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t4f 444
t4f 444
t4f 444
ENGINE
JCB T4F 444 (55kw) Engine (4 Cyl), Contents
JCB T4i 444 Elec Engine (4 Cyl),
01 - Machine
JCB T4i 448 Elec Engine (4 Cyl)
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
EN - 9806/4300 - ISSUE 5 - 09/2018
www.jcb.com
Notes:
9806/4300-5
JCB T4F 444 (55kw) Engine (4 Cyl), JCB T4F 444 (55kw) Engine (4 Cyl),
JCB T4i 444 Elec Engine (4 Cyl), JCB T4i 444 Elec Engine (4 Cyl),
JCB T4i 448 Elec Engine (4 Cyl) JCB T4i 448 Elec Engine (4 Cyl)
EN 9806/4300 EN 9806/4300
JCB T4F 444 (55kw) Engine (4 Cyl), JCB T4F 444 (55kw) Engine (4 Cyl),
JCB T4i 444 Elec Engine (4 Cyl), JCB T4i 444 Elec Engine (4 Cyl),
JCB T4i 448 Elec Engine (4 Cyl) JCB T4i 448 Elec Engine (4 Cyl)
EN 9806/4300 EN 9806/4300
9806/4300-5
9806/4300-5
01-00 Introduction
01-00-00 General ............................................................................................................................. 01-3
01-00-04 Product Compliance ......................................................................................................... 01-4
01-00-06 Intended Use .................................................................................................................... 01-5
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-7
01-03-06 Safety Warnings ............................................................................................................... 01-8
01-03-09 General Safety ................................................................................................................. 01-9
01-03-12 Maintenance Safety ....................................................................................................... 01-10
01-03-18 Operating Safety ............................................................................................................ 01-11
01-03-21 Worksite Safety .............................................................................................................. 01-12
01-03-24 Risk Assessment ............................................................................................................ 01-13
01-06 About this Manual
01-06-00 General ........................................................................................................................... 01-15
01-09 Description
01-09-00 General ........................................................................................................................... 01-17
01-12 Operation
01-12-00 General ........................................................................................................................... 01-19
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2018-07-24
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00 - Introduction
01 - 1 9806/4300-5 01 - 1
01 - 2 9806/4300-5 01 - 2
00 - General
Introduction
01 - 3 9806/4300-5 01 - 3
04 - Product Compliance
Introduction
01 - 4 9806/4300-5 01 - 4
06 - Intended Use
Introduction
01 - 5 9806/4300-5 01 - 5
01 - Machine
03 - Safety
03 - Safety
01 - 6 9806/4300-5 01 - 6
01 - Machine
03 - Safety
03 - Safety - Yours and Others
Introduction
Do not work with the machine until you are sure that
you can control it.
Do not start any work until you are sure that you and
those around you will be safe.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 7 9806/4300-5 01 - 7
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
01 - 8 9806/4300-5 01 - 8
01 - Machine
03 - Safety
09 - General Safety
01 - 9 9806/4300-5 01 - 9
01 - Machine
03 - Safety
12 - Maintenance Safety
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system. Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment. Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts. When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the maximum level of engine
oil in the sump. If the maximum is exceeded, the
excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job. Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
01 - 10 9806/4300-5 01 - 10
01 - Machine
03 - Safety
18 - Operating Safety
01 - 11 9806/4300-5 01 - 11
01 - Machine
03 - Safety
21 - Worksite Safety
01 - 12 9806/4300-5 01 - 12
01 - Machine
03 - Safety
24 - Risk Assessment
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 13 9806/4300-5 01 - 13
01 - Machine
06 - About this Manual
01 - 14 9806/4300-5 01 - 14
01 - Machine
06 - About this Manual
00 - General
00 - General
Introduction
01 - 15 9806/4300-5 01 - 15
01 - Machine
09 - Description
09 - Description
01 - 16 9806/4300-5 01 - 16
01 - Machine
09 - Description
00 - General
00 - General
Introduction
01 - 17 9806/4300-5 01 - 17
01 - Machine
12 - Operation
12 - Operation
01 - 18 9806/4300-5 01 - 18
01 - Machine
12 - Operation
00 - General
00 - General
Introduction
01 - 19 9806/4300-5 01 - 19
Notes:
01 - 20 9806/4300-5 01 - 20
06 - Body and Framework
Contents Page No.
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Notes:
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06 - Body and Framework
63 - Identification Label
63 - Identification Label
06 - 1 9806/4300-5 06 - 1
Notes:
06 - 2 9806/4300-5 06 - 2
06 - Body and Framework
63 - Identification Label
06 - Engine
06 - Engine
Introduction
Figure 2.
B
A C
Table 2.
Digit 1-2 Engine Type
DA 4.8L naturally aspirated mechanical fuel injection (Tier 2)
DB 4.8L turbocharged mechanical fuel injection (Tier 2)
DC 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 2)
DE 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 2)
DD 4.8L turbocharged mechanical fuel injection (Tier 3)
DF 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 3)
DK 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
DH 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
DJ 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
FL 3L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
SEF >55kW)
SA 4.4L naturally aspirated mechanical fuel injection (Tier 2)
SB 4.4L turbocharged mechanical fuel injection (Tier 2)
SC 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 2)
SD 4.4L turbocharged mechanical fuel injection (Tier 3)
SE 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
06 - 3 9806/4300-5 06 - 3
06 - Body and Framework
63 - Identification Label
06 - Engine
06 - 4 9806/4300-5 06 - 4
09 - Operator Station
Contents Page No.
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Notes:
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09 - Operator Station
33 - Safety Label/Chart
33 - Safety Label/Chart
09 - 1 9806/4300-5 09 - 1
Notes:
09 - 2 9806/4300-5 09 - 2
09 - Operator Station
33 - Safety Label/Chart
00 - General
00 - General
Introduction
WARNING Safety labels on the machine warn
you of particular hazards. You can be injured if
you do not obey the safety instructions shown.
09 - 3 9806/4300-5 09 - 3
Notes:
09 - 4 9806/4300-5 09 - 4
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-39
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-43
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-51
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-59
15-12-03 Main Bearing .................................................................................................................. 15-68
15-12-06 Front Oil Seal ................................................................................................................. 15-70
15-12-09 Rear Oil Seal ................................................................................................................. 15-73
15-12-12 Pulley .............................................................................................................................. 15-77
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-79
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-87
15-18-03 Drive Belt ....................................................................................................................... 15-90
15-18-21 Tensioner ........................................................................................................................ 15-94
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-97
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-105
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-109
15-30 Valve
15-30-00 General ......................................................................................................................... 15-113
15-30-12 Valve Spring ................................................................................................................. 15-122
15-30-24 Stem Seal .................................................................................................................... 15-123
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-125
15-33-06 Big-End Bearing ........................................................................................................... 15-129
15-36 Piston
15-36-00 General ......................................................................................................................... 15-135
15-36-03 Piston Ring ................................................................................................................... 15-147
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-149
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-151
15-42-06 Rocker Cover ............................................................................................................... 15-160
15-42-09 Push Rod ..................................................................................................................... 15-162
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15-42-21 Tappet ........................................................................................................................... 15-164
15-42-24 Tappet Cover ................................................................................................................ 15-166
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-169
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-175
15-51-03 Crankshaft Gear ........................................................................................................... 15-178
15-51-06 Camshaft Gear ............................................................................................................. 15-181
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-182
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-185
15-51-22 Rear Case .................................................................................................................... 15-188
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-193
15-54-03 Housing ........................................................................................................................ 15-197
15-54-09 Gear Ring ..................................................................................................................... 15-201
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-203
15-63 Mount
15-63-00 General ......................................................................................................................... 15-209
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-213
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-219
15-72-03 Pulley ............................................................................................................................ 15-225
15-72-06 Voltage Regulator ......................................................................................................... 15-226
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-229
15-75-03 Solenoid ....................................................................................................................... 15-236
15-75-06 Brush Gear ................................................................................................................... 15-237
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-239
15-84-03 Crankshaft Position ...................................................................................................... 15-250
15-84-06 Camshaft Position ........................................................................................................ 15-254
15-84-09 Knock ........................................................................................................................... 15-258
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-261
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-263
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-266
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-269
15-84-24 Fuel Temperature ......................................................................................................... 15-272
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-275
15-84-33 Coolant Temperature .................................................................................................... 15-277
15-84-42 Engine Oil Temperature ............................................................................................... 15-280
15-84-43 Engine Oil Level ........................................................................................................... 15-283
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-286
15-87 Switch
15-87-00 General ......................................................................................................................... 15-291
15-87-03 Engine Oil Pressure ..................................................................................................... 15-292
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-297
9806/4300-5
2018-09-18
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