - 47
11
15 - Engine 09 - Bedplate 00 - General
Figure 117.
available prior to assembling the components. The
parts must be installed and tightened to the
correct torque value within 5min minutes (with a
maximum permissible time of 15min).
Important BEFORE you install the bedplate DO
NOT rotate the crankshaft. Make sure that the
upper main bearing shells are flush with the
bottom face of the crankcase.
C
Install Important The crankshaft half bearings
are made of special material. Therefore, they
must be replaced every time they are removed to
prevent seizures. The lower and upper crankshaft
half bearings cannot be replaced singularly, and
both halves must be replaced together.

• C Peripheral bolts (x13)
• Carefully separate the bedplate from the
  crankcase. Use suitable lifting equipment (if the
  bedplate is lifted manually, two people will be
  required). Do not use a lever to separate the
  bedplate.
• Carefully remove the lower bearing shells from
  the bedplate.
• Figure 118.

• Make sure that all items are clean and free from
  damage and corrosion.
• Use a suitable degreasing agent to clean both
  sides of the lower bearing shells.
• Consumable Cleaner/Degreaser - General purpose
  solvent based parts cleaner
• Install the lower bearing shells into the
  bedplate. Make sure that the reference notches
  are at the correct location.
• Figure 119.

A
E
D
D
A Bedplate D Lower bearing shells (x4)
Before Installation
A

• A Bedplate
• Lower bearing shells (x4)
• Reference notch
• Lubricate the lower bearing shells with clean
  engine oil.
• Install the two shoulder half-rings onto the
  lower crankcase. Apply two dots of ITP GX100
  grease to hold the rings in position.

• Clean off all traces of the old sealant compound
  from the crankcase and bedplate mating faces.
• Use a suitable degreasing agent to carefully
  clean the main bearing saddles in the bedplate
  and crankcase. Take care not to block the oil
  ways or the piston cooling jets.
• Consumable Cleaner/Degreaser - General purpose
  solvent based parts cleaner

Important Anaerobic sealant will not start to
cure whilst it is open to the atmosphere,
however when air is excluded (for instance when
the two parts are put together) it will
immediately start to harden. Make sure that all
the necessary tools, bolts etc. are readily
15 - 47
12
15 - Engine 09 - Bedplate 00 - General
Figure 120.
Figure 122.
F
D
G
D Lower bearing shells (x4) F Shoulder
half-rings (x2) G Guide pins 6. Apply a 1.0mm
(0.04in) thick bead of Loctite 5188 around the
crankcase/bedplate mating face as shown. Figure
121. L

• Install the bedplate peripheral bolts (x13).
• Tighten the bolts to the correct torque value in
  two stages. Strictly follow the torque sequence
  shown.
• Figure 123.

H
J

• K
• H Crankcase
• Loctite 5188
• Oil feed holes
• Return oil grooves

1. Make sure that you do not block the oil feed
   holes and the return oil grooves.
2. Assemble the bedplate to the crankcase. Make
   sure that the guide pins on the crankcase are
   engaged properly in the slots on the bedplate.
3. Note The bedplate is heavy. Two people will be
   required to lift and rotate the bedplate safely
   on to the crankcase.

Important If the parts have not been tightened
to the correct torque value within the maximum
15min time period, then the parts must be
separated, thoroughly cleaned and fresh sealant
should be applied.
After Installation

1. Check that the crankshaft can be freely rotated
   by hand.
2. Measure the crankshaft end float. Make sure that
   the end float is between 0.18mm (0.007in) and
   0.38mm (0.015in).
3. Carry out the procedures listed in the 'Before
   Removal' section in reverse order.

1. Install the main bearing bolts (x8).
2. Tighten the bolts to the correct torque value in
   three stages. Strictly follow the torque sequence
   shown.

15 - 47
13
15 - Engine 09 - Bedplate 00 - General
Table 30. Torque Values

• Remove the EGR (if installed).
• Remove the inlet manifold. Refer to PIL
  18-24-03.
• Disconnect and remove the high and low pressure
  fuel pipes.
• Refer to PIL 18-96-00.
• Remove the timing gear front case. Refer to PIL
  15-51-21.
• Remove the fuel injection pump. Refer to PIL
  18-18-15.
• Remove the fuel injection drive gear. Refer to
  PIL 15-51-00.
• Remove the intermediate drive gear. Refer to
  PIL 15-51-00.
• Remove the high duty PTO device (if installed).
• Remove the fuel injectors. Refer to PIL
  18-18-03.
• Remove the rocker cover. Refer to PIL 15-42-06.
• Remove the rocker assembly including the push
  rods
• Refer to PIL 15-42-00.
• It is not necessary to remove the cylinder head
  assembly to remove the bedplate. If however, the
  cylinder head needs to be removed for other
  reasons (for piston and connecting rod removal
  for example) remove it now.
• Refer to PIL 15-06-00.
• Position the engine upside down in a suitable jig
  or fixture, supported at the front of the
  crankcase.

Item Description Nm
B Main bearing bolts (x8) (1st Stage) 40
B Main bearing bolts (x8) (2nd Stage) 70
B Main bearing bolts (x8) (3rd Stage) 120
C Peripheral bolts (x13) (4th Stage) 20
C Peripheral bolts (x13) (5th Stage) 35
(For Kohler KDI 2504 TCR) Consumables
Description Part No. Size
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
CAUTION This component is heavy. It must only be
removed or handled using a suitable lifting
method and device.
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. Get access to the engine.
4. Remove the drive belt. Refer to PIL 15-18-03.
5. Remove the oil sump. Refer to PIL 15-45-00.
6. Remove the turbocharger(if installed).
7. Remove the exhaust manifold. Refer to PIL
   18-24-04.
8. Remove the starter motor. Refer to PIL
   15-75-00.
9. Remove the flywheel housing. Refer to PIL
   15-54-03.

Remove 1. Remove the main bearing bolts in the
sequence shown.
10. Remove the crankshaft rear oil seal flange.
Refer to PIL 15-12-09.
15 - 47
14
15 - Engine 09 - Bedplate 00 - General
Figure 124.
Figure 126.
A
B
D
A

• Bedplate
• Main bearing bolts (x10)
• 2. Remove the bedplate peripheral bolts in the
  sequence shown.
• Figure 125.

A Bedplate D Lower bearing shells (x5)
Before Installation

• Clean off all traces of the old sealant compound
  from the crankcase and bedplate mating faces.
• Use a suitable degreasing agent to carefully
  clean the main bearing saddles in the bedplate
  and crankcase. Take care not to block the oil
  ways or the piston cooling jets.
• Consumable Cleaner/Degreaser - General purpose
  solvent based parts cleaner

C
Important Anaerobic sealant will not start to
cure whilst it is open to the atmosphere,
however when air is excluded (for instance when
the two parts are put together) it will
immediately start to harden. Make sure that all
the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and tightened to the
correct torque value within 5min minutes (with a
maximum permissible time of 15min). Important
Before installing the bedplate Do not rotate
the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of
the crankcase.

• C Peripheral bolts (x17)
• Carefully separate the bedplate from the
  crankcase. Use suitable lifting equipment (if the
  bedplate is lifted manually, two people will be
  required). Do not use a lever to separate the
  bedplate.
• Carefully remove the lower bearing shells from
  the bedplate.

Install Important The crankshaft half bearings
are made of special material. Therefore, they
must be replaced every time they are removed to
prevent seizures. The lower and upper crankshaft
half bearings cannot be replaced singularly, and
both halves must be replaced together.

1. Make sure that all items are clean and free from
   damage and corrosion.
2. Use a suitable degreasing agent to clean both
   sides of the lower bearing shells.

15 - 47
15
15 - Engine 09 - Bedplate 00 - General
Figure 129. L
Consumable Cleaner/Degreaser - General purpose
solvent based parts cleaner 3. Install the lower
bearing shells into the bedplate. Make sure that
the reference notches are at the correct
location. Figure 127.
H
J
E
K
D

• H Crankcase
• Loctite 5188
• Oil feed holes
• Return oil grooves
• Make sure that you do not block the oil feed
  holes and the return oil grooves.
• Assemble the bedplate to the crankcase. Make
  sure that the guide pins on the crankcase are
  engaged properly in the slots on the bedplate.
• Note The bedplate is heavy. Two people will be
  required to lift and rotate the bedplate safely
  on to the crankcase.

A

• A Bedplate
• Lower bearing shells (x5)
• Reference notch
• Lubricate the lower bearing shells with clean
  engine oil.
• Install the two shoulder half-rings onto the
  lower crankcase. Apply two dots of ITP GX100
  grease to hold the rings in position.
• Figure 128.

• Install the main bearing bolts (x10).
• Tighten the bolts to the correct torque value in
  three stages. Strictly follow the torque sequence
  shown.
• Figure 130.

F
D
B
G
D Lower bearing shells (x5) F Shoulder
half-rings (x2) G Guide pins 6. Apply a 1.0mm
(0.04in) thick bead of Loctite 5188 around the
crankcase/bedplate mating face as shown.
A

1. Install the bedplate peripheral bolts (x17).
2. Tighten the bolts to the correct torque value in
   two stages. Strictly follow the torque sequence
   shown.

15 - 47
16
15 - Engine 09 - Bedplate 00 - General
Figure 131.
C

• Important If the parts have not been tightened
  to the correct torque value within the maximum
  15min time period, then the parts must be
  separated, thoroughly cleaned and fresh sealant
  should be applied.
• After Installation
• Check that the crankshaft can be freely rotated
  by hand.
• Measure the crankshaft end float. Make sure that
  the end float is between 0.18mm (0.007in) and
  0.38mm (0.015in).
• Carry out the procedures listed in the 'Before
  Removal' section in reverse order.
• Table 31. Torque Values

Item Description Nm
B Main bearing bolts (x10) (1st Stage) 40
B Main bearing bolts (x10) (2nd Stage) 70
B Main bearing bolts (x10) (3rd Stage) 120
C Peripheral bolts (x17) (4th Stage) 20
C Peripheral bolts (x17) (5th Stage) 35
15 - 47
17
15 - Engine 12 - Crankshaft 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-57 Technical Data
...............................................
15-58 Component Identification ...................
............ 15-58 Operation ....................
................................... 15-59 Check
(Condition) ......................................
.... 15-60 Calibrate .............................
........................... 15-61 Remove and
Install .......................................
15-63
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 PIL 15-00-00.
15 - 57
18
15 - Engine 12 - Crankshaft 00 - General
Technical Data
Component Identification
Figure 132.
Table 32.
Main bearing journal di- ameter (x4)
- min 63.981mm (2.5189in)
- max 64.00mm (2.5196in)
Connecting rod bearing journal diameter
- min 54.035mm (2.1274in)
- max 54.066mm (2.1286in)
Maximum wear and ovality on journals(1)
Crankshaft end float
- min 0.18mm ( 0.0070in)
- max 0.38mm ( 0.0149in)
B
(1) No visible damage/wear or marks
A

1. Crankcase
2. Crankshaft

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19
15 - Engine 12 - Crankshaft 00 - General
Operation
Refer to Camshaft-Operation PIL 15-15-00
diameter of the upper main bearing shell allows
oil transfer to cross drillings in the
crankshaft to feed each of the big end bearings.
Crankshaft gear is 'splash' lubricated. Front
and rear crankshaft oil seals prevent oil
leakage from, and dirt ingress to, the engine.
Lubrication Oil is fed from the main gallery via
five drillings, one to each of the main
bearings. A groove around the
Figure 133.
1 Main gallery 3 Main bearings 5 Cross
drillings 7 Crankshaft oil seal
2 Drillings (x5) 4 Big end bearings 6 Crankshaft
gear 8 Crankshaft oil seal
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20
15 - Engine 12 - Crankshaft 00 - General
Check (Condition)

• Check the main bearing surfaces for damage and
  excessive wear.
• Measure the crankshaft diameters to confirm they
  are within service limits.
• Refer to PIL 15-12-00.
• 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. 4. Check that
the piston cooling oil sprayers are clear (if
installed). If the sprayers cannot be cleared
remove the fixing screws. Remove the sprayers
and discard them.
Figure 134. A
D
B
C
E
A Crankshaft C Oil spray jets (if installed) E
Main bearing shells
B Shoulder half-rings D Fixing screws
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21
15 - Engine 12 - Crankshaft 00 - General
Calibrate
Axial clearance check

1. Measure the axial shift of the crankshaft with a
   dial gauge. The axial shift must range between
   0.18-0.38mm (0.007-0.015in).
2. If the value is more than or less than the
   specified range, replace the shoulder rings.

1. To measure the axial clearance of the
crankshaft, it is necessary to assemble the
shaft in the crankcase.
Figure 135.
B
A
A Crankshaft
B Dial gauge
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22
15 - Engine 12 - Crankshaft 00 - General
Dimensional Check

1. Measure the diameter of the crank-pins and main
   journals with a micrometer.
2. Measure the internal diameter of the connecting
   rod and crankshaft half-bearings with a dial
   gauge.
3. Lubricate the contact surfaces with oil to
   prevent oxidation.
4. The crankshaft and connecting rod half-bearings
   must necessarily be replaced every time they are
   disassembled.

1. Make sure that you clean the crankshaft
   thoroughly with a suitable detergent.
2. Use a pipe cleaner into the lubrication ducts to
   remove any residual dirt.
3. Use a compressed air jet to thoroughly clean the
   oil passages.
4. Check the surfaces of the main journals and
   crank-pins for wear limit, to see whether
   grinding is necessary.
5. Install the half-bearings on the semi-crankcases,
   without crankshaft, and couple the semi-
   crankcases by tightening the fixing screws.

10. Make sure that the measurements are within
the allowable limits.
Figure 136.
A
B
C
D
A Crank-pin C Connecting rod half-bearing
B Main journal D Crankshaft half-bearing
15 - 57
23
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15 - Engine 12 - Crankshaft 00 - General
Remove and Install
Consumables

• 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.
• Get access to the engine.
• Remove the bedplate. Refer to PIL 15-09-00.
• If the pistons and connecting rods have not been
  removed, then remove the main bearing caps.
• Refer to PIL 15-12-00.

Description Part No. Size
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
CAUTION This component is heavy. It must only be
removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts
Catalogue. Figure 137. A
B
B
C
D
F
E
A Crankshaft
B Thrust Washers
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9813/2500-4
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25
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