JCB Dieselmax Engine (SA-SC Build) Service Repair Manual

Service Manual JCB Dieselmax Mechanical Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section 4 - Systems Description Section 5 - Fault Finding Section 6 - Test Procedures Section 7 - Fuel System Section 8 - Cooling System Section 9 - Lubrication System Section 10 - Electrical System Section 11 - Induction and Exhaust System Section 12 - Base Engine

Publication No.

9806/3000-05

World Class Customer Support Copyright © 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 General Information Service Manual - JCB Dieselmax Mechanical Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section 4 - Systems Description Section 5 - Fault Finding Section 6 - Test Procedures Section 7 - Fuel System Section 8 - Cooling System Section 9 - Lubrication System Section 10 - Electrical System Section 11 - Induction and Exhaust System Section 12 - Base Engine

Publication No.

9806/3000-05

World Class Customer Support Copyright © 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 - General Information

Notes:

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Section 1 - General Information Contents Page No. Introduction About this Manual .................................................................................... 1 - 1 Using the Service Manual .................................................................. 1 - 1 Section Numbering ............................................................................. 1 - 1 Left Side, Right Side ........................................................................... 1 - 1 Units of Measurement ........................................................................ 1 - 1 Machine Related Data ........................................................................ 1 - 2 Acronyms and Abbreviations ................................................................... 1 - 3 Identifying the Engine Engine Identification Plate ....................................................................... 1 - 4 Typical Engine Identification Number ................................................. 1 - 4 Component Labels ............................................................................. 1 - 5 Engine Component Identification ............................................................. 1 - 6 Independent Power Unit Component Identification ............................... 1 - 10 Technical Data Basic Engine Data - 444 Engine ............................................................

Basic Engine Data - 448 Engine ............................................................

Engine Block & Bedplate 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 .....................................................................

1 - 11 1 - 13 1 - 14 1 - 15 1 - 16 1 - 18 1 - 19 1 - 20 1 - 21 1 - 22 1 - 22 1 - 24 1 - 25 1 - 26 1 - 27 1 - 28 1 - 29 1 - 30

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ...................................

Introduction .......................................................................................

Bolts and Screws ..............................................................................

Hydraulic Connections ...........................................................................

'O' Ring Face Seal System ...............................................................

'Torque Stop' Hose System ..............................................................

Torque + Angle Explanation ..................................................................

Torque + Angle Tightening Procedure ...................................................

Engine Torque Figures ..........................................................................

1 - 32 1 - 32 1 - 32 1 - 36 1 - 36 1 - 39 1 - 40 1 - 41 1 - 42

Lubricants and Capacities Engine Lubricating Oil ...........................................................................

Recommended Oils ..........................................................................

Engine Oil Capacity ..........................................................................

Coolant Mixtures ....................................................................................

1 - 57 1 - 57 1 - 57 1 - 58

Service Aids Sealing, Retaining and Care Compounds ............................................. 1 - 59

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Section 1 - General Information Contents Contents Page No. Service Tools General Engine Tools ............................................................................ 1 - 60 Specialist Engine Tools .......................................................................... 1 - 62 Service Tool Drawings ........................................................................... 1 - 67 892/01146 - Core Plug Fitting Tool ................................................... 1 - 67 892/01147 - Crankshaft Turning Tool ............................................... 1 - 68 892/01148 - Timing Pin ..................................................................... 1 - 69 892/01149 - Sump Sealant Template ............................................... 1 - 70 892/01150 - Oil Sump Location Dowel ............................................. 1 - 71 892/01151 - Injector Sleeve Removal Tool ....................................... 1 - 72 892/01152 - Valve Stem Seal Fitting Tool ......................................... 1 - 73 892/01154 - FIP Cover Removal Tool .............................................. 1 - 74 892/01155 - FIP Gear Removal Tool ................................................ 1 - 75 892/01157 - Crankshaft Front Seal Fitting Tool ................................ 1 - 76 892/01156 - Crankshaft Rear Seal Fitting Tool ................................. 1 - 77 892/01158 - Crankshaft Rear Seal Alignment Tool ........................... 1 - 78 892/01159 - Injector Seal Fitting Tool ............................................... 1 - 78 892/01168 - Dummy Injector ............................................................ 1 - 79 892/01169 - Top Dead Centre (TDC) Setting Tool ............................ 1 - 80 Engine Mounting Frame ................................................................... 1 - 81 Service Parts and Repair Kits Engine Repair Parts and Kits Identification ........................................... 1 - 82 Engine Lifting Lifting Information .................................................................................. 1 - 98 Operating Procedures Starting the Engine ................................................................................ 1 - 99 Pre-Start Notes ................................................................................. 1 - 99 Start Procedure .............................................................................. 1 - 100 Engine Checks After Start-up ......................................................... 1 - 101 Engine Running-in Procedure ........................................................ 1 - 102 Stopping the Engine ....................................................................... 1 - 103

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Section 1 - General Information

Introduction About this Manual Using the Service Manual

5

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.

Left Side, Right Side

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of engines.

Fault Finding ...etc.

References to the `left' side and the `right' side of the engine are when viewed from the flywheel end of the engine, as shown at 1A.

A

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid, engine oil and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manufacturer's policy is one of continuous improvement. The right to change the specification of the engine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between the specifications of the engine and the descriptions contained in this publication.

Section Numbering The manual is compiled in sections, the first three are numbered and contain information as follows: 1

General Information includes torque settings and service tools.

2

Care & Safety includes warnings and cautions pertinent to aspects of workshop procedures etc.

3

Maintenance includes service recommended lubricants.

schedules

and

The remaining sections deal with Descriptions, Fault Finding, Dismantling, Overhaul etc. of specific components, for example: 4

1-1

Systems Descriptions

Fig 1.

Units of Measurement In this manual, the S.I. system of units is used. For example, liquid capacities are given in litres. The imperial units follow in parenthesis () e.g. 28 litres (6 UK gal).

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Section 1 - General Information Introduction About this Manual

Machine Related Data The JCB Dieselmax Engine can be fitted to a variety of constructions and agricultural machines. The scope of this publication is limited to the engine, but references to a typical machine installation will be made. Tasks and information specific to a machine installation will be listed in the relevant machine Service Manual, for example engine removal and replacement procedures.

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Section 1 - General Information Introduction Acronyms and Abbreviations

Acronyms and Abbreviations Some of the following acronyms and abbreviations are used in this service manual. The remainder are used in the automotive industry and are repeated for reference only.

Nm

Newton Metre

NSP

Non Serviced Part

O/D

Outside Diameter

°C

Celsius

OEM

Original Equipment Manufacturer

°F

Fahrenheit

PPM

Parts per Million

A/R

As Required

PSI

Pounds per square Inch

API

American Petroleum Institute

PTO

Power Take Off

BBDC

Before Bottom Dead Centre

RH

Right Hand

BDC

Bottom Dead Centre

RME

Rapeseed Methyl Ester

BSFC

Brake Specific Fuel Consumption

RPM

Revolutions per Minute

BTDC

Before Top Dead Centre

SAE

Society of Automotive Engineers

CCV

Crankcase Vent

SME

Sunflower Methyl Ester

CID

Cubic inch Displacement

SOME

Soyabean Methyl Ester

CSA

Cold Start Advance

STD

Standard

CSAS

Cold Start Advance Solenoid

TBA

To be Advised

cST

Centistokes

TC

Turbocharged

ECM

Electronic Control Module

TCA

Turbocharged Aftercooled

ECS

Emission Control System

TDC

Top Dead Centre

EPA

Environmental Protection Agency

TI

Technical Information

ESOS

Electric Shut-Off Solenoid or Engine ShutOff Solenoid

VOME

Vegetable Oil Methyl Esters

FAME

Fatty Acid Methyl Esters

FEAD

Front End Accessory Drive

FIE

Fuel Injection Equipment

FIP

Fuel Injection Pump

Hg

Mercury

HP

Horse Power

I/D

Inside Diameter

kg

Kilogram

KPH

Kilometres per hour

Kw

Kilowatt

LH

Left Hand

ltr

Litre

mm

Millimetre

MPH

Miles per Hour

NA

Naturally Aspirated

N/A

Not Applicable/Not Available

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Section 1 - General Information

Identifying the Engine Engine Identification Plate Typical Engine Identification Number

5

Engine serial number

Engine data labels 2B are located on the cylinder block and rocker cover (if fitted). The data label contains important engine information and includes the engine identification number.

6

Year of manufacture 09 = 2009

A typical engine identification number is explained as follows: S

A

320/40098

U

00001

04

1

2

3

4

5

6

1

Engine Displacement D = 4.8 litre series S = 4.4 litre series

2

Engine Type Tier 2 Engines A = Naturally Aspirated B = Turbocharged C = Turbocharged with Intercooler Tier 3 Engines D = Turbocharged E = Electronic Common Rail F = Turbocharged with Intercooler

3

Engine part number

4

Country of manufacture U = United Kingdom

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Section 1 - General Information Identifying the Engine Engine Identification Plate

Component Labels In addition to the engine labels, some of the machine engine components will also have a label attached, or a part number etched into the casting, these include: – the starter motor – the alternator – the fuel injection pump – engine bedplate – engine block – cylinder head – turbo charger In some instances, it may be necessary to quote the information on these labels, for instance if there is a parts query, or a warranty claim. Make a note of these numbers.

Fig 2.

The last three parts of the engine identification number are stamped on the cylinder block at position 2A as follows:

U

1-5

00001

04

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Section 1 - General Information Identifying the Engine Engine Component Identification

Engine Component Identification The following identifies the main components of a typical engine assembly visible from the exterior. Some variants may differ in detail.

Table 1. Engine - As viewed on the left hand side.

Remember that the left and right sides are determined when viewing the flywheel (rear) end of the engine.

1

Rocker cover

12

Fuel filter

2

Fuel injectors and high pressure fuel pipes

13

Lubrication oil filler cap

3

Lubrication oil filler cap

14

Lubrication oil filter

4

Timing gear case

15

Lubrication oil cooler housing

5

Flywheel housing

16

Lubrication oil dip stick

6

Bed plate

17

Low duty PTO (blanking cover if no device is fitted)

7

Lubrication oil pan (sump)

18

Water temperature sender (cold start)

8

Engine lifting eye

19

Low pressure fuel line (to tank)

9

Air Inlet manifold

20

Oil drain plug (sump)

10

Fuel injection pump

21

Oil pressure switch

11

Fuel lift pump

22

Inlet manifold induction heater (if fitted)

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Section 1 - General Information Identifying the Engine Engine Component Identification 22

3

2

2

2

2

1 9

8

10

18 14

4

5

15 13 21

19

16

6

17 20

12

7

11

Fig 3.

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Section 1 - General Information Identifying the Engine Engine Component Identification Table 2. Engine - As viewed on the right hand side Remember that the left and right sides are determined when viewing the flywheel (rear) end of the engine.

1

Rocker cover

11

Exhaust manifold

2

Breather chamber inspection cover

12

Alternator and drive pulley assembly (belt not fitted)

3

Cylinder block

13

Coolant pump drive pulley (belt not fitted)

4

Timing gear case

14

Coolant pump housing (cylinder block)

5

Flywheel housing

15

Coolant inlet/radiator hose connector

6

Bed plate

16

Heavy duty PTO (blanking cover if no device is fitted)

7

Lubrication oil pan (sump)

17

Starter motor assembly

8

Lifting eye

18

Turbocharger oil drain line (turbocharged engine only)

9

Turbocharger (turbocharged engine only)

19

Turbocharger oil feed line (turbocharged engine only)

10

Turbocharger waste gate actuator assembly

20

Oil drain plug (sump)

8

2

10

9

1 11

3 4 12

13 14

16

19 15

5

20

17

7

18

6

Fig 4.

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Section 1 - General Information Identifying the Engine Engine Component Identification Table 3. Engine - As viewed on the crankshaft pulley (front) end Remember that the left and right sides are determined when viewing the flywheel (rear) end of the engine.

1

Rocker cover

9

Drive belt tensioner and pulley

2

Cylinder head

10

Coolant pump and drive pulley assembly

3

Cylinder block

11

Idler pulley

4

Bed plate

12

Alternator and drive pulley assembly

5

Lubrication oil pan (sump)

13

Cab heater water hose connector

6

Crankshaft pulley

14

Coolant temperature sender

7

Front end accessory drive belt

15

Coolant thermostat housing/radiator hose connector

8

Idler pulley

15

14

13

1

2

11

12

8

7

9 10

3 4

5

6

Fig 5.

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Section 1 - General Information Identifying the Engine Independent Power Unit Component Identification

Independent Power Unit Component Identification The illustration below shows a typical Independent Power Unit (IPU) arrangement.

1

Coolant Fill Point

2

Air Filter

3

Dust Valve

4

Fuel Pre-Filter

5

Main Fuel Filter

6

Oil Filler

! $ " #

Fig 6.

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Section 1 - General Information Technical Data Basic Engine Data - 444 Engine

Technical Data Basic Engine Data - 444 Engine Engine Variants (Tier 2/Stage 2): - SA

Naturally Aspirated

- SB

Turbocharged

- SC

Turbocharged with Intercooler

Engine Variants (Tier 3): - SD

Naturally Aspirated

- SF

Turbocharged with Intercooler

Rated speed Vehicle applications

2200 rpm

Generator set application - 50 Hz

1500 rpm

Generator set application - 60 Hz

1800 rpm

Weight (Dry): - SA

472 kg (1040 lb)

- SB

477 kg (1052 lb)

- SC, SD, SF

477 kg (1052 lb)

Number of cylinders

4

Nominal bore size

103 mm (4.055 in)

Stroke

132 mm (5.16 in)

Cylinder arrangement

In line

Combustion Cycle

4-stroke

Firing order

1-3-4-2

Displacement

4.40 litres

Compression ratio - SA

18.6 : 1

- SB

18.3 : 1

- SC

17.5 : 1

- SD

17.2 : 1

- SE

17.1 : 1

- SF

17.2 : 1

Engine Compression

see Note (1)

Direction of rotation (viewed from front {crankshaft pulley} end)

Clockwise

Valves

4 per cylinder

Valve tip clearances (measured cold): - Inlet

1-11

0.19 to 0.27 mm (0.007 to 0.011 in)

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Section 1 - General Information Technical Data Basic Engine Data - 444 Engine - Exhaust Lubricating oil pressure

0.56 to 0.64 mm (0.022 to 0.025in) (2)

>4.6 bar (67lb in2)

Combustion system

Direct Injection

Fuel injection pump

Rotary Mechanical

(1) Compression variance between each cylinder should be no greater than 3.5 bar (50 lb in2) (2) Engine at normal operating temperature and maximum revs.

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Section 1 - General Information Technical Data Basic Engine Data - 448 Engine

Basic Engine Data - 448 Engine Engine Variants (Tier 2/Stage 2): - DA

Naturally Aspirated

- DB

Turbocharged

- DC

Turbocharged with Intercooler

Engine Variants (Tier 3): - DD

Naturally Aspirated

- DF

Turbocharged with Intercooler

Rated speed Vehicle applications

2200 rpm

Generator set application - 50 Hz

1500 rpm

Generator set application - 60 Hz

1800 rpm

Weight (Dry): - DA

472 kg (1040 lb)

- DB

477 kg (1052 lb)

- DC, DD, DF

477 kg (1052 lb)

Number of cylinders

4

Nominal bore size

106 mm (4.173 in)

Stroke

135 mm (5.315 in)

Cylinder arrangement

In line

Combustion Cycle

4-stroke

Firing order

1-3-4-2

Displacement

4.80 litres

Compression ratio - DA

18.6 : 1

- DC

18.1 : 1

Engine Compression

see Note (1)

Direction of rotation (viewed from front {crankshaft pulley} end)

Clockwise

Valves

4 per cylinder

Valve tip clearances (measured cold): - Inlet

0.19 to 0.27 mm (0.007 to 0.011 in)

- Exhaust

0.56 to 0.64 mm (0.022 to 0.025in)

Lubricating oil pressure (2)

>4.6 bar (67lb in2)

Combustion system

Direct Injection

Fuel injection pump

Rotary Mechanical

(1) Compression variance between each cylinder should be no greater than 3.5 bar (50 lb in2) (2) Engine at normal operating temperature and maximum revs.

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Section 1 - General Information Technical Data Engine Block & Bedplate Data

Engine Block & Bedplate Data 103.000 to 103.020 mm (4.055 to 4.046 in)

Cylinder bore (1) Main bearing bolts torque

(2)

- first stage

50 Nm (37 lbf ft)

- second stage

115 Nm ( 85 lbf ft)

- final stage

turn a further 180°

Surface finish for cylinder head joint

Rz < 15um; Rmax < 20um

Diameter of first oversize bore

103.500 to 103.520 mm (4.074 to 4.076 in)

Diameter of second oversize bore

104.00 to 104.020 mm (4.094 to 4.952 in)

Main bearing bore (without bearings) - numbers 1 to 4

92.000 to 92.020 mm (3.622 to 3.623 in)

- number 5

105.000 to 105.020 mm (4.134 to 4.135 in)

Main bearing bore (with bearings) - numbers 1 to 4

88.047 to 88.090 mm (3.466 to 3.468 in)

- number 5

100.047 to 100.090 mm (3.939 to 3.941 in)

Camshaft bore - numbers 1 to 4

60.040 to 60.070 mm (2.364 to 2.365 in)

- number 5 (bush) (3)

60.290 to 60.32 mm (2.374 to 2.375 in)

Permissible wave profile

wt<10m (2.5 distance)

(1) Nominal diameter to be measured 63mm below head face.

(2) 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.

(3) Bush no longer fitted from January 2008.

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Section 1 - General Information Technical Data Cylinder Head Data

Cylinder Head Data Cylinder head distortion (maximum permissible) - end to end

0.05 mm (0.002 in)

- side to side

0.03 mm (0.0012 in)

Valve recess depth - Inlet

0.85 mm (0.033 in)

- Exhaust

0.85 mm (0.033 in)

Valve seat angle - inlet

120 째 (inclusive)

- exhaust Cylinder head bolts torque

90 째 (inclusive) (1)

- first stage

40 Nm (30 lbf ft)

- second stage

75 Nm (56 lbf ft)

- third stage

repeat 75 Nm

- fourth stage

torque angle + 90 째

- final stage

torque angle + 180째

Surface finish for cylinder head joint

Rz < 15um; Rmax < 20um

Permissible wave profile

wt < 10um 2.5 distance

(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.

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Section 1 - General Information Technical Data Inlet and Exhaust Valve Data

Inlet and Exhaust Valve Data Max lift inlet - SA, SB, SC

9.37 mm @ 101° atdc

- SD, SF

9.64 mm @ 101° atdc

Max lift exhaust - SA

9.42 mm @ 110° btdc

- SB, SC

9.42 mm @ 115° btdc

- SD, SF

9.84 mm @ 115° btdc

Inlet opens (top of ramp) - SA, SB, SC

10° btdc

- SD, SF

6° btdc

Inlet closes - SA, SB, SC

32° abdc

- SD, SF

28° abdc

Exhaust opens - SA

50° bbdc

- SB, SC

60° bbdc

- SD, SF

41° bbdc

Exhaust closes - SA, SB, SC

10° atdc

- SD, SF

9° atdc

Valve stem diameter - SA, SB, SC

Inlet: 6.935 +/-0.0075 mm (0.273 +/-0.0003 in)

- SD, SF

Inlet: 6.928 to 6.943 mm (0.2727 to 0.2733 in)

Exhaust: 6.975 +/-0.0075 mm (0.275 +/-0.0003 in) Exhaust: 6.918 to 6.933 mm (0.2724 to 0.2729 in) Valve spring free length

40.18 mm (1.581 in)

Valve guide bore diameter - min

6.958 mm (0.2739 in)

- max

6.968 mm (0.2743 in)

Valve face angle - inlet

60.5 °

- exhaust

45.17 °

Valve length

131.9 to 132.4 mm (5.193 to 5.213 in)

Valve sealing

stem seal with sealing washer

Valve head depth (below cylinder head surface) - inlet

1-16

0.89 to 1.39 mm (0.035 to 0.055 in)

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Section 1 - General Information Technical Data Inlet and Exhaust Valve Data - exhaust

0.95 to 1.45 mm (0.037 to 0.057 in)

Valve rim thickness

2.98 to 3.38 mm (0.117 to 0.133 in)

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Section 1 - General Information Technical Data Rocker Levers, Rocker Shaft and Tappets Data

Rocker Levers, Rocker Shaft and Tappets Data Valve tip clearances (measured cold): - SA, SB, SC

Inlet: 0.19 to 0.27 mm (0.007 to 0.011 in)

- SD, SF

Inlet: 0.35 mm (0.014 in)

Exhaust: 0.56 to 0.64 mm (0.022 to 0.025 in) Exhaust: 0.56 to 0.64 mm (0.022 to 0.025 in) Rocker lever bore diameter - min

26.046 mm (1.025 in)

- max

26.129 mm (1.029 in)

Rocker shaft diameter - min

26.00 mm (1.0236 in)

- max

26.021 mm (1.0244 in)

Tappets stem diameter - min

19.987 mm (0.787 in)

- max

19.975 mm (0.786 in)

Tappet bore diameter - min

20.00 mm (0.7874 in)

- max

20.021 mm (0.7882 in)

Tappet height (maximum)

1-18

55.25 mm (0.0218 in)

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Section 1 - General Information Technical Data Pistons and Connecting Rods Data

Pistons and Connecting Rods Data Gudgeon pin bore diameter - min

40.008 mm (0.015751 in)

- max

40.013 mm (0.015753 in)

Piston ring clearance - top ring

keystone ring

- middle ring

0.11 to 0.07 mm (0.0043 to 0.0027 in)

- bottom (oil) ring

0.09 to 0.05 mm (0.0035 to 0.0019 in)

Piston ring gap - top ring

0.3 to 0.5 mm (0.118 to 0.019 in)

- middle ring

0.55 to 0.8 mm (0.0216 to 0.0314 in)

- bottom (oil) ring Piston height above cylinder block (cold)

0.25 to 0.50 mm (0.0098 to 0.0196 in) 0.0375 to 0.3385 mm (0.0014 to 0.013 in)

Piston groove width - top ring

3.108 to 3.133 mm (0.122 to 0.123 in)

- middle ring

2.47 to 2.67 mm (0.972 to 0.105 in)

- bottom (oil) ring Connecting rod type

(1)

Connecting rod bore diameter

4.04 to 4.06 mm (0.1590 to 0.1598 in) Split fracture 77.00 to 77.01 mm (3.0314 to 3.0318 in)

Connecting rod side clearance - min

0.05 mm (0.0019 in)

- max

0.40 mm (0.0157 in)

Big end bearings: - width

32.5 to 33.00 mm (1.279 to 1.299 in)

- thickness (at centre)

1.990 to 1.981 mm (0.0783 to 0.0779 in)

Small end bearings: - inside diameter

40.034 to 40.020 mm (1.5761 to 1.5755 in)

(1) Split fracture type connecting rods MUST NOT be dot punched, or etched in any way during disassembly - refer to relevant service procedures.

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Section 1 - General Information Technical Data Crankshaft Data

Crankshaft Data Main bearing journal diameter (x4) - min

87.98 mm (3.460 in)

- max

88.00 mm (3.464 in)

Main rear bearing journal diameter (x 1) - min

99.98 mm (3.936 in)

- max

100.00 mm (3.937 in)

Connecting rod bearing journal diameter - min

72.98 mm (2.873 in)

- max

73.00 mm (0.2755 in)

Maximum wear and ovality on journals

TBA mm

Crankshaft induction hardness

55 HRc min on surface

Thrust washer width - min

2.44 mm (0.096 in)

- max

2.50 mm (0.787 in)

Crankshaft end float - min

0.05 mm (0.002 in)

- max

0.28 mm (0.011 in)

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Section 1 - General Information Technical Data Camshaft Data

Camshaft Data Camshaft journal diameter - 4 off

59.99 to 59.97 mm (2.362 to 2.361 in)

- 1 off

60.25 to 60.22 mm (2.372 to 2.370 in)

Camshaft lobe wear limits SA, SB, SC

Inlet: 7.23 +/-0.025 mm (0.285 +/-0.001 in) Exhaust: 7.269 +/-0.025 mm (0.286 +/-0.001 in)

SD, SF

Inlet: 7.385 to 7.435 mm (0.291 to 0.293 in) Exhaust: 7.545 to 7.595 mm (0.297 to 0.299 in)

Camshaft bush diameter Camshaft Gear

(2)

(1)

60.32 to 60.29 mm (2.375 to 2.374 in) 104 teeth

(1) Bush no longer fitted from January 2008.

(2) The camshaft gear is not available as a separate service item. The gear must be heated onto the camshaft in the correct timed position. Specialist fixtures are used during the production process to achieve the correct timing.

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Section 1 - General Information Technical Data Fuel System Data

Fuel System Data Acceptable and Unacceptable Fuels Important: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.

Fuel Specification

Applicable Engines

Service Requirements

EN590 Diesel fuel types - Auto/C0/C1/C2/ C3/C4

All Dieselmax engines.

Obey the usual routine maintenance schedules and procedures

BS2869 Class A2 ASTM D975-91 Class 2, US DF1, US DF2, US DFA JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3 ASTM D975-91 Class 1DA MIL T38219 XF63 NATO F63 French EN590 (RME5) with 5% maximum AVCAT FSII, NATO F44, JP5, MIL T5624, DERD 2452, AVTOR NATO F35, JET A1, DEF STAN 91-91, DERD 2494, JP7

All Dieselmax engines. Engines Obey the usual routine operated with these fuels may have maintenance schedules and a reduced service life procedures. Fuel additives are recommended for use with low sulphur fuels K Additives ( T 1-23) All Dieselmax engines. Engines Obey the usual routine operated with these fuels will have maintenance schedules and a reduced service life procedures. Fuel additives MUST be used K Additives ( T 1-23)

AVCAT, NATO F43 (obsolete), JP5 without additives JET A (ASTM D1655) ASTM D3699 Kerosene B20 Biodiesel - RME content blended with mineral derived diesel (20% maximum) ASTM D6751, DIN 51606, ISO 14214

Dieselmax engines manufactured from 2007 on ONLY(1)

AVTAG (obsolete)

These fuels are NOT ACCEPTABLE with or without additives. Engines MUST NOT be operated with these fuels

AVTAG FSII (obsolete), NATO F40, JP4, DERD 2454 JET B (ASTM D1655)

YOU MUST obey special routine maintenance schedules and procedures. K Service Requirements for use of B20 Biodiesel ( T 1-23)

BS MA100 JIS K2203 No.2 Unmodified vegetable oils (1) The year of manufacture is part of the engine serial number. Refer to Identifying the Engine.

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