jcb 3DX Super Service Manual
jcb 3DX Super Service Manual

jcb 3DX Super Service Manual

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SERVICE MANUAL
BACKHOE LOADER
3DX Super, 3DX Xtra, 4DX
EN - 9823/0000 - ISSUE 1 - 01/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

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Summary of Contents for jcb 3DX Super

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 15 - Engine 42 - Rocker and Fittings 00 - General 00 - General Introduction Introduction ..........15-155 The rocker assembly is an indirect valve actuating Technical Data ..........15-156 system consisting of rocker arms and a shaft. Component Identification ......
  • Page 3: Technical Data

    15 - Engine 42 - Rocker and Fittings 00 - General Technical Data (For: JCB Tier 2/3 Mech Engine 4 Cyl) Table 59. Rocker Levers, Rocker Shafts and Tappets Data Valve tip clearances (measured cold): - SA, SB, SC Inlet: 0.19–0.27mm Exhaust: 0.56–0.64mm...
  • Page 4: Component Identification

    15 - Engine 42 - Rocker and Fittings 00 - General Component Identification (For: JCB Tier 2/3 Mech Engine 4 Cyl) Figure 200. 743830 1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7) 3 Rocker shaft - oil feed pedestal fixing bolt (x1)
  • Page 5: Operation

    15 - Engine 42 - Rocker and Fittings 00 - General Operation When the camshaft lobe raises the outside of the rocker arm is permitted to return due to the camshafts rocker arm, the inside presses down on the valve rotation, the inside rises to allow the valve spring to stem to open the valve.
  • Page 6: Check (Condition)

    15 - Engine 42 - Rocker and Fittings 00 - General Check (Condition) 1. Check the rocker shaft and rocker bushings for signs of damage and excessive wear. Measure the rocker shaft diameter and rocker bearing bushes to confirm they are within service limits. Refer to Technical Data.
  • Page 7: Remove And Install

    42 - Rocker and Fittings 00 - General Remove and Install 2. Get access to the engine. (For: JCB Tier 2/3 Mech Engine 4 Cyl) 3. Disconnect and remove the fuel pipes from the fuel injectors, refer to Fuel pipes (PIL 18-96). Before Removal 4.
  • Page 8 15 - Engine 42 - Rocker and Fittings 00 - General 5 Oil feed pedestal (x1) 6 Bridge pieces (x8) 7 Push rods (x8) 15 - 161 9823/0000-1 15 - 161...
  • Page 9: Before Installation

    15 - Engine 42 - Rocker and Fittings 00 - General Remove 1. Remove the rocker shaft fixing bolts. DO NOT withdraw the bolts. Lift the rocker shaft assembly from the cylinder head complete with pedestals still attached. Important: Keep all pedestals and fixing bolts in their original positions.
  • Page 10: Disassemble And Assemble

    42 - Rocker and Fittings 00 - General Disassemble and Assemble 2. Remove the rocker assembly. Refer to (PIL 15-42). (For: JCB Tier 2/3 Mech Engine 4 Cyl) Before Disassembly 1. Remove the rocker cover. Refer to (PIL 15-42). Figure 203. 1 Rocker shaft...
  • Page 11 15 - Engine 42 - Rocker and Fittings 00 - General Disassemble 1. Lift out the rocker shaft fixing bolts, then slide the pedestals, rockers and wave washers off the rocker shaft as shown. Label the pedestals and rockers to make sure that they are installed in the correct positions on assembly.
  • Page 12 Remove and Install 2. Clean the top of the rocker cover and around the fuel injectors. Refer to Engine - Clean (PIL (For: JCB Tier 2/3 Mech Engine 4 Cyl) 15-00). Before Removal 3. Disconnect and remove the fuel pipes from the injectors.
  • Page 13 15 - Engine 42 - Rocker and Fittings 06 - Rocker Cover Remove 1. Get access to the engine. 2. Disconnect the breather hose from the pipe stub. 3. Disconnect the air hose from the turbocharger outlet and inlet manifold. Remove the hose. (For Turbocharged Engine Only) 4.
  • Page 14 15 - Engine 42 - Rocker and Fittings 21 - Tappet 21 - Tappet Figure 205. Remove and Install (For: JCB Tier 2/3 Mech Engine 4 Cyl) Special Tools Description Part No. Qty. Crankshaft / 892/01148 Camshaft Timing Pin (444/448/672 Engine)
  • Page 15 15 - Engine 42 - Rocker and Fittings 21 - Tappet Inspection Figure 207. 1. Inspect the camshaft gear teeth for signs of damage or excessive wear. 2. Inspect the cam lobes for signs of excessive wear, scoring or pitting. 3.
  • Page 16 15 - Engine 42 - Rocker and Fittings 24 - Tappet Cover 24 - Tappet Cover Install 1. The installation procedure is the opposite of the Remove and Install removal procedure. Additionally do the following steps. It is not necessary to remove the tappet covers 2.
  • Page 17 15 - Engine 45 - Oil Sump 00 - General 00 - General Introduction Introduction ..........15-173 The lubrication system distributes oil around the Component Identification ......15-174 engine by a system of galleries and drillings in the crankcase and cylinder head. The oil lubricates and Remove and Install ........
  • Page 18: Component Identification

    15 - Engine 45 - Oil Sump 00 - General Component Identification (For: JCB Tier 2/3 Mech Engine 4 Cyl) Figure 210. Oil sump Suction strainer Oil pump Oil cooler Filter Camshaft - high pressure oil feed Crankshaft main bearings - high pressure oil...
  • Page 19 15 - Engine 45 - Oil Sump 00 - General Remove and Install 2. Drain the engine oil. (For: JCB Tier 2/3 Mech Engine 4 Cyl) Removal Special Tools Description Part No. Qty. 1. Remove the fixing bolts and remove the oil sump from the engine.
  • Page 20 15 - Engine 45 - Oil Sump 00 - General Installation Figure 213. 1. Lightly smear the new oil pick up seal with oil and install into the bedplate as shown. Figure 212. 3 Oil pick up seal 2. Install the two guide pins at the oil sump screw holes in the engine.
  • Page 21 15 - Engine 45 - Oil Sump 00 - General After Replacing 1. Allow the sealant to cure for Duration: 20min 2. Refill the engine with the recommended engine oil. Refer to (PIL 75-00). 3. Start the engine and check for oil leaks. Table 63.
  • Page 22: Timing Gear

    15 - Engine 51 - Timing Gear 51 - Timing Gear Contents Page No. 15-51-00 General ......................... 15-179 15-51-03 Crankshaft Gear ......................15-184 15-51-06 Camshaft Gear ......................15-187 15-51-09 Fuel Injection Pump Gear .................... 15-188 15-51-15 Heavy Duty PTO Gear ....................
  • Page 23 15 - Engine 51 - Timing Gear 00 - General 00 - General Introduction Introduction ..........15-179 The timing gears are located inside a case at the Component Identification ......15-180 flywheel end of the engine. Operation ............. 15-181 The engine must be timed so that the camshaft Check (Condition) ........
  • Page 24 15 - Engine 51 - Timing Gear 00 - General Component Identification (For: JCB Tier 2/3 Mech Engine 4 Cyl) Figure 215. 1 High duty PTO (Power Take-Off) idler gear 2 Idler gear hub 3 Idler gear hub retaining screws (x3)
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