JCB 407 (2504M TIER 4F) KOHLER ENGINE Wheel Loading Shovel Service Repair Manual From 2092103 to 2092868

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SERVICE MANUAL LOADER 406, 407, 409 EN - 9813/3100 - ISSUE 4 - 04/2018 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 2017 © 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 24 - Brake System 25 - Steering System 27 - Driveline 30 - Hydraulic System 33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales 15 - Engine 12 - Crankshaft 00 - General 15 - 53 9813/3100-4 15 - 53 Operation Lubrication Oil is fed from the main gallery via five drillings, one to each of the main bearings. A groove around the diameter of the upper main bearing shell allows oil transfer to cross drillings in the crankshaft to feed each of the big end bearings. Crankshaft gear is 'splash' lubricated. Front and rear crankshaft oil seals prevent oil leakage from, and dirt ingress to, the engine. Figure 137. 1 Main gallery 2 Drillings (x5) 3 Main bearings 4 Big end bearings 5 Cross drillings 6 Crankshaft gear 7 Crankshaft oil seal 8 Crankshaft oil seal 15 - Engine 12 - Crankshaft 00 - General 15 - 54 9813/3100-4 15 - 54 Check (Condition) 1. Check the main bearing surfaces for damage and excessive wear. 2. Measure the crankshaft diameters to confirm they are within service limits. Refer to: PIL 15-12-00. 3. Check that the oilway cross drillings in the crankshaft are clear and free from debris. Blocked or restricted oilways will cause oil starvation at the big end bearings. 4. Check that the piston cooling oil sprayers are clear (if installed). If the sprayers cannot be cleared remove the fixing screws. Remove the sprayers and discard them. Figure 138. D C A B E A Crankshaft B Shoulder half-rings C Oil spray jets (if installed) D Fixing screws E Main bearing shells 15 - Engine 12 - Crankshaft 00 - General 15 - 55 9813/3100-4 15 - 55 Calibrate Axial clearance check 1. To measure the axial clearance of the crankshaft, it is necessary to assemble the shaft in the crankcase. 2. Measure the axial shift of the crankshaft with a dial gauge. The axial shift must range between 0.18-0.38mm (0.007-0.015in). 3. If the value is more than or less than the specified range, replace the shoulder rings. Figure 139. A B A Crankshaft B Dial gauge 15 - Engine 12 - Crankshaft 00 - General 15 - 56 9813/3100-4 15 - 56 Dimensional Check 1. Make sure that you clean the crankshaft thoroughly with a suitable detergent. 2. Use a pipe cleaner into the lubrication ducts to remove any residual dirt. 3. Use a compressed air jet to thoroughly clean the oil passages. 4. Check the surfaces of the main journals and crank-pins for wear limit, to see whether grinding is necessary. 5. Install the half-bearings on the semi-crankcases, without crankshaft, and couple the semi- crankcases by tightening the fixing screws. 6. Measure the diameter of the crank-pins and main journals with a micrometer. 7. Measure the internal diameter of the connecting rod and crankshaft half-bearings with a dial gauge. 8. Lubricate the contact surfaces with oil to prevent oxidation. 9. The crankshaft and connecting rod half-bearings must necessarily be replaced every time they are disassembled. 10. Make sure that the measurements are within the allowable limits. Figure 140. A B C D A Crank-pin B Main journal C Connecting rod half-bearing D Crankshaft half-bearing 15 - Engine 12 - Crankshaft 00 - General 15 - 57 9813/3100-4 15 - 57 Remove and Install Consumables Description Part No. Size Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4 L CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. 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. Remove the bedplate. Refer to: PIL 15-09-00. 5. If the pistons and connecting rods have not been removed, then remove the main bearing caps. Refer to: PIL 15-12-00. Figure 141. D C B B A E F A Crankshaft B Thrust Washers 15 - Engine 12 - Crankshaft 00 - General 15 - 58 9813/3100-4 15 - 58 C Rear main bearing D Fixing screws E Cooling jets (x4) F Main bearing shells 15 - Engine 12 - Crankshaft 00 - General 15 - 59 9813/3100-4 15 - 59 Remove 1. Remove the thrust washers between the crankshaft and crankcase rear main bearing. 2. Put labels on the thrust washers to make sure that they are installed in the correct positions on assembly. 3. Use suitable lifting equipment to carefully lift the crankshaft from the crankcase (if the crankshaft is lifted manually, two people will be required). 4. Carefully lift out the bearing shells. It is recommended that the bearing shells are renewed. 5. If the bearing shells are to be used again, put labels on the shells to make sure that they are installed in their original positions on assembly. 6. Inspect the crankshaft and main bearings etc. for damage and excessive wear. Figure 142. D H C B B A E F G A Crankshaft B Thrust Washers C Rear main bearing D Fixing screws E Cooling jets x4 (PIL 15-03) F Main bearing shells G Bearing location tab H Oil slot-thrust washers 01 - Machine 09 - Description 12 - Main Component Locations 01 - 23 9813/3100-4 01 - 23 12 - Main Component Locations Introduction Figure 7. A B L K K J H G F C D E A Shovel B Lift arm C Coolant expansion tank D Fuel filter and water trap E Articulation lock F Engine oil filler G Engine oil dipstick H Fuel pump and filter J Trailer socket (if installed) K Battery isolation switch L Oil filter 15 - Engine 12 - Crankshaft 00 - General 15 - 60 9813/3100-4 15 - 60 Before Installation 1. Clean off all traces of the old sealant compound from the crankcase and bedplate mating faces. 2. Use a suitable degreasing agent to carefully clean the main bearing saddles in the bedplate and crankcase. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 3. Take care not to block the oil ways or the piston cooling jets. Important: Cleanliness is of the utmost importance. Blocked oil-ways or oil jets will cause engine failure. Before you install the crankshaft make sure that all oil-ways and jets are clear and free from debris. Install 1. The installation procedure is the opposite of the removal procedure. 2. Make sure that all items are clean and free from damage and corrosion. 3. If the cooling jets have been removed or a new crankcase is being installed, install the jets on the crankcase. 4. Tighten the retaining screws to the correct torque value. 5. Use a suitable degreasing agent to make sure that the surface of the upper bearing shells are clean. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 6. Assemble the bearing shells into the crankcase bearing saddles. 7. Make sure that the location tab engages into the slot. 8. Important: Make sure that the oil-way holes in the bearing saddles align with the holes in the bearing shell. Misaligned holes will cause engine failure. 9. Lubricate the upper bearing shells with clean engine oil. 10. Use suitable lifting equipment (if the crankshaft is lifted manually, two people will be required), to carefully lower the crankshaft into the crankcase. 11. DO NOT rotate the crankshaft, the bearing shells can become dislodged. Refer to step 5. 12. Slide the thrust washers between the crankshaft and the crankcase rear main bearing. 13. Make sure that they are installed in the correct positions, with the two slots facing outwards from the bearing saddle. 14. If necessary, push the crankshaft forward and then backwards to obtain clearance to install the thrust washers. 15. DO NOT rotate the crankshaft, the bearing shells can become dislodged. Refer to step 5. 16. Check that the crankshaft end float is within service limits. Refer to: PIL 15-12-00. 17. Install the bedplate. Refer to: PIL 15-09-00. Table 69. Torque Values Item Nm D 10 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 61 9813/3100-4 15 - 61 03 - Main Bearing Introduction .................................................... 15-61 Check (Condition) .......................................... 15-62 Remove and Install ....................................... 15-62 Introduction In a piston engine, the main bearings are the bearings on which the crankshaft rotates. The bearings hold the crankshaft in place and prevent the forces created by the piston and transmitted to the crankshaft by the connecting rods from dislodging the crankshaft, instead forcing the crank to convert the reciprocating movement into rotation. Figure 143. A B A Main bearing B Crankshaft 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 62 9813/3100-4 15 - 62 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: PIL 15-33-00. 3. Measure the bearing journal diameters to confirm they are within service limits. Refer to: PIL 15-12-00. 4. Replace any parts that are worn or not within the specified tolerances. Remove and Install Special Tools Description Part No. Qty. 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. Remove the fuel injectors. Refer to: PIL 18-18-03. 5. Remove the rocker cover. Refer to: PIL 15-42-06. 6. Drain the oil from the engine. Refer to: PIL 15-00-00. 7. Remove the oil sump. Refer to: PIL 15-45-00. 8. Position the engine upside down in a suitable jig or fixture, supported at the front of the crankcase. Important: The connecting rod and the main bearing cap have been fracture split and must be kept together as a set. Utmost care must be taken to avoid contamination and or damage to the fracture split surfaces. 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 63 9813/3100-4 15 - 63 Remove Figure 144. 4 3 Z 1 2 6 5 1 Piston rings 2 Piston 3 Connecting rod 4 Main bearing cap 5 Bolts 6 Big end bearing shells Z Fracture split surfaces 1. It is recommended that the main bearing caps are removed in pairs according to the firing cycle. 1.1. Cylinder 2 1.2. Cylinders 1 and 3 2. Put marks on the main bearing caps to make sure that they are installed in their original positions on assembly. 3. Rotate the crankshaft so that the main bearing caps on cylinder 2 are positioned at the top. 4. Remove the bolts and lift off the main bearing caps from the connecting rods. 5. Make sure that the bolts are not used again. Discard the bolts. Figure 145. X 1 2 1 Main bearing caps 2 Main bearing cap bolts 6. Remove the bearing shells. 6.1. Lift out the bearing shells from the main bearing caps. 6.2. Carefully rotate the crank to disengage from the connecting rods and gain access to the upper bearing shells. 6.3. Lift out the upper bearing shells. 6.4. The bearing shells must be replaced every time they are removed. 7. Carefully rotate the crankshaft to position the main bearing caps of cylinders 1 and 3. 8. Make sure that the crankshaft does not hit the connecting rod of cylinder 2. 9. Do the steps 4 to 6 to remove the bearing caps and bearing shells for cylinders 1 and 3. 10. Inspect the main bearings for signs of damage and excessive wear. Refer to: PIL 15-12-03. Install 1. Replacement is the reversal of the removal procedure. 2. Make sure that all items are clean and free from damage and corrosion. 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 64 9813/3100-4 15 - 64 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 main bearing cap. Lubricate the bearing shell with clean engine oil. 5. Use compressed air to clean the fracture surfaces of the main bearing caps before assembly. 6. Install the main bearing cap to the connecting rod. 7. Replace the fixing bolts. 8. Tighten the new bolts in two stages to the correct torque value. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) 9. Make sure that the crankshaft rotates smoothly and the connecting rods have axial play. 10. After you perform the check, rotate the crankshaft to position the first cylinder at TDC (Top Dead Centre). After Installation 1. Install the oil sump. Refer to: PIL 15-45-00. 2. Install the rocker cover. Refer to: PIL 15-42-06. 3. Install the fuel injectors. Refer to: PIL 18-18-03. 4. Fill the engine with engine oil. Refer to: PIL 15-00-00. Table 70. Torque Values Item Description Nm 2 1st Stage 40 2 2nd Stage 85 15 - Engine 12 - Crankshaft 09 - Rear Oil Seal 15 - 65 9813/3100-4 15 - 65 09 - Rear Oil Seal Remove and Install Consumables Description Part No. Size 4101/0250 0.01 L JCB Threadlocker and Sealer (Medium Strength) 4101/0251 0.05 L 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 flywheel. 4. Remove the flywheel. Refer to: PIL 15-54-00. Remove 1. Remove the screws that attach the oil seal flange to the crankcase. 2. Remove the oil seal flange and its gasket. 3. Discard the gasket. Figure 146. F B C D E A A Screws B Oil seal flange C Gasket D Crankcase E Bushings F Oil seal lip. Install 1. Make sure that the contact surfaces between the oil seal flange and crankcase are clean and free from damage and corrosion. 2. Always use a new gasket. 3. Make sure that the bushings are installed on the crankcase. 4. Lubricate the lip of the oil seal. 5. Put the new gasket and oil seal flange in position against the crankcase. 6. Make sure the gasket and flange are aligned with the bushings on the crankcase. 7. Apply locking fluid on the 2 screws which will be installed on to the bushings. Consumable: JCB Threadlocker and Sealer (Medium Strength) 8. Tighten the 2 screws by hand all the way into the bushing. 9. Install the remaining screws into the oil seal flange. 10. Tighten the screws to the correct torque value. Strictly follow the torque tightening sequence. Figure 147. 6 8 3 7 5 2 4 1 After Installation 1. Install the flywheel. Refer to: PIL 15-54-00. Table 71. Torque Values Item Nm A 10 15 - Engine 12 - Crankshaft 10 - Flange 15 - 66 9813/3100-4 15 - 66 10 - Flange Remove and Install Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 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. Remove the flywheel and get access to the crankshaft. Refer to: PIL 15-54-00. 4. Remove the screws. Figure 148. A Screw B Flange C Gasket 5. Remove the flange. 6. Discard the gasket. Install 1. Check that the contact surface between the flange and the crankcase is free of grit and dirt. 2. Make sure that the bushes are in place on the crankcase. 3. Lubricate the oil seal lip. Figure 149. E A B C D A Screw B Flange C Gasket D Bushes E Oil seal lip 4. Position the new gasket and the flange on the crankcase. 5. Apply Loctite 243 on the screws. 6. Install and hand tighten the screws. 7. Tighten the screws to the correct torque value in the specified numerical order. Refer to Figure 150. Figure 150. Table 72. Torque Values Item Description Nm A Screws 10 Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it. 15 - Engine 12 - Crankshaft 15 - Phonic Wheel 15 - 67 9813/3100-4 15 - 67 15 - Phonic Wheel Introduction .................................................... 15-67 Remove and Install ....................................... 15-68 Introduction The crankshaft position sensor is installed on the timing gear case. The sensor reads the signal from the phonic wheel that is installed on the engine pulley. The sensor sends an analogue signal to the ECM (Engine Control Module). The sensor produces a 5V square wave signal with Hall effect when the motor is rotating. This data, together with the signal from the sensor, allows the ECM to control the fuel injection with respect to the TDC (Top Dead Centre) of the piston. For gap adjustment. Refer to: PIL 15-84-00. 15 - Engine 12 - Crankshaft 15 - Phonic Wheel 15 - 68 9813/3100-4 15 - 68 Remove and Install Special Tools Description Part No. Qty. Flywheel locking tool 892/12407 1 Consumables Description Part No. Size 4003/1501 0.4 kg 4003/1506 12.5 kg Special MPL-EP Grease 4003/1510 50 kg 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. Drain the oil from the engine. Refer to: PIL 15-00-00. 3. Remove the drive belt according to the belt configuration used. Refer to: PIL 15-18-03. 4. Remove the starter motor. Refer to: PIL 15-75-00. 5. Remove the crankshaft position sensor. Refer to: PIL 15-84-03. Remove 1. Turn the crankshaft with the 1st cylinder in TDC (Top Dead Centre). Make sure that the reference point on the engine pulley points up. Figure 151. A B C A Engine pulley reference point B Engine pulley C Phonic wheel 2. Put the flywheel crown mounting tool in the seat of the starter motor and secure with the starter motor mounting bolts. Special Tool: Flywheel locking tool (Qty.: 1) Figure 152. E D D Starter motor seat E Flywheel crown mounting tool 3. Turn the engine pulley mounting bolt in clockwise direction and remove the bolt. 4. Remove the engine pulley and phonic wheel assembly. Figure 153. B F B Engine pulley F Bolt 5. Remove the screws and remove the phonic wheel with the relevant sound absorption disc from the pulley. 15 - Engine 12 - Crankshaft 15 - Phonic Wheel 15 - 69 9813/3100-4 15 - 69 Figure 154. C G H B B Engine pulley C Phonic wheel G Sound absorption disc H Screw 6. Remove the flywheel crown mounting tool from the seat of the starter motor. Install 1. Make sure that the pin is engaged properly on the pulley. 2. Put the sound absorption disc on the pulley with respect to the pin. 3. Align the phonic wheel on the pulley with respect to the pin. Figure 155. B J G C H B Engine pulley C Phonic wheel G Sound absorption disc H Screw J Pin 4. Attach the phonic wheel to the pulley with the screws. 5. Tighten the screws to the correct torque value. 6. Put the pulley unit on the crankshaft. Make sure that the pin on the crankshaft is aligned with the pulley. 7. Apply grease on the bolt thread. Consumable: Special MPL-EP Grease 8. Put the flywheel crown mounting tool in the seat of the starter motor and secure with the starter motor mounting bolts. Figure 156. E D D Starter motor seat E Flywheel crown mounting tool 9. Attach the pulley unit to the crankshaft with the bolt. Figure 157. Z B F Y B Engine pulley F Bolt Y Crankshaft pin Z Reference hole on pulley 10. Tighten the bolt to the correct torque value. 11. Remove the flywheel crown mounting tool from the seat of the starter motor. Table 73. Torque Values Item Nm F 360 H 10

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