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Jcb jcb305, js305 excavator service repair manual (from 2452101 to 2452200)

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This document is a service manual for an excavator model JCB305, JS305. It contains instructions for servicing and repairing components of the excavator, listed by system (e.g. engine, hydraulic system, electrical system). The manual provides technical specifications, diagrams, removal and installation instructions, and checking/inspection procedures for parts like the engine, pistons, connecting rods, and more. Safety warnings are included to treat the manual as part of the machine and follow all instructions to avoid injury during operation and maintenance.

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SERVICE MANUAL EXCAVATOR JCB305, JS305 EN - 9813/6700 - ISSUE 1 - 12/2016 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 6-09-02 © 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 Foreword 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
15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 15 - 128 9813/6700-1 15 - 128 Check (Condition) 1. Check the bearing shell surfaces for signs of damage and excessive wear. 2. Measure the crank pin diameters to confirm they are within service limits, refer to Technical Data (PIL 15-33). 3. Renew any parts that are worn or not within the specified tolerances. Remove and Install Special Tools Tool Category Description Part No. Qty. Special Tool Torque Wrench (10-100Nm) 993/70111 1 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. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 5. Remove the rocker cover, refer to (PIL 15-42). 6. Remove the fuel injectors, refer to (PIL 18-18). 7. Drain the oil from the engine, refer to (PIL 15-21). 8. Remove the oil sump, refer to (PIL 15-45). 9. Position the engine upside down in a suitable jig or fixture, supported at the front of the crankcase. The connecting rod and the big-end bearing cap have been fracture split and must be kept together as a set. Care must be taken to avoid contamination and or damage to the fracture split surfaces. Remove 1. It is recommended that the big-end bearing caps are removed in pairs, cylinders 1 and 4 and cylinders 2 and 3. Rotate the crankshaft so that the big-end bearing caps on cylinders 2 and 3 are positioned as shown. 2. Remove the bolts and lift off the big-end bearing caps from the connecting rods. The bolts must not be re-used, discard the bolts.
15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 15 - 129 9813/6700-1 15 - 129 Figure 148. X 1 2 1 Big-end bearing caps 2 Big-end bearing cap bolts X Cast notch 3. Lift out the bearing shells from the bearing caps. Carefully rotate the crank to disengage from the connecting rods and get access to the upper bearing shells. Lift out the upper bearing shells. It is recommended that the bearing shells are renewed. If they are to be reused, label the bearing shells to make sure that they are installed in their original positions on assembly. Figure 149. 4 3 7Z 1 2 6 5 1 Big-end bearing cap 2 Bolts 3 Connecting rod 4 Piston 5 Piston rings 6 Lower bearing shell 7 Upper bearing shell Z Fracture split surfaces 4. Carefully rotate the crankshaft to position the big- end bearing caps of cylinders 1 and 4. Make sure that the crank does not foul the connecting rods of cylinders 2 and 3. Remove the bearing caps and bearing shells as described in previous steps. 5. Inspect the big-end bearings for signs of damage and excessive wear, refer to Check Condition (PIL 15-12). Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion.
15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 15 - 130 9813/6700-1 15 - 130 3. Install the upper bearing shell to the connecting rod. Lubricate the bearing shell with clean engine oil. 4. Install the lower bearing shell to the big-end bearing cap. Lubricate the bearing shell with clean engine oil. Install the big-end bearing cap to the connecting rod. Make sure that the cast notch on the bearing cap faces to the front of the engine. Use compressed air to clean the fracture surfaces before assembly. 5. Install new fixing bolts. Tighten the new bolts in three stages to the correct torque value. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) Figure 150. T3 T3 Angle gauge (obtain locally) 6. The bolts are tightened using a torque and angle method, refer to Fasteners and Fixings, General, Introduction (PIL 72-00). Figure 151. 0° +90° Y After Installation 1. Carry out the procedures listed, Before Removal in reverse order. Table 65. Item Torque Value 2 - 1st Stage 35N·m 2 - 2nd Stage 65N·m 2 - Final Stage 90°
15 - Engine 36 - Piston 00 - General 15 - 134 9813/6700-1 15 - 134 Technical Data Table 66. Engine 444 - SE Engine 444 - excluding SE en- gine 448, 672 Gudgeon pin bore diame- ter - min. 4.0008mm 40.01mm 42.008mm - max. 40.013mm 40.015mm 42.013mm Piston ring clearance - Top ring Half keystone ring Full keystone ring Full keystone ring - Middle ring 0.11–0.07mm 0.125–0.08mm 0.125–0.08mm - Bottom (oil) ring 0.09–0.05mm 0.09–0.05mm 0.09–0.05mm Piston ring gap - Top ring 0.3–0.5mm 0.3–0.4mm 0.3–0.4mm - Middle ring 0.55–0.8mm 0.55–0.8mm 0.55–0.8mm - Bottom (oil) ring 0.25–0.5mm 0.25–0.5mm 0.25–0.5mm Piston height above crankcase (cold) 0.0375–0.3385mm 0.00025–0.36825mm (1) 0.00025–0.36825mm (1) Piston groove width - Top ring 3.108–3.133mm 3.114–3.134mm 3.114–3.134mm - Middle ring 2.56–2.58mm 2.575–2.595mm 2.575–2.595mm - Bottom (oil) ring 4.04–4.06mm 4.04–4.06mm 4.04–4.06mm Piston skirt - 102.853–102.871mm 105.851–105.869mm Piston pin - 39.994–40mm 41.994–42mm (1) Nominal measurement is 0.03325mm
15 - Engine 36 - Piston 00 - General 15 - 135 9813/6700-1 15 - 135 Component Identification Figure 152. 120° 120° 120° Y X C TOP 2A 3B 4 4a TOP TOP 1 7 6 7 5 1 Piston 2 Piston ring - compression No.1 3 Piston ring - compression No.2 4 Piston ring - oil control ring 4a Spiral wire - oil control ring 5 Connecting rod 6 Piston pin 7 Retaining circlip (x2) X Connecting rod - longest side Y Cast boss - piston
15 - Engine 36 - Piston 00 - General 15 - 136 9813/6700-1 15 - 136 Operation The groove around the diameter of the upper main bearing shells allows oil transfer to an oil jet located in the crankcase bearing saddle. Jets are installed at the main bearing positions. The jets spray oil directly to the under side of the pistons effectively transferring heat away from the top of the pistons. Oil spray also enters the small end bearing bushes via a feed hole on the top of each connecting rod. Note: On turbocharged engines additional J-jets are installed. Oilways connect the J-shaped jets fixed to the crankcase at the underside of each cylinder bore. Figure 153. 2 6 1 1 2 4 5 3 1 Groove 2 Oil jet 3 Pistons 4 Bearing bushes 5 Crankshaft 6 J shaped jets
15 - Engine 36 - Piston 00 - General 15 - 137 9813/6700-1 15 - 137 Check (Condition) 1. Check the piston for signs of damage and excessive wear. Measure the piston skirt diameter, piston pin bore and the clearance in the piston ring grooves to confirm they are within service limits. Refer to Piston, Technical Data (PIL 15-36). 2. Check the piston pin for signs of damage and excessive wear. Measure the pin diameter to confirm it is within service limits. Refer to Piston, Technical Data (PIL 15-36). The connecting rod small end bearing bush is not renewable. If the small end bearing bush is damaged or worn the connecting rod must be renewed as a complete assembly. Calibrate Piston Height Measurement Above Cylinder Block- DTI Method Refer to engine, piston, technical data, (PIL 15-36-00). In the event of sufficient liquid entering the engine, a hydraulic lock can occur. This may result in bending of one or more of the connecting rods. Bending of the connecting rod(s) can occur even when the engine is cranked by the starter motor. Bending of the connecting rod may be very slight and can be checked by carrying out this procedure prior to a full strip down: 1. With the cylinder head removed, make sure the surface of the engine block and piston are clean. 2. Zero a DTI (Dial Test Indicator) on the top face of the cylinder block adjacent to the area on the piston to be measured. The aim of the procedure is to use the DTI to take a measurement across 2 locations on the piston that are on the axis of the gudgeon pin. This will be towards the front and rear of the engine. 3. Rotate the engine and bring the piston up until it is 3mm below the engine block face. Carefully reposition the zeroed DTI above the area of the piston to be measured. 4. Rotate the engine to bring the piston up to exactly TDC (Top Dead Centre) and record the measurement at position 1. 5. Repeat steps 2 to 4 for position 2. 6. Calculate the average of the 2 readings to give a figure of the piston height above the cylinder block. 7. Compare the reading obtained to the technical data. 7.1. If the reading obtained is lower than zero, the connecting rod may be bent. 7.2. If the reading obtained is equal to the range stated in technical data, the connecting rod is not bent. 8. Repeat steps 2 to 7 to check all connecting rods/ pistons. 9. If any connecting rods are bent, strip the engine and check for further damage. 10. If the engine is serviceable, any connecting rod that is bent must be replaced.
15 - Engine 36 - Piston 00 - General 15 - 138 9813/6700-1 15 - 138 Figure 154. DTI Measurement D C A B A Gudgeon pin axis B Line of measurement above gudgeon pin axis C Piston measurement point 1 D Piston measurement point 2 Piston Height Measurement Above Cylinder Block- Straight Edge Method Refer to engine, piston, technical data, (PIL 15-36-00). If a DTI is not available, a calibrated straight edge may be used to take a measurement. The measurement will be less accurate. 1. With the cylinder head removed, make sure the surface of the engine block and piston are clean. 2. Rotate the engine until the piston to be measured is at TDC. 3. Position the straight edge on top of the piston along the axis of the gudgeon pin. 4. Use feeler gauges to measure the gap between the cylinder block face and underside of the straight edge on both sides, position 1 and position 2. 5. Calculate the average of the 2 readings to give a figure of the piston height above the cylinder block. 5.1. If the reading obtained is lower than zero, the connecting rod may be bent. 5.2. If the reading obtained is equal to the range stated in technical data, the connecting rod is not bent. 6. Repeat steps 1 to 5.2 to check all connecting rods/pistons. Figure 155. Straight Edge Measurement E F G H J K L E Straight edge F Measurement position 1 G Measurement position 2 H Cylinder block- top face J Gudgeon pin axis K Piston L Connecting rod
15 - Engine 36 - Piston 00 - General 15 - 139 9813/6700-1 15 - 139 Remove and Install Before Removal The following procedure is for one piston and connecting rod assembly. Note that each assembly must be replaced in the same cylinder bore. Label each piston and connecting rod assembly to make sure it is installed in the correct position on assembly. 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. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 5. Remove the rocker cover, refer to (PIL 15-42). 6. Remove the fuel injectors, refer to (PIL 18-18). 7. Remove the cylinder head assembly, refer to (PIL 15-06). 8. Remove the oil sump, refer to (PIL 15-45). 9. Remove the big end bearing caps, refer to (PIL 15-12).
15 - Engine 36 - Piston 00 - General 15 - 140 9813/6700-1 15 - 140 Figure 156. X 2 1 3 1 Piston 2 Piston ring 3 Connecting rod X Longest side of connecting rod
15 - Engine 36 - Piston 00 - General 15 - 141 9813/6700-1 15 - 141 Remove The piston and connecting rod assemblies are removed through the top of the crankcase. 1. Use a suitable scraper and wire wool to clean off the carbon deposits from around the top of the cylinder bore. Take care not to scratch or damage the cylinder bore. 2. Use a hammer and a short length of wood to tap the piston from the connecting rod side. Take care not to scratch or damage the cylinder bore or the connecting rod bearing surface. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. If the upper big end bearing shell has been removed replace it, refer to (PIL 15-12). 4. Lubricate the cylinder bore with clean engine oil. 5. Use a suitable compressor tool to compress the piston rings. 6. Insert the piston and connecting rod assembly into the cylinder bore, make sure that the longest side of the connecting rod is on the exhaust side of the crankcase. Take care not to damage the cooling jets when you guide the connecting rod down the cylinder bore and over the crank pin diameter. After Installation 1. Install the big end bearing caps, refer to (PIL 15-12). 2. Carry out the procedures listed under Before removal in reverse order.
15 - Engine 36 - Piston 00 - General 15 - 142 9813/6700-1 15 - 142 Disassemble and Assemble Dismantle 1. Clamp the connecting rod in a vice. Take care not to damage the connecting rod. 2. It is recommended that the piston rings are renewed. If they are to be reused, label the rings to ensure they are installed in the correct positions and the correct way up on assembly. Carefully remove the piston rings from the piston. To avoid damage or distortion to the rings, use a suitable piston ring expander tool. Note that the oil control ring is installed with a spiral wire. Pull the wire apart and remove it. 3. Remove the circlips and push out the piston pin. 4. Use a suitable cleaning agent, clean the carbon deposits from the piston.
15 - Engine 36 - Piston 00 - General 15 - 143 9813/6700-1 15 - 143 Figure 157. 120° 120° 120° Y X C TOP 2A 3B 4 4a TOP TOP 1 7 6 7 5 1 Piston 2 Piston ring - compression No.1 3 Piston ring - compression No.2 4 Piston ring - oil control ring 4a Spiral wire - oil control ring 5 Connecting rod 6 Piston pin 7 Retaining circlip (x2) X Connecting rod - longest side Y Cast boss - piston Inspect 1. Inspect the pistons for signs of wear or damage. Refer to Check (Condition) (PIL 15-36-00).
15 - Engine 36 - Piston 00 - General 15 - 144 9813/6700-1 15 - 144 Assemble 1. The assembly procedure is the opposite of the disassemble procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. Lubricate the piston pin with clean engine oil. Assemble the connecting rod to the piston and insert the piston pin. Make sure that the long side of the connecting rod is on the same side as the internal cast boss in the piston. 4. Install new circlips. Make sure that they are installed correctly in the groove in the piston. 5. Lubricate the piston with clean engine oil. Install the piston rings to the piston in sequence as follows: 5.1. Install the spiral wire for the oil control ring in the bottom groove and locate the locking wire inside both ends of the spiral as shown. Using a piston ring expander tool to install the oil control ring in the bottom groove and locate the locking wire inside both ends of the spiral as shown. Ensure that the ring gap is positioned 180° to the locking wire. Note: The correct ring orientation can also be determined from the profile shape of the ring as shown at C. 5.2. Install the No.2 compression ring into the middle groove. Note that new rings have a reference number etched on one face. Make sure that this face is installed uppermost in the piston groove. Note: The correct ring orientation can also be determined from the profile shape of the ring as shown at B. 5.3. Install the No.1 compression ring into the top groove. Note that new rings have a reference number etched on one face. Make sure that this face is installed uppermost in the piston groove. Note: The correct ring orientation can also be determined from the profile shape of the ring as shown at A. 6. Rotate the piston rings so that the ring gaps are 120° apart as shown.
15 - Engine 36 - Piston 03 - Piston Ring 15 - 145 9813/6700-1 15 - 145 03 - Piston Ring Introduction Gas sealing inside the piston is achieved by the use of piston rings. The rings are loosely installed into grooves in the piston. The rings are split at a point in the rim, to allow them to press against the cylinder with a light spring pressure. Two types of ring are used: - Upper rings have solid faces and provide gas sealing - Lower rings have narrow edges and have a U- shaped profile, to act as oil scrapers.
15 - Engine 42 - Rocker and Fittings 00 - General 15 - 150 9813/6700-1 15 - 150 Technical Data Table 67. Rocker Levers, Rocker Shafts and Tappets Data Valve clearances measured at the valve bridge piece tip of the rockers (measured cold): - Inlet 0.19–0.27mm - Exhaust 0.56–0.64mm Rocker clearances measured at the adjusting screw tip of the rockers (measured cold): - Inlet 0.15–0.2mm - Exhaust 0.43–0.5mm Rocker lever bore diameter - min 26.058mm - max 26.092mm Rocker shaft diameter - min 26.003mm - max 26.021mm Tappets stem diameter - min 19.975mm - max 19.985mm Tappet bore diameter - min 20mm - max 20.021mm Tappet height (maximum) 55.25mm
15 - Engine 42 - Rocker and Fittings 00 - General 15 - 151 9813/6700-1 15 - 151 Component Identification Figure 158. 3 1 2 2 2 2 2 2 2 2 2 2 8 7 4 5 6 9 10 1 Rocker assembly 2 Rocker shaft fixing bolts (x11) 3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x11) 5 Oil feed pedestal (x1) 6 Rockers - exhaust (x6) 7 Rockers - inlet (x6) 8 Wave washers (x6) 9 Bridge pieces (x12) 10 Push rods (x12)
15 - Engine 42 - Rocker and Fittings 00 - General 15 - 152 9813/6700-1 15 - 152 Operation When the camshaft lobe raises the outside of the rocker arm, the inside presses down on the valve stem to open the valve. When the outside of the rocker arm is permitted to return due to the camshafts rotation, the inside rises to allow the valve spring to close the valve. Figure 159. 1 Oil feed from main gallery 2 Small transfer gallery 3 Shaft pedestal 4 Rocker shaft fixing bolt hole 5 Centre rocker shaft drilling 6 Cross drillings 7 Rocker pivot bushes 8 Cross drilling 9 Groove Lubrication Oil is fed from the main gallery via a drilling which passes up through the crankcase and the cylinder head to a small transfer gallery under the rocker shaft pedestal. The oversize rocker shaft fixing bolt hole allows oil to pass into a drilling in the centre of the rocker shaft. Further cross drillings transfer oil to each of the rocker pivot bushes. A cross drilling in each rocker transfers oil to the top of the rocker where it flows by gravity along a groove to the rocker tip.
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15 - Engine 42 - Rocker and Fittings 00 - General 15 - 153 9813/6700-1 15 - 153 Check (Condition) 1. Check the rocker shaft and rocker bushings for signs of damage and excessive wear. Measure the rocker shaft diameter and rocker bearing bushes to confirm they are within service limits, refer to Technical Data (PIL 15-42). Note: The rocker bearing bushes are not renewable. If a rocker bearing bush is damaged or worn the rocker must be renewed as a complete assembly. 2. Make sure that all oil-ways and cross drillings in the rocker shaft and pedestals are clear and free from debris. Use an air line to blow through cross drillings.
15 - Engine 42 - Rocker and Fittings 00 - General 15 - 154 9813/6700-1 15 - 154 Remove and Install Before Removal 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 engine. 3. Disconnect and remove the fuel pipes from the fuel injectors, refer to Fuel pipes (PIL 18-96). 4. Remove the rocker cover, refer to (PIL 15-42). Figure 160. 3 1 2 2 2 2 2 2 2 2 2 2 8 7 4 5 6 9 10 1 Rocker assembly 2 Rocker shaft fixing bolts (x11) 3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x11) 5 Oil feed pedestal (x1) 6 Rockers - exhaust (x6) 7 Rockers - inlet (x6) 8 Wave washers (x6) 9 Bridge pieces (x12) 10 Push rods (x12)
15 - Engine 42 - Rocker and Fittings 00 - General 15 - 155 9813/6700-1 15 - 155 Remove 1. Remove the rocker shaft fixing bolts. DO NOT withdraw the bolts. Lift the rocker shaft assembly from the cylinder head complete with pedestals still attached. Important: Keep all pedestals and fixing bolts in their original positions. 2. Lift off the bridge pieces from the pairs of inlet and exhaust valves. 3. Withdraw the push rods from the cylinder block. Before Installation 1. Make sure that all items are clean and free from damage and corrosion. If components within the rocker assembly are damaged or worn. Refer to Check (Condition) (PIL 15-42). 2. Make sure that all oil-ways and cross drillings in the cylinder head, rocker shaft and pedestals are clear and free from debris. Use an air line to blow through the cross drillings. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Use a suitable degreasing agent to clean the top of the cylinder head. 3. Install the bridge pieces on to the pairs of inlet and exhaust valves in the cylinder head. 4. Insert the push rods into the cylinder block. Make sure that they engage with the camshaft tappets. 5. Install the rocker shaft assembly into the cylinder head. Make sure that the pedestals are located in their original positions. Note the position of the oil feed pedestal and the longer bolt. Make sure that the push rods engage with the tappet adjusters and that the rockers are located over the bridge pieces. 6. Tighten the bolts to the correct torque value. After Installation 1. Measure and adjust the valve clearances, refer to (PIL 15-30). Table 68. Torque Values Item Nm 2 24 3 24

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Jcb jcb305, js305 excavator service repair manual (from 2452101 to 2452200)

  • 1. SERVICE MANUAL EXCAVATOR JCB305, JS305 EN - 9813/6700 - ISSUE 1 - 12/2016 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 6-09-02 © 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 Foreword 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. 15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 15 - 128 9813/6700-1 15 - 128 Check (Condition) 1. Check the bearing shell surfaces for signs of damage and excessive wear. 2. Measure the crank pin diameters to confirm they are within service limits, refer to Technical Data (PIL 15-33). 3. Renew any parts that are worn or not within the specified tolerances. Remove and Install Special Tools Tool Category Description Part No. Qty. Special Tool Torque Wrench (10-100Nm) 993/70111 1 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. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 5. Remove the rocker cover, refer to (PIL 15-42). 6. Remove the fuel injectors, refer to (PIL 18-18). 7. Drain the oil from the engine, refer to (PIL 15-21). 8. Remove the oil sump, refer to (PIL 15-45). 9. Position the engine upside down in a suitable jig or fixture, supported at the front of the crankcase. The connecting rod and the big-end bearing cap have been fracture split and must be kept together as a set. Care must be taken to avoid contamination and or damage to the fracture split surfaces. Remove 1. It is recommended that the big-end bearing caps are removed in pairs, cylinders 1 and 4 and cylinders 2 and 3. Rotate the crankshaft so that the big-end bearing caps on cylinders 2 and 3 are positioned as shown. 2. Remove the bolts and lift off the big-end bearing caps from the connecting rods. The bolts must not be re-used, discard the bolts.
  • 3. 15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 15 - 129 9813/6700-1 15 - 129 Figure 148. X 1 2 1 Big-end bearing caps 2 Big-end bearing cap bolts X Cast notch 3. Lift out the bearing shells from the bearing caps. Carefully rotate the crank to disengage from the connecting rods and get access to the upper bearing shells. Lift out the upper bearing shells. It is recommended that the bearing shells are renewed. If they are to be reused, label the bearing shells to make sure that they are installed in their original positions on assembly. Figure 149. 4 3 7Z 1 2 6 5 1 Big-end bearing cap 2 Bolts 3 Connecting rod 4 Piston 5 Piston rings 6 Lower bearing shell 7 Upper bearing shell Z Fracture split surfaces 4. Carefully rotate the crankshaft to position the big- end bearing caps of cylinders 1 and 4. Make sure that the crank does not foul the connecting rods of cylinders 2 and 3. Remove the bearing caps and bearing shells as described in previous steps. 5. Inspect the big-end bearings for signs of damage and excessive wear, refer to Check Condition (PIL 15-12). Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion.
  • 4. 15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 15 - 130 9813/6700-1 15 - 130 3. Install the upper bearing shell to the connecting rod. Lubricate the bearing shell with clean engine oil. 4. Install the lower bearing shell to the big-end bearing cap. Lubricate the bearing shell with clean engine oil. Install the big-end bearing cap to the connecting rod. Make sure that the cast notch on the bearing cap faces to the front of the engine. Use compressed air to clean the fracture surfaces before assembly. 5. Install new fixing bolts. Tighten the new bolts in three stages to the correct torque value. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) Figure 150. T3 T3 Angle gauge (obtain locally) 6. The bolts are tightened using a torque and angle method, refer to Fasteners and Fixings, General, Introduction (PIL 72-00). Figure 151. 0° +90° Y After Installation 1. Carry out the procedures listed, Before Removal in reverse order. Table 65. Item Torque Value 2 - 1st Stage 35N·m 2 - 2nd Stage 65N·m 2 - Final Stage 90°
  • 5. 15 - Engine 36 - Piston 00 - General 15 - 134 9813/6700-1 15 - 134 Technical Data Table 66. Engine 444 - SE Engine 444 - excluding SE en- gine 448, 672 Gudgeon pin bore diame- ter - min. 4.0008mm 40.01mm 42.008mm - max. 40.013mm 40.015mm 42.013mm Piston ring clearance - Top ring Half keystone ring Full keystone ring Full keystone ring - Middle ring 0.11–0.07mm 0.125–0.08mm 0.125–0.08mm - Bottom (oil) ring 0.09–0.05mm 0.09–0.05mm 0.09–0.05mm Piston ring gap - Top ring 0.3–0.5mm 0.3–0.4mm 0.3–0.4mm - Middle ring 0.55–0.8mm 0.55–0.8mm 0.55–0.8mm - Bottom (oil) ring 0.25–0.5mm 0.25–0.5mm 0.25–0.5mm Piston height above crankcase (cold) 0.0375–0.3385mm 0.00025–0.36825mm (1) 0.00025–0.36825mm (1) Piston groove width - Top ring 3.108–3.133mm 3.114–3.134mm 3.114–3.134mm - Middle ring 2.56–2.58mm 2.575–2.595mm 2.575–2.595mm - Bottom (oil) ring 4.04–4.06mm 4.04–4.06mm 4.04–4.06mm Piston skirt - 102.853–102.871mm 105.851–105.869mm Piston pin - 39.994–40mm 41.994–42mm (1) Nominal measurement is 0.03325mm
  • 6. 15 - Engine 36 - Piston 00 - General 15 - 135 9813/6700-1 15 - 135 Component Identification Figure 152. 120° 120° 120° Y X C TOP 2A 3B 4 4a TOP TOP 1 7 6 7 5 1 Piston 2 Piston ring - compression No.1 3 Piston ring - compression No.2 4 Piston ring - oil control ring 4a Spiral wire - oil control ring 5 Connecting rod 6 Piston pin 7 Retaining circlip (x2) X Connecting rod - longest side Y Cast boss - piston
  • 7. 15 - Engine 36 - Piston 00 - General 15 - 136 9813/6700-1 15 - 136 Operation The groove around the diameter of the upper main bearing shells allows oil transfer to an oil jet located in the crankcase bearing saddle. Jets are installed at the main bearing positions. The jets spray oil directly to the under side of the pistons effectively transferring heat away from the top of the pistons. Oil spray also enters the small end bearing bushes via a feed hole on the top of each connecting rod. Note: On turbocharged engines additional J-jets are installed. Oilways connect the J-shaped jets fixed to the crankcase at the underside of each cylinder bore. Figure 153. 2 6 1 1 2 4 5 3 1 Groove 2 Oil jet 3 Pistons 4 Bearing bushes 5 Crankshaft 6 J shaped jets
  • 8. 15 - Engine 36 - Piston 00 - General 15 - 137 9813/6700-1 15 - 137 Check (Condition) 1. Check the piston for signs of damage and excessive wear. Measure the piston skirt diameter, piston pin bore and the clearance in the piston ring grooves to confirm they are within service limits. Refer to Piston, Technical Data (PIL 15-36). 2. Check the piston pin for signs of damage and excessive wear. Measure the pin diameter to confirm it is within service limits. Refer to Piston, Technical Data (PIL 15-36). The connecting rod small end bearing bush is not renewable. If the small end bearing bush is damaged or worn the connecting rod must be renewed as a complete assembly. Calibrate Piston Height Measurement Above Cylinder Block- DTI Method Refer to engine, piston, technical data, (PIL 15-36-00). In the event of sufficient liquid entering the engine, a hydraulic lock can occur. This may result in bending of one or more of the connecting rods. Bending of the connecting rod(s) can occur even when the engine is cranked by the starter motor. Bending of the connecting rod may be very slight and can be checked by carrying out this procedure prior to a full strip down: 1. With the cylinder head removed, make sure the surface of the engine block and piston are clean. 2. Zero a DTI (Dial Test Indicator) on the top face of the cylinder block adjacent to the area on the piston to be measured. The aim of the procedure is to use the DTI to take a measurement across 2 locations on the piston that are on the axis of the gudgeon pin. This will be towards the front and rear of the engine. 3. Rotate the engine and bring the piston up until it is 3mm below the engine block face. Carefully reposition the zeroed DTI above the area of the piston to be measured. 4. Rotate the engine to bring the piston up to exactly TDC (Top Dead Centre) and record the measurement at position 1. 5. Repeat steps 2 to 4 for position 2. 6. Calculate the average of the 2 readings to give a figure of the piston height above the cylinder block. 7. Compare the reading obtained to the technical data. 7.1. If the reading obtained is lower than zero, the connecting rod may be bent. 7.2. If the reading obtained is equal to the range stated in technical data, the connecting rod is not bent. 8. Repeat steps 2 to 7 to check all connecting rods/ pistons. 9. If any connecting rods are bent, strip the engine and check for further damage. 10. If the engine is serviceable, any connecting rod that is bent must be replaced.
  • 9. 15 - Engine 36 - Piston 00 - General 15 - 138 9813/6700-1 15 - 138 Figure 154. DTI Measurement D C A B A Gudgeon pin axis B Line of measurement above gudgeon pin axis C Piston measurement point 1 D Piston measurement point 2 Piston Height Measurement Above Cylinder Block- Straight Edge Method Refer to engine, piston, technical data, (PIL 15-36-00). If a DTI is not available, a calibrated straight edge may be used to take a measurement. The measurement will be less accurate. 1. With the cylinder head removed, make sure the surface of the engine block and piston are clean. 2. Rotate the engine until the piston to be measured is at TDC. 3. Position the straight edge on top of the piston along the axis of the gudgeon pin. 4. Use feeler gauges to measure the gap between the cylinder block face and underside of the straight edge on both sides, position 1 and position 2. 5. Calculate the average of the 2 readings to give a figure of the piston height above the cylinder block. 5.1. If the reading obtained is lower than zero, the connecting rod may be bent. 5.2. If the reading obtained is equal to the range stated in technical data, the connecting rod is not bent. 6. Repeat steps 1 to 5.2 to check all connecting rods/pistons. Figure 155. Straight Edge Measurement E F G H J K L E Straight edge F Measurement position 1 G Measurement position 2 H Cylinder block- top face J Gudgeon pin axis K Piston L Connecting rod
  • 10. 15 - Engine 36 - Piston 00 - General 15 - 139 9813/6700-1 15 - 139 Remove and Install Before Removal The following procedure is for one piston and connecting rod assembly. Note that each assembly must be replaced in the same cylinder bore. Label each piston and connecting rod assembly to make sure it is installed in the correct position on assembly. 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. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 5. Remove the rocker cover, refer to (PIL 15-42). 6. Remove the fuel injectors, refer to (PIL 18-18). 7. Remove the cylinder head assembly, refer to (PIL 15-06). 8. Remove the oil sump, refer to (PIL 15-45). 9. Remove the big end bearing caps, refer to (PIL 15-12).
  • 11. 15 - Engine 36 - Piston 00 - General 15 - 140 9813/6700-1 15 - 140 Figure 156. X 2 1 3 1 Piston 2 Piston ring 3 Connecting rod X Longest side of connecting rod
  • 12. 15 - Engine 36 - Piston 00 - General 15 - 141 9813/6700-1 15 - 141 Remove The piston and connecting rod assemblies are removed through the top of the crankcase. 1. Use a suitable scraper and wire wool to clean off the carbon deposits from around the top of the cylinder bore. Take care not to scratch or damage the cylinder bore. 2. Use a hammer and a short length of wood to tap the piston from the connecting rod side. Take care not to scratch or damage the cylinder bore or the connecting rod bearing surface. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. If the upper big end bearing shell has been removed replace it, refer to (PIL 15-12). 4. Lubricate the cylinder bore with clean engine oil. 5. Use a suitable compressor tool to compress the piston rings. 6. Insert the piston and connecting rod assembly into the cylinder bore, make sure that the longest side of the connecting rod is on the exhaust side of the crankcase. Take care not to damage the cooling jets when you guide the connecting rod down the cylinder bore and over the crank pin diameter. After Installation 1. Install the big end bearing caps, refer to (PIL 15-12). 2. Carry out the procedures listed under Before removal in reverse order.
  • 13. 15 - Engine 36 - Piston 00 - General 15 - 142 9813/6700-1 15 - 142 Disassemble and Assemble Dismantle 1. Clamp the connecting rod in a vice. Take care not to damage the connecting rod. 2. It is recommended that the piston rings are renewed. If they are to be reused, label the rings to ensure they are installed in the correct positions and the correct way up on assembly. Carefully remove the piston rings from the piston. To avoid damage or distortion to the rings, use a suitable piston ring expander tool. Note that the oil control ring is installed with a spiral wire. Pull the wire apart and remove it. 3. Remove the circlips and push out the piston pin. 4. Use a suitable cleaning agent, clean the carbon deposits from the piston.
  • 14. 15 - Engine 36 - Piston 00 - General 15 - 143 9813/6700-1 15 - 143 Figure 157. 120° 120° 120° Y X C TOP 2A 3B 4 4a TOP TOP 1 7 6 7 5 1 Piston 2 Piston ring - compression No.1 3 Piston ring - compression No.2 4 Piston ring - oil control ring 4a Spiral wire - oil control ring 5 Connecting rod 6 Piston pin 7 Retaining circlip (x2) X Connecting rod - longest side Y Cast boss - piston Inspect 1. Inspect the pistons for signs of wear or damage. Refer to Check (Condition) (PIL 15-36-00).
  • 15. 15 - Engine 36 - Piston 00 - General 15 - 144 9813/6700-1 15 - 144 Assemble 1. The assembly procedure is the opposite of the disassemble procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. Lubricate the piston pin with clean engine oil. Assemble the connecting rod to the piston and insert the piston pin. Make sure that the long side of the connecting rod is on the same side as the internal cast boss in the piston. 4. Install new circlips. Make sure that they are installed correctly in the groove in the piston. 5. Lubricate the piston with clean engine oil. Install the piston rings to the piston in sequence as follows: 5.1. Install the spiral wire for the oil control ring in the bottom groove and locate the locking wire inside both ends of the spiral as shown. Using a piston ring expander tool to install the oil control ring in the bottom groove and locate the locking wire inside both ends of the spiral as shown. Ensure that the ring gap is positioned 180° to the locking wire. Note: The correct ring orientation can also be determined from the profile shape of the ring as shown at C. 5.2. Install the No.2 compression ring into the middle groove. Note that new rings have a reference number etched on one face. Make sure that this face is installed uppermost in the piston groove. Note: The correct ring orientation can also be determined from the profile shape of the ring as shown at B. 5.3. Install the No.1 compression ring into the top groove. Note that new rings have a reference number etched on one face. Make sure that this face is installed uppermost in the piston groove. Note: The correct ring orientation can also be determined from the profile shape of the ring as shown at A. 6. Rotate the piston rings so that the ring gaps are 120° apart as shown.
  • 16. 15 - Engine 36 - Piston 03 - Piston Ring 15 - 145 9813/6700-1 15 - 145 03 - Piston Ring Introduction Gas sealing inside the piston is achieved by the use of piston rings. The rings are loosely installed into grooves in the piston. The rings are split at a point in the rim, to allow them to press against the cylinder with a light spring pressure. Two types of ring are used: - Upper rings have solid faces and provide gas sealing - Lower rings have narrow edges and have a U- shaped profile, to act as oil scrapers.
  • 17. 15 - Engine 42 - Rocker and Fittings 00 - General 15 - 150 9813/6700-1 15 - 150 Technical Data Table 67. Rocker Levers, Rocker Shafts and Tappets Data Valve clearances measured at the valve bridge piece tip of the rockers (measured cold): - Inlet 0.19–0.27mm - Exhaust 0.56–0.64mm Rocker clearances measured at the adjusting screw tip of the rockers (measured cold): - Inlet 0.15–0.2mm - Exhaust 0.43–0.5mm Rocker lever bore diameter - min 26.058mm - max 26.092mm Rocker shaft diameter - min 26.003mm - max 26.021mm Tappets stem diameter - min 19.975mm - max 19.985mm Tappet bore diameter - min 20mm - max 20.021mm Tappet height (maximum) 55.25mm
  • 18. 15 - Engine 42 - Rocker and Fittings 00 - General 15 - 151 9813/6700-1 15 - 151 Component Identification Figure 158. 3 1 2 2 2 2 2 2 2 2 2 2 8 7 4 5 6 9 10 1 Rocker assembly 2 Rocker shaft fixing bolts (x11) 3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x11) 5 Oil feed pedestal (x1) 6 Rockers - exhaust (x6) 7 Rockers - inlet (x6) 8 Wave washers (x6) 9 Bridge pieces (x12) 10 Push rods (x12)
  • 19. 15 - Engine 42 - Rocker and Fittings 00 - General 15 - 152 9813/6700-1 15 - 152 Operation When the camshaft lobe raises the outside of the rocker arm, the inside presses down on the valve stem to open the valve. When the outside of the rocker arm is permitted to return due to the camshafts rotation, the inside rises to allow the valve spring to close the valve. Figure 159. 1 Oil feed from main gallery 2 Small transfer gallery 3 Shaft pedestal 4 Rocker shaft fixing bolt hole 5 Centre rocker shaft drilling 6 Cross drillings 7 Rocker pivot bushes 8 Cross drilling 9 Groove Lubrication Oil is fed from the main gallery via a drilling which passes up through the crankcase and the cylinder head to a small transfer gallery under the rocker shaft pedestal. The oversize rocker shaft fixing bolt hole allows oil to pass into a drilling in the centre of the rocker shaft. Further cross drillings transfer oil to each of the rocker pivot bushes. A cross drilling in each rocker transfers oil to the top of the rocker where it flows by gravity along a groove to the rocker tip.
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  • 21. 15 - Engine 42 - Rocker and Fittings 00 - General 15 - 153 9813/6700-1 15 - 153 Check (Condition) 1. Check the rocker shaft and rocker bushings for signs of damage and excessive wear. Measure the rocker shaft diameter and rocker bearing bushes to confirm they are within service limits, refer to Technical Data (PIL 15-42). Note: The rocker bearing bushes are not renewable. If a rocker bearing bush is damaged or worn the rocker must be renewed as a complete assembly. 2. Make sure that all oil-ways and cross drillings in the rocker shaft and pedestals are clear and free from debris. Use an air line to blow through cross drillings.
  • 22. 15 - Engine 42 - Rocker and Fittings 00 - General 15 - 154 9813/6700-1 15 - 154 Remove and Install Before Removal 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 engine. 3. Disconnect and remove the fuel pipes from the fuel injectors, refer to Fuel pipes (PIL 18-96). 4. Remove the rocker cover, refer to (PIL 15-42). Figure 160. 3 1 2 2 2 2 2 2 2 2 2 2 8 7 4 5 6 9 10 1 Rocker assembly 2 Rocker shaft fixing bolts (x11) 3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x11) 5 Oil feed pedestal (x1) 6 Rockers - exhaust (x6) 7 Rockers - inlet (x6) 8 Wave washers (x6) 9 Bridge pieces (x12) 10 Push rods (x12)
  • 23. 15 - Engine 42 - Rocker and Fittings 00 - General 15 - 155 9813/6700-1 15 - 155 Remove 1. Remove the rocker shaft fixing bolts. DO NOT withdraw the bolts. Lift the rocker shaft assembly from the cylinder head complete with pedestals still attached. Important: Keep all pedestals and fixing bolts in their original positions. 2. Lift off the bridge pieces from the pairs of inlet and exhaust valves. 3. Withdraw the push rods from the cylinder block. Before Installation 1. Make sure that all items are clean and free from damage and corrosion. If components within the rocker assembly are damaged or worn. Refer to Check (Condition) (PIL 15-42). 2. Make sure that all oil-ways and cross drillings in the cylinder head, rocker shaft and pedestals are clear and free from debris. Use an air line to blow through the cross drillings. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Use a suitable degreasing agent to clean the top of the cylinder head. 3. Install the bridge pieces on to the pairs of inlet and exhaust valves in the cylinder head. 4. Insert the push rods into the cylinder block. Make sure that they engage with the camshaft tappets. 5. Install the rocker shaft assembly into the cylinder head. Make sure that the pedestals are located in their original positions. Note the position of the oil feed pedestal and the longer bolt. Make sure that the push rods engage with the tappet adjusters and that the rockers are located over the bridge pieces. 6. Tighten the bolts to the correct torque value. After Installation 1. Measure and adjust the valve clearances, refer to (PIL 15-30). Table 68. Torque Values Item Nm 2 24 3 24