About this Manual
Using the Service Manual
Section Numbering
Left Side, Right Side
Units of Measurement
Machine Related Data
Acronyms and Abbreviations
Identifying the Engine
Engine Identification Plate
Engine Labels
Component Labels
Engine Identification Number Explanation
Engine Component Identification
Technical Data
Basic Engine Data
Engine Specifications
Engine Block & Bed plate Data
Cylinder Head Data
Inlet and Exhaust Valve Data
Rocker Levers, Rocker Shaft and Tappets Data
Pistons and Connecting Rods Data
Crankshaft Data
Camshaft Data
Fuel System Data
Acceptable and Unacceptable Fuels
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Lubrication System Data
Cooling System Data
Electrical Equipment Data
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
Torque + Angle Explanation
Torque+ Angle Tightening Procedure
Engine Torque Figures
Lubricants and Capacities
Engine Lubricating Oil
Recommended Oils
Engine Oil Capacity
Service Aids
Sealing, Retaining and Care Compounds
Service Tools
General Engine Tools
Specialist Engine Tools
Service Tool Drawings
Core Plug Fitting Tool
Crankshaft Turning Tool
Timing Pin
Sump Sealant Template
Oil Sump Location Dowel
Injector Sleeve Removal Tool
Valve Stem Seal Fitting Tool
Cover Removal Tool
Gear Removal Tool
Crankshaft Front Seal Fitting Tool
Crankshaft Rear Seal Fitting Tool
Crankshaft Rear Seal Alignment Tool
Injector Seal Fitting Tool
Dummy Injector
Top Dead Centre (TDC) Setting Tool
Engine Mounting Frame
Service Parts and Repair Kits
Engine Repair Parts and Kits Identification
Engine Lifting
Lifting Information
Operating Procedures
Starting the Engine
Pre Start Notes
Start Procedure
Engine Checks After Start up
Engine Running in Procedure
Stopping the Engine
Routine Maintenance
Maintenance Procedures
Cleaning the Engine
High Pressure Cleaning
Lubricants Health and Safety
Waste Disposal
First Aid Oi I
Spillage
Fires
Service Schedules
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Engine Cooling System
Coolant Mixtures
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive (FEAD) Belt
Engine Fuel System
Draining the Water Separator and Fuel Filter
Changing the Filter Element
Changing the Water Separator Pre Filter
Priming the Fuel System
Air Intake System
Cleaning the Engine Breather Gauze
Engine Overview
External
Internal
The Four Stroke Cycle
Camshaft and Valve Operation
The Four Cylinder Cycle JCB Engine
Firing Order
Timing Gears
Timing
Valve Train
Front End Accessory Drive (FEAD) Belt System
Lubrication System
Oil Cooler and Filter
Oil Cooler Matrix
Oil Filter
Camshaft Lubrication
Crankshaft Lubrication
Rocker Assembly Lubrication
Piston Cooling and Small End Bearing Lubrication
Fuel System
Basic Description
Pre Filter/Water Separator, Lift Pump and Fuel Filter
Pre Filter/Water Separator
Lift Pump
Fuel Injection Pump Injection Cycle
State A Charging
State B Injecting
Fuel Injector Pump Governor
State A Increasing Engine Speed
State B Decreasing Engine Speed
Features of the Delphi DP /DP Fuel Injection Pump
Cold Start Advance Shown at A
Hydraulic Light Load Advance
Variable Fueling Shown at B
Latch Valve
ESOS Electric Shut Off Solenoid
Turbo Boost Control (Turbocharged engines only)
Injectors and Combustion
Combustion
Induction, Exhaust and Breather Systems
Induction and Exhaust Systems
Naturally Aspirated
Turbocharged
Intercooled
Exhaust Gas Recirculation (EGR)
Engine Breather
SA, SB, SC Engines
SD, SF Engines
Cooling System
Description
State A 'Closed' Engine Cooled
State B 'Open' Engine Hot
Injectors
Electrical System
Electrical Circuit Schematic
Electrical Components
Fault Finding
Introduction
Fault Finding Charts
A Charts Engine
B Charts Fuel
C Charts Lubricating Oil
D Charts Coolant
Test Procedures Introduction
Lift Pump Operation
Pressure Test Procedures
Measuring the Inlet Restriction
Fuel Injection Pump Delivery
Engine Compression
Engine Oil Pressure
High Lubrication Oil Pressure
Low Lubrication Oil Pressure
Air System and Turbocharger
Air Filters
Air Intake Connections
Exhaust Manifold Leaks (Turbocharged Engines)
Turbocharger Checks
Wastegate Operational Check
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid Electrolyte
Testing
Specific Gravity Testing
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starting Circuit Test
Fuel Filter
Fuel Lines
Identification
High Pressure Fuel Lines
Low Pressure Fuel Lines
Fuel Bleed off Lines (Low Pressure)
Fuel Lift Pump
Fuel Injection Pump
Component Identification
Before Removing:
Fuel Injectors (Atomisers)
Bleeding Air From The System
Drive Belt Coolant Pump
Front End Accessory Drive Belt (FEAD)
Thermostat
Coolant Inlet Assembly
Coolant Pump
Lubricating Oil Cooler
Oil Filter Head
Oil Pan (Sump)
Oil Pump
Lubricating Oil Cooler and Filter Head
Starter Motor
Alternator
Electric Shut Off Solenoid (ESOS)
Cold Start Advance Solenoid
Engine Cold Start Switch
Engine Oil Pressure Switch
Coolant Temperature Sender Unit
Turbocharger
Dismantling
Assembly
Exhaust Manifold
After Replacing
Inlet Manifold
Before Removing
Removal
Inspection
Replacement
Cylinder Head
Rocker Cover
Dismantling and Assembly
Rocker Assembly
Valve Clearances
Cylinder Head Assembly
Valves, Valve Springs and Stem Seals
Front End Accessory Drive Belt System (FEAD)
Tensioner
Flywheel and Housing
Flywheel
Flywheel Gear Ring
Flywheel Housing
Timing Case and Drive Gears Assembly
Drive Gear Fuel Injection Pump
Drive Gear Crankshaft
Drive Gear High Duty P T O Idler
Drive Gear Camshaft
Camshaft and Tappets
Timing Case Rear
Pistons and Connecting Rods
Big End Bearing
Removal, Inspection and Assembly
Piston and Connecting Rod Assembly
Dismantling, Inspection and Assembly
Crankshaft Assembly
Crankshaft Pulley
Rear Oil Seal
Front Oil Seal
Crankshaft
Removal and Replacement
3: JCB Bulletins & Safety Procedures
1300+ pages PDF
30 to 40 safety issues & 500+ issues for AFFECTED MACHINES:
3CX, 4CX, 214, 215, 217 And Variants Below !!
this 3rd Bonus pdf explains the procedures to repair
Yes indicates a safety issue ex: 024 1 yes Backhoe Pivot Pins
________________________________________________
001 1 no Backhoe Loader/Unloader Valve Improvements 01/11/89 3547
002 1 no Backhoe Breaker Conversion Kit 01/11/89 354