JCB 4DX Backhoe Loader Service Repair Manual Instant Download

General Information 1 Care & Safety 2 Routine Maintenance 3 Service Manual 4DX Attachments A Body & Framework B Electrics C Controls D Backhoe Loader Hydraulics E Published by Transmission F Product Support Department, JCB India Limited 23/7, Mathura Road, Ballabhgarh 121004 INDIA Brakes G Steering H Tel: 0091 129 4299251 Fax 0091 129 2309051 Engine K Part No: 550/42914 June 2006 Issue 1

General Information Section 1 Section 1 Contents Page No. Machine Identification Plate 1 - 1 Engine Identification Number 1 - 2 Serial Plates 1 - 2 Torque Settings 2 - 1 Service Tools - - - Body & Framework Hydraulics Transmission 3 - 1 3 - 3 3 - 4 June 2006 Issue 1

General Information Machine Identification Section 1 1-1 Section 1 1-1 Machine Identification Plate Your machine has an identification plate X mounted on the loader tower as shown. The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. June 2006 Issue 1

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General Information Unit Identification Section 1 1-2 Section 1 1-2 Engine Serial Plate The engine serial number is stamped on a label which is fastened to the left side of the cylinder block (looking from the rear). Rear Axle Serial Plate The rear axle serial number is stamped on a plate mounted to the front face of the axle, as shown. June 2006 Issue 1

General Information Unit Identification Section 1 1-3 Section 1 1-3 Front Axle Serial Plate The front axle serial number is stamped on a plate mounted on the axle. Syncro Shuttle Serial Plate The Syncro Shuttle serial number is stamped on a label which is mounted adjacent to the Suction strainer. June 2006 Issue 1

General Information Torque Section 1 2-1 Section 1 2-1 Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size in Hexagon (A/F) in Torque Settings Nm (mm) kgf m lbf ft 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 11/4 11/2 (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1) 7/16 1/2 9/16 5/8 3/4 13/16 15/16 11/8 15/16 11/2 17/8 21/4 14 28 49 78 117 170 238 407 650 970 1940 3390 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0 10 20 36 58 87 125 175 300 480 715 1430 2500 Metric Grade 8.8 Bolts Bolt Size Hexagon (A/F) mm Torque Settings Nm (mm) kgf m lbf ft M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 (5) (6) (8) (10) (12) (16) (20) (24) (30) (36) 8 10 13 17 19 24 30 36 46 55 7 12 28 56 98 244 476 822 1633 2854 0.7 1.2 3.0 5.7 10 25 48 84 166 291 5 9 21 42 72 180 352 607 1205 2105 Rivet Nut Bolts/Screws Bolt Size Torque Settings (for steel rivet nuts) Nm kgf m (mm) lbf ft M3 M4 M5 M6 M8 M10 M12 (3) (4) (5) (6) (8) (10) (12) 1.2 3.0 6.0 10.0 24.0 48.0 82.0 0.12 0.3 0.6 1.0 2.5 4.9 8.4 0.9 2.0 4.5 7.5 18.0 35.5 60.5 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. June 2006 Issue 1

Section 1 3-1 General Information Special Tools Section 1 3-1 Service Tools Section B Body & Framework June 2006 Issue 1

General Information Special Tools Section 1 3-2 Section 1 3-2 Service Tools Section B Body & Framework June 2006 Issue 1

General Information Special Tools Section 1 3-3 Section 1 3-3 Service Tools Section E Hydraulics June 2006 Issue 1

Routine Maintenance Coolants Section 3 2-5 Section 3 2-5 Castrol heavy duty coolant Use ethylene glycol antifreeze diluted with coolant blend as mentioned below in the following proportion in (radiator) cooling system: Ambient temperature Deg. Centigrade Ratio by volume of antifreeze to cooling water - blend + 50 to 20 33 : 67 -20 to 40 50 : 50 -40 to 69 68 : 32 Water quality requirements for use as engine coolant Water used in engine coolant should be of drinking quality with following limits: Parameters Maximum allowable limit Total hardness 170 ppm (measured as caco3) Total dissolved solids 340 ppm Chlorides (cl) 50 ppm as cl Sulphates (so4) 100 ppm as so4 Water of above defined quality along with use of additives shall ensure trouble free operation of cooling system . Additives for cooling system should serve the following objectives: ?? Protect cooling water system against corrosion. ?? designed heat transfer efficiency and prevents overheating of engines. Keep waterside heat transfer surfaces clean and free of scale and corrosion deposits. This maintains ?? Be compatible with rubber hoses and other non-metallic parts of the cooling water. It is recommended to drain the system after every 1200 hrs. Or 6 months whichever is earlier and refill the radiator with the same proportion of the coolant and water. June 2006 Issue 1

Routine Maintenance Engine Preservation Section 3 2-6 Section 3 2-6 Engine Preservation System: Following preservatives are recommended for engine to be supplied overseas & also when it is to be kept idle ( out of use) for a prolonged period (more than 12 months). Bharat Petroleum Bharat Preserve Oil 30 Oil 30 Hindustan Petroleum Autoprun T 120 Indian Oil Corporation Servo Preserve 30 Or Servo Run N Oil 30 Servo Cut 5 20% Emulsion With Water. Veedol Tide Water Oil Co. Veedol 30 / 40 Manufacturer Castrol India Engine Lub. Oil & Fuel System Engine Cooling System Bharat Sherol B Emulsion With Water Ratio 1:20 Koolkit 40 5% Emulsion With Water Veedol Amul Kut 4 Emulsion With Water Ratio 1 : 20 Veedol Raspro 1t Unpainted Ferrous Metal Parts Bharat Rustol 152 Rustop 274 Servo Rp 125 Rustilo DW 904 Or DW 901 Notes: Rust protective film coverage: 15 20 m2 / lt., when machine is to be transported by sea. Following rust protective coating can be applied on stevedore special machines: Castrol Rustilo DWX 32 or rustguard rust preventive oil P 219. 1. 2. 3. 4. Castrol grades are manufactured by M/s Castrol India Limited. HP / Hylub grades are manufactured by M/s Hindustan Petroleum Corporation Limited. Mobil grades are manufactured by M/s Mobil Oil Corporation Limited. June 2006 Issue 1

Section 3 3-1 Routine Maintenance Greasing Section 3 3-1 Greasing Loader Arms Greasing must be done regularly to keep the machine working efficiently. Regular greasing lengthen the machine s working life. For each grease point there is another on the other side of the machine. 11 grease points each side - Total 22 grease points. Greasing should be done with a Grease gun. Normally two strokes of the grease gun should be sufficient. Stop greasing when fresh grease appears at the joint. June 2006 Issue 1

Routine Maintenance Greasing Section 3 3-2 Section 3 3-2 Backhoe A - Standard Dipper 27 Grease Points B - Extending Dipper - 27 Grease Points Not : Do not grease the kingpost mounting rails. June 2006 Issue 1

Routine Maintenance Greasing Section 3 3-3 Section 3 3-3 Front Axle (2 Wheel Drive Machines) 11 Grease Points June 2006 Issue 1

Routine Maintenance Greasing Section 3 3-4 Section 3 3-4 Front Axle ( 4 Wheel Drive Machines ) 5 Grease Points June 2006 Issue 1

Routine Maintenance Greasing Section 3 3-5 Section 3 3-5 Rear Propshaft 3 Grease Points Front Propshaft ( 4 Wheel drive ) 3 Grease Points June 2006 Issue 1

Routine Maintenance Greasing Section 3 3-6 Section 3 3-6 6 - in - 1 Clamshovel Backhoe Quick-Hitch For grease points 2 & 3 there is another on the opposite side of the Quick-Hitch (4 and 5). For each grease point there is another at the other end of the bucket. Total 5 grease points 3 grease points on each side Total 6 grease points. Loader Quick-Hitch 2 grease points each side Total 4 grease points. June 2006 Issue 1

Routine Maintenance Greasing Section 3 3-7 Section 3 3-7 Extending Dipper WARNING Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply In a well-ventilated area. Extend the dipper. Coat the working surfaces with Waxoyl. June 2006 Issue 1

Routine Maintenance Oiling Section 3 3-8 Section 3 3-8 Oiling Parking Brake Cable Oil the clevis at the brake end of the cable and at the base of the lever. Control Levers Oil the clevis at the bottom of every attachment control lever. June 2006 Issue 1

Section 3 4-1 Routine Maintenance Engine Air Filter Section 3 4-1 Cleaning the Pre Cleaner Note: Do not run the engine with the filter pre-cleaner or the rain cap removed. If the pre-cleaner is more than a third full of dust, empty it. Remove the Cover 1 Unscrew the wingnut A and lift off the cover B. Empty and Clean the Bowl 2 fully remove the dust bowl C and empty out the dust. Make sure the dust does not fall into the air filter intake. Wipe the bowl clean. Remove oil or grease by washing in hot water with a little detergent. Dry the bowl before refitting it. Fit the Bowl 3 Carefully set the bowl in position on the air filter. Fit and tighten the wingnut. June 2006 Issue 1

Routine Maintenance Engine Air Filters Section 3 4-2 Section 3 4-2 Renew Outer Element Renew Inner Element CAUTION The inner element must only be replaced and at latest every third time the outer element is renewed. As a record, mark the inner element with a felt tip pen each time the outer element is renewed. The outer element must be renewed with a new one after it has been cleaned twice. The cleaning of the Filter should be undertaken only when the Restriction indicator shows Red / the warning light on the Instrument panel illuminates. 1 Prevent dust from entering the engine by disconnecting the induction hose. * Note: Do not run the engine with rain-cap, pre-cleaner or dust valve removed. Unlock Clips B and lift off cover C. Remove Outer Element. 2 Gently pull out the Outer element D. 1 3 Press and Rotate Anti-clockwise to unlock the Filter F. Clean inside canister H, Cover C and dust valve J. 2 4 Carefully remove inner element. Fit new element D. Test seating of seal K by smearing with grease and checking for witness mark at base of canister. 3 Clean inside of canister H and dust valve J. 5 6 Insert new inner element and lock it in place by presssing and rotating clockwise 4 If the seal is correct, re-insert new outer element and clamp the cover. Insert new outer element B and test seating of seal D as previously described. 7 Ensure that dust valve J is at the bottom when refitting. 5 8 If the seal is correct, re-insert new outer element. 6 Check the security and condition of the induction hose and its clips. Ensure that the restriction indicator is fitted properly and reset / it s sensor is connected. 9 Reconnect the induction hose. Ensure that the restriction indicator sensor is reconnected. June 2006 Issue 1

Section 3 4-3 Routine Maintenance Engine Oil and Filter Section 3 4-3 Check Level Change Oil & Filter CAUTION 1. Make sure that the oil level is between the two marks on the dipstick A. Oil is toxic. If you swallow any oil, do not Induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. 2. If necessary, top up with JCB recommended oil through filler point B. 3. Replace dipstick. Remove drain plug C and discard the 'O' ring. Drain the oil into a suitable container. Clean and refit the drain plug with a new 'O' ring. Tighten to 34 Nm (25 lbf ft). 1 2 Change the filter: a Unscrew oil filter canister D. b Clean the filter head E. c Smear the new filter canister seal F with engine oil. d Screw in the new filter canister - hand tight only. 3 Fill the engine with new oil. Wipe off any spilt oil. Check the system for leaks. 4 Replace filler cap. June 2006 Issue 1

Routine Maintenance Fan Belt Section 3 4-4 Section 3 4-4 Fan Belt Check Tension Adjustment 1 Park the machine on level ground. Loosen bolts A, B, C, and D holding the 2 alternator. 3 point X is approximately 10 15 mm ( with moderate thumb pressure, 45N or 4.6 kgf. Reposition the alternator unit belt deflection at CAUTION If any leverage is necessary, use a length of wood at the drive end bracket only; otherwise damage to the alternator may be caused. Tighten bolts A, B, C, and D ensuring that bolt at the rear of the alternator is the last to be tightened. 4 Note: If a new belt is fitted, the belt tension must be checked again after the first 20 hours of operation. Routine Maintenance Section 3 Section 3 June 2006 Issue 1

Fuel Tank 4-5 4-5 Filling the Tank ! WARNING Lower the loader arms and switch off the engine before refuelling. Do not permit operation of the machine controls while refuelling. At the end of every working day, fill the tank with the correct type of fuel. overnight condensation from developing in the fuel. This will prevent The cap A incorporates a side mounted barrel lock that is operated by the ignition/door key. Fit the Cap Once the key has been removed, the cap will simply rotate on the filler neck. To remove the cap from the filler neck, the key must be reinserted and the cap unlocked. Note: The key MUST be inserted in the cap when removing and fitting. Routine Maintenance Fuel Filters Section 3 4-6 Section 3 4-6 June 2006 Issue 1

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Moisture Separator Fuel Filter Look in bowl A ( on RH side of machine) every 50 hours. If it contains water, drain off the water by opening tap B. Make sure tap B is tightened back after draining Unscrew the filter element by loosening the bolts at the top plate. Take out the filter element. The filter will be full of fuel. Discard and destroy the old filters and use new filters. To assist with bleeding, fill the new filter element with fuel before fitting. A B Bleeding Loosen the air vent screw A on the primary fuel filter as shown 1. Operate the Fuel lift pump X till fuel flows without air bubbles 2. 3. Tighten the air vent screw and then similarly bleed the Pump by opening the vent screw B and tighten it after removing the air lock. June 2006 Issue 1

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