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SERVICE MANUAL LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) 526-56, 531-70, 535-95, 536-60, 536-70, 536-70LP, 541-70, 550-80, 560-80 EN - 9813/7600 - ISSUE 3 - 03/2018 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 2018 © 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

JCB 536-70LP Tier 4 Telescopic Handler Service Repair Manual SN from 2460601 onwards

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  • SERVICE MANUAL

    LOADALL (ROUGH TERRAINVARIABLE REACH TRUCK)

    526-56, 531-70, 535-95, 536-60, 536-70,536-70LP, 541-70, 550-80, 560-80

    EN - 9813/7600 - ISSUE 3 - 03/2018

    This manual contains original instructions, verified bythe manufacturer (or their authorized representative).

    Copyright 2018 © JCB SERVICEAll rights reserved. No part of this publication may

    be reproduced, stored in a retrieval system, ortransmitted 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 injuredif you operate or maintain the machine withoutfirst studying the Operator's Manual. You mustunderstand and follow the instructions in theOperator's Manual. If you do not understandanything, ask your employer or JCB dealer toexplain it.

    Do not operate the machine without an Operator'sManual, or if there is anything on the machine youdo not understand.

    Treat the Operator's Manual as part of the machine.Keep it clean and in good condition. Replace theOperator's Manual immediately if it is lost, damagedor becomes unreadable.

    Contents01 - Machine03 - Attachments, Couplings and LoadHandling06 - Body and Framework09 - Operator Station12 - Heating, Ventilating and Air-Conditioning (HVAC)15 - Engine18 - Fuel and Exhaust System21 - Cooling System24 - Brake System25 - Steering System27 - Driveline30 - Hydraulic System33 - Electrical System72 - Fasteners and Fixings75 - Consumable Products78 - After Sales

  • 18 - Fuel and Exhaust System 18 - Injection

    03 - Injector

    18 - 60 9813/7600-3 18 - 60

    03 - Injector

    Introduction .................................................... 18-60Component Identification ............................... 18-61Check (Operation) ......................................... 18-61Remove and Install ....................................... 18-62

    Introduction

    The fuel Injectors are electronically controlled andincorporate a small solenoid valve. The injectors aresupplied with pressurised fuel by the high pressurefuel injection pump and when energised, the injectoratomizes the fuel into a fine mist so that it can burneasily by the vehicle’s engine.

    The fuel injectors are mounted in the inlet manifoldso that fuel is sprayed directly at the inlet valves. Afuel supply rail connects all of the fuel injectors to thefuel supply.

    The injector tips are located inside the combustionchambers, so effective cooling is essential. A specialthin walled sleeve is screwed into the cylinder headwhich allows a coolant jacket close to the injector.The coolant jacket is sealed at the bottom by sealanton the sleeve thread and at the top by O-ring.

    Figure 390.

    5 1 4

    6

    52

    3

    1 Injector2 Sleeve3 Cylinder head4 Coolant jacket5 Sleeve thread6 O-ring

  • 18 - Fuel and Exhaust System 18 - Injection

    03 - Injector

    18 - 61 9813/7600-3 18 - 61

    Component Identification

    Figure 391.

    N

    A

    B

    D FG

    H

    M

    CJ

    L

    E

    A Multi-point injector nozzleB NeedleC SpacerD NutE ValveF Solenoid coilG Valve springH Calibration dowelJ Injector springL Electrical connectorM Return port (bleed off)N High pressure port and filter element

    Check (Operation)Special Tools

    Description Part No. Qty.Injector Leak-off TestKit ((Electronic Engine))

    892/12350 1

    Injector Cap Kit 892/12359 1

    The injectors can be tested using Servicemasterdiagnostics and by means of a leak off test. To testfor a defective injector first use Servicemaster todiagnose the problems with the high pressure fuelinjection equipment, specifically when the enginedoes not start.

    Leak Off Test

    The leak off test kit must be installed on the engineand the ServiceMaster must be used to test theengine.

    1. Operate the engine until it reaches its normaloperating temperature.

    2. Stop the engine. Remove the bleed off pipe ateach injector. Refer to (PIL 18-96). Cap the openconnectors on the pipes with the caps in theinjector leak off test kit.Special Tool: Injector Leak-off Test Kit((Electronic Engine)) (Qty.: 1)Special Tool: Injector Cap Kit (Qty.: 1)

    3. Connect the test pipes to the leak off ports on thefour injectors.

    4. Position the four plastic bottles as upright aspossible. Keep the test equipment clear ofcomponents that get hot when the engine isoperated.

    5. Connect a test pipe to the leak off ports on theHigh Pressure valve outlet. Cap the open pipe.

    6. Make sure it is safe to start the engine.

    7. Use ServiceMaster to control the tests. Refer toFuel Injection - Check Operation (PIL 18-18).

    7.1. Fuel System Diagnostic Test (CrankingOnly).

    7.2. Fuel System Diagnostic Tests (EngineRunning).

    8. Examine the fuel levels in the test bottles. If thedifference between any of the levels is more than10 ml. this indicates that there are one or moredefective injectors.

    9. Remove the test equipment and replace thebleed off pipes. Refer to (PIL 18-96).

  • 18 - Fuel and Exhaust System 18 - Injection

    03 - Injector

    18 - 62 9813/7600-3 18 - 62

    Figure 392.

    A

    A

    A

    A

    B

    A Injectors (x4)B HP valve

    Remove and Install

    The following procedure is for one injector, theprocedures are identical for all injectors.

    Note: The original injector calibration codes arelocated on a label on the rocker cover.

    Before Removal1. Make sure that the engine is safe to work on. If

    the engine has been running, let it cool beforeyou start the service work.

    2. Get access to the engine.

    3. Remove the high pressure fuel pipes. Refer toFuel Pipes (PIL 18-96).

    4. Remove the fuel bleed off fuel pipes. Refer toFuel Pipes (PIL 18-96).

    5. Remove the rocker cover, refer to (PIL 15-42).

    6. Record which injector is for which cylinder. Theinjectors must be installed in the same positions.

    Note: If a fuel injector is defective, it must bereplaced.

    Remove1. Remove the injector clamp retaining bolt and lift

    the clamp away.

  • 18 - Fuel and Exhaust System 18 - Injection

    03 - Injector

    18 - 63 9813/7600-3 18 - 63

    Figure 393.

    X 14

    3

    2

    1 Injector2 Injector clamp3 Retaining bolt4 Injector sleeveX Injector bleed-off port

    2. Remove and discard the sealing washer. Labelthe injector to make sure it is installed in itsoriginal cylinder. Put a clean protective cap overthe nozzle of the injector.

    3. Remove and discard the O-ring.

    Figure 394.

    5

    7

    6

    5 Protective cap6 Protective cap7 Sealing washer

    Install

    Important: The fuel injectors are not interchangeablebetween cylinders or other engines. Make sure youinstall the injectors in the same positions. If a newor different injector is installed, the engine electroniccontrol unit (ECU) must be re-programmed. Refer to(PIL 33-45), Engine Electronic Control Unit, VehicleSet Up Data.

    When new or different injectors are installed, recordthe calibration code. Record which cylinder theinjector is installed into. Refer to (PIL 33-45), EngineElectronic Control Unit, Vehicle Set Up Data.

  • 18 - Fuel and Exhaust System 18 - Injection

    03 - Injector

    18 - 64 9813/7600-3 18 - 64

    Figure 395.

    B

    A

    CD

    A Correction factor (20 characters)B Manufacturers referenceC JCB part numberD Injector serial number

    1. The installation procedure is the opposite of theremoval procedure. Additionally do the followingsteps.

    2. Clean off any sludge or oil from the inner boreof the injector sleeve. Make sure you do notdamage the surface of the bore. Any damageor surface contamination will cause the injectorsealing O-ring to fail.

    3. Install a new O-ring.

    4. Install a new sealing washer.

    5. Make sure that the injector is installed in thecorrect orientation, with the bleed-off port facingthe right hand side (exhaust manifold) of theengine. Make sure the injector is pushed fully intothe cylinder head.

    6. Tighten the injector clamp bolt to the correcttorque value.

    After Installation1. Replace the rocker cover, refer to (PIL 15-42).

    2. Renew the high pressure fuel pipes, Refer to FuelPipes (PIL 18-96).

    3. Replace the low pressure fuel pipes, Refer toFuel Pipes (PIL 18-96).

    4. Start the engine and check for fuel leaks.

    Table 171. Torque ValuesItem Nm

    3 284 39

  • 18 - Fuel and Exhaust System 18 - Injection

    07 - Injector Seal

    18 - 65 9813/7600-3 18 - 65

    07 - Injector Seal

    Remove and Install

    Special ToolsDescription Part No. Qty.

    Injector SealInstallation Tool(Electronic Engine)

    892/12346 1

    Injector SleeveInstallation/RemovalTool

    892/12348 1

    Before Removal1. Make sure that the engine is safe to work on. If

    the engine has been running, let it cool beforeyou start the service work.

    2. Clean the engine. Refer to Engine- Clean (PIL15-00).

    Figure 396.

    B

    A

    C

    D

    A Rocker cover B BoltsC Gasket D Injector seals

  • 18 - Fuel and Exhaust System 18 - Injection

    07 - Injector Seal

    18 - 66 9813/7600-3 18 - 66

    Remove1. Get access to the engine.

    2. Remove the high pressure fuel pipes. Refer toFuel Pipes (PIL 18-96).

    3. Remove the rocker cover from the cylinder head.Refer to (PIL 15-42).

    4. Put wooden supports under the rocker cover andtap out the injector seals using the special tool.Discard the seals.Special Tool: Injector Seal Installation Tool(Electronic Engine) (Qty.: 1)

    Figure 397.

    EF

    GE Injector seal installation toolF Injector sealsG Wooden supports

    Install1. The installation procedure is the opposite of the

    removal procedure. Additionally do the followingsteps.

    2. Remove all oil and sludge contamination frominside the valve chamber.

    3. Renew the injector seals. Put supports under therocker cover and tap in the new seals using thespecial tool.Special Tool: Injector Seal Installation Tool(Electronic Engine) (Qty.: 1)

    Figure 398.

    E

    F

    GE Injector seal installation toolF Injector sealsG Wooden supports

    4. Renew the rocker cover gasket.

    5. Prevent damage to the seals. Put sleeves/coverson the injectors. Apply a rubber lubricant to theseals.Special Tool: Injector Sleeve Installation/Removal Tool (Qty.: 1)

    6. Install the rocker cover. Refer to (PIL 15-42).

    After Installation1. The high pressure fuel pipes must be replaced

    with new parts. Refer to Fuel Pipes (PIL 18-96).

    2. Start the engine and check for oil and fuel leaks.

  • 18 - Fuel and Exhaust System 18 - Injection

    12 - Rail

    18 - 67 9813/7600-3 18 - 67

    12 - Rail

    Introduction .................................................... 18-67Remove and Install ....................................... 18-68

    Introduction

    The fuel rail also known as a common rail, is apipe resembling a rail that is used to deliver fuelto individual fuel injectors on internal combustionengines. It is designed to have an outlet for eachinjector, an inlet for a fuel supply and an outlet for afuel bleed off.

    The fuel rail also incorporates an attached fuelpressure sensor and a fuel valve. DO NOTremove the high pressure fuel valve or the fuelpressure sensor from the rail. If these componentsare defective replace the complete common railassembly.

    Figure 399.A

    D

    C

    E

    B

    F

    A Fuel pressure sensorB OutletC Bleed offD High pressure fuel valveE InletF Rail assembly

  • 18 - Fuel and Exhaust System 18 - Injection

    12 - Rail

    18 - 68 9813/7600-3 18 - 68

    Remove and Install

    Before Removal1. Obey all fuel system health and safety

    information. Refer to (PIL 18-00).

    2. Make sure that the engine is safe to work on. Theengine must cool and pressure in the fuel systemmust decay before you start work. If the enginehas been running, wait at least one hour beforeyou start work.

    3. Clean the engine. Refer to Engine-Clean (PIL15-00).

    4. Remove the high pressure fuel pipes. Refer toFuel Pipes (high pressure) - Remove and Install(PIL 18-96).

    5. Remove the fuel bleed off pipe at the rail. Refer toFuel Pipes (low pressure) - Remove and Install(PIL 18-96).

    Remove1. Disconnect the electrical connector at the high

    pressure fuel valve.

    2. Disconnect the electrical connector at the fuelpressure sensor.

    3. Remove the bolts and lift off the common railassembly.

    Seal the common rail assembly inside a clean plasticbag until it is ready for use. If the assembly isdefective discard it and get a new one.

    Install1. The installation procedure is the opposite of the

    removal procedure. Additionally do the followingsteps.

    2. Tighten the bolts to the correct torque value.

    When renewing the rail assembly make sure toreplace all of the high pressure fuel pipes. Refer to(PIL 18-96).

    Figure 400.A

    D

    C

    B

    FE

    E

    A Fuel pressure sensorB High pressure fuel pipeC Fuel bleed off pipeD High pressure fuel valveE BoltsF Rail assembly

    Table 172. Torque ValuesItem Nm

    C 24

  • 18 - Fuel and Exhaust System 18 - Injection

    15 - Pump

    18 - 70 9813/7600-3 18 - 70

    Component Identification

    Figure 401.

    12

    7

    1

    8 2 10

    39

    13

    4 2

    56

    111 Fuel injection pump2 Pump fixing nuts (x3)3 Injection pump gear cover4 Inlet metering valve electrical connector5 Fuel temperature sensor electrical connector6 Fuel pipe connector (inlet)7 Fuel bleed-off connector8 Fuel bleed-off connector, injector bleed off9 Drive shaft nut10 Drive gear11 Injection pump O-ring oil seal12 High pressure fuel outlet port13 Gear cover O-ring oil seal

    Operation

    The high pressure fuel injection pump is driven via agear on the engine and rotates at half engine speed.The pump comprises of two sections, the transferpump and the high pressure pump.

    Although the pump does not control fuel injectiontiming, it is still timed in relation to engine phasing.By timing the pump pressure pulses, the load on theengine timing gears is reduced together with reducedmechanical noise.

    Transfer Pump Operation

    The integral transfer pump is a vane type. Anengine driven rotor houses four vanes in slots.The rotor rotates inside an eccentric liner. Thevanes are held in contact with the liner by springs.Fuel is drawn into the pump chamber at port X,pressurised by the decreasing volume inside thechamber and expelled at port Y. Fuel pressuregenerated by the transfer pump is limited to aspecified pressure by an integral pressure regulatingvalve. This pressure is maintained regardless ofengine speed.6bar (87.0psi)

    Figure 402.

    A

    D

    C

    B

    X Y

    E

    A RotorB Vanes (x4)C Eccentric linerD SpringsE Regulating valveX Port XY Port Y

    High Pressure Pump Operation

    Fuel passes to the high pressure pump via the IMV(Inlet Metering Valve). The ECM (Engine Control

  • 18 - Fuel and Exhaust System 18 - Injection

    15 - Pump

    18 - 71 9813/7600-3 18 - 71

    Module) controlled IMV determines the amount offuel transferred to the high pressure pump. Theplunger actuator block is located on the engine driveneccentric shaft. When the shaft rotates the actuatorblock operates the two plungers. As one plunger ispushed up its chamber the other is pushed down byits spring.

    State 1 - Charging

    Note: The description is for one plunger. Theopposite plunger operates in an identical way. Theinlet and delivery ports from each plunger areconnected by internal galleries.

    When the eccentric shaft is in the position shownforce from spring moves the plunger down itschamber. Pressure in the chamber falls below therail pressure and the delivery valve closes. Transferpressure is now sufficient to force inlet valve off itsseat and allow the fuel to fill the chamber.

    Figure 403.

    A

    B

    E

    C

    F

    D

    A Eccentric shaftB Actuator blockC PlungerD Inlet valveE Delivery valveF Spring

    State 2 - Pumping

    Note: The description is for one plunger. Theopposite plunger operates in an identical way. Theinlet and delivery ports from each plunger areconnected by internal galleries.

    When the eccentric shaft is in the position shown theactuator block moves the plunger up its chamber.

    Fuel pressure in the chamber rises and forces theinlet valve on to its seat. As the plunger is pushedfurther up its chamber the fuel pressure exceeds thatof the rail pressure and the delivery valve is forced offits seat. Fuel is forced into the rail at high pressure.

    Figure 404.

    A

    B

    E

    C

    D

    A Eccentric shaftB Actuator blockC PlungerD Inlet valveE Delivery valve

  • 18 - Fuel and Exhaust System 18 - Injection

    15 - Pump

    18 - 72 9813/7600-3 18 - 72

    Remove and InstallSpecial Tools

    Description Part No. Qty.Crankshaft Turning Tool(95.25mm PCD)- JCB4 Cylinder Ecomax andDieselmax

    892/01147 1

    Crankshaft /Camshaft Timing Pin(444/448/672 Engine)

    892/01148 1

    Tamper proof CoverRemoval Tool

    892/01154 1

    Pump Gear RemovalTool

    892/01155 1

    C-Shaped RingSpanner

    892/01179 1

    Torque Wrench(10-100Nm)

    993/70111 1

    Important: The following procedures include removaland replacement of fuel system components. Beforestarting the procedures the engine assembly must becleaned. Clean the engine. Refer to Engine- Clean(PIL 15-00).

    Important: Service procedures on the high pressurefuel pump can only be carried out by specialistpersonnel with the relevant training and equipment.

    Before Removal1. Make sure that the engine is safe to work on. If

    the engine has been running, let it cool beforeyou start the service work.

    2. Get access to the engine.

    3. Remove the high pressure fuel pipe at port 12,refer to Fuel Pipes- Remove and Install. Cap allopen ports and pipes, refer to (PIL 18-96).

    4. To improve access to the pump, remove the fuelfilter, refer to (PIL 18-09).

    Important: When removing components dirt anddebris may become exposed or dislodged. Stop theremoval procedures and clean away the exposeddeposits. Refer to Engine- Clean (PIL 15-00).

    Figure 405.

    12

    7

    1

    8 2 10

    39

    13

    4 2

    56

    111 Fuel injection pump2 Pump fixing nuts (x3)3 Injection pump gear cover4 IMV (Inlet Metering Valve) electrical connector5 Fuel temperature sensor electrical connector6 Fuel pipe connector (inlet)7 Fuel bleed-off connector8 Fuel bleed-off connector, injector bleed off9 Drive shaft nut10 Drive gear11 Injection pump O-ring oil seal12 High pressure fuel outlet port13 Gear cover O-ring oil seal

    Remove1. Release the fuel pipe couplings at the inlet

    connection 6 and bleed-off connections 7 and 8on the pump. Cap all open ports and pipes.

    2. Uncouple the electrical connectors at the IMVand the fuel temperature sensor.

    3. Remove the bedplate plug.

  • 18 - Fuel and Exhaust System 18 - Injection

    15 - Pump

    18 - 73 9813/7600-3 18 - 73

    Figure 406.

    A

    C

    1

    1 Bedplate plugA Crankshaft / Camshaft timing pinC Crankshaft turning tool

    4. Use the crankshaft turning tool to turn thecrankshaft until the timing pin engages in thecrankshaft timing hole.Special Tool: Crankshaft Turning Tool (95.25mmPCD)- JCB 4 Cylinder Ecomax and Dieselmax(Qty.: 1)Special Tool: Crankshaft / Camshaft Timing Pin(444/448/672 Engine) (Qty.: 1)

    5. Use the gear removal tool and a suitable ratchetdrive to remove the fuel injection pump gearcover.Special Tool: Pump Gear Removal Tool (Qty.: 1)

    6. Remove the drive shaft nut.

    Figure 407.

    B3

    11

    F G

    H

    E

    3 Gear cover11 Drive shaft nutB Gear removal toolE Pump gear removal tool, comprises:F Pump gear removal tool (Reaction cap)G Pump gear removal tool (Body)H Pump gear removal tool (Bolt)

    7. Remove the nuts. Use the special C shapedring spanner to remove the nut closest to thecrankcase. Make sure you remove all nuts (X3).

    8. Install the reaction cap over the pump shaft.Screw the body to the housing. Use a suitableratchet drive and socket to screw the bolt in untilyou feel a slight resistance.Special Tool: C-Shaped Ring Spanner (Qty.: 1)Special Tool: Pump Gear Removal Tool (Qty.: 1)

  • 18 - Fuel and Exhaust System 18 - Injection

    15 - Pump

    18 - 74 9813/7600-3 18 - 74

    Figure 408.

    2

    H

    G

    F

    10

    2 Fixing nuts10 Injection pump drive gearF Pump gear removal tool (Reaction cap)G Pump gear removal tool (Body)H Pump gear removal tool (Bolt)

    9. The injection pump drive gear is located on ataper on the pump drive shaft. To remove thepump the taper lock must be broken. Supportthe fuel pump. Tap the end of the bolt H with asoft faced hammer. When the taper breaks therewill be an audible sound. Note: The pump drivegear connects to the injection pump drive shaft bymeans of taper lock alone, there is no mechanicallocking key.

    10. Remove the service tools. Withdraw the pumpfrom the flywheel housing.

    Install1. Make sure that the taper surfaces on the injection

    pump drive shaft and gear are clean and freefrom oil and damage.

    Figure 409.

    9

    2

    2 12

    10

    2 Fixing nuts9 Gear pump nut10 Drive gear12 Drive shaft

    2. Make sure that the oil seal is correctly located onthe pump mounting face.

    Figure 410.

    16

    16 Oil seal

    3. Locate the pump on to the mounting studs.Locate the drive gear over the pump drive shaft.

    4. Install the fixing nuts and tighten to the correcttorque value.

    5. Install the gear pump nut and tighten to thecorrect torque value. Note: If a washer is suppliedwith a replacement pump, Do not install thewasher. Secure the gear with the gear pump nutonly.

    6. Use the tamperproof cover removal tool to installthe gear cover. Make sure its sealing O-ring iscorrectly installed. Tighten the gear cover to thecorrect torque value.Special Tool: Torque Wrench (10-100Nm) (Qty.:1)Special Tool: Tamper proof Cover Removal Tool(Qty.: 1)

  • 18 - Fuel and Exhaust System 18 - Injection

    15 - Pump

    18 - 75 9813/7600-3 18 - 75

    Figure 411.

    B3

    3 Gear coverB Tamperproof cover removal tool

    After Installation1. Remove the crankshaft turning tool.

    2. Remove the crankshaft timing pin and install thebedplate plug.

    3. Reconnect the fuel pipe couplings at the inletconnection, reconnect the bleed-off connectionson the pump.

    4. Install a new high pressure fuel pipe, removethe protective caps from the ports, refer to FuelPipes- Remove and Install, refer to (PIL 18-96).

    5. Connect the electrical connectors at the IMV andthe fuel temperature sensor.

    6. Replace the fuel filter, refer to (PIL 18-09).

    7. Start the engine and check for fuel leaks.

    Figure 412.

    12

    7 8

    4

    56

    4 IMV electrical connector5 Fuel temperature sensor electrical connector6 Fuel pipe connector (inlet)7 Fuel pump bleed-off connection8 Fuel pump bleed-off connection12 High pressure fuel outlet port

    Table 173. Torque ValuesItem Nm

    2 243 709 65

  • 18 - Fuel and Exhaust System 18 - Injection

    27 - High Pressure Rail Valve

    18 - 76 9813/7600-3 18 - 76

    27 - High Pressure Rail Valve

    Introduction .................................................... 18-76Operation ....................................................... 18-77Check (Operation) ......................................... 18-77Remove and Install ....................................... 18-78

    Introduction

    The HPV (High Pressure Valve) is an integral partof the common fuel rail assembly, If the valveis defective replace the complete common railassembly. (Refer to PIL 18-18).

    Figure 413. High pressure valve location

    Figure 414.

    A

    B

    A HPVB Solenoid coil

  • 18 - Fuel and Exhaust System 18 - Injection

    27 - High Pressure Rail Valve

    18 - 77 9813/7600-3 18 - 77

    Operation

    In certain operating conditions, the HPV (HighPressure Valve) controls the fuel pressure inside thecommon rail.

    When the valve opens, fuel is bled from the rail backto the fuel tank, reducing the fuel pressure inside thefuel rail. The valve is actuated by a solenoid coil andfeatures proportional control. The fuel flow throughthe valve is proportional to the current supplied tothe coil. The current value is controlled by the ECM(Engine Control Module) using PWM (Pulse WidthModulation).

    During normal engine operation, the fuel pressure iscontrolled solely by the IMV (Inlet Metering Valve),refer to (PIL 18-18).

    In some operating circumstances, the IMV is unableto alter the fuel pressure in the common rail quicklyenough. At these times, the ECM activates the HPV.Typically the valve is used in the following conditions:

    • Extreme transients, for example if the operatorgoes from full throttle to no throttle quickly.

    • When the fuel is cold.

    In the event of an IMV failure, the ECM compensatesby altering the control of the HPV to ensure theengine performance is sufficient to limp home.

    Check (Operation)

    For the full inspection and testing procedure, refer tothe help files in ServiceMaster.

  • 18 - Fuel and Exhaust System 18 - Injection

    27 - High Pressure Rail Valve

    18 - 78 9813/7600-3 18 - 78

    Remove and Install

    This part is a non-serviceable component, if itis defective, replace the complete common railassembly. Refer to: PIL 18-18-12.

  • 18 - Fuel and Exhaust System 24 - Exhaust

    03 - Inlet Manifold

    18 - 90 9813/7600-3 18 - 90

    Component Identification

    Figure 418.

    1

    1 Inlet Manifold

    Check (Condition)

    1. Check the manifold mating faces for signs ofdamage and distortion.

    2. Check the manifold casting for signs of cracks.

    3. Renew the manifold if there are any signs ofdefect.

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  • 18 - Fuel and Exhaust System 24 - Exhaust

    03 - Inlet Manifold

    18 - 91 9813/7600-3 18 - 91

    Remove and Install

    Before Removal1. This procedure requires service parts. Make

    sure you have obtained the correct service partsbefore you start, refer to Parts Catalogue.

    2. Make sure that the engine is safe to work on. Ifthe engine has been running, let it cool beforeyou start the service work.

    3. Get access to the engine.

    4. Remove the fuel rail assembly. Refer to (PIL18-18).

    Figure 419.

    2

    3

    3

    45

    12

    8

    9

    11 106

    7

    13

    1

    1 Inlet manifold 2 Manifold gasket3 Flanged hexagon bolt (x8) 4 Fuel rail mount5 Screw (x4) 6 EGR (Exhaust Gas Recirculation) mixer tube7 EGR Plug 8 Inlet manifold adaptor / throttle valve (not

    shown)9 Throttle O-ring 10 Flanged hexagon bolt (x4)11 Inlet manifold bracket 12 Bolt M6 x 16mm (x1)13 Bolt M8 x 25mm (x1)

    Remove1. Disconnect the TMAP (Temperature Manifold Air

    Pressure) sensor electrical connector.

    2. Disconnect the air inlet hose.

    3. Remove the bolts 3 and lift the inlet manifold fromthe cylinder head. Discard the gasket.

    4. Cap the inlet ports with blanking caps to preventingress of dirt.

    5. Inspect the manifold, refer to Check Condition(PIL 18-24).

  • 18 - Fuel and Exhaust System 24 - Exhaust

    03 - Inlet Manifold

    18 - 92 9813/7600-3 18 - 92

    Install1. The installation procedure is the opposite of the

    removal procedure. Additionally do the followingsteps.

    2. Renew the manifold gasket.

    3. Loosely assemble the manifold, together with thenew inlet gasket to the cylinder head, use the twobolts (one at each end).

    4. With the manifold and gasket in position, installthe remaining six bolts.

    5. Tighten the bolts to the correct torque value.

    Table 177. Torque ValuesItem Nm

    3 43

  • 18 - Fuel and Exhaust System 24 - Exhaust

    04 - Outlet Manifold

    18 - 93 9813/7600-3 18 - 93

    04 - Outlet Manifold

    Introduction .................................................... 18-93Component Identification ............................... 18-94Check (Condition) .......................................... 18-94Remove and Install ....................................... 18-95

    IntroductionFor: JCB T4F 4.4 over 55kw ElectronicDieselmax Turbocharged AftercooledEngine, JCB Tier 4F Engine 4 Cyl, JCB Tier4i /T4F