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jcb VM117 Service Manual
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SERVICE MANUAL
VM117, VM137
EN - 9813/4900 - ISSUE 1 - 09/2015
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2015 © 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
06 - Body and Framework
09 - Operator Station
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brakes
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

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Summary of Contents for jcb VM117

  • Page 1 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. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2: Engine Oil Pressure

    15 - Engine 00 - General 00 - General Engine Oil Pressure 5. Start the engine, increase the engine revs to the rated speed. Record the pressure gauge reading, refer to Technical Data (PIL 15-00), for Use the following procedures to measure the engine the recommended circuit pressure.
  • Page 3: Remove And Install

    15 - Engine 00 - General 00 - General Remove and Install Special Tools recommended lifting equipment is shown. Use a spreader bar when lifting the engine. Never attempt Description Part No. Qty. to manually lift heavy components on your own. Lifting Bracket Front 320/09062 Always use lifting equipment, or obtain the help of...
  • Page 4 15 - Engine 00 - General 00 - General Electrical connector- engine ECM (Engine Lifting bracket fixing bolts Control Module) machine side connector Fixing bolts- gearbox to engine (grey) Electrical connector- engine harness Electrical connections- alternator Top hose Hose connection- cab heater Bottom hose Electrical sensor- engine oil level Air inlet hose...
  • Page 5: Before Removal

    15 - Engine 00 - General 00 - General Before Removal 16. Ensure that all relevant harnesses and hoses are unclipped from the engine and tied out of the way. 1. Make sure that the engine is safe to work on. If 17.
  • Page 6 15 - Engine 00 - General 00 - General Lifting equipment Install 1. Replacement is a reversal of the removal procedure. Note the following: 2. Important: It is vitally important that the torque converter is installed at the gearbox and engine flywheel correctly.
  • Page 7 2.3. Using a suitable power supply at the correct voltage, crank the engine over. All engines despatched from JCB will have been subjected to a hot test (checking items such as oil 2.4. During cranking, check that the oil pressure switch opens using a multimeter.
  • Page 8 15 - Engine 00 - General 00 - General Table 31. Hot Test Profile Stage Mode Speed Torque Time (rpm) (Nm) (secs) Speed/ Torque Speed/ 1300 Torque Speed/ 2500 Torque Speed/ 1300 Torque Speed/ Torque 15 - 34 9813/4900-1 15 - 34...
  • Page 9 15 - Engine 03 - Crankcase 00 - General 00 - General Introduction Introduction ............ 15-37 The crankcase is the housing for the crankshaft. Technical Data ..........15-38 The enclosure forms the largest cavity in the engine and is located below the cylinders. It is integral with the cylinder bank and forms an engine block.
  • Page 10: Technical Data

    15 - Engine 03 - Crankcase 00 - General Technical Data Table 32. Crankcase and Bedplate Data 4.4L 4.8L 103–103.02mm 106–106.02mm Cylinder bore Main bearing bolts torque First stage 50N·m 50N·m Second stage 115N·m 115N·m Final stage Turn a further 180° Turn a further 180°...
  • Page 11: Cylinder Head

    15 - Engine 06 - Cylinder Head 00 - General Technical Data Table 33. Cylinder Head Data Cylinder head distortion (maximum permissible) - End to end 0.05mm - Side to side 0.03mm Valve recess depth - Inlet 0.85mm - Exhaust 0.85mm Valve seat angle - Inlet...
  • Page 12 15 - Engine 06 - Cylinder Head 00 - General Remove and Install Special Tools 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before Description Part No. Qty. you start the service work.
  • Page 13 15 - Engine 06 - Cylinder Head 00 - General Figure 42. 0° +90° +180° 1-18 Cylinder head fixing bolts (x18) Location dowels (x2) Cylinder head Cylinder head gasket Crankcase 15 - 44 9813/4900-1 15 - 44...
  • Page 14: Before Assembly

    15 - Engine 06 - Cylinder Head 00 - General Remove Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) 1. Progressively remove the cylinder head bolts in 4.2. Then, further tighten the bolts, starting with reverse order, starting at bolt 18. Note that the the middle pair and working outwards (in bolts MUST NOT be re-used.
  • Page 15 15 - Engine 09 - Bedplate 00 - General 00 - General Introduction Introduction ............ 15-47 The bedplate acts as the main strength component Remove and Install ........15-48 of the engine. it maintains the correct alignment and supports the weight of the internal components. Figure 43.
  • Page 16 15 - Engine 09 - Bedplate 00 - General Remove and Install Special Tools 10. Remove the rocker assembly including the push rods, refer to (PIL 15-42). Description Part No. Qty. Template for Sealant 892/12356 11. It is not necessary to remove the cylinder head Bedplate to Crankcase assembly to remove the crankshaft.
  • Page 17 15 - Engine 09 - Bedplate 00 - General Figure 44. 1-10 Main bearing bolts (x10) Upper bearing shell (x5) Bedplate peripheral bolts (x16) O-ring (if installed) Bedplate Lifting bolts (obtain locally) Crankcase 15 - 49 9813/4900-1 15 - 49...
  • Page 18 15 - Engine 09 - Bedplate 00 - General Remove suitable lifting equipment (if the bedplate is lifted manually, two people will be required). DO NOT 1. Remove the bedplate peripheral bolts. use a lever to separate the bedplate. 2. Progressively remove the main bearing bolts in 4.
  • Page 19 15 - Engine 09 - Bedplate 00 - General Lower bearing shells (x5) Sealant template portion for removal Left side template Bearing tab Right side template Rear main bearing Angle Gauge (obtain locally) Bearing location tab Guide pins (x2 obtain locally) Anaerobic sealant Sealant template O-ring...
  • Page 20: Before Installation

    15 - Engine 09 - Bedplate 00 - General Before Installation crankcase/bedplate mating face as shown to the dimension specified. 1. Clean off all traces of the old sealant compound Length/Dimension/Distance: 1.5mm from the crankcase and bedplate mating faces. 9. Remove the four fixing bolts at positions Y. 2.
  • Page 21 15 - Engine 12 - Crankshaft 00 - General 00 - General Introduction Introduction ............ 15-55 Figure 46. Technical Data ..........15-56 Component Identification ....... 15-57 Operation ............15-58 Check (Condition) .......... 15-59 Remove and Install ........15-60 Crankcase Crankshaft 15 - 55 9813/4900-1 15 - 55...
  • Page 22 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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