jcb 512-56 - Service Manual

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Operator's Manual31 pages

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Summary

15 - Engine

Engine General Information

Covers engine general information, health and safety, and component identification, specifically for engine belts.

Engine Drive Belt System

Details the engine drive belt system, including identification, safety, checks, and maintenance procedures.

Drive Belt Tensioner Service

Provides instructions for removing and installing the drive belt tensioner assembly.

Engine Oil Filter Maintenance

Covers engine oil filter safety, identification, operation, level check, and replacement procedures.

Engine Air Filter Service

Details engine air filter service, including condition checks and replacement of filter elements.

Crankcase Ventilation Filter (CCV)

Explains the crankcase ventilation system and procedures for filter element replacement.

Valve Train System and Data

Describes the engine valve train system and provides technical data for valves.

This document is a service manual for the JCB Loadall (Rough Terrain Variable Reach Truck) models 506-36, 507-42, 509-42, 510-42, 510-56, 512-56, 514-56, and 516-42. It is identified as EN - 9813/5050 - ISSUE 2 - 08/2017.

The manual provides comprehensive information for the operation and maintenance of these machines, emphasizing the importance of understanding and following all instructions to prevent injury or damage. It explicitly states that the Operator's Manual is part of the machine and must be kept clean, in good condition, and replaced if lost, damaged, or unreadable.

The table of contents outlines the various systems and components covered:

01 - Machine: General machine information.
03 - Attachments, Couplings and Load Handling: Details on how to use and maintain attachments and manage loads.
06 - Body and Framework: Information regarding the structural components of the machine.
09 - Operator Station: Covers the controls and environment for the operator.
12 - Heating, Ventilating and Air-Conditioning (HVAC): Maintenance and operation of the climate control system.
15 - Engine: Extensive section on the engine, including its various sub-systems.
18 - Fuel and Exhaust System: Details on fuel delivery and exhaust management.
21 - Cooling System: Information on engine cooling.
24 - Brake System: Maintenance and operation of the braking system.
25 - Steering System: Details on the steering mechanism.
27 - Driveline: Covers the components that transmit power from the engine to the wheels.
30 - Hydraulic System: Information on the hydraulic circuits and components.
33 - Electrical System: Details on the machine's electrical components and wiring.
72 - Fasteners and Fixings: Guidance on proper use of fasteners.
75 - Consumable Products: Information on fluids and other consumables.
78 - After Sales: Support and service information.

Within the "15 - Engine" section, specific sub-sections are detailed:

- Engine Belt:

This section covers the Front End Accessory Drive (FEAD) belt system.

Function Description: A crankshaft pulley drives the FEAD belt, which in turn drives the coolant pump and, depending on the machine application, other engine-mounted accessories like the alternator, cooling fan, and air conditioning compressor. Some applications may have a second crankshaft pulley for a dedicated fan belt driving an engine-mounted cooling fan. The belt tension is maintained by a spring-loaded tensioner, and idler wheels are used to achieve the necessary belt/pulley contact area.
Usage Features: The manual warns against turning the engine by pulling the fan or fan belt to avoid injury or premature component failure. It also emphasizes switching off the engine before working in the engine compartment due to exposed rotating parts and not operating the machine with the engine cover open. A loose drive belt can cause damage to itself and/or other engine parts.
Maintenance Features:
- Check (Condition): Visual inspection of the drive belt for damage (cracks, missing pieces, fraying) at recommended service intervals. If damage is found, the belt must be renewed.
- Adjust: Adjustment is not possible with this drive belt; the spring-loaded tensioning unit ensures correct tension.
- Remove and Install:
  1. Make the machine safe and allow the engine to cool.
  2. Use a 16mm socket on the hexagon spigot nut to carefully rotate the tensioner against spring force. Avoid excessive force to prevent damage.
  3. Hold the tensioner and lift the belt off the drive tensioner pulley.
  4. Slowly release the spring force by rotating the tensioner unit in the opposite direction.
  5. Installation is the reverse of removal. Before installing a new belt, check that the tensioner roller and fan pulley rotate smoothly and have no play in the bearings.

- Tensioner:

Function Description: The drive belt tensioner is a non-serviceable item designed to maintain constant tension on the drive belt.
Maintenance Features:
- Before Removal: Make the machine safe, ensure the engine is cool, gain access to the engine, and remove the drive belt.
- Remove: If the tensioner or idler wheel is faulty or damaged, it must be replaced as a complete assembly. Remove the fixing bolts and lift the tensioner pulley from the cylinder block.
- Install: Installation is the reverse of removal. Tighten the fixing bolts to 24 Nm. Reinstall the drive belt and ensure it is under tension, and the locking pin is removed before starting the engine.

- Oil Filter:

Health and Safety: Warnings are provided regarding the toxicity of oil, the harmful contaminants in used engine oil (which can cause skin cancer), and the importance of using barrier cream or gloves. It is illegal to pollute drains, sewers, or the ground, and all spilt fluids, lubricants, filters, and contaminated materials must be disposed of in accordance with local regulations. Caution is given about oil gushing from the drain plug and potential spills from the oil filter canister.
Function Description:
- At Engine Running: The oil pump delivers pressurized oil to the filter. The anti-drain seal is forced open, allowing oil to flow through a paper element. Filtered oil then enters the inner part of the filter before leaving the filter head.
- At Engine Stopped: Oil pressure in the galleries and filter decays. The anti-drain seal closes, preventing oil from draining from the filter assembly. An anti-drain pipe prevents approximately half of the filter's oil capacity from draining, protecting the engine from oil starvation during startup.
Component Identification: The manual includes detailed diagrams identifying components such as the oil cooler and filter housing, oil filter head, oil cooler matrix, coolant gallery, oil filler cap, oil gallery paths, oil filter drain down plug, oil filler port, oil pressure switch, filter element, spring, O-ring, anti-drain seal, oil temperature sensor, and anti-drain pipe.
Check (Level): Engine oil and oil filter replacement must follow service schedules to prevent serious engine failure.
1. Make the machine safe.
2. Gain access to the engine.
3. Check the oil level on the dipstick (between two marks).
4. Add recommended oil through one of the filler points if necessary.
Remove and Install:
- Special Tools: Oil Filter Removal Tool (Part No. 892/00292), Data Link Adaptor (DLA) Kit (Part No. 892/01174).
- Procedure:
  1. Drain warm oil to ensure contaminants are suspended. Caution: Oil will gush from the drain plug.
  2. Remove the oil sump drain plug and 'O' ring, drain oil, clean, and reinstall with a new 'O' ring. Tighten to 40 Nm.
  3. Loosen and remove the filter housing drain plug, drain oil, and reinstall. Tighten to 40 Nm.
  4. Unscrew the filter canister using the special tool.
  5. Clean the seal face of the filter head.
  6. Smear the seal on the new filter canister with clean engine oil.
  7. Screw in the new filter canister (hand tight only).
  8. Fill the engine with recommended oil to the MAX mark on the dipstick. Install the filler cap securely.
  9. Dead Crank Feature (if applicable): Turn ignition key ON/OFF 5 times, wait 30s for ECU shutdown, then turn to START. Engine will crank for an extended time to prime oil pressure (10s).
  10. No Dead Crank Feature: Connect a laptop with a DLA kit and open Servicemaster. Perform the IMV (Inlet Metering Valve) Override test for 10s to prime oil pressure.
  11. Operate the engine at idle. Ensure the oil pressure low warning light extinguishes immediately. If not, investigate the cause.
  12. Check for oil leakage. After oil cools, recheck the level and top up if necessary.

- Air Filter:

Function Description: The air filter prevents dirt and debris from entering the combustion chamber. A dirty or blocked air cleaner element reduces air intake, leading to engine misfiring, black smoke, low output power, excessive oil consumption, abrasion of cylinder bores and valves (dusting), and reduced engine life.
Usage Features: In hostile environments, air filter elements should be changed more frequently. Some applications may have an air filter pre-cleaner.
Maintenance Features:
- Health and Safety: Do not run the engine when the element has been removed. The outer element must be renewed immediately if the warning light on the instrument panel illuminates.
- Check (Condition): Change air filter elements at recommended service intervals (Refer to PIL 78-24). Check all hose connections for looseness, damage (splits/cracks), especially on the air intake to the turbo compressor and crossover tube. Renew damaged components. Most air filter housings have a vacuum switch that detects air intake restriction and activates warning indicators (audible alarm/visual indicator).
- Remove and Install:
  1. Do not wash or clean elements; they must only be renewed. Mark the inner element each time the outer element is changed as a reminder.
  2. Make the machine safe and gain access to the engine.
  3. Depress clips and lift off the cover.
  4. Remove the outer element carefully.
  5. If changing the inner element, lift up pulls and remove it.
  6. Clean inside the housing and cover, ensuring air holes are clear.
  7. Install the cover and fasten the latch, ensuring the dust valve is at the bottom.

- Crankcase Ventilation Filter:

Function Description: The engine uses a filtered open loop crankcase ventilation (CCV) system. Crankcase emissions (unburned fuel, 'blow by gases' with hydrocarbons and oil contaminants) are prevented from entering the atmosphere by the CCV filter assembly. Vapour flows from the rocker cover to the filter assembly, where two-stage filter elements remove about 90% of contaminants. Trapped oil drains back to the sump via a non-return valve, and filtered vapour vents to the atmosphere. If the filter assembly pressure rises due to a blocked filter, the non-return valve in the oil drain line prevents vapour from being forced back into the crankcase. A pressure relief valve bypasses the filter if it becomes blocked, preventing pressure buildup and serious engine damage, though filtration is then inactive.
Maintenance Features:
- Remove and Install: The filter element must be changed at recommended maintenance intervals (Refer to PIL 78-24).
  1. Make the machine safe and gain access to the engine.
  2. Rotate the filter cover anti-clockwise and remove.
  3. Lift out and discard the filter element.
  4. Clean the inside of the filter housing, removing all oil and sludge.
  5. Ensure the oil drain in the bottom of the housing is not blocked.
  6. Install a new, correct type of filter element.
  7. Align arrows on both parts to install the filter cover.

- Valve:

Function Description: The valve train system opens and closes valves with correct timing relative to piston movements. Each push rod connects a valve tappet to a rocker arm. An adjusting screw with a ball-shaped end sets the valve clearance. Valves extend through the cylinder head without sleeves or guides. They are made from special metal for long service life; damaged or worn valves cannot be lapped or reground and must be replaced. Each valve stem has an oil seal. Valve seat inserts are pressed into the cylinder head, also made from special metal, and can be replaced if damaged or worn.
Important Technical Specifications (Table 89. Inlet and Exhaust Valve Data):
- Max lift: Inlet 9.64mm @ 101° ATDC, Exhaust 9.84mm @ 115° BTDC
- Opens (top of ramp): Inlet 6° BTDC, Exhaust 41° BTDC
- Closes: Inlet 28° ATDC, Exhaust 6° ATDC
- Valve stem diameter: Inlet 6.928–6.943mm, Exhaust 6.918–6.933mm
- Valve spring free length: 51.1mm
- Valve guide bore diameter: min 6.958mm, max 6.973mm
- Valve face angle: Inlet 60.5°, Exhaust 45.17°
- Valve length: 131.9–132.4mm
- Valve sealing: Stem seal with sealing washer
- Valve head depth (below cylinder head surface): Inlet 0.89–1.39mm, Exhaust 0.95–1.45mm
- Valve rim thickness: 2.98–3.38mm
- Valve Clearances (engine cold): Inlet 0.15–0.21mm, Exhaust 0.43–0.49mm (values refer to the tappet adjuster end of the valve rockers).