- This service manual PDF download for the JCB 444 Mechanical Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
TABLE OF CONTENTS :
Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section 4 - Systems Description Section 5 - Fault Finding Section 6 - Test Procedures Section 7 - Fuel System Section 8 - Cooling System Section 9 - Lubrication System Section 10 - Electrical System Section 11 - Induction and Exhaust System Section 12 - Base Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9806/3000-04 Total Pages : 426
This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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9806-3000
Section 1 - General Information General Information Introduction About this Manual Using the Service Manual Section Numbering Left Side, Right Side Units of Measurement Machine Related Data Acronyms and Abbreviations Identifying the Engine Engine Identification Plate Engine Labels Component Labels Engine Identification Number Explanation Engine Component Identification Technical Data Basic Engine Data Engine Specifications Engine Block & Bedplate Data Cylinder Head Data Inlet and Exhaust Valve Data Rocker Levers, Rocker Shaft and Tappets Data Pistons and Connecting Rods Data Crankshaft Data Camshaft Data Fuel System Data Acceptable and Unacceptable Fuels Fuel Types Usage and Effects of Fuels Sulphur Content Effects of Fuel Contaminates Lubrication System Data Cooling System Data Electrical Equipment Data Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Bolts and Screws Hydraulic Connections 'O' Ring Face Seal System 'Torque Stop' Hose System Torque + Angle Explanation Torque + Angle Tightening Procedure Engine Torque Figures Lubricants and Capacities Engine Lubricating Oil Recommended Oils Engine Oil Capacity Coolant Mixtures Service Aids Sealing, Retaining and Care Compounds Service Tools General Engine Tools Specialist Engine Tools Service Tool Drawings 892/01146 - Core Plug Fitting Tool 892/01147 - Crankshaft Turning Tool 892/01148 - Timing Pin 892/01149 - Sump Sealant Template 892/01150 - Oil Sump Location Dowel 892/01151 - Injector Sleeve Removal Tool 892/01152 - Valve Stem Seal Fitting Tool 892/01154 - FIP Cover Removal Tool 892/01155 - FIP Gear Removal Tool 892/01157 - Crankshaft Front Seal Fitting Tool 892/01156 - Crankshaft Rear Seal Fitting Tool 892/01158 - Crankshaft Rear Seal Alignment Tool 892/01159 - Injector Seal Fitting Tool 892/01168 - Dummy Injector 892/01169 - Top Dead Centre (TDC) Setting Tool Engine Mounting Frame Service Parts and Repair Kits Engine Repair Parts and Kits Identification Engine Lifting Lifting Information Operating Procedures Starting the Engine Pre-Start Notes Start Procedure Engine Checks After Start-up Engine Running-in Procedure Stopping the Engine
Section 2 - Care and Safety Care and Safety Safety Notices Introduction Safety Checklist General Safety Operating Safety Maintenance Safety
Section 3 - Routine Maintenance Routine Maintenance Routine Maintenance Introduction Maintenance Procedures Cleaning the Engine High Pressure Cleaning Lubricants - Health and Safety Hygiene Storage Waste Disposal First Aid - Oil Spillage Fires Service Schedules Engine Oil and Filter Checking the Oil Level Changing the Oil and Filter Engine Cooling System Coolant Mixtures Checking the Coolant Level Changing the Coolant Front End Accessory Drive (FEAD) Belt Engine Fuel System Draining the Water Separator and Fuel Filter Changing the Filter Element Changing the Water Separator Pre- Filter Priming the Fuel System Air Intake System Engine Breather Cleaning the Engine Breather Gauze
Section 4 - Systems Description Systems Description Engine Overview Component Identification External Internal Basic Description The Four Stroke Cycle Camshaft and Valve Operation The Four Cylinder Cycle - JCB 444 Engine Firing Order Timing Gears Timing Valve Train Front End Accessory Drive (FEAD) Belt System Lubrication System Basic Description Oil Pump Oil Cooler and Filter Oil Cooler Matrix Oil Filter Camshaft Lubrication Crankshaft Lubrication Rocker Assembly Lubrication Piston Cooling and Small End Bearing Lubrication Fuel System Basic Description Pre-Filter/Water Separator, Lift Pump and Fuel Filter Pre Filter/Water Separator Lift Pump Fuel Filter Fuel Injection Pump - Injection Cycle State A - Charging State B - Injecting Fuel Injector Pump - Governor State A - Increasing Engine Speed State B - Decreasing Engine Speed Features of the Delphi DP210/DP310 Fuel Injection Pump Cold Start Advance - Shown at A Hydraulic Light Load Advance Variable Fuelling - Shown at B Latch Valve ESOS - Electric Shut Off Solenoid Turbo Boost Control (Turbocharged engines only) Injectors and Combustion Injectors Combustion Induction, Exhaust and Breather Systems Induction and Exhaust Systems Naturally Aspirated Turbocharged Intercooled Exhaust Gas Recirculation (EGR) Engine Breather SA, SB, SC Engines SD, SF Engines Cooling System Description Thermostat State A - `Closed' - Engine Cooled State B - `Open' - Engine Hot Injectors Coolant Pump Electrical System Electrical Circuit Schematic Electrical Components
Section 5 - Fault Finding Fault Finding Fault Finding Introduction Fault Finding Charts A Charts - Engine B Charts - Fuel C Charts - Lubricating Oil D Charts - Coolant
Section 6 - Test Procedures Test Procedures Introduction Test Procedures Introduction Testing Lift Pump Operation Pressure Test Procedures Measuring the Inlet Restriction Fuel Injection Pump Delivery Engine Compression Engine Oil Pressure High Lubrication Oil Pressure Low Lubrication Oil Pressure Thermostat Air System and Turbocharger Air Filters Air Intake Connections Exhaust Manifold Leaks (Turbocharged Engines) Turbocharger Checks Wastegate Operational Check Using a Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity Measuring Frequency Testing a Diode or a Diode Wire Battery Maintenance First Aid - Electrolyte Testing Specific Gravity Testing Alternator General Description Service Precautions Charging Circuit Test Alternator Charging Test Starter Motor Starting Circuit Test
Section 7 - Fuel System Fuel System Fuel Filter Removal and Replacement Fuel Lines Identification Removal and Replacement High Pressure Fuel Lines Low Pressure Fuel Lines Fuel Bleed-off Lines (Low Pressure) Fuel Lift Pump Removal and Replacement Removal Replacement Fuel Injection Pump Removal and Replacement Component Identification Before Removing: Removal Replacement After Replacing Fuel Injectors (Atomisers) Removal and Replacement Removal Replacement Bleeding Air From The System Bleeding Air From The System
Section 8 - Cooling System Cooling System Drive Belt - Coolant Pump Front End Accessory Drive Belt (FEAD) Removal and Replacement Thermostat Removal and Replacement Before Removing Removal Replacement After Replacing Coolant Inlet Assembly Removal and Replacement Before Removing Removal Replacement After Replacing Coolant Pump Removal and Replacement Before Removing Removal Replacement After Replacing Lubricating Oil Cooler Removal and Replacement
Section 9 - Lubrication System Lubrication System Oil Filter Head Removal and Replacement Oil Pan (Sump) Removal and Replacement Before Removing Removal Replacement After Replacing Oil Pump Removal and Replacement Before Removing Removal Inspection Replacement After Replacing Lubricating Oil Cooler and Filter Head Removal and Replacement Before Removing Removal Replacement After Replacing Dismantling, Inspection and Assembly Dismantling Inspection Assembly
Section 10 - Electrical System Electrical System Starter Motor Removal and Replacement Before Removing Removal Inspection Replacement Dismantling and Assembly Alternator Removal and Replacement Before Removing Removal Inspection Replacement After Replacing Dismantling and Assembly Electric Shut-Off Solenoid (ESOS) Removal and Replacement Before Removing Removal Inspection Replacement Cold Start Advance Solenoid Removal and Replacement Before Removing Removal Inspection Replacement Engine Cold Start Switch Removal and Replacement Before Removing Removal Inspection Replacement After Replacing Engine Oil Pressure Switch Removal and Replacement Before Removing Removal Inspection Replacement Coolant Temperature Sender Unit Removal and Replacement Before Removing Removal Inspection Replacement After Replacing
Section 11 - Induction and Exhaust System Induction and Exhaust System Turbocharger Removal and Replacement Before Removing Removal Inspection Replacement After Replacing Dismantling and Assembly Dismantling Assembly Exhaust Manifold Removal and Replacement Before Removing Removal Inspection Replacement After Replacing Inlet Manifold Removal and Replacement Before Removing Removal Inspection Replacement
Section 12 - Base Engine Base Engine Cylinder Head Rocker Cover Removal and Replacement Dismantling and Assembly Rocker Assembly Removal and Replacement Dismantling, Inspection and Assembly Valve Clearances Adjustment Cylinder Head Assembly Removal and Replacement Valves, Valve Springs and Stem Seals Removal and Replacement Front End Accessory Drive Belt System (FEAD) Tensioner Removal and Replacement Flywheel and Housing Flywheel Removal and Replacement Flywheel Gear Ring Removal and Replacement Flywheel Housing Removal and Replacement Timing Case and Drive Gears Assembly Drive Gear - Fuel Injection Pump Removal and Replacement Drive Gear - Crankshaft Removal and Replacement Drive Gear - High Duty P.T.O. Idler Removal and Replacement Drive Gear - Camshaft Removal and Replcement Camshaft and Tappets Removal and Replacement Timing Case - Rear Removal and Replacement Pistons and Connecting Rods Big End Bearing Removal, Inspection and Assembly Piston and Connecting Rod Assembly Removal and Replacement Piston and Connecting Rod Assembly Dismantling, Inspection and Assembly Crankshaft Assembly Crankshaft Pulley Removal and Replacement Rear Oil Seal Removal and Replacement Front Oil Seal Removal and Replacement Crankshaft Removal and Replacement