JCB 525-60 Telescopic Handler Service Repair Manual Instant Download

1
Foreword
SERVICE MANUAL LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK) 525-60 EN -
9813/3900 - ISSUE 3 - 02/2018 This manual
contains original instructions, verified by the
manufacturer (or their authorized
representative). Copyright 2018 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 00 - Engine 00 - General
00 - General
Introduction
Introduction .....................................
................. 15-3 Health and Safety
...........................................
15-5 Technical Data ..............................
................... 15-6 Component Identification
................................. 15-7 Operation
..................................................
..... 15-10 Diagram ..............................
........................... 15-14 Fault-Finding
..................................................
15-15 Drain and Fill ............................
..................... 15-18 Clean
..................................................
........... 15-19 Check (Pressure)
..........................................
15-20 Remove and Install .........................
.............. 15-20 Store and Recommission
.............................. 15-22
This section contains information about the
complete engine assembly. For specific engine
technical information refer to the technical
data section.
Make sure that the correct engine service tools,
consumables and torque figures are used when you
perform service procedures.
Replacement of oil seals, gaskets, etc., and any
component that show signs of wear or damage, is
expected as a matter of course.
It is expected that components will be cleaned
and lubricated where required, and that any
opened hose or pipe connections will be blanked
to prevent excessive loss of hydraulic fluid,
engine oil and ingress of dirt.
Basic Description The Kohler KDI engine is a 4
cylinder diesel engine in which the fuel is
ignited by compression ignition (C.I.). The
engine operates on a four stroke cycle. The
engine is started by an electric starter motor.
The starter motor turns the engine via a pinion
and teeth on the engine flywheel. When the
engine runs the crankshaft drives the camshaft
though the gears. The camshaft opens and closes
the inlet and exhaust valves and through push
rods in time with the four stroke cycle. The
engine has 16 valves, 2 inlet and 2 exhaust
valves for each cylinder. The crankshaft also
drives a mechanical high pressure fuel pump via
gears. The pump is part of the electronically
controlled common rail fuel injection
system. Air is drawn into the engine through the
inlet manifold and exhaust gases exit through
the exhaust manifold. The engine uses a variable
geometry turbocharger which pressurises the air
at the inlet manifold. A mechanical lubrication
oil pump is driven by the crankshaft through
gears. The pump pressurises and circulates oil
for engine lubrication and cooling purposes. A
drive belt again driven by the crankshaft, drives
a coolant circulation pump and
alternator. Internal The following identifies the
main internal components of a typical engine
assembly. Some variants may differ in detail.
9813/3900-3
15 - 10
3
15 - Engine 00 - Engine 00 - General
Figure 135.
H
D
G
F E
C B
A
B Crankshaft gear D Camshaft gear F Tappet H
Valve
A Crankshaft C Intermediate gear E Camshaft G
Push rod Figure 136. C
Figure 137.
D
M
Q
N
P
L
K
H
J

• A B
• Crankshaft
• Crankshaft gear
• Intermediate gear
• Camshaft control gear J Camshaft phonic wheel K
  Intermediate gear pin
• L Phonic wheel positioning reference pin on
  camshaft

G

• Rocker arm push rod
• Valve
• Articulation control valve
• Valve control bridge
• Hydraulic tappet
• Rocker arm

9813/3900-3
15 - 10
4
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5
15 - Engine 00 - Engine 00 - General
Health and Safety 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. Turning the Engine Do
not try to turn the engine by pulling the fan or
fan belt. This could cause injury or premature
component failure. Notice The engine and other
components could be damaged by high pressure
washing systems. Special precautions must be
taken if the machine is to be washed using a
high pressure system.Make sure that the
alternator, starter motor and any other
electrical components are shielded and not
directly cleaned by the high pressure cleaning
system. Do not aim the water jet directly at
bearings, oil seals or the engine air induction
system. WARNING! To bleed the injectors you must
turn the engine. When the engine is turning,
there are parts rotating in the engine
compartment.Before starting this job make sure
that you have no loose clothing (cuffs, ties
etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts. Notice 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. Notice Do not exceed the correct level
of engine oil in the sump. If the maximum is
exceeded, the excess must be drained to the
correct level. An excess of engine oil could
cause the engine speed to increase rapidly
without control. 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. WARNING!
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this
job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin
cancer. Notice A drive belt that is loose can
cause damage to itself and/or other engine
parts. WARNING! Do not open the high pressure
fuel system with the engine running. Engine
operation causes high fuel pressure. High
pressure fuel spray can cause serious injury or
death. CAUTION! It is illegal to pollute drains,
sewers or the ground. Clean up all spilt fluids
and/or lubricants.Used fluids and/or lubricants,
filters and contaminated materials must be
disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
6
15 - Engine 00 - Engine 00 - General
Technical Data Table 46.
Description
Engine Type KDI 2504 TCR
Emission compliance US-EPA Tier 4 final, EU Stage IIIB
Max. operating speed 2200 RPM (Revolutions Per Minute)
Power Output 55kW at 2200 RPM
Weight (Dry) 233kg
Number of cylinders 4
Nominal bore size 88mm
Stroke 102mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.482L
Compression ratio 17 1
Direction of rotation (viewed from flywheel end) Counterclockwise
Valves 4 per cylinder
Tappets Hydraulic
Lubricating oil pressure (Dependent on engine temperature and speed) 12.8bar (14.540.6psi)
Filter type Screw-on canister
Pressure to open by- pass valve 2.5 0.5bar (36.2 7.2psi)
Oil pressure switch set- ting 0.8 0.1bar (11.6 1.4psi) falling
Oil pump(1) Integral unit with relief valve
Combustion system Common rail direct In- jection
High pressure fuel pump High pressure with elec- tronically controlled fuel metering
(1) The oil pump is a non-serviceable part
7
15 - Engine 00 - Engine 00 - General
Component Identification
External The following identifies the main
components of a typical engine assembly visible
from the exterior. Some variants may differ in
detail. Figure 138.
L
K J
M
H
N
G F
E
A
B
P
C
D
A Flywheel housingRefer to PIL 15-54-03. C Fuel
filterRefer to PIL 18-09-00. E DipstickRefer
to PIL 15-45-09. G Oil coolerRefer to PIL
15-69-00. J High pressure fuel pumpRefer to PIL
18-18-15. L Catalytic converterRefer to PIL
18-24-18.
B FlywheelRefer to PIL 15-54-00. D Fuel filter
drain plugRefer to PIL 18-09-00. F Oil
filterRefer to PIL 15-21-00. H PTO (Power
Take-Off) cover (If installed) K Inlet
manifoldRefer to PIL 18-24-03.
M EGR (Exhaust Gas Recirculation) valveRefer to
PIL 18-27-06. P ECM (Engine Control Module)
N Engine harness
8
15 - Engine 00 - Engine 00 - General
Figure 139.
R
A
Q
B
P
C D
N
M
K
E
L
H
F
G
J
A ThermostatRefer to PIL 21-12-00. C Cooling
pumpRefer to PIL 21-09-00. E Crankshaft phonic
wheelRefer to PIL 15-12-15. G Timing gear
caseRefer to PIL 15-51-21. J Oil sump drain
plugRefer to PIL 15-45-03. L BedplateRefer to
PIL 15-09-00.
B Oil filler capRefer to PIL 15-57-00. D Drive
beltRefer to PIL 15-18-03. F Oil sumpRefer to
PIL 15-45-00.
H AlternatorRefer to PIL 15-72-00. K
CrankcaseRefer to PIL 15-03-00. M Crankcase
ventilation filterRefer to PIL 15-27-00. P Oil
pressure sensorRefer to PIL 15-84-21. R Outlet
manifoldRefer to PIL 18-24-04.
N Starter motorRefer to PIL 15-75-00. Q Cylinder
headRefer to PIL 15-06-00.
9
15 - Engine 00 - Engine 00 - General
Figure 140.
H
J
G
K
A
F E
B
C
D
A InjectorRefer to PIL 18-18-03. C Turbocharger
actuatorRefer to PIL 18-35-00. E Turbocharger
linkRefer to PIL 18-35-00. G Low pressure fuel
return pipesRefer to PIL 18-96-06. J High
pressure fuel pipesRefer to PIL 18-96-03.
B Rocker coverRefer to PIL 15-42-06. D
TurbochargerRefer to PIL 18-35-00. F Oil filler
capRefer to PIL 15-57-00. H EGR coolerRefer to
PIL 18-27-09.
K Fuel railRefer to PIL 18-18-12.
10
15 - Engine 00 - Engine 00 - General
Operation
Firing Order A cylinder is said to be firing,
when the fuel/air mixture ignites and the piston
is about to start its power stroke. From the
stages described, it can be seen that number 1
cylinder will be next to fire. Number 3 cylinder
is starting its compression stroke and is next
in the cycle, followed by cylinders 4 and 2. The
firing order is therefore 1, 3, 4, 2. The
stages in the four stroke cycle for each cylinder
are as follows
The Four Cylinder Cycle This section describes
the cycle sequence for the 4 cylinder
engine. With the crankshaft positioned as shown,
the pistons in numbers 1 and 4 cylinders are at
top dead centre and pistons in numbers 2 and 3
cylinders are at bottom dead centre. It is
important to note that number 1 cylinder is
firing and about to start its Power stroke.
Rotating the crankshaft a further full rotation
would position the pistons as described but the
engine would be at a different stage in its four
stroke cycle, with number 1 cylinder about to
start its Induction stroke.
Table 47. The Four Stroke Cycle
Cylinder number Piston operation Valve operation
1 The piston is at the top of its Compression stroke and is about to start its Power stroke. Inlet and exhaust valves closed
2 The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke. Inlet valves closed, exhaust valves about to open
3 The piston is at the bottom of its Induction stroke and is about to start its Compression stroke. Exhaust valves closed, inlet valves about to close.
4 The piston is at the top of its Exhaust stroke and is about to start its Induction stroke. Valve Operation Exhaust valves about to close, inlet valves about to open
11
15 - Engine 00 - Engine 00 - General
Figure 141. Typical Four Cylinder
Engine CYL2 CYL3 CYL4
CYL1
1
2
5
A
C B
C B
C B
C B
G
H
J
K
4
3
F
745620
745620
G
H
J
K
C
B
B
C
A
A
A
A
B
C
C
B
CYL1 Cylinder number 1 CYL2 Cylinder number 2
CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
12
15 - Engine 00 - Engine 00 - General
Four Stroke Cycle Induction As the piston travels
down the cylinder, it draws filtered air at
atmospheric pressure and ambient temperature
through an air filter and inlet valves into the
cylinder.
The temperature rises to a point at which the
fuel/air mixture ignites. A cylinder is said to
be firing when the fuel/air mixture ignites.
This combustion causes a very rapid rise in both
temperature and pressure. The high pressure
generated propels the piston downwards turning
the crankshaft and producing energy.
Exhaust Once the piston has reached the bottom of
its travel, the exhaust valves open and momentum
stored in the flywheel forces the piston up the
cylinder expelling the exhaust gases.
Compression When the piston reaches the bottom of
its stroke, the inlet valves close. The piston
then starts to rise up the cylinder compressing
the air trapped in the cylinder. This causes the
temperature and pressure of the air to rise.
Fuel is injected into the cylinder when the
piston is near to TDC (Top Dead Centre).
In a running engine, these four phases are
continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle
of a four stroke engine, the crankshaft revolves
twice.
Power The piston continues to rise after the
start of fuel injection, causing a further
increase in pressure and temperature.
Figure 142.
3
2
C
B
4
1
746030
1 Induction stroke 2 Compression stroke
3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC
13
15 - Engine 00 - Engine 00 - General
Figure 143.
717620
1
2
3
4
B
C
A
A
A
A
B C
B
C
B
C
1 Induction stroke 3 Power stroke A Camshaft C
Camshaft lobe - Exhaust valve operation
2 Compression stroke 4 Exhaust stroke B Camshaft
lobe - Inlet valve operation
14
15 - Engine 00 - Engine 00 - General
Diagram
Electrical Operation and Schematics The schematic
diagram shows a typical system. For machine
specific schematics, refer to electrical system-
general, refer to (PIL 33-00). The schematic is
shown with the ignition switch set to position
III and the transmission set to N. A
signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
CAN (Controller Area Network)bus to tell the
Engine ECU that the transmission is in Neutral.
The engine ECU provides power to the engine
compartment fusebox to energise the start relay,
the fuel pump relay, the starter motor and the
fuel pump.
Figure 144.
Charge D
A
W
ECU
F
M D
-VE
VE
B
3
4 5
H
6 7
1
M
2
E
8
K
9 10
J
C
ECU
L
G
-VE
VE
A Alternator C Ignition switch E Primary fuse G
Engine compartment fusebox J Fuel pump relay L
Engine ECU
B Battery D Starter motor F RHC/LMS (Loadall
Monitoring System) display H Start signal relay K
Fuel pump
15
15 - Engine 00 - Engine 00 - General
Drain and Fill Oil Oil is toxic. If you swallow
any oil, do not induce vomiting, seek medical
advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not
handle used engine oil more than necessary.
Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use
petrol, diesel fuel or paraffin to clean your
skin. CAUTION! It is illegal to pollute drains,
sewers or the ground. Clean up all spilt fluids
and/or lubricants.Used fluids and/or lubricants,
filters and contaminated materials must be
disposed of in accordance with local
regulations. Use authorised waste disposal sites.
CAUTION! Oil will gush from the hole when the
drain plug is removed. Keep to one side when you
remove the plug.

1. Remove the oil dipstick.
2. Remove the oil sump drain plug and O-ring from
   both sides of the oil sump.
3. Drain the engine oil into an suitable container.
4. Clean and install the drain plug with a new O-
   ring. Tighten the plug to the correct torque
   value.

10. Through one of the filler points, fill the
engine with the recommended oil to the MAX mark
on the dipstick. Figure 146.
Engine oil replacement must be completed in
accordance with the service schedules. Failure to
replace the oil replacement at the recommended
interval could cause serious engine failure.
A
Drain the oil when the engine is warm as
contaminants held in suspension will then be
drained with the oil.

• Make the machine safe. Refer to PIL 01-03-27.
• Park the machine on a hard level surface for
  accurate measurement of the oil level.
• Get access to the engine.
• Place a container of suitable size beneath the
  drain plug.
• Remove the oil filler cap.
• Figure 145.

A Oil filler cap
Figure 147.
D
E
F
A

• Dipstick
• Maximum level mark
• Minimum level mark
• Wipe off any spilt oil, install the filler cap
  and make sure it is secure.
• Operate the engine, until the oil pressure low
  warning light has extinguished.
• Check for oil leakage.
• When the oil has cooled, check the oil level
  again, and if necessary top up with clean engine
  oil.

C
B
A Oil filler cap B Drain plug C O-ring
9813/3900-3
15 - 18
16
15 - Engine 00 - Engine 00 - General
Clean Notice 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. Notice The engine and other components
could be damaged by high pressure washing
systems. Special precautions must be taken if
the machine is to be washed using a high
pressure system. Make sure that the alternator,
starter motor and any other electrical
components are shielded and not directly cleaned
by the high pressure cleaning system. Do not aim
the water jet directly at bearings, oil seals or
the engine air induction system.

1. When the pressure washing is complete, move the
   machine away from the wash area, or
   alternatively, clean away the material washed
   from the machine.
2. Before working on specific areas of the engine,
   use a compressed air jet to dry off any moisture.
   When the area is dry, use a soft clean brush to
   remove any sand or grit particles that remain.
3. When removing components, be aware of any dirt
   or debris that may be exposed. Cover any open
   ports and clean away the deposits before
   proceeding.

Additional cleaning must be carried out prior to
working on the high pressure fuel system. Refer
to Fuel System, General, Clean.

• Before carrying out any service procedures that
  require components to be removed, the engine must
  be properly cleaned.
• Cleaning must be carried out either in the area
  of components to be removed or, in the case of
  major work, or work on the fuel system, the
  whole engine and surrounding machine must be
  cleaned.
• Stop the engine and allow it to cool for at least
  one hour. DO NOT attempt to clean any part of
  the engine while it is running.
• Make sure that the electrical system is isolated.
• Make sure that all electrical connectors are
  correctly connected. If connectors are open
  install the correct caps or seal with water proof
  tape.
• Cover the alternator with a plastic bag to
  prevent water ingress.
• Seal the engine air intake, exhaust and breather
  system.
• Make sure that the oil filler caps and dipstick
  are correctly installed.
• Use a low pressure water jet and brush to soak
  off mud or dirt.
• Apply an approved cleaning and degreasing agent
  with a brush. Obey the manufacturers
  instructions.
• Use a pressure washer to remove the soft dirt
  and oil. Important DO NOT aim the water jet
  directly at oil seals or electrical and
  electronic components such as the engine
  electronic control unit (ECU), alternator or
  fuel injectors. DO NOT place the jet nozzle
  closer than the specified distance to any part
  of the engine.
• Distance 600mm

9813/3900-3
15 - 18
17
15 - Engine 00 - Engine 00 - General
Check (Pressure) Special Tools
Remove and Install Lifting Equipment You can be
injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the
item to be lifted then choose lifting equipment
that is strong enough and suitable for the job.
Make sure that lifting equipment is in good
condition and complies with all local
regulations.
Description Part No. Qty.
Pressure Gauge (0-40 Bar) 892/00278 1

• Make the machine safe with the excavator/lift
  arm lowered.
• Refer to PIL 01-03-27.
• Make sure that the engine oil and fuel are at the
  correct level.
• Remove the pressure switch. Refer to PIL
  15-84-21.
• Connect a pressure gauge to the pressure switch
  fitting.
• Special Tool Pressure Gauge (0-40 Bar) (Qty. 1)
• Figure 148.

The lifting equipment used must be an approved
type and capable of lifting the engine safely.
The recommended lifting equipment is shown. Use
a spreader bar when lifting the engine. Never
attempt to manually lift heavy components on
your own. Always use lifting equipment, or
obtain the help of an assistant. Inspect the
lifting brackets for signs of damage. The
brackets must be correctly torqued to the
crankcase. Make sure the lifting equipment does
not damage any of the engine dressing and the
rocker cover.
There will be some component differences
depending on the machine variant. Before
attempting to remove the engine ensure that all
the necessary components have either been
removed, or safely disconnected from the engine.
A
Before Removal

• 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.
• Position the machine on firm level ground. Make
  the machine safe.
• Refer to PIL 01-03-27.
• Get access to the engine. Refer to PIL 06-06-06.

1. Start the engine.
2. Monitor the oil pressure with respect to the oil
   temperature.

Remove
7. The oil pressure should specified
value. Pressure 1.5bar (21.7psi)
be more than the

1. Disconnect and remove the battery. Refer to PIL
   33-03-00.
2. Drain the engine oil. Refer to PIL 15-00-00.
3. Drain the engine cooling system. Refer to PIL
   21-00-00.
4. Remove the cooling pack.
5. Discharge the hydraulic pressure. Refer to PIL
   30-00-00.

1. Stop the engine and allow it to cool.
2. Remove the pressure gauge and install the
   pressure switch.

9813/3900-3
15 - 18
18
15 - Engine 00 - Engine 00 - General

1. Drain the hydraulic tank. Disconnect and plug
   the hydraulic pipes. Label the hoses to help
   installation.
2. Disconnect and plug the hydraulic cooler hoses.
   Label the hoses to help installation.

Figure 149.

1. Disconnect the exhaust system.
2. Label the cab heater hoses at the engine
   crankcase. Release the hose clips and remove the
   hoses.

B
B

• Disconnect the wiring starter motor.
• Refer to PIL 15-75-00.
• Disconnect the wiring alternator.
• Refer to PIL 15-72-00.
• Disconnect the wiring

connections from the
A
A

• Lifting eye
• Sling
• Take the weight of the engine on the hoist and
  remove the engine mounting bolts.
• Withdraw the engine in a level attitude until it
  is clear of the chassis. Raise the engine to
  lift it clear of the machine.
• Lower the engine into a suitable stand that is
  capable of supporting the weight of the engine.

connections from the
connections from the
engine sensors and actuators. Refer to PIL
15-84.

1. Disconnect the fuel supply line at the fuel lift
   pump and the spill line at the fuel injection
   pump. Cap all hoses and ports to prevent ingress
   of dirt.
2. Disconnect the electrical harness at the engine
   harness.
3. Uncouple the electrical harness at the ECM
   (Engine Control Module) machine side connector.
   Important DO NOT touch the connector pins on
   the ECM or harness connectors. Cover the
   connectors to prevent contamination.
4. Ensure that all relevant harnesses and hoses are
   unclipped from the engine and tied out of the
   way.
5. Disconnect and plug the hoses at the hydraulic
   pump.
6. Disconnect the wiring to the hydraulic pump.
7. Attach slings to the engine lifting eyes.

Install

• Replacement is a reversal of the removal
  procedure. Note the following
• Fill the cooling system with the correct mix of
  coolant fluid.
• Refer to PIL 75-00-00.
• Fill and Check the hydraulic fluid level. Refer
  to PIL 30-00-00.
• Fill and Check the engine oil level. Refer to
  PIL 15-00-00.
• On completion, check the hydraulic and cooling
  system for leakage and levels.
• Check the function of the drive and hydraulic
  services.

Table 70. Torque Values
Item Nm
A 25
9813/3900-3
15 - 18
19
15 - Engine 00 - Engine 00 - General
Store and Recommission Consumables

1. Seal the exhaust and intake ducts to prevent
   contamination.
2. Clean the engine. Refer to PIL 15-00-00.
3. Apply protective paints on non-painted parts.
4. Loosen the alternator belt.
5. Cover the engine with a proper protective sheet
   to prevent it from dampness and atmospheric
   contaminants.

Description Part No. Size
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
Engine Storage (up to 6 months) Before you store
the engine make sure that

• The environment is not humid or exposed to bad
  weather.
• The storage place is not near an electrical
  panel.
• Prevent storing the engine in direct contact with
  the ground.
• 1. Cover the engine with a proper protective
  sheet to prevent it from dampness and
  atmospheric contaminants.

Engine Starting After Storage

• Remove the protective sheet.
• Use a cloth soaked in degreasing fluid to remove
  the protective treatment from the external parts.
• Consumable Cleaner/Degreaser - General purpose
  solvent based parts cleaner
• Inject lubricating oil (not more than 2cm³) into
  the intake ducts.
• Adjust the alternator belt tension. Refer to
  PIL 15-18-00.
• Refuel the machine.
• Make sure that the oil and the coolant are up to
  the maximum level.
• Start the engine and run it at idle speed for the
  specified duration.
• Duration 2min
• Bring the engine to 75 of the maximum rated
  speed for the specified duration.
• Duration 510min
• Stop the engine.

Engine Storage (over 6 months)

• Follows the precautions mentioned in the above
  procedure.
• Fill the engine housing with protective oil up to
  the maximum level.
• Refuel the machine with fuel additives for long
  storage.
• For machines with expansion tank
• Make sure that the coolant is up to the maximum
  level.
• For machines without expansion tank
• Fill the coolant until the pipes inside the
  radiator are covered by specified distance.
• Distance 5mm
• Do not overfill the radiator, but leave
  sufficient space for the fuel to expand.
• Start the engine and run it at idle speed for the
  specified duration.
• Duration 2min
• Bring the engine to 75 of the maximum rated
  speed for the specified duration.
• Duration 510min
• Turn off the engine.
• Drain the fuel tank completely.

• While the oil is still hot, drain the protective
  oil in a suitable container.
• Put new oil up to the maximum level.
• Replace the filters (air, oil, fuel).
• Drain the cooling circuit completely and put new
  coolant up to the maximum level.
• Important Over time, lubricants and filters lose
  their properties, so it is important to consider
  whether they need replacing, also based on the
  criteria mentioned in the maintenance schedules.
• If the engine is not to be used for an extended
  period, the protective treatment procedure must
  be repeated within 730d of the previous one.

10. Spray engine oil (SAE 10W40) on the exhaust
and intake manifolds.
9813/3900-3
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15 - Engine 03 - Crankcase 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-25 Technical Data
...............................................
15-26 Clean ......................................
....................... 15-27 Calibrate
..................................................
...... 15-28 Remove and Install
....................................... 15-29
The crankcase is the housing for the crankshaft.
The enclosure forms the largest cavity in the
engine and is located below the cylinders. It is
integral with the cylinder bank and forms an
engine block. It has an opening in the bottom to
which an oil sump is attached with a gasket and
bolted joint.
The crankcase protects the crankshaft and
connecting rods from foreign objects it also
keeps the engine oil contained and allows the
oil to be pressurised and also provide the rigid
structure with which to join the engine to the
transmission. Figure 150.
B
A

1. Crankcase
2. Crankshaft

9813/3900-3
15 - 25
21
15 - Engine 03 - Crankcase 00 - General
Technical Data
Fourth stage 20Nm
Fifth stage 35Nm
Table 71. Crankcase and Bedplate Data (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. Table 72.
Cylinder bore Data
Main bearing bolts torque(1)
First stage 40Nm
Second stage 70Nm
Third stage 120Nm
Peripheral bolts
Dimensional Class(1) Cylinder Diameter(1) Piston Diameter(1) Clearance(1)
STD 88.003mm (3.4647in)-88.017mm (3.4652in) 87.943mm (3.4623in)-87.957mm (3.4628in) 0.046mm ( 0.0018in)-0.074mm (0.0029in)
R0.1 88.103mm (3.4686in)-88.117mm (3.4691in) 88.043mm (3.4663in)-88.057mm (3.4668in) 0.046mm ( 0.0018in)-0.074mm (0.0029in)
0.5 88.503mm (3.4843in)-88.517mm (3.4849in) 88.443mm (3.4820in)-88.457mm (3.4826im) 0.046mm ( 0.0018in)-0.074mm (0.0029in)
1 89.003mm (3.5041in)-89.017mm (3.5046in) 88.943mm ( 3.5017in)-88.957mm (3.5022in) 0.046mm ( 0.0018in)-0.074mm (0.0029in)
(1) This table shows the reference values and
their classification applicable for new engines
only.
9813/3900-3
15 - 25
22
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15 - Engine 03 - Crankcase 00 - General
Clean
2. Put a pipe cleaner in all the open ports to
clean the oil pipes,as shown.
Oil pipes Important Make sure you keep a safe
distance from all of the open ports. 1. Remove
all the plugs.

1. Use a compressed air line to remaining oil.
2. Install all the plugs with Loctite.

remove any
Figure 151. A
A
B
A
A
A Plug
B Oil pipe
15 - 27
9813/3900-3
15 - 27
24
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