Engine

1
 16

16
52 TDC
34
Stroke length 52
3
4
BDC

Stroke volume = area of circle X stroke length = Displacement X 6 = 7.2L

Area of circle = Pai X r X r = 3.14 x 53 X 53 = 8820

8820 x 135 = 1190700 = 1190.7 cc x6 = 7182cc = 7.18

360 x 2 = 721/ 6 = 120 dig

2
NA
NA
TC

Boost pressure TCA

3
Engine Type Electronic, Turbocharged Direction of rotation
with Intercooler (viewed from front Clockwise
{crankshaft pulley} end)
Model JCB DieselMax 672
Valves 4 per cylinder
Rated speed 2200 rpm
Valve clearances measured at the tappet end of the rockers
Weight (Dry) 680 kg (1500 lb) (measured cold):
(Dry weight. No cooling fan Inlet 0.15 to 0.21 mm (0.006 to 0.008 in)
drive.)
Exhaust 0.43 to 0.49 mm (0.017 to 0.019 in)
Number of cylinders 6
Lubricating oil pressure 1.6 - 6.5 bar
Nominal bore size 106 mm (4.173 in) (Dependent on engine temperature and
speed.)
Stroke 135 mm (5.314 in)
Combustion system Common rail direct Injection High
Cylinder arrangement In line pressure fuel pump High pressure with
electronically controlled fuel metering
Combustion Cycle 4-stroke

Firing order 1-5-3-6-2-4

Displacement 7.148 litres

Compression ratio 16.9: 1

Compression variance between each cylinder should be no
greater than 3.5 bar (50 lb in2)

4
 Engine identification plate
E K 320/40001 U 00001 13
1 2 3 4 5 6

1 Engine Displacement
S = 4.4 litre series
D = 4.8 litre series
E = 7.2 litre series

2 A = naturally aspirated (Tier 2)

B = turbocharged (Tier 2)
C = turbocharged and intercooled (Tier 2)
D = turbocharged mechanical fuel injection 3 Engine part number
(mechanical Tier 3)
E = electronic common rail fuel injection (Tier 3) 4 Country of manufacture
F = turbocharged and aftercooled (mechanical U = United Kingdom
Tier 3)
H = turbocharged and aftercooled electronic 5 Engine serial number
common rail fuel injection (Tier 4i)
K=electronic turbocharged and aftercooled 6 Year of manufacture

5
 Engine view from right hand side
Turbocharger Turbocharger
oil feed line

Timing gear case

Exhaust manifold
Heavy duty
PTO (blanking Alternator
cover if no
device is fitted)

Flywheel housing
Coolant pump
housing
(cylinder block)

Coolant
inlet/radiator
hose connector
Bed plate

Starter motor assembly Turbocharger oil drain line

Lubrication oil pan (sump)

Oil drain plug (sump) 6
 View from pulley end
Coolant temperature sensor Rocker cover
Turbocharger

Coolant thermostat
housing/radiator hose
connector

Cylinder head

Alternator and
Cylinder block
drive pulley
assembly

FEAD tensioner
Coolant pump and
drive pulley assembly

Torsional vibration damper Bed plate

Lubrication oil pan (sump)

7
 View from flywheel end

Turbocharger

Engine electrical harness Rocker cover

Cylinder head

High pressure fuel pump

drive gear cover Flywheel housing

Flywheel

8
Components Identification

9
Components Identification

10
Four strokes

11
Four strokes

12
 Timing Gears

Timing gears are located inside the casing at

the flywheel end of the engine.

Driver gear – Crankshaft gear ‘A’

Driven gears -
Camshaft gear ‘B’
Oil pump gear ‘C’
High pressure fuel pump gear
PTO is driven visa idler gear (if fitted)

Valve timing is achieved by ensuring that the

camshaft drive gear B is meshed to the
crankshaft gear A at their correct angular
positions

13
14
Valve train

15
16
 Front end accessory drive
Idler pulley
Alternator drive pulley

Belt tensioner pulley

Coolant pump drive AC compressor drive pulley

pulley

Crank shaft drive pulley

17
 Lubrication system
1 Oil pan (sump)

2 Suction strainer

3 Oil pump

4 Oil cooler

5 Filter

6 Camshaft - high pressure oil feed

7 Crankshaft main bearings - high pressure oil

feed

8 Rocker assembly - high pressure oil feed

9 PTO idler gear bearing/timing case - high

pressure oil feed

10 External high pressure oil feed connection

(engine block) - Turbo charger (if fitted)

11 Main high pressure oil feed gallery (engine

block)

18
Oil Viscosity Minimum Maximum
Temperature °C (°F) Temperature °C (°F)
SAE 0W30 - 40 (-40) + 30 (86)
SAE 0W20 - 40 (-40) + 10 (50)
SAE 5W20 - 30 (-22) + 10 (50)
SAE 5W40 - 30 (-22) + 40 (104)
SAE 10W30 - 20 (-4) + 40 (104)
SAE 15W40 - 15 (-5) + 50 (122)

Recommended Engine Oil - JCB Extreme Performance

Specification - ACEA E5/B3/A3, API CH-4/SJ

Capacity litres (UK Gal) - 20 (4.3) - 24 (5.3)

19
Oil pump

20
Oil filter

21
Oil cooler

22
Cam shaft lubrication

23
Crank shaft lubrication

24
Rocker and rocker arm shaft lubrication

25
Piston cooling and small end bearing lubrication

26
 Lubrication system data

Filter type Screw-on canister (with drain facility)

Pressure to open by-pass valve 2.5 bar (36 lb/in2)

Oil pressure relief valve setting 6.0 bar (87 lb/in2)

Oil pump (1) Integral unit with relief valve

(1) The oil pump is a non-serviceable part.

27
 Fuel system
The common rail fuel injection system enables the following advantages when
compared with mechanical direct injection systems:

1 Reduced engine noise

2 Reduced polluting emissions

3 Increased engine performance, higher torque at lower engine speeds in particular.

4 Improved fuel economy.

Prevention of fuel system contamination is even more important than with

mechanical direct injection systems. To this end a water separator and 2 micron
pre-filter is fitted in addition to a 2 micron main filter.

28
 Fuel system data

High Pressure Pump Type Delphi DFP 4.2

Direction of rotation from drive end Anti-clockwise

Fuel Lift Pump Type Electrically operated

Fuel return restriction maximum 0.3 bar (4.3 lb/in2)

Injector information Electronically controlled solenoid actuated

injectors. Each injector is marked with a unique
calibration code.

29
 CRI fuel system component layout

1 Engine electronic control

unit (ECU)

2 High pressure pump

assembly (engine driven)

3 Common rail

6 Electric fuel injectors

13 Main fuel filter (2 micron)

14 Water separator and

pre-filter (2 micron)

15 Electric Feed pump

16 Fuel Tank

A Electrical sensors

30
CRI fuel system component layout

31
A High pressure fuel valve
B Fuel pressure sensor
C Bolts (2)
D Rail assembly
E Fuel connector
F Copper washer
32
Fuel filters

33
1 Fuel injection pump
2 Pump fixing nuts (3 off)
3 Injection pump gear cover
4 Inlet metering valve electrical
connector
5 Fuel temperature sensor
electrical connector
6 Fuel line connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector,
injector bleed off
9 Drive shaft nut
10 Drive gear
11 Injection pump `O' ring oil seal
12 High pressure fuel outlet
13 Gear cover `O' ring oil seal

34
Fuel supply pump assembly

35
Low pressure pump

A Drive rotor

B Vanes

C Eccentric liner

D Springs

E Integral pressure regulating

valve (6 bar)

X Pump intake

Y Pump outlet

36
High pressure pump

37
High pressure pump

38
 Removal of fuel pump from engine
1 Release the fuel line couplings at the inlet
connection and bleed-off connections and on the
pump. Cap all open ports and pipes.

2 Uncouple the electrical connectors at the inlet

metering valve solenoid and fuel temperature
sensor.

3 Remove plug 1.

4 Using the crankshaft turning tool turn the

crankshaft until timing pin A engages in the
crankshaft timing hole.

39
5 Remove fuel injection pump gear cover using service tool
and a suitable ratchet drive.

6 Undo and remove the drive shaft nut .

7 Undo and remove the nuts. Use special spanner J to undo

the nut close to the cylinder block. Be sure to remove all
nuts.

8 Fit reaction cap (service tool) over the pump shaft. Screw
service tool to the housing. Using a suitable ratchet drive and
socket screw in bolt (service tool) until resistance is felt.

9 The injection pump drive gear is located on a taper on the

pump drive shaft. To remove the pump the taper lock must
be `broken'. Support the fuel pump. Tap the end of bolt with
a soft faced hammer. When the taper `breaks' there will be
an audible sound.

10 Remove service tools. Withdraw the pump from the

flywheel housing.

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Fuel injectors

A Multi-point injector
nozzle
B Needle
C Spacer
D Nut
E Valve
F Solenoid coil
G Valve spring
H Calibration dowel
J Injector spring
L Electrical connector
M Return port (bleed off)
N High pressure port and
filter element

41
Injectors in operation

42
Injectors calibration

43
 A Correction factor (13C) 20
characters
B Manufacturers reference
C JCB reference
D Injector serial number

Important: The fuel injectors are not

interchangeable between cylinders or
other engines. Be sure to install injectors
in same positions. If a new or different
injector is installed the engine electronic
control unit (ECU) must be re-
programmed.

44
 Engine Electronic Control System

The prime function of the ECU is to initiate fuel injection. The engine cannot run without the
ECU.

Signals from electrical `sensors' are continually monitored and processed by the ECU to
determine when, how much and to which cylinder fuel must be injected.

The ECU controls fuel injection by energising electrical `actuators' in the fuel injectors, High
pressure pump and common rail.

Electrical Sensors Electrical Actuators

Fuel temperature sensor Inlet metering valve (IMV)
High pressure rail fuel pressure sensor High pressure rail fuel valve (HPV)
Engine coolant temperature sensor Fuel injector solenoid valve (integral
Crankshaft position sensor with each fuel injector)
Inlet air temperature and mass air pressure
sensor (TMAP)
Camshaft position sensor
Knock sensors (2 fitted)

45
 Fuel injection control
Pressure Control
Fuel pressure in the common rail is varied according to engine operating parameters.

The ECU actuates the inlet metering valve and high pressure rail fuel valve to control fuel
pressure.

Injection Control
Injection control requires ECU calculation of the following:

Engine phase - to determine which cylinder is firing.

Injection timing - to determine when injection takes place in relation to crankshaft position.

Fuel flow - to determine how much fuel and therefore, the duration of injection.

The ECU uses data from the various engine sensors to calculate the injection timing and fuel
flow requirements using a `data map' stored in its memory.

46
Fuel injection cycle (one cylinder)

47
48
Engine sensors

49
 Engine sensors

CR fuel pressure sensor

Fuel temperature sensor
50
 Engine sensors

Coolant temperature sensor TMAP sensor 51

 Engine sensors

Crank shaft position sensor - The sensor

is mounted under a protection plate on Cam shaft position sensor
the underside of the gear case, on the
centre line of the engine next to the
sump.

52
 Inlet metering valve

The inlet metering valve (IMV) ‘A’ is located on

the high pressure pump assembly. It is used to
control the amount of fuel supplied to the high
pressure pump by the transfer section of the
pump. This has the effect of controlling the
fuel pressure in the common rail.

The valve is actuated by a solenoid coil A and

features proportional control. The fuel flow
through the valve is proportional to the current
supplied to the coil. Since the valve is `normally
open' the higher the current the lower the
flow. The current value is controlled by the
ECU using the pulse width modulation method
(PWM).

53
 High pressure valve at Rail

The high pressure rail fuel valve

(HPV) 3b is located on the common
rail assembly. In certain operating
conditions the valve controls the fuel
pressure inside the common rail 3.
When the valve opens fuel is bled
from the rail back to tank, reducing
the fuel pressure inside the rail. The
valve is actuated by a solenoid coil A
and features proportional control.
The fuel flow through the valve is
proportional to the current supplied
to the coil. The current value is
controlled by the ECU using the
pulse width modulation method
(PWM)

54
 Grid heater

The cold start manifold grid heater A is

located on the inlet manifold. An output from
the ECU is designed to energise a relay to
activate the grid heater. The ECU energises
the relay based on the following parameters:

Inlet manifold air temperature.

Engine coolant temperature.

55
 Fuel injection equipment diagnostic tests
To test the fuel injection system, two test options are available. Actuator tests, which
supply a voltage signal to the actuators and diagnostic tests which require the engine to be
cranked or started.

Static Actuator Tests Diagnostic Tests

The IMV, HPV and injectors can each be tested To diagnose fuel system faults the return flow from
using the engine diagnostic tool within the fuel system must be measured using the fuel
Servicemaster. 1)The IMV test can be found Injector leak off test kit 892/12350.
under the fuel system tab in DieselMax
actuators section. The test sends a signal to the There are two sets of dynamic tests, one for when
IMV, normally the IMV can be heard operating the engine does not start (Cranking only) and one
and the test results will be displayed. for when the engine does start (Engine running).
2) The HPV test can be found under the fuel
system tab in DieselMax actuators section. The
test sends a signal to the HPV, normally the HPV
can be heard operating.
3) The injector test can be found under the
injector test tab in DieselMax actuators section.
The test sends a signal to each individual
injector, normally the injector can be heard
operating.

56
Cooling system

57
 Cooling system data

Radiator cap pressure setting 1 bar (14.5 lb/in2)

Thermostat Wax element with by-pass

blanking (2 per Engine)

Thermostat operating temperature:

nominal temperature 88°C (190°F)
start to open temperature 86 - 90°C (186 - 194°F)
full open temperature 101°C (214°F)
travel (fully open) 9mm (0.354 in.)

Water pump (1) Bolt on, belt driven unit

Fan Belt Stretch type belt with fan hub

mounted tensioner, 14 rib

(1) The water pump is a non-serviceable part.

58
 Thermostat

1 Thermostat 2 Spring 3 Thermostat top valve plate

4 Thermostat bottom valve plate 5 Wax pellet 6 Diaphragm
7 Actuating rod 8 Outlet port - to radiator top hose
9 Inlet port - thermostat housing 10 Outlet port - by-pass gallery
11 1.0 mm (0.039 in.) diameter orifice 59
 Coolant pump

The coolant pump is a centrifugal type located in the

front of the cylinder block, and is driven via a pulley
by the front end accessory drive belt. The impeller
rotates clockwise to circulate the coolant through the
cooling system. The pump shaft bearing and seal are
not renewable.

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Item Description
1 Engine ECU (bound)
2 Livelink ECU (if fitted) (bound)
3 Display ECU (DECU) (bound)
4 Automatic Temperature Control (ATC) ECU
5 Machine control ECU (MECU)
6 Hydraulic control ECU (HECU) (if fitted)
7 Servicemaster diagnostics connector (cab fuse and relay PCB)TBA
8 CANbus wires -
9 CAN termination resistor

61
62
2 Engine Fuse and Relay Box
19 CANbus Shield
23 CANbus Low
27 CANbus High
39 Engine fuse and relay box
40 Engine fuse and relay box
44 Engine fuse and relay box
49 Engine fuse and relay box
53 Engine fuse and relay box
55 Water in fuel sensor input
57 Engine fuse and relay box
60 Engine fuse and relay box
63
64
65
ECU- Engine interface connector

66
67
68
69
70
The fan 1 draws air through the machine cooling
pack. The fan consists of a electrically controlled
solenoid 3 and viscous clutch 4. A 24V PWM signal
controls the solenoid and fan speed.
A speed sensor assembly 2 operates on a 5V supply.

If a 100% PWM signal is applied (24V DC), the clutch

will disengage after the hydraulic oil has drained and
the fan will free wheel on the pulley.

If the electrical control of the clutch fails the clutch

will fully engage and the fan will run at 100% speed.

A Speed sensor supply (+ 5V )

B PWM signal - solenoid (24V)
C Return - solenoid
D Return - speed sensor (0V)
E Speed sensor signal

71
72
73
Coolant temperature sensor

Fuel pressure regulator

TMAP sensor
Rail pressure sensor

Oil pressure sensor

Fuel temperature sensor

Engine ECU connector Camshaft position sensor

Fuel inlet metering valve

Crankshaft speed sensor

Oil level sensor switch 74

 Cylinder block data
Cylinder bore 106.000-106.020 mm (3.937- 3.938 in)
(Nominal diameter to be measured 63mm below head face.)

Main bearing bolts torque (1) first stage 50 Nm (37 lbf ft)
second stage 115 Nm (85 lbf ft)
final stage turn a further 180°

Diameter of first oversize bore 106.500-106.520 mm (4.192-4.193 in)

Diameter of second oversize bore 107.00-107.020 mm (4.232- 4.233 in)

Main bearing bore (without bearings)

numbers 1 to 6 92.000-92.020 mm (3.622-3.623 in)
number 7 105.000-105.020 mm (4.134-4.135 in)

Main bearing bore (with bearings)

numbers 1 to 6 88.047-88.090 mm (3.466-3.468 in)
number 7 100.047-100.090 mm (3.939-3.941 in)

Camshaft bore
numbers 1 to 6 60.040-60.070 mm (2.364-2.365 in)
number 7 60.290-60.32 mm (2.374-2.375 in)

(1) Torque information MUST be used in conjunction with recommended procedures contained in
this manual. Failure to use the appropriate and correct removal, replacement, dismantle and
assembly procedures may result in an engine failure in service. Refer also to the procedures for the
correct bolt tightening sequence. 75
 Cylinder head data

Cylinder head bolts torque (2)

first stage 40 Nm (30 lbf ft)
second stage 75 Nm (56 lbf ft)
third stage repeat 75Nm
fourth stage torque angle + 90 °
final stage torque angle + 180°

Inlet opens (top of ramp) 6° btdc

Inlet closes 28° abdc

Exhaust opens 41° bbdc

Exhaust closes 9° atdc

(2) Torque information MUST be used in conjunction with recommended procedures contained in
this manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly
procedures may result in an engine failure in service. Refer also to the procedures for the correct bolt
tightening sequence.

76
 Piston and Connecting rod data
Piston ring clearance Connecting rod type (1) Split fracture
top ring Keystone ring
middle ring 0.125 to 0.08mm Connecting rod bore diameter 77.00 to 77.019 mm
(0.0049 to 0.0031 in) (3.0314 to 3.0322 in)
bottom (oil) ring 0.09 to 0.05mm
(0.0035 to 0.0019 in) Connecting rod side clearance
min 0.05mm (0.0019 in)
Piston ring gap max 0.40mm (0.0157 in)
top ring 0.3 to 0.5mm
(0.118 to 0.0197 in) Big end bearings:
middle ring 0.55 to 0.8mm width 32.5 to 33.00 mm
(0.0216 to 0.0314 in) (1.279 to 1.299 in)
bottom (oil) ring 0.25 to 0.50 mm thickness (at centre) 1.990 to 1.981mm
(0.0098 to 0.0196 in) (0.0783 to 0.0779 in)
Small end bearings:
Piston height above inside diameter 42.034 to 42.021mm
cylinder block (cold) 0.0375 to 0.3385 mm (1.6548 to 1.6543 in)
(0.0014 to 0.013 in)

(1) Split fracture type connecting rods MUST NOT be dot

punched, or etched in any way during disassembly - refer to
relevant service procedures.

77
Crankshaft data
Main bearing journal diameter (x6)
min 87.98 mm (3.460 in)
max 88.00 mm (3.464 in)

Main rear bearing journal diameter (x 1)

min 99.98 mm (3.936 in)
max 100.00 mm (3.937 in)

Connecting rod bearing journal diameter

min 72.98 mm (2.873 in)
max 73.00 mm (0.2755 in)

Maximum wear and ovality on journals No visible damage/wear or

marks

Crankshaft induction hardness 55 HRc min on surface

Thrust washer width

min 2.44 mm (0.096 in)
max 2.50 mm (0.787 in)

Crankshaft end float

min 0.05 mm (0.002 in)
max 0.25 mm (0.010 in)

78
 Camshaft data

Camshaft journal diameter

6 off 59.99 to 59.97mm (2.362 to 2.361 in)
1 off 60.25 to 60.22mm (2.372 to 2.370 in)

Camshaft lobe wear limits

Inlet 7.385-7.435mm (0.291-0.293 in)
Exhaust 7.545-7.595mm (0.297-0.299 in)

Camshaft Gear (1) 104 teeth

(1) The camshaft gear is not available as a separate service item. The gear
must be heated onto the camshaft in the correct timed position. Specialist
fixtures are used during the production process to achieve the correct
timing.

79
 Electrical equipment data

Alternator
Make Letrica

Rating 55Amp 24V Standard (Standard), 100Amp 24 V (Optional)

Cooling Internal Fan

W-terminal For engine speed indication

Alternator speed 2.8 x engine speed

Starter Motor (1)

Make Letrica

Rating 24V, 4.2kW

Operating range -30 to +120°C (-22 to 248°F)

Number of pinion teeth 11

(1) Never operate the starter motor longer than 20 seconds. Allow at least 2
minutes for cooling and battery recovery before operating again. Overheating caused
by excessive operation will seriously damage the starter motor.

80
 Electrical equipment data

Coolant Temperature Sender

Type Temperature dependent resistance

Temperature v resistance table

Temperature °C (°F) Resistance - Ohms +/-%
100 (212) 1870 2.0
80 (176) 3230 2.9
25 (77) 20620 5.7
0 (32) 58960 7.3

81
 Electrical equipment data
Inlet Manifold Air Pressure and Temperature Sensor (TMAP)
Supply voltage 5V

Temperature Sensor
Type temperature dependent resistor
Temperature v resistance table
Temperature °C (°F) resistance - Ohms +/- %
-10 (14) 7800-8800 5.1
15 (59) 2900-3100 5.2
25 (77) 1800-2062 5.7
50 (122) 833-1230 4.3
80(176) 250-348 4.3
100 (212) 187-210 2.0
110 (230) 144-168 2.4

Pressure Sensor
Type Piezo - resistive

Atmospheric pressure v voltage

atmospheric pressure mbar output voltage V +/- V
980 +/- 25 1.84 0.05

82