Dept.

of service
JCB Maquinaria, SA .

1. BASIC TECHNICAL DATA

MODEL DESCRIPTION WEIGHT

COMPRESSION RATIO

SA NATURAL ASPIRATION 425kg 18.6:1

S.B. TURBO 430kg 18.3:1

S.C. TURBO - INTERCOOLER 430kg 17.5:1

· Number of cylinders 4

· Valves per cylinder 4

· Nominal caliber 103mm

· Career 132mm

· 4.4 liters
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 Dept. of service
JCB Maquinaria, SA .

· Combustion system Direct injection

· Rotary mechanical injection pump
Delphi DP210
Counterclockwise rotation

· Gas emission: Tier 2

· Max RPM without charge: 2200rpm

· Compression pressure ( Pending information )
The difference between cylinders must be less than 3.5 bar
· Firing order: 1-3-4–2

· Direction of rotation: Clockwise (viewed from front of engine)

· Grease pressure: 4.6 bar (at max. Engine RPM)

· Oil pressure switch 0.6 bar

· Valve clearance (cold)

· Admission 0.19 – 0.27mm
· Exhaust 0.56 – 0.64mm

· Split type (single type of connecting rod - no different grades)

Cranks
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JCB Maquinaria, SA .

· Engine block Can be machined. Oversized pistons (0.5 and 1.0 mm)
Start · of opening 86-90ºC
Fully open Thermostat 102ºC · Noise level 89dBA (1 m distance)

· Electric equipment
Iskra – AAK alternator
14V, 95Amp
Note: mounted on the motor (no use of brackets)

Iskra starter motor – AZF 45 12V, 4.2 Kw

Temp Sensor refrigerant

Temperature (ºC) Resistance – Q

25 500

50 197,4

100 41,9

110 32

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· engine oil JCB Extreme Performance

12 liters (Minimum Level) - 15 liters (Maximum Level)

· Oil consumption 0.2-0.5% of fuel consumption

· Refrigerant JCB Four Seasons (antifreeze mixture 60-50%)

· Specific Fuel Consumption ( SFC )

SFC: Consumption in grams of fuel burned per KW of useful power in one hour.

SB (TURBO)

RPM
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JCB Maquinaria, SA .

2. PREVENTIVE MAINTENANCE
Edge checks before starting. Job lOh 50 500 1000 2000 6000
hours hours hours hours
Maintenance points and fluid levels
Oil level Find out •
Coolant level Find out •
fluid leaks Find out •
Diesel filter and water settler Check and drain •
Oil and Filter (1) Change •
Diesel filter Change •
Hose status Find out •
Radiator Clean •
Belt Find out •
Air filter (outer element) Change •
Refrigerant Check status •
Air filter (inner element) Change •
Valve clearance Check and adjust •
Engine breather filter Clean •
Oil filler cap and dipstick gaskets Change •
Check and adjust •
RPM (idle)
Refrigerant Change •
Rocker cover gaskets and injectors Change •
Belt Change •
Injectors Change •
Injector Drain Lines Change •
High pressure diesel lines Find out •
(1) If you work in extreme working conditions, the filter and oil must be changed every 250 hours

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JCB Maquinaria, SA .

3. JCB ENGINE vs PERKINS Series 1100

JCB 4x4x4 Perkins 1104 (Vista) JCB engine advantages
BUTT Cross air flow 4 valves per Cross air flow 2 valves per Improved air flow 4 valves allow
cylinder cylinder the injectors to be placed in the
center of the combustion chamber.

TURBO Borg Warner Garrett GT25

PERFORMANCE Push rod / rocker arm Push rod / rocker arm
VALVES
GAME Screw with locking thread Locking Screw/Nut Easier adjustment
VALVES
ENGINE BLOCK Conventional design 'Open top' design Simplified manufacturing.
Better heat distribution
CRANKSHAFT Main bushings Increased crankshaft rigidity
$ 88
Main
76mmbushings $
mm (rear
CRANKSHAFT 125mm thick motor base Conventional main bushing Greater structural rigidity Reduced
LOCATION support system noise level

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JCB Maquinaria, SA .

JCB ENGINE vs PERKINS Series 1100

JCB 4x4x4 Perkins 1104 (Vista) JCB engine advantages
PISTONS Aluminium alloy. Aluminium alloy. Injectors in the center of the
3 segments per cylinder. 3 segments per cylinder. combustion chamber.
Central combustion Central combustion chamber.
chamber.

CRANKS “Fractured” connecting “Fractured” connecting rods

rods
CALIBER 103mm 105mm Perkins value very close to the
structural limit.
CAREER 132mm 127mm

CYLINDER 4.4 LITERS 4.4 LITERS

DISTRIBUTION Cylindrical gears (rear of Helical gears (front of engine) Greater contact surface. The
engine) position of the gears reduces
vibrations.
INJECTION Delphi DP210 Delphi DP210 or Different DP210 pumps (different
PUMP Bosch EPVE (Asp. Nat.) direction of rotation)

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JCB Maquinaria, SA .

JCB ENGINE vs PERKINS Series 1100

JCB 4x4x4 Perkins 1104 (Vista) JCB engine advantages

FIXATION Mounted directly on the Mounting on adjustable Greater assembly reliability.
ALTERNATOR engine support.

FIXATION Mounted directly on the Mounting on adjustable Greater assembly reliability.

A/C COMPRESSOR engine support.

WATER PUMP dragged by leash Driven by gear

AUX SOCKETS OF 11.2 kW (15 hp) 37kW (50hp) Greater flexibility for different
STRENGTH 60 kW (80 hp) installations

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engine
Dept. of service

4.VALVE
COMPONENTS
ADJUSTMENT
AND OPERATION

· Crankshaft rotation using tool

4 stroke cycle
892/01147
· Cold setting values
CYLINDER VALVES
Admission 0.19 – 0.27mm

Exhaust 0.56 – 0.64mm

Cylinder #1 Admission: Closed
TDC – end of compression stroke Exhaust: Closed
Passed Reference cylinder Cylinder valves adjustment
Cylinder #2 Admission: Closed
PMI – end of combustion stroke Exhaust: Opening started
1
Cylinder 4 Cylinder 1
Cylinder #3
(Exhaust closing) Admission: closed)
(Admission Closing has begun
PMI – final admissionopening)
(admission race Exhaust: closed)
(Exhaust Closed
Cylinder
2 #4
Cylinder 2 Admission:
Cylinder 3 Start opening Escape:
TDC – end of exhaust stroke Closing started

3 Cylinder 1 Cylinder 4

4 Cylinder 3 Cylinder 2

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Dept. of service
JCB Maquinaria, SA .

engine
BUTT
· Fixed by 18 bolts (1 to 18). The bolts
must be changed with each assembly
(single use).
· Dismantling order: From 18 to 1.
· Assembly order and pairs: From 1 to 18

SQUEEZE Nm ANGLE
IN
1st 40 ---

2nd 75 ---

3rd 75 ---

4th --- 90º

5th --- 180º

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Dept. of service

FLYWHEEL

· Fixed by 8 bolts

SQUEEZE Nm ANGLE
IN
1st 30 ---

2nd 75 ---

3rd --- 180º

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Dept. of service
JCB Maquinaria, SA .

engine
FLYWHEEL HOUSING Tightening
torques Item 4 –
Components 47 Nm Item 5-
24 Nm Item 7-
1 Housing
24 Nm
2.3 Centering pivots
4 Fixing bolts (6 units) M10
5 Fixing bolts (12 units)
6· Registration cover
7· Manhole cover bolts

After applying the sealant to the housing assembly, the assembly of bolts and tightening must be carried
out in less than 5 minutes.

744130

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JCB Maquinaria, SA .
JCB Maquinaria, SA .

JCB 444
PISTON AND
CRANKSHAFT
CONNECTING AND
engine
CAMSHAFT
ROD LOCK
· Split type connecting
rods
· Tightening
torques
Specific tooling (ref.: 892/01148)
Same useful for locking the camshaft
and crankshaft.
SQUEEZE
Nm ANGLE
IN
1st 35 ---

2nd 65 ---

3rd --- 90º

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 JCB 444
Dept. of service
JCB Maquinaria, SA .

engine
PISTON AND CONNECTING ROD

Item 2: 1st compression segment

Item 3: 2nd compression segment
Item 4: Oil control segment

The segments must be rotated relative to each other

by 120º.

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JCB 444 JCB Maquinaria, SA .

engine
BELT ASSEMBLY
(SYSTEM WITHOUT A/C)

Item 1: Crankshaft gear

Item 2: Oil pump gear
Item 3: Alternator gear
Item 4: Idler gear
Item 5: Belt tensioner
Item 6: Fan pulley
 Dept. of service

JCB 444 JCB Maquinaria, SA .

BELT ASSEMBLY
engine
(SYSTEM WITH A/C)

Item 1: Crankshaft pulley

Item 2: Oil pump pulley
Item 3: Alternator pulley
Item 4: Free pulley
Item 5: Belt tensioner
Item 6: Fan pulley
Item 7: A/C compressor
pulley
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Dept. of service
JCB Maquinaria, SA .

engine
B. OIL PAN

· Incorporation of deflector
plates that prevent foam
formation and allow work at
greater angles of inclination.

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Dept. of service
JCB Maquinaria, SA .

DP210 PUMP engine

Disassembly/Assembly of pump

As steps to highlight when assembling the pump:

1- It is necessary to lock the crankshaft with the 1st cylinder at TDC (special tool “A”:
892/01148)

2- Remove pump gear (special tool “B”: 892/01154)

3- Lock the injection pump shaft

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Dept. of service
JCB Maquinaria, SA .

engine
ELECTRIC SYSTEM
Engine components:
1- Starting motor
2- Alternator
3- Heaters (cold weather option)
4- Sediment switch (presence of water)
5- Coolant temperature switch/sensor
6- Oil pressure switch
7- stop solenoid
8- Cold start switch
9- cold start solenoid

Machine components:
A- Battery isolator
8- Battery
C,D,F,G- Fuses
E- Start key
H- “Alternator without load” lamp
J- Tachometer
K- Heater timer relay
L- Water in fuel lamp
M- High coolant temperature lamp N- Coolant
temperature indicator P- Low oil pressure lamp
R- Alarm buzzer.

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JCB Maquinaria, SA .

5. SPECIFIC TOOLS

Ref.:
Key for disassembling the injection pump.

Ref.: 892/01159
Useful assembly of injector gaskets (rocker cover).

Ref.: 892/01168
Useful mounting instead of injector for compression tests.

Ref.: 892/01152
Useful assembly of engine valve gaskets.

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JCB Maquinaria, SA .

SPECIFIC TOOLS
Ref.:
Torx wrenches for mounting and disassembling engine bolts.

Ref.: 892/01150
Oil pan centering tool.

Ref.: 892/01151
Useful for mounting/dismounting injector covers.
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Dept. of service
JCB Maquinaria, SA .

engine
B.
Ref.: 892/01147
Useful manual turning of the crankshaft

Ref.: 892/01169
Useful TDC adjustment of cylinder #1

Ref.: 892/01148
Useful for locking the crankshaft and camshaft.

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JCB Maquinaria, SA .

SPECIFIC TOOLS
Ref.: 892/01155
Useful for disassembling the injection pump gear.

Ref.: 892/01154
Useful for disassembling the front casing.

Ref.: ------
Engine to frame fixing bolts.

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