JBL T2 Service Manual
JBL T2 Service Manual

JBL T2 Service Manual

Elec engine 4 cyl

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SERVICE MANUAL
ENGINE
JCB T2/3 Elec Engine 4 Cyl
EN - 9806/7000 - ISSUE 2 - 10/2017
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
06 - Body and Framework
09 - Operator Station
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

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Summary of Contents for JBL T2

  • Page 1 Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable. ENGINE JCB T2/3 Elec Engine 4 Cyl Contents 01 - Machine 06 - Body and Framework 09 - Operator Station...
  • Page 2: Table Of Contents

    15 - Engine 00 - Engine 00 - General 00 - General Introduction Introduction ............15-3 This section contains information about the complete Health and Safety ........... 15-7 engine assembly. For specific engine technical information refer to the technical data section. Technical Data ..........
  • Page 3: 00 - General

    15 - Engine 00 - Engine 00 - General Figure 3. 1 Flywheel Crankshaft 3 Camshaft Inlet valves (x8) 5 Exhaust valves (x8) Push rods (x8) 7 High pressure fuel pump drive gear Turbocharger 9 Lubrication oil pump 10 Front end drive belt 15 - 4 9806/7000-2 15 - 4...
  • Page 4 15 - Engine 00 - Engine 00 - General Internal The following identifies the main internal components of a typical engine assembly. Some variants may differ in detail. Figure 4. Rocker assembly Valve bridge piece (x8) Valve spring (x16) Inlet valve (x8) Exhaust valve (x8) Piston assembly (x4) 6a Piston ring - top compression (x4)
  • Page 5 15 - Engine 00 - Engine 00 - General Figure 5. Flywheel 1A Flywheel - crankshaft fixing bolts (x8) Fuel injector (atomiser) (x4) Flywheel hub Crankshaft drive gear High duty PTO idler gear (if installed) Camshaft drive gear Lubrication oil pump High pressure fuel pump drive gear Camshaft 10 Tappet (x8)
  • Page 6: Health And Safety

    15 - Engine 00 - Engine 00 - General Health and Safety accordance with local regulations. Use authorised waste disposal sites. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running.
  • Page 7: Technical Data

    15 - Engine 00 - Engine 00 - General Technical Data Table 4. Description SK Engine SE Engine DE Engine DK Engine Engine Variants Turbocharged with Turbocharged with Turbocharged with Turbocharged with Intercooler Intercooler Intercooler Intercooler Emission compli- US-EPA Tier 2, EU US-EPA Tier 3, EU US-EPA Tier 2, EU US-EPA Tier 3, EU...
  • Page 8 15 - Engine 00 - Engine 00 - General Description SK Engine SE Engine DE Engine DK Engine Combustion system Common rail direct Common rail direct Common rail direct Common rail direct Injection Injection Injection Injection High pressure fuel High pressure with High pressure with High pressure with High pressure with...
  • Page 9: Component Identification

    15 - Engine 00 - Engine 00 - General Component Identification Figure 6. Engine - As viewed on the left hand side A Rocker cover B Lubrication oil filler cap C Fuel injectors and high pressure fuel pipes D TMAP (Temperature Manifold Air Pressure) sensor E Tappet covers (x4) F High pressure fuel pipe - rail feed...
  • Page 10 15 - Engine 00 - Engine 00 - General 1 Lubrication oil dipstick 2 Oil filter housing drain plug 3 Oil pressure switch 4 Lubrication oil filter 5 Lubrication oil filler cap 6 Lubrication oil cooler housing 7 Fuel pressure dump valve Figure 7.
  • Page 11 15 - Engine 00 - Engine 00 - General Figure 8. Engine - As viewed on the crankshaft pulley (front) end A Coolant thermostat housing / radiator hose B Coolant temperature sensor connector C Cab heater water hose connector D Rocker cover E Inlet manifold induction heater (if installed) F Cylinder head G Crankcase...
  • Page 12 15 - Engine 00 - Engine 00 - General Figure 9. Engine - As viewed on the flywheel (rear) end A Rocker cover B CCV chamber C Crankcase pressure relief valve D Engine electrical harness E Cylinder head F CCV hose G Flywheel housing H Crankshaft position target disc J Crankshaft position sensor...
  • Page 13: Operation

    15 - Engine 00 - Engine 00 - General Operation The Four Stroke Cycle - 4 Cylinder It is important to note that number 1 cylinder is firing and about to start its power stroke. Rotating the Engine crankshaft a further full rotation would position the pistons as described but the engine would be at a This section describes the cycle sequence, for the 4 different stage in its four stroke cycle, with number 1...
  • Page 14 15 - Engine 00 - Engine 00 - General Figure 10. CYL1 CYL2 CYL3 CYL4 745620 745620 CYL1 CYL2 Cylinder number 1 Cylinder number 2 CYL3 Cylinder number 3 CYL4 Cylinder number 4 Camshaft Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation Front of engine Exhaust valves...
  • Page 15 15 - Engine 00 - Engine 00 - General Four Stroke Cycle revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice. Induction Figure 11. As the piston travels down the cylinder, it draws filtered air through inlet valves into the cylinder.
  • Page 16 15 - Engine 00 - Engine 00 - General Figure 12. 717620 1 Induction stroke 2 Compression stroke 3 Power stroke 4 Exhaust stroke A Camshaft B Camshaft lobe - Inlet valve operation C Camshaft lobe - Exhaust valve operation 15 - 17 9806/7000-2 15 - 17...
  • Page 17: Drain And Fill

    15 - Engine 00 - Engine 00 - General Drain and Fill Clean Notice: Clean the engine before you start engine Refer to Engine, Oil Filter, (PIL 15-21-00). maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine.
  • Page 18 15 - Engine 00 - Engine 00 - General 9. When the pressure washing is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine. 10. Before working on specific areas of the engine use a compressed air jet to dry off any moisture.
  • Page 19: Check (Pressure)

    15 - Engine 00 - Engine 00 - General Check (Pressure) Special Tools rotating in the engine compartment.Before starting this job make sure that you have no loose clothing Description Part No. Qty. (cuffs, ties etc) which could get caught in rotating Pressure Gauge (0-40 892/00278 parts.When the engine is turning, keep clear of...
  • Page 20 15 - Engine 00 - Engine 00 - General Figure 13. A Dummy injector 15 - 31 9806/7000-2 15 - 31...
  • Page 21: Engine Oil Pressure

    15 - Engine 00 - Engine 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 22: Remove And Install

    15 - Engine 00 - Engine 00 - General Remove and Install Special Tools to manually lift heavy components on your own. Always use lifting equipment, or obtain the help of Description Part No. Qty. an assistant. Inspect the lifting brackets for signs Lifting Brackets 892/01160 of damage.
  • Page 23 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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