JCB 2DXL Super Loader Service Repair Manual Instant Download (From 2475501 To 2475700)

SERVICE MANUAL

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.

00 - General

The exhaust system is used to guide exhaust gases away from the controlled combustion inside the engine by means of an exhaust pipe. Depending on the machine design, the exhaust gas may flow through the following components:

•Cylinder head and exhaust manifold.

•Turbocharger to increase the engine power (if installed).

•A catalytic converter or EGR (Exhaust Gas Recirculation) system to reduce air pollution (if installed).

•SCR (Selective Catalytic Reduction) (if installed). In SCR system exhaust gases pass through the DEF (Diesel Exhaust Fluid) injection chamber to lower the NOx (Nitrogen Oxide) concentration in the exhaust gases.

•A silencer or muffler to reduce noise (if installed).

The exhaust pipe carries the toxic and noxious gases away from the users of the machine. Note machines or generators that work indoors can quickly fill an enclosed space with carbon monoxide or other poisonous exhaust gases if they are not properly vented to the outdoors.

Health and Safety

Exhaust Gases

Machine exhaust gases can harm and possibly kill you or bystanders if they are inhaled. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, install an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air.

Sparks

Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

Hazardous Atmospheres

This machine is designed for use in normal out door atmospheric conditions. It must not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer.

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.

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.

Check (Condition)

Excessive smoke from the exhaust stack combined with a complaint of low power could be as a result of:

•Dirt or dust (unfiltered air) ingested directly into the engine, resulting in damage to the cylinder bores, there will also be a possible increase in oil consumption.

•Air leaks from the air hose connections.

•Exhaust manifold leaks.

03 - Inlet Manifold

Introduction

On compression ignition (diesel) engines, the inlet manifold (also called the intake manifold) is the part of the air intake system that distributes air for combustion to the cylinders via each inlet port in the cylinder head. The design of the manifold is important to make sure that air is distributed as evenly as possible under all engine speed and load conditions.

Check (Condition)

1.Check the manifold mating faces for signs of damage and distortion.

2.Check the manifold casting for signs of cracks.

3.Renew the manifold if there are any signs of defect.

04 - Outlet Manifold Check (Condition)

1.Check the manifold mating faces for signs of damage and distortion.

2.Check the manifold casting for signs of cracks.

3.Renew the manifold if there are any signs of defect.

4.Visuallyinspectforleaksattheexhaustmanifold. Make sure all gaskets are in good condition, replace as required.

00 - General

18-31

18-32

18-32

Important: The high pressure fuel pipes must be replaced every time they are removed. If you install the original pipes, it will cause leaks at the fuel pipe connections.

High Pressure Pipe

The high pressure pipes are thick walled and seamless tubes made of steel. The high pressure fuel pipes supply pressurised fuel from the high pressure fuel pump to the fuel rail. From the rail, fuel is supplied to the electronic injectors through the high pressure pipes.

Theendsofthetubesareformedwithconicalnipples for proper installation in the sealing cones on the fuel rail and on the injector port.

Low Pressure Pipe

During fuel injection some fuel bleeds off the electronic injectors and is sent back to the tank through the low pressure pipes. The return fuel from the high pressure fuel pump is also transferred through the low pressure pipe.

All the low pressure return fuel is collected at a common fuel distributor and is sent to the tank through the low pressure pipes.

The low pressure fuel pipe also supplies low pressurefuelfromthetanktothehighpressurepump through the fuel filter.

Health and Safety

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. Notice: Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair.

Component Identification

Refer to Fuel System- Component Identification (PIL 18-00).

21 - Cooling System

Acronyms Glossary

ECMEngine Control Module

Notes:

00 - General

Introduction

During the working cycle of the engine a great deal of heat is generated. It is important that the engine is kept at its normal operating temperature to achieve maximum efficiency. It is the function of the cooling system to allow the engine to reach this temperature quickly and then maintain it.

Health and Safety

CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.

CAUTION Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.

Fault-Finding

Fault

Coolant - Loss.

Coolant - Over Temperature.

Coolant - Under Temperature.

Coolant - Contaminated.

Table 8. Coolant - Loss.

Table 8. Page 21-5

Table 9. Page 21-5

Table 10. Page 21-6

Table 11. Page 21-6

Cause Remedy

Incorrect coolant level. Check the level.

Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and connection to locate the leak. If oil is present in the coolant, check for a transmission or engine oil cooler leak.

External engine coolant leak. Visually inspect the engine and components for seal, gasket hose connection leaks. Make sure all hose clips are in good condition and torqued to the recommended figure. Make sure all spring band clamps are in good condition and apply sufficient pressure to the hoses.

Overheating or compression gases leaking, resulting in loss through the radiator overflow.

See Also: Table 9. Coolant - Over Temperature. If installed, transmission cooler leak. Check/replace the transmission cooler. Check for coolant in the inlet manifold and in the oil.

Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the oil.

Cylinder head gasket leak. Check/replace the head gasket.

Cylinder head cracked or porous. Check/replace the cylinder head. Crankcase coolant passages leaking. Check/replace the crankcase.

Table 9. Coolant - Over Temperature. Cause Remedy

Incorrect coolant level (low). Check the level.

See Also: Table 8. Coolant - Loss.

External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix. Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing, shutters, fan sensors, fan speeds as required.

Coolant pump or fan drive belts loose. Check/correct belt tension.

Radiator hose collapsed, restricted or leaking. Check/replace hose.

Oil level overfilled. Check oil level.

Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system. Over concentration of anti-freeze. Remove part of the coolant from cooling system and replace with water.

Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the gauge and temperature sensor are accurate.

Thermostat faulty, incorrect or missing. Check/replace the thermostat.

Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the correct vented thermostat is installed. If aeration continued, check for a compression leak through the head gasket.

Coolant pump faulty. Check/replace the coolant pump.

Vent line from engine and/or radiator blocked or incorrectly routed (sudden overheating).

Check routing and operation or vent line.

Cause Remedy

Leak between the top tank and the auxiliary tank (sudden overheating).

Check for coolant leakage between radiator auxiliary tank and radiator top tank.

Cooling passages in radiator, cylinder head, head gasket or crankcase blocked. Flush the system and fill with clean coolant.

ECM (Engine Control Module) or electrical sensor fault. Check the electronic fault codes. Check the electrical connections at the ECM and sensors.

One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical connections at the injectors.

Cause Remedy

Air flow across the radiator excessive.

Check/repair fan shroud, anti-recirculation sealing, shutters, fan sensors, fan speeds as required.

Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the gauge and temperature sensor are accurate.

Thermostat faulty, (open - not sealing). Check/replace the thermostat.

Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss may result in the gauge showing low temperature initially. In which case, check the level.

Cause Remedy

Coolant rusty, operation without correct mixture of antifreeze and water.

Engine oil cooler, or cooler housing allowing cross contamination of coolant with engine oil.

Transmission lubricating oil cooler leaking (if applicable).

Lubricating oil leaks from lubricating oil cooler, head gasket, head and crankcase.

Drain and flush the cooling system. Fill with correct mixture of antifreeze and water. Review the coolant change interval.

Remove the oil cooler assembly and check relevant sealing elements for damage.

Check/replace lubricating oil cooler. Refer to equipment manufacturer's procedures.

See Also: Table 8. Coolant - Loss.

Table 10. Coolant - Under Temperature.

Table 11. Coolant - Contaminated.

Drain and Fill

Visually check the coolant level daily.

Check the quality of the antifreeze mixture and change it according to the service schedule.

1.Open the engine compartment cover. Refer to (PIL 06-06).

2.Make sure that the coolant level should be between the MIN and the MAX marks on coolant reservoir.

3.If the level in the expansion bottle is low, then continue with steps 4 to 9.

4.Carefully loosen the cap just enough to let any pressure escape.

5.Remove the cap when all pressure is released.

6.Fill with pre-mixed water/antifreeze until it reaches the correct level.

7.Fill the expansion tank, using the necessary antifreeze solution, to the level indicated.

Consumable: Antifreeze HP/Coolant ASTM D6210 Concentrate

8.Run the engine for a while to raise the coolant to working temperature and pressure.

9.Stop the engine and checks for leaks.

Check (Leaks)

Before you start the machine, inspect the system for leaks:

1.Make the machine safe. Refer to (PIL 01-03).

2.Get access to the cooling pack. Refer to (PIL 06-06).

3.Check under the cooling pack and cooling hoses for signs of leaks.

4.Repair or replace any damaged components before starting the machine.

Check (Level)

The graphic shows a typical engine cooling system, the system you are working on may look slightly different.

1.Make the machine safe. Refer to (PIL 01-03).

2.Open the access cover to get access to the engine.

3.Check the level of coolant in the coolant expansion tank. If necessary remove the filler cap and top up to the level indicated.

4.Install the filler cap and make sure it is tight.

5.Run the engine for a while to raise the coolant to working temperature and pressure.

6.Stop the engine and check for leaks.

Figure 90.

A Cap

B Bottom radiator hose

C Coolant expansion tank

00 - General

The cooling pack contains the following major components:

•Radiator

•Cooling fan

•Condenser (air conditioning machines)

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Clean

The cooling pack is located in front of the engine, the pack consists of the engine cooling radiator, hydraulic oil cooler, intercooler and air-conditioning condenser (optional). If the cooler tubes/fins get clogged (by dirt and flies etc.) the radiator and coolers will be less efficient.

1.Remove the front grille. Refer to (PIL 06-06-21).

2.Brushoffalldebrisfromthecoolertubesandfins. Make sure the loosened material is brushed out of the cooler enclosure.

2.1.When cleaning the matrix make sure that the brush follows the same direction as the fins are to avoid damaging them. Damaged fins will reduce the cooling efficiency of the matrix.

3.Install the front grille.

Machines with air conditioning have a condenser matrix installed in front of the oil cooler, the fins of the condenser matrix may get clogged. In this case, clean the tubes/fins of the condenser matrix as described above.

Figure 91.