jcb 3CX, Service Manual

Page 1: ...echanical photocopying or otherwise without prior permission from JCB SERVICE World Class Customer Support S2 eng Publication No Issued by JCB Technical Publications JCB Service World Parts Centre Bea...

Page 2: ...214 215 217 VARIANTS Backhoe Loader From M c No 930000 Onwards From M c No 903000 Onwards USA PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE WORLD PARTS CENTRE WATERLOO PARK UTTOXE...

Page 3: ...ne The remaining sections are alphabetically coded and deal with Dismantling Overhaul etc of specific components for example A Attachments B Body Framework etc The page numbering in each alphabeticall...

Page 4: ...tral circuit pressure and M R V operating pressure Pressure Pressure that is above neutral circuit pressure but lower than that denoted by red Servo Oil pressure used in controlling a device servo Neu...

Page 5: ...dentification Number VIN 1 1 Typical Engine Identification Number 1 1 Serial Plates 1 2 Torque Settings 2 1 Service Tools Numerical List 3 1 Service Tools Body Framework 4 1 Electrics 4 4 Hydraulics 4...

Page 6: ...umbers can help identify exactly the type of equipment you have 1 1 Typical Vehicle Identification Number VIN SLP 3CX T S V E 930000 A B C C D D E E F F G G A World Manufacturer Identification B Machi...

Page 7: ...e D Rear Axle 4WS machine E Synchro Shuttle Transmission F Powershift Transmission G Engine Section 1 General Information 9803 3280 Section 1 1 2 Issue 1 E E F F G G A A S257580 A401030 S260120 B B C...

Page 8: ...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...

Page 9: ...Pressure Test T Adapter 4 6 816 60096 Adapter 4 8 823 10420 Shim Kit Powershift gearbox layshaft clutch 4 17 825 00410 Crowfoot Wrench 4 4 825 99833 Adapter for 825 00410 4 4 826 01099 Rivet Nut 4 1...

Page 10: ...892 01033 Electronic Service Tool Kit 4 18 892 01079 Ring Socket Spanner Mainshaft setting ring 4 13 892 01080 Ring Socket Spanner Layshaft setting ring 4 13 892 01077 Synchro Shuttle Gearbox Selector...

Page 11: ...UNF 4 3 993 68109 Adaptor M20 x M12 4 3 993 68110 Adaptor M20 x 5 8 UNF Shoulder 4 3 993 68111 Adaptor M20 x 1 2 UNF 4 3 Section 1 General Information 9803 3280 Section 1 3 3 Issue 5 Service Tools Nu...

Page 12: ...1310 454g 1 lb tub S186240 826 01099 M6 x 16mm Rivet Nut 826 01101 M6 x 19mm Rivet Nut 826 01103 M8 x 18mm Rivet Nut 826 01102 M8 x 21mm Rivet Nut 826 01104 M10 x 23mm Rivet Nut 826 01105 M10 x 26mm...

Page 13: ...g supplied Note 110V models available upon request contact JCB Technical Service JCB part number 992 12400 2 Cartridge x 240V 992 12600 6 Cartridge x 240V Wire Starter used to access braided cutting w...

Page 14: ...8102 End Stops 7 993 68107 Bar M20 x M20 X 800MM 3 993 68103 Adaptor M20 x 5 8 UNF 8 993 68108 Adaptor M20 x 7 8 UNF 4 993 68104 Adaptor M20 x 1 UNF 9 993 68109 Adaptor M20 x M12 5 993 68105 Adaptor M...

Page 15: ...VO Test Kit 1 892 00283 Tool Kit Case 2 892 00298 Fluke Meter 85 3 892 00286 Surface Temperature Probe 4 892 00284 Venture Microtach Digital Tachometer 5 892 00282 100 amp Shunt open type 6 892 00285...

Page 16: ...Housing 5B 7214 0004 4 Way Pin Retainer 5C 7214 0003 4 Way Socket Retainer 5D 7214 0001 4 Way Socket Connector 6A 7216 0002 6 Way Pin Housing 6B 7216 0004 6 Way Pin Retainer 6C 7216 0003 6 Way Socket...

Page 17: ...00263 5 8 in M BSP x 5 8 in F BSP x Test Point 892 00264 3 4 in M BSP x 3 4 in F BSP x Test Point 892 00265 1 in M BSP x 1 in F BSP x Test Point 4 6 Section 1 General Information 9803 3280 Section 1...

Page 18: ...Section 1 4 7 Issue 1 Service Tools cont d Section E Hydraulics 892 00881 Valve Spool Seal Fitting Tool Components for Valve Block A R V Testing For 4CX Variable Flow machines use 25 201103 892 00309...

Page 19: ...816 00294 1 4 in BSP 816 00189 3 8 in BSP 816 00190 1 2 in BSP 816 00197 5 8 in BSP 816 00196 3 4 in BSP 816 00193 1 in BSP S193880 892 00047 3 8 in BSP A x 1 4 in BSP B 892 00048 1 2 in BSP A x 1 4 i...

Page 20: ...01020 For 50 mm Rod Diameter slew ram 892 01021 For 60 mm Rod Diameter 892 01022 For 60 mm Rod Diameter slew ram 892 01023 For 65 mm Rod Diameter 892 01024 For 70 mm Rod Diameter 892 01025 For 75 mm R...

Page 21: ...pling Spanner for front axle and gearbox yoke couplings S196720 S188200 A 892 00920 Flow Test Adapter B 892 00301 Flow Test Adapter C 892 00302 Flow Test Adapter S266880 S188160 A B C Torque Measuring...

Page 22: ...t transmission S197070 4 11 Section 1 General Information 9803 3280 Section 1 4 11 Issue 1 Service Tools cont d Section F Transmission 892 00817 17 mm A F x 3 4in square drive 892 00818 22 mm A F x 3...

Page 23: ...ltiplier use in conjunction with a torque wrench to give a 5 1 multiplication when tightening pinion nuts S197030 Test Point 1 892 00964 Test point 1 8 BSP Powershift 2 892 00965 Test point 3 8 BSP Po...

Page 24: ...ners A396590 A396600 892 01078 Synchro Shuttle Gearbox Mainshaft Adjuster A396510 892 01079 Mainshaft setting ring 892 01080 Layshaft setting ring A313250 7 1 3 6 5 2 4 Powershift Gearbox Flow Test Ad...

Page 25: ...hydraulic system tests 892 00268 Flow Monitoring Unit 892 00269 Sensor Head 0 100 l min 0 22 UK gal min 892 00293 Connector Pipe 892 00270 Load Valve 1406 0021 Bonded Washer 1604 0006 Adapter 3 4 in M...

Page 26: ...4 15 Section 1 General Information 9803 3280 Section 1 4 15 Issue 3 Service Tools cont d Section F Transmission 1 2 8 9 7 6 5 A396950 3 4 A396580 A396930 A396960 A396940 1a 1b 1c...

Page 27: ...921 53302 13 675 921 53303 13 700 921 53304 13 725 921 53305 13 750 921 53306 13 775 921 53307 13 800 921 53308 13 825 921 53309 13 850 Spacer thickness mm 829 30953 13 675 829 30954 13 650 829 30955...

Page 28: ...moved with torque converter housing fitted to gearbox Manufacture locally for details see Section F Service Tools Service Tools cont d Section F Transmission 823 10420 Thrust Washer Kit Powershift gea...

Page 29: ...ises 1A Data Link Adaptor DLA enables data exchange between the machine ECU Electronic Control Unit and a laptop PC loaded with the applicable ShiftMaster diagnostics software 2A Interconnecting cable...

Page 30: ...601Z 2 5 Reaction Tube 998 10614 1 6 ModifiedWheel Stud 998 10624 2 7 Wheel Bearing Carrier Puller 998 10615 2 8 Nut M20 1370 0701Z 4 9 Washer M20 1420 0012Z 2 10 Puller Rod 998 10610 2 11 Nut M12 137...

Page 31: ...neral Information 9803 3280 Section 1 4 20 Issue 1 Service Tools cont d Section H Steering S216230 892 00180 Seal Fitting Tool for fitting O ring and kin ring to Hydraulic Steer Unit 892 00181 Replace...

Page 32: ...ne removal S219080 892 00041 De glazing Tool for Cylinder Bores to assist bedding in of new piston rings S192390 For details of other engine service tools refer to the Engine Service Manual publicatio...

Page 33: ...02 1951 50ml Threadlocker A locking fluid for use on threads larger than 50mm dia 4101 0451 50ml Activator A cleaning primer which speeds the curing rate 4104 0251 1ltr of anaerobic products 4104 0253...

Page 34: ...i Section 2 Care Safety 9803 3280 Section 2 i Issue 1 Contents Page No Safety Notices 1 1 General Safety 2 1 Operating Safety 3 1 Maintenance Safety 4 1...

Page 35: ...s If proper precautions are not taken it is highly probable that the operator or others could be killed or seriously injured INT 1 2 1 WARNING Denotes a hazard exists If proper precautions are not tak...

Page 36: ...RNING Care and Alertness All the time you are working with or on the machine take care and stay alert Always be careful Always be alert for hazards INT 1 3 5 WARNING Clothing You can be injured if you...

Page 37: ...n exhaust extension If you begin to feel drowsy stop the machine at once Get out of the cab into fresh air INT 2 1 10 WARNING ROPS FOPS Structure The machine is fitted with a Roll Over Protection Stru...

Page 38: ...el fuel in storage tanks the petrol will rise to the top and form flammable vapours INT 3 1 6 WARNING Battery A battery with frozen electrolyte can explode if it is used or charged Do not use a machin...

Page 39: ...components under pressure from springs This will protect against eye injury from components accidently flying out GEN 6 2 CAUTION Rams The efficiency of the rams will be affected if they are not kept...

Page 40: ...g Dipper Lubricant JCB Extradig dipper lubricant contains 1 53 lead The repeated swallowing of very small quantities can cause chronic lead poisoning Do not smoke or touch food while handling this lub...

Page 41: ...6 Spillage 1 6 Fires 1 6 Service Schedules 2 1 Loader Arm Safety Strut Installing and Removing 2 4 Engine Panels Opening and Closing the Bonnet 2 5 Removing and Fitting a Side Panel 2 6 Removing and F...

Page 42: ...ent Bowl 3 22 Cleaning the Fuel Lift Pump Strainer 3 24 AK and AR Build Engines Only Bleed the System 3 25 Fuel Pipes Removal and Replacement 3 26 RE and RG Build Engines Only Synchro Shuttle Gearbox...

Page 43: ...s 4 2 First Aid Electrolyte 4 3 Checking the Electrolyte Level 4 3 Battery Isolator if fitted 4 4 Stabiliser Legs Sideshift Machines Only Wear Pads 5 1 Wear Pad Adjustment 5 1 Extending Dipper Wear Pa...

Page 44: ...e undamaged and secure Check for broken or cracked window glass Replace damaged items Check all bucket teeth for damage and security Check all lamp lenses for damage Inspect the tyres for damage and p...

Page 45: ...such as straw grass wood shavings etc must not be allowed to accumulate within the engine compartment or in the propshaft guards when fitted Please inspect these areas frequently and clean at the begi...

Page 46: ...he belt mounting bolts are undamaged correctly fitted and tightened Section 3 Routine Maintenance 9803 3280 Section 3 1 3 Issue 1 Seat Belt S170520 Fire Extinguisher when fitted Checking the Fire Exti...

Page 47: ...re for checking the ROPS FOPS structure is described in the Body Framework section Refer to Section B Body Framework Service Procedures Cab ROPS FOPS Structure Checks Section 3 Routine Maintenance 980...

Page 48: ...hnical Data for recommended tyres and pressures for your machine Use an air hose fitted with a self locking air chuck and remote shut off valve 3 Add the Air Make sure that the air hose is correctly c...

Page 49: ...are no special precautions needed for the handling or use of new oil beside the normal care and hygiene practices Used Oil Used engine crankcase lubricants contain harmful contaminants Here are preca...

Page 50: ...ssion Strainer Clean Drive Shafts Security Grease Steer Axle Movement Shimming Check Steer Axle Pivots and Linkages Grease Front Axle Main Pivot Grease HYDRAULICS Oil Level Check Oil Sample Change Oil...

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