JCB 4DX Backhoe Loader Service Repair Manual Instant Download

1
Service Manual 4DX Backhoe Loader Published
by Product Support Department, JCB India
Limited 23/7, Mathura Road, Ballabhgarh
121004 INDIA Tel [phone] Fax [phone]
2309051 Part No 550/42914
General Information 1 Care Safety 2
Routine Maintenance 3
Attachments A Body Framework B
Electrics Controls
C D
Hydraulics Transmission
E F
Brakes Steering
G H
Engine
K
2
Section 1
General Information
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 3 - 1
- Hydraulics 3 - 3
- Transmission 3 - 4
3
Section 1 General Information Section 1
1-1 Machine Identification 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.
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Section 1 General Information Section 1
1-2 Unit Identification 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.
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Section 1 General Information Section 1
1-3 Front Axle Serial Plate Unit Identification 1-3
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.
7
Section 1 General Information Section 1
2-1 Torque 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 Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
1/4 (6.3) 7/16 14 1.4 10
5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size (mm) Hexagon (A/F) mm Torque Settings Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Rivet Nut Bolts/Screws Bolt Size (mm)
Torque Settings (for steel rivet nuts) Nm kgf
m lbf ft
M3 (3) 1.2 0.12 0.9
M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5
Note All bolts used on JCB machines are high
tensile and must not be replaced by bolts of a
lesser tensile specification.
8
Section 1 3-1
General Information Special Tools
Section 1 3-1
Service Tools Section B Body Framework
9
Section 1 3-2
General Information Special Tools
Section 1 3-2
Service Tools Section B Body Framework
10
Section 1 General Information Section 1
3-3 Special Tools 3-3
Service Tools
Section E Hydraulics
11
Section 3 2-5
Routine Maintenance Coolants
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. Keep waterside heat transfer surfaces
clean and free of scale and corrosion deposits.
This maintains designed heat transfer efficiency
and prevents overheating of engines. 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.
12
Section 3 Routine Maintenance Section 3
2-6 Engine Preservation 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).
Manufacturer Bharat Petroleum Hindustan Petroleum Indian Oil Corporation Castrol India Veedol Tide Water Oil Co.
Engine Lub. Oil Fuel System Bharat Preserve Oil 30 Oil 30 Autoprun T 120 Servo Preserve 30 Or Servo Run N Oil 30 Veedol 30 / 40
Engine Cooling System Bharat Sherol B Emulsion With Water Ratio 120 Koolkit 40 5 Emulsion With Water Servo Cut 5 20 Emulsion With Water. Veedol Amul Kut 4 Emulsion With Water Ratio 1 20
Unpainted Ferrous Metal Parts Bharat Rustol 152 Rustop 274 Servo Rp 125 Rustilo DW 904 Or DW 901 Veedol Raspro 1t

• 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.
• 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.

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Section 3 Routine Maintenance Section 3
3-1 Greasing 3-1
Greasing Greasing must be done regularly to keep
the machine working efficiently. Regular
greasing lengthen the machines working
life. 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.
Loader Arms For each grease point there is
another on the other side of the machine. 11
grease points each side - Total 22 grease points.
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Section 3 Routine Maintenance Section 3
3-2 Greasing 3-2
Backhoe A - Standard Dipper 27 Grease
Points B - Extending Dipper - 27 Grease
Points Not Do not grease the kingpost mounting
rails.
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Section 3 Routine Maintenance Section 3
3-3 Greasing 3-3
Front Axle (2 Wheel Drive Machines) 11 Grease
Points
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Section 3 Routine Maintenance Section 3
3-4 Greasing 3-4
Front Axle ( 4 Wheel Drive Machines ) 5 Grease
Points
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Section 3 Routine Maintenance Section 3
3-5 Greasing 3-5
Rear Propshaft 3 Grease Points
Front Propshaft ( 4 Wheel drive ) 3 Grease Points
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Section 3 Routine Maintenance Section 3
3-6 Greasing 3-6
6 - in - 1 Clamshovel For each grease point there
is another at the other end of the bucket. 3
grease points on each side Total 6 grease points.
Backhoe Quick-Hitch For grease points 2 3 there
is another on the opposite side of the
Quick-Hitch (4 and 5). Total 5 grease points
Loader Quick-Hitch 2 grease points each
side Total 4 grease points.
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Section 3 Routine Maintenance Section 3
3-7 Greasing 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.
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Section 3 Routine Maintenance Section 3
3-8 Oiling 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.
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Section 3 Routine Maintenance Section 3
4-1 Engine Air Filter 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.
1
Remove the Cover 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. 3 Fit the Bowl Carefully set the bowl in
position on the air filter. Fit and tighten the
wingnut.
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Section 3 Routine Maintenance Section 3
4-2 Engine Air Filters 4-2
Renew Outer Element CAUTION 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. Note Do not run the engine
with rain-cap, pre-cleaner or dust valve removed.
Renew Inner Element 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.

• Prevent dust from entering the engine by
  disconnecting the induction hose.
• Unlock Clips B and lift off cover C. Remove Outer
  Element.
• Press and Rotate Anti-clockwise to unlock the
  Filter
• F.
• Carefully remove inner element.
• Clean inside of canister H and dust valve J.
• Insert new inner element and lock it in place by
  presssing and rotating clockwise
• Insert new outer element B and test seating of
  seal
• D as previously described.
• If the seal is correct, re-insert new outer
  element.
• Reconnect the induction hose. Ensure that the
  restriction indicator sensor is reconnected.

1. Gently pull out the Outer element D.
2. Clean inside canister H, Cover C and dust valve
   J.
3. Fit new element D. Test seating of seal K by
   smearing with grease and checking for witness
   mark at base of canister.
4. If the seal is correct, re-insert new outer
   element and clamp the cover.
5. Ensure that dust valve J is at the bottom when
   refitting.
6. Check the security and condition of the induction
   hose and its clips. Ensure that the restriction
   indicator is fitted properly and reset / its
   sensor is connected.

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Section 3 Routine Maintenance Section 3
4-3 Engine Oil and Filter 4-3
Check Level
Change Oil Filter CAUTION 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.
1.
Make sure that the oil level is between the two
marks on the dipstick A.
2.
If necessary, top up with JCB recommended oil
through filler point B. Replace dipstick.
3.

• 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).
• Change the filter
• Unscrew oil filter canister D.
• Clean the filter head E.
• Smear the new filter canister seal F with engine
  oil.
• Screw in the new filter canister - hand tight
• only.
• Fill the engine with new oil. Wipe off any spilt
  oil. Check the system for leaks.
• Replace filler cap.

24
Section 3 4-4
Routine Maintenance Fan Belt
Section 3 4-4

• Fan Belt
• Check Tension Adjustment
• Park the machine on level ground.
• Loosen bolts A, B, C, and D holding the
  alternator.
• Reposition the alternator unit belt deflection at
  point X is approximately 10 15 mm ( with
  moderate thumb pressure, 45N or 4.6 kgf.
• 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.
• Note If a new belt is fitted, the belt tension
  must be checked again after the first 20 hours of
  operation.

Section 3
Routine Maintenance
Section 3
25
4-5
Fuel Tank
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. This will prevent overnight condensation
from developing in the fuel. 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.
Section 3 Routine Maintenance Section 3
4-6 Fuel Filters 4-6
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Moisture Separator 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
Fuel Filter 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
• Operate the Fuel lift pump X till fuel flows
  without air bubbles
• 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
28
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available for immediate download. https//www.ebo
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