JCB 4DX Backhoe Loader Service Repair Manual Instant Download

General Information

1

Care & Safety

2

Routine Maintenance 3

Service Manual 4DX Backhoe Loader

Attachments

A

Body & Framework

B

Electrics

C

Controls

D

Hydraulics

E

Transmission

F

Brakes

G

Steering

H

Engine

K

Published by

Product Support Department, JCB India Limited 23/7, Mathura Road, Ballabhgarh – 121004 INDIA Tel: 0091 129 4299251 Fax 0091 129 2309051

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 -

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Body & Framework Hydraulics Transmission

3-1 3-3 3-4

Issue 1

Section 1

General Information

1-1

Machine Identification

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.

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Issue 1

Section 1 1-2

General Information

Section 1 1-2

Unit Identification

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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Issue 1

Section 1 1-3

General Information Unit Identification

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.

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Issue 1

General Information

Section 1 2-1

Section 1 2-1

Torque

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

(mm)

Hexagon (A/F) in

Torque Settings Nm 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

(mm)

Hexagon (A/F) mm

Torque Settings Nm kgf m

lbf ft

(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

5 9 21 42 72 180 352 607 1205 2105

Metric Grade 8.8 Bolts Bolt Size M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

0.7 1.2 3.0 5.7 10 25 48 84 166 291

Rivet Nut Bolts/Screws Bolt Size M3 M4 M5 M6 M8 M10 M12

(mm)

Torque Settings (for steel rivet nuts) Nm kgf m lbf ft

(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

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Section 1 3-2

General Information Special Tools

Section 1 3-2

Service Tools Section B – Body & Framework

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Section 1 3-3

General Information Special Tools

Section 1 3-3

Service Tools Section E – Hydraulics

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Routine Maintenance

Section 3 2-5

Section 3 2-5

Coolants

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.

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Routine Maintenance

Section 3 2-6

Section 3 2-6

Engine Preservation

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

Hindustan Petroleum

Indian Oil Corporation

Engine Lub. Oil & Fuel System

Bharat Preserve Oil 30 Oil 30

Autoprun T – 120

Engine Cooling System

Bharat Sherol – Koolkit 40 B Emulsion With 5% Emulsion Water Ratio 1:20 With Water

Servo Preserve 30 Or Servo Run – N Oil 30 Servo Cut – 5 20% Emulsion With Water.

Unpainted Ferrous Metal Parts

Bharat Rustol 152

Manufacturer

Rustop 274

Servo Rp 125

Castrol India

Veedol Tide Water Oil Co. Veedol 30 / 40

Rustilo DW – 904 Or DW – 901

Veedol Amul Kut 4 Emulsion With Water Ratio 1 : 20 Veedol Raspro 1t

Notes: 2

Rust protective film coverage: 15 – 20 m / lt., when machine is to be transported by sea.

Following rust protective coating can be applied on stevedore special machines: 1.

Castrol Rustilo DWX – 32 or rustguard rust preventive oil P – 219.

2.

3.

Castrol grades are manufactured by M/s Castrol India Limited.

HP / Hylub grades are manufactured by M/s Hindustan Petroleum Corporation Limited.

4. Mobil grades are manufactured by M/s Mobil Oil Corporation Limited.

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Issue 1

Section 3 3-1

Routine Maintenance

Section 3 3-1

Greasing

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.

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.

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11 grease points each side Total 22 grease points.

Issue 1

Section 3

Routine Maintenance

3-2

Section 3 3-2

Greasing

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

3-3

Section 3 3-3

Greasing

Front Axle (2 Wheel Drive Machines) 11 Grease Points

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Section 3

Routine Maintenance

3-4

Section 3 3-4

Greasing

Front Axle ( 4 Wheel Drive Machines ) 5 Grease Points

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Section 3 3-5

Routine Maintenance

Section 3 3-5

Greasing

Rear Propshaft 3 Grease Points

Front Propshaft ( 4 Wheel drive ) 3 Grease Points

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Section 3 3-6

Routine Maintenance

Section 3 3-6

Greasing

6 - in - 1 Clamshovel

Backhoe Quick-Hitch

For each grease point there is another at the other end of the bucket.

For grease points 2 & 3 there is another on the opposite side of the Quick-Hitch (4 and 5).

3 grease points on each side Total 6 grease points.

Total 5 grease points

Loader Quick-Hitch 2 grease points each side Total 4 grease points.

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Section 3

Routine Maintenance

3-7

Section 3 3-7

Greasing

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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Issue 1

Section 3 3-8

Routine Maintenance Oiling

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.

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Issue 1

Section 3 4-1

Routine Maintenance

Section 3 4-1

Engine Air Filter

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.

2

Empty and Clean the Bowl

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

4-2

Section 3 4-2

Engine Air Filters

Renew Outer Element

Renew Inner 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.

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.

* Note: Do not run the engine with rain-cap, pre-cleaner or dust valve removed.

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 / it’s sensor is connected.

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1

Prevent dust from entering the disconnecting the induction hose.

engine

2

Unlock Clips B and lift off cover C. Remove Outer Element.

3

Press and Rotate Anti-clockwise to unlock the Filter F.

4

Carefully remove inner element.

5

Clean inside of canister H and dust valve J.

6

Insert new inner element and lock it in place by presssing and rotating clockwise

7

Insert new outer element B and test seating of seal D as previously described.

8

If the seal is correct, re-insert new outer element.

9

Reconnect the induction hose. Ensure that the restriction indicator sensor is reconnected.

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Section 3 4-3

Routine Maintenance

Section 3 4-3

Engine Oil and Filter

Check Level

Change Oil & Filter

1.

Make sure that the oil level is between the two marks on the dipstick A.

2.

If necessary, top up with recommended oil through filler point B.

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.

3.

Replace dipstick.

JCB

1

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).

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.

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3

Fill the engine with new oil. Wipe off any spilt oil. Check the system for leaks.

4

Replace filler cap.

Issue 1

Section 3

Routine Maintenance

4-4

Section 3 4-4

Fan Belt

Fan Belt Check Tension Adjustment 1

Park the machine on level ground.

2 Loosen bolts A, B, C, and D holding the alternator.

3 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.

4

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 June 2006

Routine Maintenance

Section 3 Issue 1

4-5

4-5

Fuel Tank

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 4-6

June 2006

Routine Maintenance

Section 3 4-6

Fuel Filters

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 1. Loosen the air vent screw A on the primary fuel filter as shown 2. Operate the Fuel lift pump X till fuel flows without air bubbles 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

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