Section K

Engine
Service Manual - 1CX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section K - Engine

Publication No.
9803-9960-1



Copyright © 2004 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.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section K - Section K

Notes:

K-0 9803-9960-1 K-0

 Section K - Engine

Contents Page No.

Technical Data
100 Series Engine up to machine no. 807552 .......................................... K-1
400 Series Engine from machine no. 807553 .......................................... K-2

Engine Unit
Removal and Replacement ...................................................................... K-3

K-i K-i
 Section K - Engine

Contents Page No.

K-ii K-ii
 Section K - Engine

Technical Data
100 Series Engine up to machine no. 807552

Type 4 cylinder in-line, compression ignition, naturally

aspirated.
Bore (nominal) 84 mm (3.31 in)
Stroke 100 mm (3.94 in)
Swept Volume 2216 cm 3 (135.2 in3)
Compression Ratio 22 : 1
Injection Sequence 1,3,4,2
Valve Clearance - Cold - Inlet and Exhaust 0.2 mm (0.0078 in)
Oil Pressure 2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2)

Speeds
Rated Speed 2800 rev/min
Idling Speed 850 - 950 rev/min

Fuel System
Governing Mechanical
Static Timing 19° - 21° BTDC
Injector Codes PN: 130506140
Injector Setting Pressure 150 - 162 bar (2175 - 2350 lbf/in2, 153 - 165 kgf/cm 2)

Cooling System
Fan Type Mechanical
Coolant Pressure 0.5 bar (7.25 lbf/in2, 0.5 kgf/cm 2)
Thermostat operating temperature 82 - 94 °C (180 - 200 °F)
Temperature Warning Light operates at 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is

necessary to fit a new engine, then after the first 50
operating hours a new engine oil filter must be fitted and
the engine oil changed. Failure to complete this could
damage the engine.

Note: Should further details be required, refer to Engine

Service Manual 9806/2100.

K-1 K-1
 Section K - Engine
Technical Data
400 Series Engine from machine no. 807553

400 Series Engine from machine no. 807553

Type 4 cylinder in-line, compression ignition,

naturally aspirated.
Bore (nominal) 84 mm (3.31 in)
Stroke 100 mm (3.94 in)
Swept Volume 2216 cm 3 (135.2 in3)
Injection Sequence 23.3 : 1
Injection Sequence 1,3,4,2
Valve Clearance - Cold - Inlet and Exhaust 0.2 mm (0.0078 in)
Oil Pressure 1 bar (15 lbf/in2) min

Speeds
Rated Speed 2800 rev/min
Idling Speed 900 ±25 rev/min
Maximum No Load 2950 ±25 rev/min

Fuel System
Governing Mechanical
Static Timing 19° - 21° BTDC
Injector Codes 131 406 360
Injector Setting Pressure 147 bar (2133 lbf/in2)

Cooling System
Fan Type Mechanical
Coolant Pressure 1 bar (14.5 lbf/in2)
Thermostat operating temperature
- opens at: 82 °C (180 °F)
- fully open at: 95 °C (202 °F)
Temperature Warning Light operates at 97 - 103 °C (207 - 217 °F)

Note: If at anytime during the life of a machine it is

necessary to fit a new engine, then after the first 50
operating hours a new engine oil filter must be fitted and
the engine oil changed. Failure to complete this could
damage the engine.

Note: Should further details be required, refer to Engine

Service Manual 9806/2190.

K-2 K-2
 Section K - Engine

Engine Unit
Removal and Replacement

Removal 9 Disconnect wiring connections from the starter motor

and alternator, also water temperature and oil
1 Position the machine on firm level ground. Fully lower pressure senders from the engine.
the lift arms and stop the engine.
10 Disconnect the engine/chassis earth strip.
2 Open the bonnet and remove engine compartment
side panels. 11 Disconnect the engine oil cooler hose.

3 Disconnect and remove the battery. 12 Disconnect the throttle and stop controls at the fuel
pump.
4 Remove the exhaust and air filter assembly.
13 Disconnect the fuel supply line and spill line at the
5 Drain the cooling system, then disconnect the engine.
radiator top hose, air vent hose and bottom hose.
14 Disconnect and plug all hydraulic lines (11 off) at the
6 Remove the coolant header tank and the bracket hydraulic pump assembly.
supporting it.
15 Disconnect wiring connections from the pump
assembly.

16 Attach slings to the engine lifting eyes.

!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

17 Take the weight of the engine on the hoist and remove

mounting bolts A (4 off). Fig 2. ( K-4)

18 Withdraw the engine in a level attitude until the

hydraulic pump is clear of the cab floor. Raise the
engine to lift it clear of the machine.

204290-B1
Fig 1.

7 Support the weight of the cooling pack and remove

the securing bolts E (4 off).

8 Lift the cooling pack clear.

K-3 K-3
 Section K - Engine
Engine Unit
Removal and Replacement

205180-B1

Fig 2.

Replacement Torque Settings

Replacement is a reversal of the removal procedure.

Item Nm kgf m lbf ft
On completion, check hydraulic and cooling systems for A 56 5.7 42
leakage and level.
B 56 5.7 42
Note: If the mounting brackets are removed from the C   
engine block it is necessary to use JCB Lock and Seal D   
when reinstalling the mounting bolts B before torque
tightening.

Note: The metalastic flexible mounts can be removed by

removing bolts C.

Note: The front left hand engine mount also carries the
alternator and is held by 3 x M8 bolt D as opposed to 2 x
M10 bolt B.

K-4 K-4