jcb 3CX Manuals

Manuals and User Guides for jcb 3CX. We have 9 jcb 3CX manuals available for free PDF download: Service Manual, Operator's Manual

jcb 3CX Service Manual

jcb 3CX Service Manual (891 pages)

Backhoe Loader

Brand: jcb | Category: Other | Size: 39.2 MB

Table of Contents

Machine Nomenclature
2
Colour Coding
3
Table of Contents
4
Machine Identification Plate
5
Typical Vehicle Identification Number (VIN)
5
Serial Plates
6
Torque Settings
7
Service Tools Numerical List
8
- 12V Mobile Oven
  11
- Body & Framework
  11
  - Cartridge Gun
    11
  - Hand Cleaner
    11
  - Service Tools - Body and Framework
    11
  - 240V Static Oven
    12
  - Glass Extractor (Handles)
    12
  - Glass Lifter
    12
  - Wire Starter
    12
  - Braided Cutting Wire
    13
  - Long Knife
    13
  - Nylon Spatula
    13
  - Rubber Spacer Blocks
    13
  - AVO Test Kit
    14
  - Battery Tester
    14
  - Service Tools - Electrics
    14
  - Socket for Alternator Pulley Nut
    14
  - Electrical Repair Kit
    15
  - Flow Test Equipment
    16
  - Hydraulic Circuit Pressure Test Kit
    16
  - Pressure Test Adapters
    16
  - Service Tools - Hydraulics
    16
  - Bonded Washers
    17
  - Hand Pump Equipment
    17
  - Male Adapters
    17
  - Valve Spool
    17
  - Female Cone Blanking Plug
    18
  - Female Connectors
    18
  - Male Cone Blanking Cap
    18
  - Piston Seal Assembly Tool
    19
  - Ram Seal Protection Sleeves
    19
  - Replacement Plastic Boss
    19
  - Seal Fitting Tool
    19
  - Bearing Press
    20
  - Drive Coupling Spanner
    20
  - Fitting Tool Assembly
    20
  - Torque Measuring Tool for Wheel Hub Seals
    20
- Transmission
  20
  - Adapter - Impulse Extractor
    21
  - Impulse Extractor Set for Hub Bearing Seals
    21
  - Measuring Cup
    21
  - Splined Bolt Socket for Driveshafts
    21
  - Bearing Pad Driver
    22
  - Flange Spanner
    22
  - Service Tools - Transmission
    22
  - Torque Multiplier
    22
  - Powershift Gearbox Flow Test Adaptor
    23
  - Synchro Shuttle Gearbox
    23
  - Flow Test Equipment List
    24
  - Hydraulic Circuit Pressure Test Kit - List
    24
  - Solid Spacer Setting Kit
    26
  - Spacer Kit
    26
  - Powershift
    27
  - Speed Sensor Test Harness
    27
  - Thrust Washer Kit
    27
  - Transmission Jack
    27
  - Powershift Gearbox - 6 Speed (Shiftmaster) Electronic Service Tool Kit
    28
  - Adaptor for Compression Testing (AK, AM, AR)
    29
  - De-Glazing Tool for Cylinder Bores
    29
- Issue
  29
  - Lifting Wire Assembly
    29
  - Service Tools - Engine
    29
  - Sealing and Retaining Compounds
    30
  - Care & Safety
    31
  - Safety Notices
    32
  - General Safety
    33
  - Operating Safety
    34
  - Maintenance Safety
    35
  - Routine Maintenance
    38
  - First Aid - Oil
    41
- Hygiene
  41
  - Lubricants - Health and Safety
    41
  - Spillage
    41
  - Waste Disposal
    41
  - Pre-Start Cold Checks
    42
- Service Schedules
  42
- Checking for Damage
  46
- Cleaning the Machine
  47
  - Engine Panels
    48
  - Opening and Closing the Bonnet
    48
- Removing and Fitting a Side Panel
  48
- Loader Arms
  50
- Backhoe & Quickhitch
  51
- Front Axle (2 Wheel Drive Machines)
  52
- Front Axle (4 Wheel Drive Machines)
  52
- Front Axle (All Wheel Steer Machines)
  53
  - Rear Axle (All Wheel Steer Machines)
    53
  - Driveshafts
    54
- Extending Dipper
  54
  - 6 - in - 1 Clamshovel
    55
  - Loader Quickhitch
    55
  - Stabilisers (Centremount Machines)
    55
  - Kingpost
    56
- Power Sideshift
  56
- Backhoe Quickhitch (Hydraulic)
  57
- Knuckle (if Fitted)
  57
- Checking the Wheel Nut Torques
  58
  - Tyre Inflation
    58
  - Tyres and Wheels Maintenance
    58
  - Brakes Maintenance
    59
- Checking the Foot Brake Fluid Level
  59
- Changing the Oil and Filter
  61
- Checking the Oil Level
  61
- Engine Oil and Filter Maintenance
  61
- Changing the Coolant
  62
- Checking the Coolant
  62
- Engine Cooling System Maintenance
  62
- Adjusting the Fan Belt
  63
- Cleaning the Cab Heater Filter
  63
- Advice
  64
- Fuel Standards
  64
- Fuel System Maintenance
  64
- Low Temperature Fuels
  64
- Petrol
  64
- Types of Fuel
  64
- Changing the Filter Element
  65
- Draining the Filter
  65
- Filling the Tank
  65
- Bleed the System
  66
- Draining the Sediment Bowl
  66
- Checking the Fluid Level
  70
- Hydraulic System Maintenance
  70
- Hydraulic Tank Cap
  70
- Changing the Filter Element (Hydraulic System)
  71
- Changing the Suction Strainer
  72
- Checking the Differential Oil Level
  73
- Front and Rear Axle (All Wheel Steer Machines) Maintenance
  73
- Changing the Hub Oil
  74
- Checking the Hub Oil Levels
  74
- Changing the Oil
  75
- Checking the Oil Level
  75
- Front and Rear Axle (Two Wheel Steer Machines)
  75
  - Battery Maintenance
    76
  - Battery: Warning Symbols
    76
- Checking the Electrolyte Level
  77
- First Aid - Electrolyte
  77
- Battery Isolator
  78
- Cleaning the Tubes/Fins
  79
- Hydraulic Oil Cooler
  79
- Stabiliser Legs (Sideshift Machines Only)
  80
- Wear Pad Adjustment
  80
- Adjusting the Compressor Drive Belt
  81
- Air Conditioning Maintenance
  81
- Checking Hose Burst Protection Valve
  82
- Hose Burst Protection Valve (if Fitted)
  82
- Lowering a Load
  82
- Service Capacities and Lubricants
  83
- Coolant Mixtures
  84
  - Body & Framework
    86
  - Body & Framework: Service Tools
    88
- Slide Hammer Kit Procedure
  91
- Rivet Nut Tool Procedure
  92
  - Air Conditioning Data
    93
  - Body and Framework: Technical Data
    93
  - Body & Framework - Basic Operation
    94
  - Air Conditioning
    95
  - R-134A Refrigerant
    95
  - System Operation
    95
- Air Conditioning
  96
- Basic Operation
  96
- System Control
  96
- System Operation
  96
- Technical Data Air Conditioning (Option)
  96
- Safety Procedures (Air Conditioning System)
  97
- Fault Finding
  98
  - General Fault Indications (Air Conditioning)
    98
  - Sight Glass Indications
    98
  - Fault Finding (Air Conditioning)
    99
  - No Air Conditioning
    99
  - Air Conditioning - System Diagnosis
    100
  - Normally Functioning A/C System
    100
  - Low R-134A Charge
    101
  - Poor Refrigerant Circulation
    101
- System Diagnosis
  101
- Wiring Continuity Checks
  105
- Air Conditioning: Service Procedures
  106
- Checking Refrigerant Charge Level
  106
- Leak Testing
  106
- Tightening Leaking Hoses
  106
- Refrigerant Charging and Discharging
  107
  - Refrigerant Recovery
    107
  - Evacuating (Vacuuming)
    108
  - Electronic Vacuum Gauge
    109
  - Relubricating
    110
  - Refrigerant Charging
    111
- Binary Pressure Switch Testing
  112
- Condenser Matrix Cleaning
  113
- Filters - Changing and Cleaning
  114
- Compressor Drive Belt - Adjusting
  115
- Glazing
  116
- Removing Broken Glass and Old Sealant
  116
  - Preparing the Cab Frame Aperture
    118
  - Preparing the New Glass
    119
  - Installing the New Glass
    120
- Cab ROPS/FOPS Structure - Checks
  122
- Engine Panels - Removing and Fitting
  123
- Stabiliser Leg - Wear Pad Adjustment
  124
- Stabiliser Legs Wear Pads
  124
- Extending Dipper - Wear Pad Adjustment
  125
  - Inspecting the Top Wear Pads
    125
  - Adjusting the Bottom Wear Pads
    126
- Sideshift - Hydraclamp Clearance Setting
  127
- Power Sideshift - Wear Pad Renewal
  128
- Power Sideshift - Chain Adjustment
  129
- Air Conditioning Hvac*/Air Conditioning Unit - Removal and Replacement
  131
- Freeze Protection Thermostat
  131
- Alternator
  155
- Electrics: General Electrical Data
  155
- System Type
  155
- Technical Data
  155
  - Fuses and Relays
    156
  - Link Box Fuses
    158
  - Relays
    158
  - Circuit Schematic - Basic Machine
    159
- Basic System Operation
  160
  - Circuit Schematic - Powershift
    163
  - Circuit Schematic - Synchro Shuttle
    163
  - 2 Wheel Steer/Brake Mode
    165
  - 2 Wheel Steer/Brake Mode (Germany)
    165
  - Circuit Schematics - Options
    165
  - Steer Mode - 4CX and 3CX Super (4X4X4)
    165
  - S Mode Schematics
    166
  - Steermode 3CX Super (4X4X4) Schematics
    166
  - All Wheel Steer/Brake Mode Schematics
    167
  - Auxiliary and Hydraclamp Hydraulics Schematics
    167
  - Speedometer Schematics
    167
- All Wheel Steer/Brake Mode
  168
- Auxiliary and Hydraclamp Hydraulics
  168
- Speedometer
  168
- Dedicated Quickhitch
  169
- Hand Held Tools
  169
- Hydraulic Speed Control (HSC)
  169
- Pole Planter
  169
- Return to Dig (Shovel Reset)
  169
- Smooth Ride System (SRS)
  169
  - Autoshift Transmission Schematics
    171
  - Circuit Schematics - 6 Speed Powershift (Shiftmaster)
    171
- Speed Powershift (Shiftmaster)
  172
- Measuring Continuity
  179
- Measuring DC Voltage
  179
- Measuring Resistance
  179
  - Testing a Diode or a Diode Wire
    181
  - Battery - Maintenance
    182
  - Battery Safety
    182
  - Battery Testing
    183
- Specific Gravity Testing
  183
  - Alternator - Charging Test
    184
  - Alternator - General Description
    184
  - Alternator - Service Precautions
    184
- Starter Motor
  185
- Starting Circuit Test
  185
- Repair Procedure
  187
- Wiring Harness
  187
  - Alternator Removal and Replacement
    190
  - Starter Motor Diagram
    191
  - Starter Motor Inspection
    192
  - Starter Motor Removal and Replacement
    192
- Earth Points
  193
- Harness Data Drawings
  193
- Removal and Replacement
  232
- Shovel Reset (214E Machines)
  235
  - Shovel Reset Diagrams
    235
  - Shovel Reset (214E Machines Only)
    236
  - Return to Dig Diagram
    237
  - Return to Dig Adjustment
    238
  - Return to Dig Operation
    238
  - Precision Control (Servo) - Basic System Operation
    239
  - Precision Control (Servo) - Component Location
    239
- Circuit Description
  240
- Electrical Connections
  244
- Renewing the Pilot Supply Valve Oil Filter
  250
- Testing the Pilot Pressure
  250
- Pilot Hose Removal and Replacement
  252
- Seat Arms Control Lever - Adjustment
  253
- Basic System Operation
  260
- Component Location
  260
- Circuit Description
  261
- Component Identification
  261
- Hydraulic Operation
  262
- Pump Dump Controller (Power Management ECU)
  265
- Joystick Controllers - Description
  266
- Servo Pressure Supply Valve - Description
  267
  - Precision Control (Servo) Fault Finding
    268
  - Chart A: no Servo Controls (System Fails to Operate)
    269
- Dismantling and Assembly
  269
- Service Procedures - Testing the Servo Pressure
  276
- Loader Valve Controls
  279
- Excavator Valve Controls (JCB + Pattern)
  281
- Cab Heater Controls
  283
- Control Cables Removal and Replacement
  283
- Stabiliser Controls
  285
- Boom Lock Cable
  287
- Boom Stop Setting
  288
- Engine Throttle Cable
  289
- Auxiliary Footpedal Cable
  291
  - Hydraulics
    292
  - Hydraulics Service Tools
    297
- Service Tools
  300
- Fixed Flow
  301
  - Hydraulic Pumps
    301
  - Hydraulics Technical Data
    301
- Variable Flow
  303
- Loader Valve - Fixed Flow
  304
- Relief Valve Pressures
  304
- Loader Valve - Precision Control (Servo)
  305
- Machines up to Serial No. 931159
  305
- Loader Valve - Variable Flow
  307
- Excavator Valve - Fixed Flow
  308
- Excavator Valve - Precision Control (Servo)
  309
- Auxiliary Valve - Fixed Flow
  311
- Smooth Ride System
  312
- Basic System Operation
  319
- Introduction to Hydraulic Schematic Symbols
  319
- Circuit Schematics Fixed Flow
  325
- Machines from January 2003
  339
- Double Pump - Operation
  342
- Hydraulic Pump - Fixed Flow
  342
  - Hydraulics - Circuit Descriptions
    342
  - Single Pump - Operation
    342
- Hydraulic Pump - Variable Flow
  344
- Operation
  344
- Pressure/Flow Regulator Valve
  346
- Arms Lower
  358
- Float
  358
  - Loader Valve - A.R.V. Operation
    359
  - Main Relief Valve (MRV) - Operation
    362
  - Pilot Valve Opens
    362
  - Valve at Rest
    362
  - Valve Moves off Its Seat
    362
  - Loader Valve - Variable Flow Operation
    363
  - Priority Inlet Section Operation
    364
  - Auxiliary Spool
    366
  - Loader Shovel Spool
    367
  - Loader Lift Spool
    368
  - Shuttle Valve Signal Network
    369
- Excavator Valve
  370
  - Manual Control - Neutral Circuit
    370
  - Excavator Valve - Load Hold Check Valves
    373
  - Excavator Valve - One Way Restrictor Operation
    374
  - Excavator Valve - Slew Operation
    374
  - Excavator Valve - A.R.V. Operation
    377
  - Excavator Valve - Slew A.R.V. and Anti-Cavitation Operation
    377
  - Pilot - Operated Pressure Relief Valve Operation
    378
  - Excavator Valve - Manual Control
    380
  - Hydraclamp Valve Operation (Sideshift Machines)
    380
  - Excavator Valve - Precision Control (Servo) (Machines up to Serial No. 931159)
    381
  - Load Sense (Isolator Compensator) Valve Operation
    384
  - No Service Is Selected (All Spools in Neutral)
    384
  - Spool at Point of Operating a Service
    384
  - Spool Fully Operating a Service
    384
  - Clamps Locked up
    385
  - Clamps Pressurised
    385
  - Clamps Released
    385
  - Hydraclamp Valve Operation
    385
  - Excavator Valve - Precision Control (Servo (Machines from January 2003)
    386
  - No Service Selected
    386
  - Servo Spool Actuation
    386
  - When a Service Is Selected
    386
  - Load Sense - Pressure Compensator Valves Operation
    387
  - Operating an Individual Service
    390
  - Operating Multiple Services
    390
  - Smooth Ride System Diagram
    391
  - Boom & Dipper Operation
    393
  - Hose Burst Protection Valve
    393
  - Operation 1 - Load Raise
    393
  - Operation 2 - Load Lower
    393
  - Operation 3 - Relief Valve
    396
  - Operation 4 - Hose Burst Condition
    396
  - Hose Burst Protection Valve - Loader Operation
    397
  - Hydraulic System - Fixed Flow
    401
  - Hydraulics: Fault Finding
    401
  - Lack of Power in All Hydraulic Functions
    401
  - All Hydraulic Rams Slow to Operate
    402
  - One Hydraulic Service Fails to Operate or Is Slow to Operate
    402
  - The Engine Tends to Stall When Hydraulics Are under Load
    402
  - A Spool Is Sticking
    403
  - Leaking Oil Seal (Control Valves)
    403
  - Ram Creep
    403
  - Hydraulic Oil Becomes too Hot
    404
  - Hydraulic System - Variable Flow
    405
  - Smooth Ride System Fault Finding
    407
  - Contaminant Standards
    408
  - Hydraulic Contamination
    408
  - Hydraulic Fluid Quality
    408
  - Hydraulics - Service Procedures
    408
  - Checking Flow
    410
  - Fitting/Removing a Flow Meter and Load Valve
    410
  - Fixed Flow Pumps
    410
  - Flow and Pressure Testing
    410
  - Variable Flow Pumps - Flow and Pressure Testing
    411
  - Load Sensing Pressure
    412
  - Stand-By Pressure
    412
  - Maximum Hydraulic Stall
    413
  - Load Sense Line Flow
    414
  - Pump Flow
    414
  - Flow Regulator Spool
    415
  - Pressure Regulator Spool
    415
  - Regulator Valve Adjustment
    415
  - Renewing Drive Shaft Seal
    417
  - Shuttle Valve Signal Network - Testing
    418
  - Loader Valve - Pressure Testing
    419
  - Main Relief Valve (M.R.V.)
    419
  - Unloader Valve
    420
  - Hydraulic Speed Control (HSC)
    421
  - Auxiliary Relief Valves - Using Hand Pump
    422
  - Excavator Valve - Precision Control (Servo (Machines up to Serial No. 931159) - Pressure Testing
    427
  - Load Sense Drain Regulator and Relief Valve
    427
- Precision Control (Servo)
  427
- Manual Control
  447
- Machines from January 2003
  501
- Precision Control (Servo)
  501
- Flow Regulator Valve
  502
- JCB Ram Sealing Procedure
  536
- System Type
  813
- Basic System Operation
  814
- Pedals Locked - Compensating Operation
  814
- Pedals Locked - Normal Operation
  814
- Pedals Unlocked - Normal Operation
  814
- Brake System Fault Finding
  815
- Brake Light Switch - Adjustment
  818
- Brakes - Service Procedures
  818
- Brake Piston Seal Leakage Test
  819
- Parking Brake - Testing
  820
  - Cable Adjustment
    821
  - Lever Adjustment
    821
  - Parking Brake - Adjustment
    821
  - Renewing a Worn or Damaged Cable
    821
  - Parking Brake - Switch Adjustment
    822
  - Pad Inspection
    823
  - Pad Removal
    823
  - Pad Replacement
    823
  - Parking Brake - Renewing the Brake Pads
    823
  - Master Cylinder and Servo Unit Removal and Replacement
    825
  - Master Cylinder and Servo Unit Dismantling and Assembly
    826
  - Service Brakes Dismantling and Assembly
    827
  - Service Brakes Bleeding
    828
  - Parking Brake - Torque Figures
    829
  - Parking Brake - Calliper Removal and Replacement
    830
  - Parking Brake Diagram
    831
- Calliper Dismantling and Assembly
  832
- Parking Brake Assembly
  834
- Brake Disc - Removal and Replacement
  835
  - Steering
    836
  - Steering - Service Tools
    837
  - Steering Technical Data
    838
- System Type
  838
- Wheel Steer Machines
  838
- 2 Wheel Steer Machines
  839
- Steer System Schematics
  839
- Proximity Switch - Setting
  868
- Steer Mode Valve - Checking Solenoid Operation
  869
- Priority Valve - Cleaning
  870
  - Priority Valve - Standby Pressure Testing
    871
  - Power Track Rod Removal and Replacement
    872
- Link Arms - Removal and Replacement
  873
- Rams Dismantling and Assembly
  875
- Rams - Dismantling and Assembly
  876
  - Priority Valve Bleeding
    877
  - Priority Valve Dismantling and Assembly
    877
  - Priority Valve Removal and Replacement
    877
  - Steer Mode Valve Removal and Replacement
    878
  - Steer Mode Valve Dismantling and Assembly
    879
  - Hydraulic Steer Unit Removal and Replacement
    880
  - Hydraulic Steer Unit Diagram
    881
  - Hydraulic Steer Unit Dismantling and Assembly
    882
  - Pressure Relief Valve Cartridge
    883
  - Shock Valves
    883
  - Engine
    884
  - Engine - Service Tools
    885
  - Engine Technical Data
    886
  - Engine Service Procedures
    887
  - Fuel Lift Pump - Cleaning the Strainer
    887
  - Engine Removal
    889
  - Engine Replacement
    890

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Table of Contents

General Information

5
- Table of Contents
  5
- Machine Identification Plate
  6
- Typical Vehicle Identification Number (VIN)
  6
- Typical Engine Identification Number
  6
- Serial Plates
  7
- Torque Settings
  8
- Service Tools Numerical List
  9
- Service Tools
  12
  - Body & Framework
    12
  - Electrics
    15
  - Hydraulics
    17
  - Transmission
    28
  - Engine
    32
- Sealing and Retaining Compounds
  33
Section 3 Section 3 Routine Maintenance

41
- Checking for Damage
  
  44
- Cleaning the Machine
  
  45
- Seat Belt
  
  46
  - Checking the Seat Belt Condition and Security
    46
- Fire Extinguisher (When Fitted)
  
  46
  - Checking the Fire Extinguisher
    46
- ROPS/FOPS Structure
  
  47
  - Checking the ROPS/FOPS Structure
    47
- Tyres and Wheels
  
  48
  - Tyre Inflation
    48
  - Checking the Wheel Nut Torques
    48
- Lubricants - Health and Safety
  
  49
  - Hygiene
    49
  - Storage
    49
  - Waste Disposal
    49
  - Handling
    49
  - First Aid - Oil
    49
  - Spillage
    49
  - Fires
    49
- Service Schedules
  
  50

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