Service Manual Midi CX Backhoe Loader Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine
Publication No.
9803/9400-08
World Class Customer Support Copyright © 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1 - General Information Contents Page No. Introduction About this Publication ...............................................................................1 - 1 Using the Service Manual ...................................................................1 - 1 Section Numbering ..............................................................................1 - 1 Units of Measurement .........................................................................1 - 1 Left Side, Right Side ............................................................................1 - 2 Cab/Canopy ........................................................................................1 - 2 Cross References ................................................................................1 - 2 Identifying the Machine .............................................................................1 - 3 Machine Identification Plate ................................................................1 - 3 Component Identification Plates ..........................................................1 - 4 Fuel ..........................................................................................................1 - 7 Types of Fuel .......................................................................................1 - 7 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................1 - 10 Introduction ........................................................................................1 - 10 Bolts and Screws ...............................................................................1 - 10 Hydraulic Connections ............................................................................1 - 14 'O' Ring Face Seal System ................................................................1 - 14 'Torque Stop' Hose System ...............................................................1 - 17 Service Tools Numerical List .........................................................................................1 - 18 Service Aids Sealing and Retaining Compounds ........................................................1 - 20 Terms and Definitions Colour Coding .........................................................................................1 - 21 Hydraulic Schematic Colour Codes ...................................................1 - 21
1-i
1-i
Section 1 - General Information Introduction About this Publication
Introduction About this Publication Using the Service Manual
1
General Information - includes torque settings and service tools.
2
Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3
Maintenance - includes service schedules and recommended lubricants for all the machine.
T11-004
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. 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.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A
Attachments
B
Body and Framework, etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
Units of Measurement T1-001_2
In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).
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 may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first!
Section Numbering T11-005
The manual is compiled in sections, the first three are numbered and contain information as follows:
1-1
9803/9400-08
1-1
Section 1 - General Information Introduction About this Publication
Left Side, Right Side P2-1002
In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. This is so whether you are facing the loader (front) or the backhoe (rear).
A
B
A
B C003690
Fig 1.
Cab/Canopy T1-003_2
This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines.
Cross References T1-004_2
In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-2).
1-2
9803/9400-08
1-2
Section 1 - General Information Introduction Identifying the Machine
Identifying the Machine Machine Identification Plate The machine has an identification plate mounted on the loader tower. 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 unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have.
Typical Vehicle Identification Number (VIN) T025210-1
Fig 2. SLP
Midi
T
S
6
E
972021
1
2
3
4
5
6
7
Typical Product Identification Number (PIN) P2-1006
1
World Manufacturer Identification (SLP = JCB)
2
Machine Model
3
Steer Type (T= 2WS, F= 4WS)
4
Build Type (S=Sideshift, C=Centremount, L=Loader)
1
World Manufacturer Identification (3 Digits)
5
Year of Manufacture:
2
Machine Model (5 Digits)
6 = 2006
3
Check Letter (1 Digit)
T016220-8
Fig 3.
7 = 2007
The Check Letter is used to verify the authenticity of a machine's PIN.
8 = 2008 4
Machine Serial Number (8 Digits)
9 = 2009 Each machine has a unique serial number. 6
Manufacturer Location (E = England)
7
Machine Serial Number
1-3
9803/9400-08
1-3
Section 1 - General Information Introduction Identifying the Machine
Component Identification Plates A Typical Engine Identification Number
Perkins
The full engine serial number is stamped on an identification plate A on the right-hand side of the cylinder block. 404C-22
50262
U
500405
N
1
2
3
4
5
1
LIST NO
TYPE
SERIAL NO
TYPE
Engine Type = 400 series 404C-22 = 4 cylinder, 2.2 litres naturally aspirated 404D-22 = 4 cylinder, 2.2 litres naturally aspirated
2
Build Number
3
Country of Manufacture
Fig 4. Engine
U = United Kingdom 4
Engine Serial Number
5
Year of Manufacture N = 2006 P = 2007
1-4
9803/9400-08
1-4
Section 1 - General Information Introduction Identifying the Machine Transmission Identification Numbers
ROPS/FOPS Certification plate
The transmission components have a serial number stamped on a data plate A as shown.
A
Fig 7. Cab
Fig 5. Front Axle
Machines built to ROPS/FOPS standards have an identification label fitted to the inside of the cab. K Fig 7. ( T 1-5). The FOPS structure provides Level II Impact Protection against falling objects (as defined in ISO 3449:2005). Definition of terms: ROPS Roll Over Protection Structure FOPS
A
Falling Objects Protection Structure
FOPS Data Plate
!MWARNING Fig 6. Rear Axle
Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17
If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. There are two levels of FOPS:
1-5
9803/9400-08
1-5
Section 1 - General Information Introduction Identifying the Machine – Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services. – Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.
1-6
9803/9400-08
1-6
Section 1 - General Information Introduction Fuel
Fuel
!MCAUTION
Types of Fuel Acceptable and Unacceptable Fuels T3-048
Important: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.
Fuel Specification
Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2
Table 1. Applicable Engines
EN590 Diesel fuel types - Auto/C0/C1/C2/ All C3/C4
Service Requirements Obey the maintenance procedures.
BS2869 Class A2
usual routine schedules and
ASTM D975-076 2-D, US DF1, US DF2, US DFA JIS K2204 Grades 1, 2, 3 and Special Grade 3 ASTM D975-076 1-D MIL T38219 JP7 NATO F63 French EN590 (RME5) with 5% maximum
All
Obey the usual routine maintenance schedules and Important: Engines operated with procedures. Fuel additives are these fuels may have a reduced recommended for use with low service life. sulphur fuels(1). K Additives ( T 1-9).
AVTURFSII, NATO F34, JP8, MIL T83133, All DERD 2463, DEF STAN 91-87 AVCAT FSII, NATO F44, JP5, MIL T5624, Important: Engines operated with these fuels may have a reduced DERD 2452, AVTOR service life. NATO F35, JET A1, DEF STAN 91-91, DERD 2494, XF63
Obey the usual routine maintenance schedules and procedures. Fuel additives must be used(1). K Additives ( T 1-9).
AVCAT, NATO F43 (obsolete), JP5 without additives JET A (ASTM D1655) ASTM D3699 Kerosene B5 Biodiesel - RME content blended with Tier 3 only(2). mineral derived diesel (5% maximum) ASTM D6751, DIN 51606, ISO 14214
You must obey special routine maintenance schedules and procedures. K Warranty ( T 1-9).
AVTAG (obsolete)
These fuels are not acceptable with AVTAG FSII (obsolete), NATO F40, JP4, or without additives. Engines must not be operated with these fuels. DERD 2454 JET B (ASTM D1655) BS MA100 JIS K2203 No.2 Unmodified vegetable oils
1-7
9803/9400-08
1-7
Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
Section 1 - General Information Introduction Fuel Additives
tank (or the storage tank). Water will encourage micobacterial growth.
The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They must be used as specified by your fuel supplier who will understand the concentration level necessary.
– Make sure that the fuel pre-filter is drained daily (not every week as currently advised). – Only Tier 3 engines (factory filled with CH4 oil) - this is not approved with other manufacturers. – Use heater kits in low ambient temperature territories.
Important: The lubricity wear scar diameter must not be more than 460 microns, as tested on a high frequency reciprocating rig at 60°C (140°F). Refer to ISO 12156-1. – Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels. – Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm. – Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%). Note: These products are given as examples only. The information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. Service Requirements for use of B5 Biodiesel – The engine oil must be a grade CH4 as minimum specification. – Do not leave unused B5 biodiesel in the fuel tank for extended periods (top up each day).
– The biodiesel must meet the following standards: ASTM D6751, DIN 51606, ISO 14214 Note: If necessary use a test kit to confirm the fuel specification. Testing kits are available (not from JCB currently), use the internet as a source for the kits. Note: If performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, then the fuel system must be filled with standard diesel (at least 2 x tank fills) to EN590 specification and relevant stall speeds recorded prior to making the report. Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Using a B5 blend of biodiesel requires caution and additional servicing of the engine is required. K Service Requirements for use of B5 Biodiesel ( T 1-9).
– Make sure that 1 in 5 fuel tank fills use standard diesel to EN590 specification, this will help to prevent 'gumming'.
Failure to follow the additional recommended service requirements may lead to a warranty claim being declined.
– Make sure regular oil sampling is completed (look for excessive unburnt fuel content, water or wear particles.
Failures resulting by the incorrect use of biodiesels or other fuel additives are not defects of the engine workmanship and therefore will not be supported by JCB Warranty.
– Change the engine oil and filter more frequently (as a minimum half the recommended intervals), or as indicated by oil sampling. – Change the fuel filters more frequently (as a minimum half the recommended intervals), or if there are engine performance related issues. – Make sure the fuel is stored correctly, care must be taken to make sure no water enters the machine fuel
1-9
9803/9400-08
1-9
Section 1 - General Information Introduction Fuel Sulphur Content
Effects of Fuel Contaminates T3-032
T3-033
High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently. K Table 2. Sulphur Content ( T 1-10).
The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment:
Low sulphur fuels must have the appropriate fuel lubricity additives, these lubricity improvers must not create residual deposits that block the fuel system, e.g. injectors, filters etc. Contact your fuel Supplier.
!MCAUTION A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. ENG-3-2
Table 2. Sulphur Content Percentage of sulphur in Oil Change Interval the fuel (%) Less than 0.5
Normal
0.5 to 1.0
0.75 of normal
More than 1.0
0.50 of normal
1-10
– Dirt - A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven running and poor fuel delivery. – Water - Water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt, causing rapid wear, corrosion and in severe cases, even seizure. It is vitally important that water is prevented from reaching the fuel injection equipment. The filter/water trap must be drained regularly. – Wax - Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's cloud point, causing a restriction in fuel flow resulting in rough engine running. Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity and limit wax formation.
9803/9400-08
1-10
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners
Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002
Introduction
Bolts and Screws
Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.
Use the following torque setting tables only where no torque setting is specified in the text.
The two types of fasteners can be readily identified by colour and part number suffix. K Table 3. Fastener Types ( T 1-10).
Torque settings are given for the following conditions:
Fastener Type
Table 3. Fastener Types Colour Part No. Suffix
Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.
Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners
Zinc and Yellow
Golden finish
'Z' (e.g. 1315/3712Z)
Dacromet
Mottled silver finish 'D' (e.g. 1315/3712D)
Condition 2 – Zinc flake (Dacromet) fasteners
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.
– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bolts
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.
1-10
Fig 8. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
9803/9400-08
1-10