SERVICE MANUAL BACKHOE LOADER 3CX, 4CX, 5CX EN - 9813/6950 - ISSUE 3 - 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 06Handling-Body and Framework 09 - Operator Station 12 - Heating, Ventilating and AirConditioning (HVAC) 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
15 - Engine 54 - Flywheel 00 - General 15 - 217 9813/6950-3 15 - 217 00 - General Introduction 15-217 Component Identification 15-218 Remove and Install 15-219
In such cases, the flywheel stores energy when torque is applied by the energy source, and it releases stored energy when the energy source is not applying torque to it.
Introduction Flywheels are used to provide continuous energy in systems, where the energy source is not continuous.
In a reciprocating engine, a flywheel is used to maintain constant angular velocity of the crankshaft. The flywheel, which is mounted on the crankshaft, stores energy when torque is exerted on it by a firing piston, and it releases energy to its mechanical loads when no piston is exerting torque on it.
15 - Engine 54 - Flywheel 00 - General 15 - 218 9813/6950-3 15 - 218 Component Identification Figure 329. 2 1 1 Flywheel 2 Flywheel gear ring
15 - Engine 54 - Flywheel 00 - General 15 - 219 9813/6950-3 15 - 219 Remove and Install Before Removal 1.This procedure requires service parts. Make sure you have obtained the correct service parts before you start. The flywheel is installed with a crankshaft position sensor target disc. DO NOT remove the target disc. If the disc is defective the flywheel must be replaced. 2.Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3.Get access to the engine. Removal 1.Remove the bolts and withdraw the flywheel from the crankshaft hub. The bolts MUST NOT be reused. Discard the bolts. Figure 330. 1 312 T3 1 Flywheel 2 Flywheel fixing bolts (x8) 3 Flywheel location dowel Y Angle tightening mark
15 - Engine 54 - Flywheel 00 - General 15 - 220 9813/6950-3 15 - 220 Installation 1.The installation procedure is the opposite of the removal procedure. Additionally do the following 2.Makesteps.sure that all items are clean and free from damage and corrosion. 3.Align the flywheel location dowel. 4.Renew the fixing bolts. Tighten the new bolts to the correct torque value in three stages. Tighten the bolts in sequence in diagonally opposing pairs. As a visual check, mark the bolts to the flywheel before you start. When the bolts have been angle tightened the marks will appear as at 120° Table 111. Torque Table Item Torque Value (Nm) Angle grees)(de2 (Ist Stage) 40 2 (2nd Stage) 120 2 (Final Stage) +120
15 - Engine 54 - Flywheel 03 - Housing 15 - 221 9813/6950-3 15 - 221 03RemoveHousingand Install SpecialDescriptionTools Part No. Qty. Template for Sealant Flywheel Housing to Gear Case (4 Cyl Elec ) 892/12349 1 Before Removal The flywheel housing is integral with the drive gears front case. When the housing is removed the drive gears will be exposed. DO NOT attempt to remove the camshaft and the drive gears. Removing the camshaft with the engine in the upright position will cause the tappets to dislodge, requiring the engine block to be dismantled. 1.This procedure requires service parts. Make sure you have obtained the correct service parts before you start. 2.Remove the flywheel. Refer to (PIL 15-54). 3.Remove the starter motor. Refer to (PIL 15-75). Removal 1.Remove the flywheel housing fixing bolts and then separate the flywheel housing from the gear 2.Ifcase.required,undotheboltsandremovetheaccess 3.Removecover. and discard the crankshaft rear oil seal. Take care not to damage the seal bore in the housing.
15 - Engine 54 - Flywheel 03 - Housing 15 - 222 9813/6950-3 15 - 222 Figure 331. 4 2 5 1 7 6 3 2X T4Y YY Z 1 Flywheel housing 2 Dowel - 12 mm 3 Dowel - 10 mm 4 Flywheel housing fixing bolts (x6) M10 5 Flywheel housing fixing bolts (x12) M8 6 Access cover 7 Access cover fixing bolts (x2) Y Fixing point X Flywheel housing mating face Z Alternative fixing holes T3 Alignment pins T4 Sealant template Before Installation 1.Carefully remove all traces of the old sealant compound from the flywheel housing mating faces. 2.Use a suitable degreasing agent to clean the inside of the flywheel housing. 3.Carefully inspect all gears, bearings and shafts for signs of excessive wear or damage. If wear or damage is evident, the components must be renewed.
5.Use the template T4 as a guide, apply a continuous bead of sealant around the flywheel housing mating
4 47
2.Install
Installation
Anaerobic sealant will not start to cure whilst it is open to the atmosphere, however when air is excluded (for instance when the two parts are put together) it will immediately start to harden. Make sure that all the necessary tools, bolts etc. are readily available prior to assembling the components. The parts must be installed and torque tightened within5min with a maximum permissible time of
Special Tool: Template for Sealant Flywheel Housing to Gear Case (4 Cyl Elec ) (Qty.: 1)
7.2.The parts must be separated, thoroughly cleaned and fresh sealant applied if the parts have not been torque tightened within the maximum time period.
15 - Engine 54 - Flywheel 03 - Housing 15 - 223 9813/6950-3 15 - 223
7.1.Removethealignmentpinstoinstallthelast two M10 fixing bolts.
Table
Duration: 15min
6.Remove the three fixing bolts at positions. Remove the template T4, make sure not to smudge the sealant. Discard the template.
3.Install
1.The15mininstallation procedure is the opposite of the removal procedure. Additionally do the following
3.Make sure that the dowels are installed to the mating face of the flywheel housing.
8.Install the access cover and use the bolts to secure. Tighten the bolts to the correct torque value. Refer to Table 112. After Installation a new crankshaft rear oil seal. the flywheel. the starter motor. 112. Torque Values Item Nm 5 24 7 24
4.Install the sealant template T4 on the housing. Locate the holes in the template, use the dowel and three fixing bolts in the fixing points.
2.Makesteps.sure that all items are clean and free from damage and corrosion.
5.1.Some engines feature a flywheel housing with a different fixing hole pattern. Use the template to apply the sealant but apply sealant manually in the position shown at Z.
Length/Dimension/Distance:face 1.5mm
1.Install
7.Locate the flywheel housing on the alignment pins T3 on the crankcase and install the fixing bolts. Progressively tighten the bolts to the correct torque value.
3.When sufficiently heated, install the gear ring into position over the flywheel. Make sure that the gear ring is installed the correct way around.
Installation 1.Make sure that all items are clean and free from damage and corrosion.
1.This procedure requires service parts. Make sure you have obtained the correct service parts before you start.
15 - Engine 54 - Flywheel 09 - Gear Ring 15 - 224 9813/6950-3 15 - 224 09 - Gear Ring Remove and Install CAUTION Wear eye protection when you drive the gear ring off the flywheel.
Before Removal
2.Place the flywheel flat on a firm surface. Drill a hole through the gear ring below the root of one of the gear teeth as shown. Drive a chisel into the adjacent tooth to spread the gear ring apart. Take care not to damage the flywheel or the position sensor target disc.
After Installation 1.Install the flywheel to the crankshaft hub.
Iftheflywheelgearteetharedamagedorexcessively worn, the gear ring can be replaced with a new one.
1.Note that the gear teeth have a lead-in chamfer on one side to assist the starter motor pinion to engage. Note which way around the gear ring is installed to make sure that the new gear ring is installed the same way on assembly.
2.Remove the flywheel from the crankshaft hub. Figure 332. 1 2 X 1 Flywheel 2 Gear ring x Position of hole Removal
2.Heat up the new gear ring, preferably in an oven to make sure that the heat is applied evenly around the circumference. Do not heat the gear ring Temperature:above 200°C (391.7°F)
Introduction
When rotated the gap between the inner and outer rotor lobes increases, drawing oil in through the inlet port. After a half rotation the gap reaches a maximum, the inlet port is closed and the outlet port Furtheropens.
The oil pump is a rotor type pump located inside the timing gear case. The pump is driven by gears via the Thecrankshaft.pumpconsists of two rotors, one running inside the other. The outer rotor has one more lobe than the inner rotor and turns on a different axis.
A pressure relief valve assembly is integral with the pump body. As oil pressure increases it acts on a spool to overcome the pressure of the spring. As the spool moves it uncovers a port allowing pressurised oil directly back to the inlet port. In practice the spool is continually opening and closing to maintain the correct oil pressure value. The valve is not adjustable.
rotation causes the gap between the lobes to diminish, forcing the oil out through the outlet port.
15 - Engine 60 - Oil Pump 00 - General 15 - 227 9813/6950-3 15 - 227 00 - General Introduction 15-227 Component Identification 15-228 Check (Condition) 15-230 Remove and Install 15-231
15 - Engine 60 - Oil Pump 00 - General 15 - 228 9813/6950-3 15 - 228 Component Identification Figure 333. 1 1 3 2 4 94 6 1 7 7a 8 8a 5 5 1 Oil pump 2 Outer rotor 3 Inner rotor 4 Inlet port 5 Outlet port 6 Relief valve assembly 7 Relief valve spring 7a Relief valve port (return to inlet port 4) 8 Relief valve spool 8a Relief valve pressure port (connected to port 5) 9 Oil pump connecting ports (engine bed plate)
15 - Engine 60 - Oil Pump 00 - General 15 - 229 9813/6950-3 15 - 229 Figure 334. 10 10 CCV Anti drain back valve
15 - Engine 60 - Oil Pump 00 - General 15 - 230 9813/6950-3 15 - 230 Check (Condition) 1.Check the oil pump internal parts for signs of damage and excessive wear. 2.Use feeler gauges to measure the inner and outer rotor clearance, and the rotor end float to confirm they are within service limits. Refer to: PIL 15-12-00.
15 - Engine 60 - Oil Pump 00 - General 15 - 231 9813/6950-3 15 - 231 Remove and Install SpecialDescriptionTools Part No. Qty. Torque (10-100Nm)Wrench 993/70111 1 The illustrations show the engine inverted. If the oil pump is being removed prior to crankshaft or camshaft removal, the engine must be inverted. If the oil pump only is being removed (for inspection or renewal) then the engine need not be inverted. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. Before Removal 1.Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 2.Drain the oil from the engine, refer to (PIL 15-21). 3.Remove the starter motor, refer to (PIL 15-75). 4.Remove the flywheel, refer to (PIL 15-54). 5.Remove the flywheel housing, refer to (PIL 15-54). Figure 335. X Y 2 1 43 1 Oil pump 2 Oil pump fixing bolts (x4) 3 Flywheel hub 4 Flywheel hub fixing bolt X Crankshaft gear Y Oil pump location dowel
15 - Engine 60 - Oil Pump 00 - General 15 - 232 9813/6950-3 15 - 232 Remove 1.Remove the flywheel hub fixing bolt. 2.Remove the flywheel hub. DO NOT remove the crankshaft gear. 3.Remove the oil pump fixing bolts and lift the oil pump away from the timing gear case. The oil pump is a non-serviceable item. If the oil pump is damaged or worn it must be renewed as a complete assembly. Install 1.The installation procedure is the opposite of the removal procedure. Additionally do the following 2.Makesteps.sure that all parts are clean and free from damage and corrosion. 3.Lubricate the pump rotor with clean engine oil. 4.Make sure that the oil pump location dowel locates into the hole in the gear timing case. 5.Install the flywheel hub into the crankshaft gear, locating on the dowel. Tighten the bolts to the correct torque value. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) After Replacement 1.Install the flywheel housing, refer to (PIL 15-54). 2.Install the flywheel to the crankshaft hub, refer to (PIL 3.Install15-54).thestarter motor, refer to (PIL 15-75). 4.Fill the engine with engine oil, refer to (PIL 15-21). Table 113. Torque Values Item Nm 2 24 4 47
15 - Engine 84 - Sensor 09 - Knock 15 - 289 9813/6950-3 15 - 289 Remove and Install The following procedure is for one knock sensor. The procedure for both sensors is identical. Before Removal 1.Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. Remove 1.Get access to the engine. 2.Disconnect the electrical connector at the knock 3.Removesensor. the bolt and remove the knock sensor from the crankcase. The knock sensor is a non-serviceable item. If the sensor is defective it must be replaced. Figure 366. A B C A Knock sensor B Electrical connector C Bolt Install 1.The installation procedure is the opposite of the removal procedure. Additionally do the following 2.Makesteps.sure that the sensor mates fully with the adjacent face on the crankcase. 3.Tighten the bolt to the correct torque value. Torque: 22–26N·m
15 - Engine 84 - Sensor 14 - Exhaust Manifold Temperature 15 - 290 9813/6950-3 15 - 290 14 - Exhaust Manifold Temperature Introduction 15-290 Operation 15-291 Check (Operation) 15-291 Remove and Install 15-292 Introduction Theexhaustmanifoldtemperaturesensorisscrewed directly into the top of the exhaust manifold between cylinder 3 and 4 exhaust outlet ports. Figure 367. Exhaust manifold temperature sensor location
15 - Engine 84 - Sensor 14 - Exhaust Manifold Temperature 15 - 291 9813/6950-3 15 - 291 Operation The exhaust manifold temperature sensor measures the exhaust gas temperature from the engine, before it reaches the turbocharger. The analogue voltage signal is 1–4.5V Check (Operation) For the full inspection and testing procedure, refer to the help files in ServiceMaster.
15 - Engine 84 - Sensor 14 - Exhaust Manifold Temperature 15 - 292 9813/6950-3 15 - 292 Remove and Install SpecialDescriptionTools Part No. Qty. Deep Socket 892/12351 1 Before Removal 1.Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. Figure 368. A A Exhaust manifold temperature sensor Remove 1.Get access to the engine. 2.Disconnect the electrical connector at the exhaust manifold temperature sensor. 3.Use the special tool to remove the sensor from the exhaust manifold. Special Tool: Deep Socket (Qty.: 1) 4.Discard the sealing washer. The exhaust manifold temperature sensor is a nonserviceable item. If the sensor is faulty or damaged it must be renewed. Install 1.The installation procedure is the opposite of the removal procedure. Additionally do the following 2.Renewsteps. the sealing washer. 3.Tighten the exhaust manifold temperature sensor to the correct torque value. Table 138. Torque Values Item Nm N 45
15 - Engine 84 - Sensor 16 - Exhaust Manifold Pressure 15 - 293 9813/6950-3 15 - 293 16 - Exhaust Manifold Pressure Introduction 15-293 Operation 15-294 Check (Operation) 15-294 Remove and Install 15-295 Introduction The exhaust manifold pressure sensor also known as the manifold absolute pressure sensor is a device that is used to calibrate the fuel delivery on an ECM (Engine Control Module) Controlled engine. The sensor is mounted in the rear section of the rocker cover. Figure 369. C C C Exhaust manifold pressure sensor
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15 - Engine 84 - Sensor 16 - Exhaust Manifold Pressure 15 - 294 9813/6950-3 15 - 294 Operation
Check (Operation) 1.For
The sensor produces an analogue signal from 1–4.5V which informs the ECM of the exhaust manifoldpressure.Thevoltageoutputproportionalto pressure is 0.5–4.5V the full inspection and testing procedure, refer to the help files in ServiceMaster.
The exhaust manifold pressure sensor informs the ECM (Engine Control Module) of the exhaust manifold pressure. To attain an accurate and stable reading the take-off point is piped from the exhaust manifold between cylinders 3 and 4. This is fed to a sample chamber in the corner of the rocker cover where the sensor is screwed directly into the pressure path.
15 - Engine 84 - Sensor 16 - Exhaust Manifold Pressure 15 - 295 9813/6950-3 15 - 295 Remove and Install SpecialDescriptionTools Part No. Qty. Deep Socket 892/12351 1 Before Removal 1.Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. Figure 370. 1 P1 2 1 Exhaust manifold pressure sensor 2 Electrical connector P1 Sealing washer Remove 1.Get access to the engine. 2.Disconnect the electrical connector at the exhaust manifold pressure sensor. 3.Use the special tool to remove the sensor from the exhaust manifold. Special Tool: Deep Socket (Qty.: 1) 4.Discard the sealing washer. The exhaust manifold pressure sensor is a nonserviceable item. If the sensor is faulty or damaged it must be renewed. Install 1.The installation procedure is the opposite of the removal procedure. Additionally do the following 2.Renewsteps. the sealing washer. 3.Use the special tool to tighten the exhaust manifold pressure sensor to the correct torque value. Table 139. Torque Values Item Nm 1 22.5
15 - Engine 84 - Sensor 17 - Temperature and Manifold Air Pressure (TMAP) 15 - 296 9813/6950-3 15 - 296 17 - Temperature and Manifold Air Pressure (TMAP) Introduction .................................................. 15-296 Operation ..................................................... 15-297 Check (Operation) 15-297 Remove and Install 15-298 Introduction The TMAP (Temperature Manifold Air Pressure) sensor is mounted in a port on top of the inlet manifold. It measures the inlet manifold boost air pressure and temperature. The sensor incorporates a piezo-resistive element and resistor. Figure 371. D D D TMAPsensor
