service manual download

1. June 2006 Issue 1
General Information 1
Care & Safety 2
Routine Maintenance 3
Attachments A
Body & Framework B
Electrics C
Controls D
Hydraulics E
Transmission F
Brakes G
Steering H
Engine K
Service
Manual
4DX
Backhoe Loader
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

2. June 2006 Issue 1
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. June 2006 Issue 1
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.

4. June 2006 Issue 1
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.

5. June 2006 Issue 1
Section 1 General Information Section 1
1-3 Unit Identification 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.

6. June 2006 Issue 1
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 Hexagon (A/F) Torque Settings
(mm) mm 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 Torque Settings (for steel rivet nuts)
(mm) 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.

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

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

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

10. June 2006 Issue 1
Section 3 Routine Maintenance Section 3
2-5 Coolants 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°
-20° to –40°
-40° to –69°
33 : 67
50 : 50
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
Total dissolved solids
Chlorides (cl)
Sulphates (so4)
170 ppm (measured as caco3)
340 ppm
50 ppm as cl
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.

11. June 2006 Issue 1
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 1:20
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 m
2
/ 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. Castrol grades are manufactured by M/s Castrol India Limited.
3. HP / Hylub grades are manufactured by M/s Hindustan Petroleum Corporation Limited.
4. Mobil grades are manufactured by M/s Mobil Oil Corporation Limited.

12. June 2006 Issue 1
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 machine’s 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.

13. June 2006 Issue 1
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.

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

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

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

17. June 2006 Issue 1
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.

18. June 2006 Issue 1
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.

19. June 2006 Issue 1
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.

20. June 2006 Issue 1
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.
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.

21. June 2006 Issue 1
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.
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.
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.
1 Prevent dust from entering the engine by
disconnecting the induction hose.
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.

22. June 2006 Issue 1
Section 3 Routine Maintenance Section 3
4-3 Engine Oil and Filter 4-3
Check Level
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.
3. Replace dipstick.
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 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.
3 Fill the engine with new oil. Wipe off any spilt
oil. Check the system for leaks.
4 Replace filler cap.

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24. June 2006 Issue 1
Section 3 Routine Maintenance Section 3
4-4 Fan Belt 4-4
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 Routine Maintenance Section 3

25. June 2006 Issue 1
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

26. June 2006 Issue 1
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.
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.
A
B