jcb Stage-V 448 Elec Engine 4 Cyl Operator's Manual
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jcb Stage-V 448 Elec Engine 4 Cyl Operator's Manual

jcb Stage-V 448 Elec Engine 4 Cyl Operator's Manual

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OPERATOR'S MANUAL
ENGINE
JCB Stage-V 448 Elec Engine 4 Cyl
EN - 9841/4050 ISSUE 1 - 03/2020
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

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  • Page 1 OPERATOR'S MANUAL ENGINE JCB Stage-V 448 Elec Engine 4 Cyl EN - 9841/4050 ISSUE 1 - 03/2020 THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE...
  • Page 3 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. OPERATOR'S Do not operate the machine without an Operator's...
  • Page 4 Notes: 9841/4050-1...

  • Page 5: Table Of Contents

    Table of Contents Contents Page No. Acronyms Glossary ............................Introduction About this Manual Using the Manual ..........................1 Using the Product ..........................1 Left-Hand Side, Right-Hand Side ......................1 Cross References ..........................2 Safety Safety - Yours and Others ........................3 Safety Warnings ............................
  • Page 6 Table of Contents Preservation and Storage Cleaning General ..............................27 Preparation ............................28 Storage General ..............................29 Put into Storage ..........................29 During Storage ............................ 32 Take out of Storage ..........................32 Maintenance Introduction General ..............................35 Obtaining Spare Parts ........................35 Maintenance Safety General ..............................
  • Page 7 Table of Contents Fluids, Lubricants and Capacities General ..............................72 Fuel ..............................73 Diesel Exhaust Fluid (DEF) ........................ 76 Coolant ..............................78 Torque Values General ..............................80 Electrical System General ..............................86 Engine Exhaust After Treatment (EAT) ......................87 Warranty Information General ..............................

  • Page 8: Acronyms Glossary

    Table of Contents Acronyms Glossary Crankcase Ventilation Diesel Exhaust Fluid Diesel Oxidation Catalyst Diesel Particulate Filter Exhaust After Treatment Engine Control Module Electronic Control Unit FEAD Front End Accessory Drive HEST High Exhaust System Temperature High Pressure Valve Inlet Metering Valve International Organization for Standardization Malfunction Indicator Lamp Nitrogen Oxide...

  • Page 9: Introduction

    Particular attention must be given to all the safety aspects of operating and maintaining the engine. If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured.

  • Page 10: Cross References

    Introduction About this Manual Figure 1. A Front of engine (viewed from crankshaft pulley B Exhaust manifold side of engine end) C Rear of engine (Flywheel end of engine) D Inlet manifold side of engine Cross References In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The number of the page upon which the subject begins is indicated within the brackets.

  • Page 11: Safety

    If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them.

  • Page 12: Clothing And Personal Protective Equipment (Ppe)

    This engine 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 engine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer. Vapours and Solvents Vapours from solvents, thinners and adhesives can be highly flammable.

  • Page 13: About The Product

    Product Compliance Your JCB engine was designed to comply with the laws and regulations applicable at the time of its manufacture for the market in which it was first sold. In many markets laws and regulations exist that require the engine to be operated and maintained according to JCB instructions to maintain compliance to the emissions regulations at the level relevant to the engine when first produced.

  • Page 14: Description

    The scope of this publication is limited to the engine, but references to a typical installation will be made. When the JCB Engine is used as a power source for pumps, generators, independent power units etc., the operating controls and procedures must be provided by the Original Equipment Manufacturer (OEM). Always refer to Original Equipment Manufacturer (OEM) Operator Manual for safe operating instructions.
  • Page 15 About the Product Description Figure 3. Left hand Side Rocker cover Fuel injectors and high pressure fuel pipes Lubrication oil filler cap Timing gear case Flywheel housing Bedplate Lubrication oil sump Air inlet manifold High pressure fuel pump 10 Fuel filter Lubrication oil dipstick 12 Lubrication oil cooler housing 13 Low duty PTO (Power Take-Off) (blanking...
  • Page 16 About the Product Description Figure 4. Right Hand Side Turbocharger oil drain line Heatshield Timing gear case Flywheel housing Bedplate Lubrication oil sump Turbocharger Turbocharger air outlet Alternator 10 Heavy duty PTO (blanking cover if no device is installed) Coolant inlet / radiator hose connector 12 Starter motor assembly 13 Turbocharger oil feed line 14 Oil drain plug (sump)
  • Page 17 About the Product Description Figure 5. Front End Rocker cover Cylinder head Crankcase Bedplate Lubrication oil sump Crankshaft pulley FEAD (Front End Accessory Drive) tensioner Coolant pump and drive pulley assembly 10 Coolant thermostat housing/radiator top hose Alternator and drive pulley assembly connector Turbocharger 12 Coolant temperature sensor...
  • Page 18 About the Product Description Figure 6. Rear End 1 Rocker cover Cylinder head 3 Flywheel High pressure fuel pump drive gear cover 5 Flywheel housing Engine electrical harness 7 Linkage Actuator 9 Turbocharger 10 Low pressure fuel return line to tank 9841/4050-1...
  • Page 19 About the Product Description Engine Sensors and Actuators Figure 7. Coolant temperature sensor Turbocharger actuator Temperature manifold air pressure sensor Fuel temperature sensor Fuel inlet metering valve Camshaft position sensor Crankshaft position sensor fly lead (sensor Oil temperature sensor not shown) Oil pressure switch 10 Inter cooler outlet temperature sensor Air inlet throttle...
  • Page 20 About the Product Description Figure 8. 1 Exhaust manifold pressure sensor 2 Fuel pressure relief valve HPV (High Pressure Valve) 3 Exhaust manifold temperature sensor 4 Oil level switch (optional not shown) 9841/4050-1...

  • Page 21: Product And Component Identification

    About the Product Product and Component Identification Product and Component Identification Engine The engine data labels are attached to the cylinder block as shown. Figure 9. A Engine data label - rocker cover B Stamp C Engine data label - crankcase D Engine data label - rocker cover E Engine identification number The data label includes the engine identification number.

  • Page 22: Operation Introduction General

    Introduction General JCB may not have any control over the installation and use of their products, thus it is necessary to read this operation section in conjunction with the manufacturers operators manual through from beginning to end. The operator must always be aware of events happening in or around the product. Safety must always be the most important factor when you operate the product.

  • Page 23: Operating Safety

    This engine 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 engine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer. Engine Safety Stop the engine at once if a fault develops.

  • Page 24: Battery Isolator

    Operation Battery Isolator Battery Isolator General To allow the engine ECU (Electronic Control Unit) to shut down correctly, you must wait 60s before you isolate the battery. The 60s period starts when you turn the ignition off. Disconnect the Electrics: 1.

  • Page 25: Before Starting The Engine

    Operation Before Starting the Engine Before Starting the Engine General Notice: Do not keep the accelerator pedal fully depressed when the engine has started. Do not race the engine until the oil pressure low light has gone out. Racing the engine too soon could damage the turbo- charger due to insufficient lubrication.

  • Page 26: Starting The Engine

    Operation Starting the Engine Starting the Engine General Start Procedure Notice: Do not operate the starter motor for more than 20 s at one time. Let the starter motor cool for at least 2 min. 1. Make sure that all controls (if applicable) are set correctly for starting. Consult the manufacturers operators manual for further information as the actual installation may differ.
  • Page 27 Operation Starting the Engine Engine Checks After Start-up WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates your skin, get medical help immediately. Notice: Stop the engine and investigate the cause if any of the following conditions occur: The warning lights fail to go off when the engine has been started.

  • Page 28: Warming Up

    Operation Starting the Engine Figure 11. RPM x 100 RPM x 100 Warming Up Warming up requirements will depend on the type of installation. Consult the machine manufacturers instructions. 9841/4050-1...

  • Page 29: Stopping And Parking

    Operation Stopping and Parking Stopping and Parking General Stopping the Engine Notice: Allow turbocharged engines to run at approximately 1000 rpm and reduced load or idle for 2 –3 min before shut down. This will allow the turbocharger to cool. Failure to follow this procedure could result in turbocharger damage.

  • Page 30: Lifting The Product

    Operation Lifting the Product Lifting the Product General For the various engine weights. Refer to: Technical Data (Page 71). The lifting equipment used must be an approved type and capable of lifting the engine safely. The recommended lifting equipment is shown in figure. Use spreader bar when lifting the engine. Refer to Figure 12. Never attempt to manually lift heavy components such as the cylinder head, crankshaft etc.

  • Page 31: Operating Environment

    1. Consult the machine manufacturers operators manual. 2. Drain the water collected in the fuel system to prevent it freezing. 3. Additional low temperature fuel and lubricants and batteries may be required. Contact your local JCB engine dealer for advice.

  • Page 32: Operating In High Temperatures

    4. If appropriate to the installation, install a cold weather starting aid. In very low temperatures (less than the value shown) additional starting aids may be needed. For example are fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -18°C (-0.4°F) Operating in High Temperatures 1.

  • Page 33: Refuelling

    Notice: A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. Use of high sulphur fuels will poison the SCR catalyst and must not be used. Notice: Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of. Filling the Tank Notice: 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.
  • Page 34 Operation Refuelling 1. Remove all unwanted material around the DEF cap. 2. Remove the DEF cap. 3. Add the DEF through the filler neck as necessary. 4. Install the DEF cap. 5. Lock the DEF cap to prevent theft and tampering. 9841/4050-1...

  • Page 35: Preservation And Storage

    Preservation and Storage Cleaning Preservation and Storage Cleaning General WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.

  • Page 36: Preparation

    Preservation and Storage Cleaning Preparation 1. Make the machine safe. 2. Stop the engine and let it cool for at least one hour. Do not try to clean any part of the engine while it is running. 3. Make sure that all of the electrical connectors are correctly coupled. If the connectors are open, attach the correct caps or seal with water proof tape.

  • Page 37: Storage

    Preservation and Storage Storage Storage General If the machine will not be used for an extended period (greater than two months), you must store the machine correctly. If you prepare the machine carefully and apply on-going care you can prevent deterioration and damage to the machine while it is in storage.
  • Page 38 Preservation and Storage Storage Figure 13. Typical engine Top hose cap Bottom hose cap Turbocharger intake cap Turbocharger compressor outlet cap Turbocharger exhaust outlet cap Inlet manifold cap Dipstick plug ECM (Engine Control Module) machine harness connector cap Fuel spill back line cap 10 Low duty PTO (Power Take-Off) (if installed) Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots...
  • Page 39 After three separate 20 second cranking periods, If the oil pressure switch does not open (indicating no, or low oil pressure), contact your JCB engine dealer. 2.5. Recap all engine openings.

  • Page 40: During Storage

    Preservation and Storage Storage All engines despatched from JCB will have been subjected to a hot test (checking items such as oil pressure, engines speeds, torque values etc.) and therefore the interior surfaces will have been coated with engine oil.
  • Page 41 Preservation and Storage Storage Stored engines will also require re-inhibiting with CRODAFLUID PA75 every 12 months, including hot testing on a dynamometer. 9841/4050-1...
  • Page 42 Notes: 9841/4050-1...

  • Page 43: Maintenance Introduction General

    If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause engine failure. A parts book for your engine is available from your JCB dealer. The parts book will help you identify parts and order them from your JCB dealer.

  • Page 44: Maintenance Safety

    Engine Modifications This engine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer. Repairs If your engine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health.
  • Page 45 Maintenance Maintenance Safety However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.
  • Page 46 Maintenance Maintenance Safety Swallowing If oil is swallowed do not induce vomiting. Get medical advice. Skin In the case of excessive skin contact, wash with soap and water. Spillage Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

  • Page 47: Maintenance Schedules

    Maintenance Maintenance Schedules Maintenance Schedules General WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the battery isolator if installed) when you are not using electrical power.

  • Page 48: Pre-Start Cold Checks, Service Points And Fluid Levels

    Pre-start Cold Checks, Service Points and Fluid Levels The following maintenance procedure refers to the JCB engine only. It does not apply to the machine or equipment in which it is installed. Consult the manufacturers operation manual for further information.

  • Page 49: Maintenance Positions

    Maintenance Maintenance Positions Maintenance Positions General Consult the machine manufacturers operators manual 9841/4050-1...

  • Page 50: Service Points

    Maintenance Service Points Service Points General Consult the machine manufacturers operators manual 9841/4050-1...

  • Page 51: Access Apertures

    Maintenance Access Apertures Access Apertures General Consult the machine manufacturers operators manual 9841/4050-1...

  • Page 52: Engine

    Maintenance Engine Engine General Clean Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system.

  • Page 53: Oil

    3. Check the engine and the area below for oil leaks. 4. Close the engine cover (if applicable). 5. If necessary, contact your JCB dealer. Check (Level) WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil.
  • Page 54 Maintenance Engine Replace Special Tools Description Part No. Qty. Oil Filter Removal Tool 320/B4374 Data Link Adaptor (DLA) Kit 892/01174 Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil. CAUTION! Oil will gush from the hole when the drain plug is removed.

  • Page 55: Front End Accessory Drive (Fead) Belt

    Refer to: Stopping and Parking (Page 21). 2. Open the engine compartment cover (if applicable). Refer to: Access Apertures (Page 43). 3. Get access to the drive belt. 4. Check the drive belt tension, if necessary contact your JCB dealer for any service requirements. 9841/4050-1...

  • Page 56: Emissions Control System

    Maintenance Engine 5. Renew the belt if it has cracks or if it is frayed or has pieces of material missing. Contact your JCB dealer for any service requirements. 6. Close and latch the engine compartment cover (if applicable). Emissions Control System General Notice: Make sure that genuine Diesel Exhaust Fluid is used (DIN 70070 or ISO 22241 certified).

  • Page 57: Air Filter

    Maintenance Air Filter Air Filter General Check (Condition) Engine performance and durability will be severely affected if the quality of the air intake is poor. A dirty and blocked air cleaner element will reduce the amount of air entering the combustion chamber which can cause engine mis-firing, black smoke and low output power.

  • Page 58: Fuel System

    1. Make the machine safe. 2. Get access to the engine compartment (if applicable). 3. Check the engine compartment (if applicable), fuel lines and the area below for leaks. 4. If necessary, contact your JCB dealer. Primary Fuel Filter Drain Draining the Water Separator 1.
  • Page 59 Maintenance Fuel System Replace Remove 1. Make the machine safe. 2. Get access to the filter. 3. Set the fuel shut-off valve to isolate the fuel supply. 4. Drain the water separator bowl. 5. Disconnect the WIF (Water in Fuel) connector. 6.

  • Page 60: Secondary Fuel Filter

    Maintenance Fuel System Secondary Fuel Filter Replace Special Tools Description Part No. Qty. Spanner - HP Fuel Filter 334/G5933 Fuel Filter Removal Tool (4 cyl) 892/01383 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.
  • Page 61 Maintenance Fuel System Remove Figure 19. A Filter head B Filter element C Drain tap 1. Use the applicable service tool to unscrew the filter element from the filter head (anticlockwise). Special Tool: Fuel Filter Removal Tool (4 cyl) (Qty.: 1) Special Tool: Spanner - HP Fuel Filter (Qty.: 1) Install 1.

  • Page 62: Cooling System

    Before you start the engine, inspect the system for leaks: 1. Make the machine safe. 2. Get access to the cooling pack. 3. Check the cooling system for leaks. 4. If necessary, contact your JCB dealer. Coolant Check (Condition) Refer to: Coolant (Page 78).
  • Page 63 Maintenance Cooling System Refer to: Maintenance Positions (Page 41). 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Access Apertures (Page 43). 4. Check the condition of the hoses, radiator and fan for: 4.1. Condition. 4.2.

  • Page 64: Electrical System

    Maintenance Electrical System Electrical System Fuses Replace For details of fuse locations and ratings, please consult the machine manufacturers Operators Manual. Relays Replace For information about the locations and types of relays fitted, please consult the machine manufacturers Operators Manual. 9841/4050-1...

  • Page 65: Fault-Finding

    If a fuel injector or engine ECU is possibly defective, contact your JCB engine dealer who has the correct electronic diagnostic and service tools.
  • Page 66 Maintenance Fault-Finding Fault Finding Tables Table 13. A Charts Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Refer to Table 17. Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Refer to Table 18. Engine - Will Not Crank or Cranks Slowly Refer to Table 19.
  • Page 67 One or more fuel injector worn or malfunctioning. Check the electronic fault codes. Check the electrical connections at the injectors (specialist task - contact your JCB dealer). ECU (Electronic Control Unit) or electrical sensor Check the electronic fault codes. Check the electrical fault.
  • Page 68 Check the electronic fault codes. Check the electrical connections at the ECU and sensors. Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Contact your JCB Engine Dealer. Table 19. Engine-Will Not Crank or Cranks Slowly Remedy...
  • Page 69 Check the electronic fault codes. Check the electrical connections at the ECU and sensors. Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Contact your JCB Engine Dealer. Camshaft or tappets damaged. Contact your JCB Engine Dealer.
  • Page 70 ECU or electrical sensor fault. Check the electronic fault codes. Check the electrical connections at the ECU and sensors. Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Contact your JCB Engine Dealer. Table 23. Engine-Noise Excessive Cause...
  • Page 71 Fault-Finding Cause Remedy Excessive camshaft bearing wear. Contact your JCB Engine Dealer. Worn or damaged pistons and/or piston rings. Contact your JCB Engine Dealer. One or more fuel injector worn or malfunctioning. Check the electronic fault codes. Check the electrical connections at the injectors (specialist task - contact your JCB dealer).
  • Page 72 Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended clear- ances. Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Contact your JCB Engine Dealer. Engine compression low in one or more cylinders. Contact your JCB Engine Dealer.
  • Page 73 Check the electronic fault codes. Check the electrical connections at the injectors (specialist task - contact your JCB dealer). Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Contact your JCB Engine Dealer. Table 27. Engine-RPM Surges Cause Remedy Fuel level low.
  • Page 74 (specialist task - contact your JCB dealer). Engine compression low in one or more cylinders. Contact your JCB Engine Dealer. Smokes under load at all speeds, but mainly low to mid speed range. Table 30. Engine-Exhaust Smoke Excessive (White/Blue Smoke)
  • Page 75 Check/correct leaks in the manifold or turbocharger gaskets. Look for a cracked manifold. Valve guide seals are leaking. Contact your JCB Engine Dealer. ECU or electrical sensor fault. Check the electronic fault codes. Check the electrical connections at the ECU and sensors.
  • Page 76 One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical connections at the injectors (specialist task - contact your JCB dealer). Have oil sample analysed. Repair engine as required. Table 36. Lubricating Oil-Pressure Low...
  • Page 77 Maintenance Fault-Finding Cause Remedy Suction pump pressure relief valve stuck open. Contact your JCB Engine Dealer. Oil pump pressure relief valve stuck open. Contact your JCB Engine Dealer. Lubricating oil pump worn. Contact your JCB Engine Dealer. Table 37. Lubricating Oil-Pressure High...
  • Page 78 ECU and sensors. One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical connections at the injectors (specialist task - contact your JCB dealer). Table 40. Coolant-Under Temperature Cause Remedy Air flow across the radiator excessive.

  • Page 79: Technical Data

    Technical Data Performance Dimensions Technical Data Performance Dimensions General Table 42. Description DPEngine Engine Variants Turbocharged with intercooler and exhaust after treatment system Emission compliance EU Stage V Rated speed 2200 rpm Weight (Dry) (Dry weight-No cooling fan drive) 496kg Number of cylinders Nominal bore size 106mm...

  • Page 80: Fluids, Lubricants And Capacities

    46°C (114.7°F) SAE 10W30 -15°C (5.0°F) 46°C (114.7°F) Recommended Oils Table 44. With exhaust after treatment Engine Oil Specification JCB 5W30 (Part 4001/3100) CJ-4 JCB 5W40 (Part 4001/3400) CJ-4 JCB 10W30 (Part 4001/3000) CJ-4 JCB 10W30 (Part 4001/3700) CK-4 JCB 5W40 (Part 4001/3800)

  • Page 81: Fuel

    Technical Data Fluids, Lubricants and Capacities Fuel This engine has been certified for Stage V emissions for use within the EU member states and for any countries that have the same Stage V certification requirement for emissions. The Stage V engine has been certified on the standard market fuel for the EU (EN590 and non-road gas oil). For requirements of this standard market fuel: Refer to Table 46.
  • Page 82 Technical Data Fluids, Lubricants and Capacities Table 47. EN15940 paraffinic diesel Property Test method Minimum Maximum Cetane number EN ISO 15195 Density at 15°C (59.0°F) EN ISO 12185 765kg/m³ 800kg/m³ Total aromatic hydrocarbons EN 12916 1.1% concentra- tion by mass Sulphur content EN ISO 20846 5mg/kg...
  • Page 83 Technical Data Fluids, Lubricants and Capacities Property Test method Minimum Maximum Lubricity, corrected wear scar diameter (wsd 1.4) EN ISO 12156-1 460µm at 60°C (139.9°F) Viscosity at 40°C (103.9°F) EN ISO 3104 2mm²/s 4.5mm²/s Distillation % concentration by volume recovered at 250°C EN ISO 3405 65% concentra- (481.6°F)

  • Page 84: Diesel Exhaust Fluid (Def)

    Technical Data Fluids, Lubricants and Capacities none of which are desirable in the FIE. These effects are known to be accelerated when the fuel is stored in the presence of air and water together. An extract 'common statement' from the FIE manufactures specifies that "The fuel injection equipment manufacturers can accept no liability whatsoever for failure attributable to operating their products with fuels for which the products were not designed, and no warranties or representations are made as to the possible effects of running these products with such fuels".
  • Page 85 In order to prevent damage to the SCR system, DEF used must be compliant to the ISO 22241-1 standard. ISO 22241-1 DEF is available from all JCB dealers Every machine equipped with a JCB SCR system is fitted with a quality sensor in the DEF tank to help prevent problems caused by cross contamination with other fluids DEF needs to be kept free from dirt and other particle contaminants at all times to prevent damage to the SCR system.

  • Page 86: Coolant

    The diesel cap is also clearly marked with lettering. Every JCB DEF cap is lockable with a special key with a blue key fob, which can be given to a site supervisor or other person of responsibility. There is a special magnet fitted in the DEF filler neck which will allow some DEF electric dispensing pumps to start if it has the matching ISO feature, as all forecourt dispensing systems have, thus preventing DEF being dispensed if nozzle is not in the DEF tank.
  • Page 87 Technical Data Fluids, Lubricants and Capacities • Make sure that the antifreeze complies with International Specification ASTM D6210. • Always read and understand the manufacturer's instructions. • Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used.

  • Page 88: Torque Values

    Torque Values General This section details all the torque figures to be used on the JCB Ecomax Engine. Some of the torques must be used in conjunction with the recommended procedures contained in this manual, for instance if the torques need to be applied in a specific sequence.
  • Page 89 Technical Data Torque Values Table 53. Oil Sump Plug and Retaining Bolts Item Torque Angle Figure N·m A. Oil sump retaining 22–26 bolts B. Oil sump plug 40–60 Table 54. Fuel Filter Mounting Bolt Item Torque Angle Figure N·m Fuel filter bolt Table 55.
  • Page 90 Technical Data Torque Values Table 56. Thermostat Housing Bolts Item Torque Angle Figure N·m Thermostat housing re- 22–26 taining bolts Table 57. Water Inlet Connector Bolts Item Torque Angle Figure N·m Water inlet connector 22–26 retaining bolts Table 58. Water Temperature Sender/Switch Item Torque Angle...
  • Page 91 Technical Data Torque Values Table 59. Exhaust Manifold Bolts Item Torque Angle Figure N·m Exhaust manifold retain- ing bolts (T3) - first stage - final stage angle 90° torque Table 60. Inlet Manifold Bolts Item Torque Angle Figure N·m Inlet manifold retaining 43–47 bolts (T3) Table 61.
  • Page 92 Technical Data Torque Values Table 62. Lifting Bracket Bolts Item Torque Angle Figure N·m Lifting bracket retaining 43–51 bolts Table 63. Alternator Retaining Bolts Item Torque Angle Figure N·m Alternator retaining bolts 47 9841/4050-1...
  • Page 93 Technical Data Torque Values Table 64. Starter Motor Retaining Bolts Item Torque Angle Figure N·m Starter motor retaining 43–51 bolts Table 65. DEF Filter Cover Item Torque Angle Figure N·m DEF Filter cover 22.5 ± 2.5N·m Table 66. exhaust v band clamps Item Torque Angle...

  • Page 94: Electrical System

    Technical Data Electrical System Electrical System General Consult the machine manufacturers documentation. 9841/4050-1...

  • Page 95: Engine

    Technical Data Engine Engine Exhaust After Treatment (EAT) Introduction For the applicable regulations this engine has been designed in compliance with, the emissions control system is essential for meeting the requirements of exhaust emission content. The emissions control system is defined as any device, system or element of design which controls or reduces engine exhaust emissions.
  • Page 96 Technical Data Engine • No DPF lamp. HEST (High Exhaust System Temperature) lamp used to show when regeneration is active and exhaust temperatures are high. • Manual regeneration is available to the operator. • Dealer regeneration is available via service tool without unlock. Level 2: DPF Regeneration required.
  • Page 97 Technical Data Engine Figure 20. DEF Level Warning Graph A DEF level Low. Early warning to operator (Level B DEF level indicated critical low. Last warning to 0) - Fill up this shift operator - Fill up now C 0% DEF level indicated on level gauge. D Engine torque will remain at the levels shown Machine starts to derate (reduced torque) - Fill for a period (Level 1) - Fill up now...
  • Page 98 Don't mix DEF with your diesel; it is not a fuel additive. • Don't put DEF in your diesel tank – if you do, do not start the engine, call your JCB dealer immediately. • Don't add chemicals to your DEF to prevent freezing.

  • Page 99: Warranty Information

    Technical Data Warranty Information Warranty Information General Table 69. Signature and stamp Date Annual Insurance (Yes) Hours Figure 22. Installation Checklist Figure 23. 500h/6 Month Figure 24. 1000h/12 Month 9841/4050-1...
  • Page 100 Technical Data Warranty Information Figure 25. 1500h/18 Month Figure 26. 2000h/24 Month Figure 27. 2500h/30 Month Figure 28. 3000h/36 Month 9841/4050-1...
  • Page 101 Technical Data Warranty Information Figure 29. 3500h/42 Month Figure 30. 4000h/48 Month Figure 31. 4500h/54 Month Figure 32. 5000h/60Month 9841/4050-1...
  • Page 102 Technical Data Warranty Information Figure 33. 5500h/66 Month Figure 34. 6000h/72 Month Figure 35. 6500h/78 Month Figure 36. 7000h/84 Month 9841/4050-1...
  • Page 103 Technical Data Warranty Information Figure 37. 7500h/90 Month Figure 38. 8000h/96 Month Figure 39. 8500h/102 Month Figure 40. 9000h/108 Month 9841/4050-1...
  • Page 104 Technical Data Warranty Information Figure 41. 9500h/114 Month Figure 42. 10000h/120 Month Figure 43. 10500h/126 Month Figure 44. 11000h/132 Month 9841/4050-1...

  • Page 105: Service Record Sheet

    Technical Data Warranty Information Service Record Sheet Table 70. Date Annual Insurance (Yes) Hours Signature and stamp Figure 45. Installation Checklist Figure 46. 500h/3 Month Figure 47. 1000h/6 Month 9841/4050-1...
  • Page 106 Technical Data Warranty Information Figure 48. 1500h/9 Month Figure 49. 2000h/12 Month Figure 50. 2500h/15 Month Figure 51. 3000h/18 Month 9841/4050-1...
  • Page 107 Technical Data Warranty Information Figure 52. 3500h/21 Month Figure 53. 4000h/24 Month Figure 54. 4500h/27 Month Figure 55. 5000h/30Month 9841/4050-1...
  • Page 108 Technical Data Warranty Information Figure 56. 5500h/33 Month Figure 57. 6000h/36 Month Figure 58. 6500h/39 Month Figure 59. 7000h/42 Month 9841/4050-1...
  • Page 109 Technical Data Warranty Information Figure 60. 7500h/45 Month Figure 61. 8000h/48 Month Figure 62. 8500h/51 Month Figure 63. 9000h/54 Month 9841/4050-1...
  • Page 110 Technical Data Warranty Information Figure 64. 9500h/57 Month Figure 65. 10000h/60 Month Figure 66. 10500h/63 Month Figure 67. 11000h/66 Month 9841/4050-1...

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