JCB 3DX Backhoe Loader Service Manual 550-42426JCB 3DX Backhoe Loader Service Manual 550-42426
FILE DETAILS:
JCB 3DX Backhoe Loader Service Manual 550-42426
JCB Backhoe Loader 3DX Service Manual
Size: 38 MB
Fomat: PDF
Language: English
Brand: JCB
Type of machine: Backhoe Loader 3DX
Type of document: Service Manual
Model: 550-42426
Page of number: 568
Date modifided:
From: 1484000 To: 1502999
From: 1361000 To: 1389999
From: 1244500 To: 1269999
DESCRIPTION:
JCB 3DX Backhoe Loader Service Manual 550-42426
About this Publication:
This publication is designed for the benefit of JCB Dealer Service Engineers who are receiving, or have received, training by JCB Inida Product Support Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earth moving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 General Information – includes torque settings and service tools.
2 Care & Safety – includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 Routine Maintenance – includes service schedules and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
Table 1.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads the figures may be reduced by one third. ‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing for wards. Machine Nomenclature In this Service Manual, reference is made to machine models,e.g. 3DX.3DX.Super and 3DXL these are Indian model names.
A Attachments
B Body and Framework etc.
TABLE OF CONTENTS:
JCB 3DX Backhoe Loader Service Manual 550-42426
Steering
Basic Operation H-1
2 Wheel Steer Machines H-1
Steering
Service Procedure H-5
Priority Valve – Standby Pressure Testing H-6
Priority Valve – Cleaning H-6
Steering
Power Track Rod H-9
Removal and Replacement H-9
Removal H-9
Rams H-13
Priority Valve H-14
Steering
Hydraulic Steer Unit H-17
Introduction
About this Publication 1-1
Machine Nomenclature 1-1
Machine Identification
Machine Identification Plate 1-3
Kirloskar Engine Identification 1-3
Engine Serial Plate 1-4
Ecomax Engine Identification 1-4
Rear Axle Serial Plate 1-4
Front Axle Serial Plate 1-4
Syncro Shuttle Gearbox Serial Plate 1-5
Service Tools
Tool detail reference 1-6
Section B- Body and Framework 1-6
Section – E Hydraulic 1-8
Section F- Transmission 1-9
Steering 1-14
Safety Notices
Important Information 2-1
The Operator Manual 2-1
Safety Warnings 2-1
Safety Check List 2-2
Safety – Yours and Others 2-2
General Safety 2-2
Operating Safety 2-4
Maintenance Safety 2-7
Safety Decals 2-12
Routine Maintenance
Checking for Damage 3 – 1
Cleaning the Machine 3 – 2
Tyres and Wheels 3 – 3
Tyre Inflation 3 – 3
Health and Safety 3 – 4
Lubricants 3 – 4
Loader Arm Safety Strut 3 – 6
Installing 3 – 6
Fitting 3 – 6
Removing 3 – 6
Engine Panel 3 – 7
Opening and Closing the Bonnet 3 – 7
Engine Panel 3 – 8
Opening and Closing the Bonnet 3 – 8
Service Schedules 3 – 9
Introduction 3 – 9
How to Use the Service Schedules 3 – 9
Pre-start Cold Checks, Service Points and Fluid Levels 3 – 10
Functional Test and Final Inspection 3 – 14
Fluids, Lubricants and Capacities 3 – 16
Coolant Mixtures 3 – 17
Fuels 3 – 18
Greasing 3 – 22
Loader Arms 3 – 22
Front Axle (2 Wheel Drive Machines) 3 – 25
Front Axle (4 Wheel Drive Machines) 3 – 26
6 – In – 1 Clamshovel 3 – 26
Backhoe Quickhitch (Hydraulic) 3 – 28
Oiling 3 – 29
Parking Brake cable 3 – 29
Control Levers 3 – 29
Ecomax Engine 3 – 30
Oil and Filter 3 – 30
Drive Belt 3 – 32
Front End Accessory Drive (FEAD) Belt 3 – 33
Fuel System-Kirloskar Engine 3 – 35
Types of Fuel 3 – 35
Filling the Tank 3 – 36
Draining the Water Seperator and Engine Fuel Filter 3 – 37
Changing the Water Seperator Filter 3 – 37
Changing the Engine Fuel Filter Element 3 – 38
Bleeding the System 3 – 39
Fuel System-Ecomax Engine 3 – 40
Water Separator and Engine Fuel Filter 3 – 40
Changing the Engine Fuel Filter Element 3 – 44
Bleeding the System 3 – 45
Engine Air Filter 3 – 46
Cleaning the Pre Cleaner 3 – 46
Renew Outer Element 3 – 46
Engine Air Filters 3 – 47
Renew Inner Element 3 – 47
Engine Oil Filter 3 – 48
Change Oil and Filter 3 – 48
Section 3 – Maintenance
Contents
3 – ii 3 – ii
Contents Page No
Fan Belt 3 – 49
Check Tension Adjustment 3 – 49
Filling the Tank 3 – 50
Fit the Cap 3 – 50
Fuel Filter 3 – 51
Moisture Separator 3 – 51
Hydraulic 3 – 52
Check Level 3 – 52
Hydraulic System 3 – 53
Changing the Suction Strainern Strainer 3 – 53
Hydraulic Oil Cooler 3 – 53
Replacement 3 – 55
Transmission 3 – 56
Checking the Synchro Shuttle 3 – 56
Axles 3 – 57
Front Axle (All Wheel Steer Machines) 3 – 57
Rear Axle 3 – 59
Brakes 3 – 60
Parking Brake Adjustment 3 – 60
Battery 3 – 61
Checking the Electrolyte Level 3 – 61
First Aid- Electrolyte 3 – 62
Jump Starting The Engine 3 – 62
Hammer Master 360
Technical Data 3-1
Hammer Master Identification 3-2
Major Components 3-3
Basic Operation 3-4
Start-Up 3-4
Raising the Piston 3-5
Piston Stroke 3-6
Torque Settings 3-7
External Components 3-7
Internal Components 3-8
Lubricants 3-9
External Components 3-9
Internal Components 3-10
Service Schedules 3-11
Every 2-4 Hours 3-11
Daily 3-11
Weekly 3-11
Initial 50-100 Hour Service 3-11
Every 500 Hours or Yearly 3-12
Service Procedures 3-13
Tool Bushings 3-13
Side Plates 3-13
Hydraulic Pressure Testing 3-14
Lower Tool Bushing and Tools 3-15
Checking For Excessive Wear (Monthly) 3-15
Lower Tool Bushing 3-16
Side Plates 3-17
Removal 3-17
Swivel Couplings 3-18
Removal and Dismantling 3-18
Assembly and Replacement 3-18
Accumulators 3-19
Removal and Replacement 3-19
Dismantling and Assembly 3-20
Charging 3-21
Pressure Adjusting Valve 3-22
Dismantling and Assembly 3-22
Adjustment 3-23
Tie Rods 3-24
Removal and Replacement 3-24
Inspection 3-24
Valve Body 3-25
Removal and Dismantling 3-25
Assembly and Replacement 3-25
Cylinder 3-26
Removal and Replacement 3-26
Front Head 3-27
Dismantling and Assembly 3-27
Charging Procedure 3-28
Service Procedures
Cab Structure B-1
Direct Glazing B-1
Service Tools
Slide Hammer Kit B-7
Fitting Procedure B-7
Rivet Nuts B-8
Fitting Procedure B-9
Body and Framework
Welding B-10
Cab Seat
Removal and Replacement B-12
Cab Mountings
Removal and Replacement B-13
Removal, Front Mountings B-13
Removal, Rear Mountings B-14
Replacement B-15
Fuel Tank
Removal and Replacement B-16
Fuel Level Sender B-17
Hydraulic Tank
Removal and Replacement B-18
Fluid Level Sight Glass B-19
Stabiliser Legs
Side shift Machines B-20
Removal and Replacement B-21
Centre Mount B-22
Removal and Replacement B-22
Loader Arms B-23
Removal B-24
Replacement B-24
Boom B-26
Removal and Replacement B-27
Dipper B-28
Removal and Replacement B-29
Clearances B-30
Clearance on Backhoe, loader and mainframe B-31
Backhoe
King post and carriage B-32
Removal and Replacement B-33
King post B-33
Side shift Carriage B-35
Service Procedure
Using a Multimeter 1-1
Measuring DC Voltage 1-2
Measuring Resistance 1-2
Measuring Continuity 1-3
Measuring Frequency 1-3
Testing a Diode or a Diode Wire 1-4
Battery 1-5
Maintenance 1-5
First Aid – Electrolyte 1-5
Testing 1-6
Specific Gravity Testing 1-7
Alternator 1-8
General Description 1-8
Service Precautions 1-8
Charging Circuit Test 1-8
Alternator Charging Test 1-9
Starter Motor 1-11
Starting Circuit Test 1-11
Circuit Schematics
Electrical Circuit 1-13
Electrical Circuit 1-14
Maxi Fuses harness 1-15
Electrical harness 1-16
Panel harness 4 WD 1-17
Cab harness -2WD 1-18
Panel harness 4 WD 1-19
Fuses
1-20
Controls
Steering column D-1
Dismantling and Assembly D-2
Dismantle and Assemble D-3
Loader Valve Controls D-3
Excavator Valve Controls D-5
Auxiliary Foot pedal Control D-7
Loader Control Knob D-9
Dismantling and Assembly D-9
Basic System Operation
Component Location and Neutral Circuit Descriptions E-1
Gear pump – Double Pump E-1
Component Location and Neutral Circuit Descriptions E-3
Gear pump – Double Pump E-3
Introduction to Hydraulic Schematic Symbols E-5
General (Basic and Functional Symbols) E-5
Control Valves E-9
Example of Schematic Circuit E-10
Service Procedures
Hydraulic Contamination E-11
Hydraulic Fluid Quality E-11
Effects of Contamination E-11
Cleaning Operation E-11
Contaminant Standards E-12
Filters E-12
Gearpump E-13
Flow and Pressure Testing E-13
Loader Valve – Pressure Testing E-15
Main Relief Valve (MRV) E-15
Unloader Valve E-16
Hydraulic Speed Control (HSC) E-17
Auxiliary Relief Valves – Using Hand Pump E-18
Excavator Valve – Pressure Testing E-23
Auxiliary Relief Valves – Using Hand Pump E-23
Ram Creep Tests – All Services E-24
Quick Release Couplings E-30
Connecting and Disconnecting E-30
Smooth Ride System (SRS) Accumulator E-32
Charging and Discharging E-32
Hose Burst Protection Valves – if fitted E-34
Checking E-34
Lowering a Load – In a Failure Condition E-35
Pressure Testing – Loader Lift Ram E-36
Valve Block Spool Seals E-38
Seal Fitting E-38
`Positional Type’ Hydraulic Adaptors E-41
Fitting Procedure E-41
Hydraulic Schematics
3DX E-43
Fault Finding
E-44
Introduction E-44
Section E – Hydraulics
Contents
E-ii E-ii
Contents Page No
Hydraulic Pump
Gear pump – Operation E-50
Single Pump – Operation E-50
Double Pump E-50
Machines from serial no 964125 (High Pressure) E-51
Hydraulic Speed Control (HSC) E-53
Unloader Valve E-55
Main Relief Valve (MRV) Operation E-56
Main Relief Valve (MRV) E-57
Loader Valve – Neutral Circuits E-59
Neutral Circuit E-59
Unloader Operation – If fitted E-61
Loader Valve-Load Hold Check Valves E-62
Arms Lower Operation E-64
Float E-65
Auxiliary Relief Valve E-68
Loader Valve – ARV Operation E-69
Excavator Valve E-70
Neutral Circuit E-70
Excavator Valve E-72
One Way Restrictor E-72
Excavator Valve – Slew Operation E-73
Slew Ram End Damping E-75
Slew ARV and Anti-Cavitation Operation E-76
Excavator Valve – ARV Operation E-76
Auxiliary Relief Valve Operation E-77
Auxiliary Relief Valve Anti-cavitation E-78
Excavator Valve – Dipper Make-Up Check Valve and Anti-Cavitation Operation
E-79
Hydra clamp (Sideshift Machines) E-81
Smooth Ride System (SRS) – if fitted E-83
Smooth Ride System E-83
Technical Data
Machine Hydraulics E-86
Gear pump E-87
Loader Valve Block E-88
Main Relief Valve E-88
Excavator valve Block E-89
Backhoe E-89
Service Procedures
Hydraulic Contamination E-90
Hydraulic Fluid Quality E-90
Effects of Contamination E-90
Cleaning Operation E-90
Hydraulic Pump E-91
Flow and Pressure Testing E-91
Main Relief Valve (MRV) E-92
Auxiliary Relief Valves – Using Hand Pump E-94
Loader valve (Unloader valve) E-98
Shovel Ram Rod Side ARV Pressure Testing E-98
Hydraulics E-100
Ram Creep Tests – All Services E-100
Section E – Hydraulics
Contents
E-iii E-iii
Contents Page No
Valve Block Spool Seals E-103
Seal Fitting E-103
Smooth Ride System (SRS) Accumulator E-106
Charging and Discharging E-106
Hydraulic Pump E-107
Removal and Replacement E-107
Hydraulic Pump E-108
Valves E-111
Removal and Replacement E-111
Main Relief Valve (MRV) E-111
Auxiliary Relief Valves (ARV’s) E-112
Unloader Valve E-114
Standard Spool E-116
Float Spool E-118
Excavator Valve E-120
Auxiliary Relief Valves E-122
Hydra clamp valve Dismantling and Assembly E-123
Loader Valve
Removal and Replacement E-126
Dismantle and Assemble E-128
Main Relief Valve (MRV) E-128
Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV) E-130
Unloader Valve E-132
Standard Spool E-134
Float Spool E-136
Electric Detent Spool E-138
Excavator Valve
Removal and Replacement E-140
Dismantle and Assemble E-142
Valve Block E-142
Auxiliary Relief Valves (ARV’s) E-145
Hydraclamp Valve (Sideshift Machines) E-147
Hoses and Pipes (Sideshift Valve) E-149
Hoses and Pipes (Centremount Valve) E-151
Hydraulic Rams
Precautions During Use E-152
Installation E-152
Caution During Use E-152
Maintenance, Inspection Points E-152
Removal and Replacement E-154
Loader Shovel Ram E-154
Loader Lift Ram E-156
Bucket Crowd Ram E-159
Slew Ram E-161
Stabiliser Ram (Sideshift) E-164
Priority Valve E-166
When Dismantling E-166
Dipper Ram E-168
Boom Ram E-170
JCB Ram Sealing Procedure E-172
Section E – Hydraulics
Contents
E-iv E-iv
Contents Page No
Smooth Ride System E-174
Accumulator E-174
Replacement E-174
Accumulator E-175
Inspection E-175
Dismantling and Assembly – Slew Ram E-178
Assembly – Slew Ram E-178
Torque Settings E-178
Brakes
Technical Data G-1
Brakes
Basic Operation G-3
Master Cylinder G-3
Compensating Master Cylinder G-4
Pedals Locked – Normal Operation G-4
Pedals Locked – Compensating Operation G-4
Pedals Unlocked – Normal Operation G-4
Brakes
Fault Finding Without compensatory G-7
Fault Finding componsatory G-9
Brakes
Service Procedure G-13
Service Brakes G-13
Parking Brake – Adjustment G-17
Bleeding G-20
Park Brake Caliper G-22
Dismantling and Assembly G-22
Steering
Basic Operation H-1
2 Wheel Steer Machines H-1
Steering
Service Procedure H-5
Priority Valve – Standby Pressure Testing H-6
Priority Valve – Cleaning H-6
Steering
Power Track Rod H-9
Removal and Replacement H-9
Removal H-9
Rams H-13
Priority Valve H-14
Hydraulic Steer Unit H-17
Hydraulic steer unit EATON H-18
Disassembly H-21
Reassembly H-23
Steering
Power Track Rod H-27
Removal and Replacement H-27
Removal H-27
Rams H-31
Priority Valve H-33
Steering
H-35
Fault Finding Contents H-35
Steering
H-39
Neutral H-39
Operation 1 – Neutral H-39
Load Sensing Dynamic Signal Non Load Reaction H-45
VLC Priority Valve (BOPV) H-46
Steering
Technical Data H-47
Engine
Removal and Replacement K-1
Removal K-2
Replacement K-3
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