JCB 3CX, 4CX, 5CX Backhoe Loader Service Repair Manual Instant Download 1

1
Foreword
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
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
Handling 06 - Body and Framework 09 - Operator
Station
and Load
12 -
Heating, Ventilating and Air-
Conditioning (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
2
15 - Engine 54 - Flywheel 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-217 Component Identification
............................. 15-218 Remove and
Install .....................................
15-219
Flywheels are used to provide continuous energy
in systems, where the energy source is not
continuous. 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.
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.
9813/6950-3
15 - 217
3
15 - Engine 54 - Flywheel 00 - General
Component Identification Figure 329. 2 1

1. Flywheel
2. Flywheel gear ring

9813/6950-3
15 - 217
4
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5
15 - Engine 54 - Flywheel 00 - General
Remove and Install
Before Removal
3. Get access to the engine.

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.

Removal 1. Remove the bolts and withdraw the
flywheel from the crankshaft hub. The bolts MUST
NOT be reused. Discard the bolts.
Figure 330.
2
1
3
1
T3
1 Flywheel 3 Flywheel location dowel
2 Flywheel fixing bolts (x8) Y Angle tightening
mark
6
15 - Engine 54 - Flywheel 00 - General

• Installation
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Make sure that all items are clean and free from
  damage and corrosion.
• Align the flywheel location dowel.
• 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 (de- grees)
2 (Ist Stage) 40
2 (2nd Stage) 120
2 (Final Stage) 120
7
15 - Engine 54 - Flywheel 03 - Housing
03 - Housing Remove and Install
Special Tools

1. Remove the flywheel. Refer to (PIL 15-54).
2. Remove the starter motor. Refer to (PIL 15-75).

Description Part No. Qty.
Template for Sealant Flywheel Housing to Gear Case (4 Cyl Elec ) 892/12349 1
Removal

1. Remove the flywheel housing fixing bolts and
   then separate the flywheel housing from the gear
   case.
2. If required, undo the bolts and remove the access
   cover.
3. Remove and discard the crankshaft rear oil seal.
   Take care not to damage the seal bore in the
   housing.

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.
8
15 - Engine 54 - Flywheel 03 - Housing
Figure 331.
1 5
4
Z
3
Y
Y
2
6 7
X
2
Y
T4
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.

1. Use a suitable degreasing agent to clean the
   inside of the flywheel housing.
2. 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.

9
15 - Engine 54 - Flywheel 03 - Housing
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
15min
After Installation

• Install a new crankshaft rear oil seal.
• Install the flywheel.
• Install the starter motor.
• Table 112. Torque Values

Item Nm
4 47
5 24
7 24

• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Make sure that all items are clean and free from
  damage and corrosion.
• Make sure that the dowels are installed to the
  mating face of the flywheel housing.
• 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.
• Special Tool Template for Sealant Flywheel
  Housing to Gear Case (4 Cyl Elec ) (Qty. 1)
• Use the template T4 as a guide, apply a
  continuous bead of sealant around the flywheel
  housing mating face
• Length/Dimension/Distance 1.5mm
• 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.
• Remove the three fixing bolts at positions.
  Remove the template T4, make sure not to smudge
  the sealant. Discard the template.
• 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.
• Remove the alignment pins to install the last
  two M10 fixing bolts.
• The parts must be separated, thoroughly cleaned
  and fresh sealant applied if the parts have not
  been torque tightened within the maximum time
  period.
• Duration 15min
• Install the access cover and use the bolts to
  secure. Tighten the bolts to the correct torque
  value. Refer to Table 112.

10
15 - Engine 54 - Flywheel 09 - Gear Ring
09 - Gear Ring Remove and Install CAUTION Wear
eye protection when you drive the gear ring off
the flywheel.
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.
Installation

• Make sure that all items are clean and free from
  damage and corrosion.
• 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 above
• Temperature 200C (391.7F)
• When sufficiently heated, install the gear ring
  into position over the flywheel. Make sure that
  the gear ring is installed the correct way
  around.

If the flywheel gear teeth are damaged or
excessively worn, the gear ring can be replaced
with a new one.
Before Removal

• This procedure requires service parts. Make sure
  you have obtained the correct service parts
  before you start.
• Remove the flywheel from the crankshaft hub.
• Figure 332.
• X

After Installation 1. Install the flywheel to the
crankshaft hub.
2
1

• Flywheel
• Gear ring
• x Position of hole
• Removal
• 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.
• Place the flywheel flat on a firm surface. Drill
  a hole through the gear ring below the root of
  one

11
15 - Engine 60 - Oil Pump 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-227 Component Identification
............................. 15-228 Check
(Condition) ......................................
.. 15-230 Remove and Install .....................
................ 15-231
The oil pump is a rotor type pump located inside
the timing gear case. The pump is driven by
gears via the crankshaft.
The pump consists 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.
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 opens. Further rotation causes
the gap between the lobes to diminish, forcing
the oil out through the outlet port. 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.
9813/6950-3
15 - 227
12
15 - Engine 60 - Oil Pump 00 - General
Component Identification
Figure 333. 5
1
1
3 2
4
5
1
8 8a 7 7a
4
9
6

• 1 Oil pump
• 3 Inner rotor
• 5 Outlet port
• Relief valve spring
• Relief valve spool
• Oil pump connecting ports (engine bed plate)

2 Outer rotor 4 Inlet port 6 Relief valve
assembly 7a Relief valve port (return to inlet
port 4) 8a Relief valve pressure port (connected
to port 5)
9813/6950-3
15 - 227
13
15 - Engine 60 - Oil Pump 00 - General
Figure 334.
10
10 CCV Anti drain back valve
9813/6950-3
15 - 227
14
15 - Engine 60 - Oil Pump 00 - General

• Check (Condition)
• Check the oil pump internal parts for signs of
  damage and excessive wear.
• 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.

9813/6950-3
15 - 227
15
15 - Engine 60 - Oil Pump 00 - General
Remove and Install
Before Removal
Special Tools
Description Part No. Qty.
Torque Wrench (10-100Nm) 993/70111 1

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).

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.
Figure 335. Y
4
3
X
2 1
1 Oil pump 3 Flywheel hub X Crankshaft gear
2 Oil pump fixing bolts (x4) 4 Flywheel hub
fixing bolt Y Oil pump location dowel
9813/6950-3
15 - 227
16
15 - Engine 60 - Oil Pump 00 - General

• Remove
• Remove the flywheel hub fixing bolt.
• Remove the flywheel hub. DO NOT remove the
  crankshaft gear.
• 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
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Make sure that all parts are clean and free from
  damage and corrosion.
• Lubricate the pump rotor with clean engine oil.
• Make sure that the oil pump location dowel
  locates into the hole in the gear timing case.
• 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
• Install the flywheel housing, refer to (PIL
  15-54).
• Install the flywheel to the crankshaft hub, refer
  to (PIL 15-54).
• Install the starter motor, refer to (PIL 15-75).

Item Nm
2 24
4 47
9813/6950-3
15 - 227
17
15 - Engine 84 - Sensor 09 - Knock
3. Tighten the bolt to the correct torque value.
Torque 2226Nm
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
• Get access to the engine.
• Disconnect the electrical connector at the knock
  sensor.
• Remove 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
C
B

• Knock sensor
• Electrical connector
• Bolt
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Make sure that the sensor mates fully with the
  adjacent face on the crankcase.

9813/6950-3
15 - 289
18
15 - Engine 84 - Sensor 14 - Exhaust Manifold
Temperature
14 - Exhaust Manifold Temperature
Introduction
Introduction .....................................
............. 15-290 Operation ...................
.................................. 15-291 Check
(Operation) ......................................
. 15-291 Remove and Install ......................
............... 15-292
The exhaust manifold temperature sensor is
screwed directly into the top of the exhaust
manifold between cylinder 3 and 4 exhaust outlet
ports.
Figure 367. Exhaust manifold temperature sensor
location
9813/6950-3
15 - 289
19
15 - Engine 84 - Sensor 14 - Exhaust Manifold
Temperature
Operation
Check (Operation)
The exhaust manifold temperature sensor measures
the exhaust gas temperature from the engine,
before it reaches the turbocharger. The analogue
voltage signal is 14.5V.
For the full inspection and testing procedure,
refer to the help files in ServiceMaster.
9813/6950-3
15 - 289
20
15 - Engine 84 - Sensor 14 - Exhaust Manifold
Temperature
Remove and Install Special Tools
Description 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
• Get access to the engine.
• Disconnect the electrical connector at the
  exhaust manifold temperature sensor.
• Use the special tool to remove the sensor from
  the exhaust manifold.
• Special Tool Deep Socket (Qty. 1)
• Discard the sealing washer.
• The exhaust manifold temperature sensor is a non-
  serviceable item. If the sensor is faulty or
  damaged it must be renewed.
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Renew the sealing washer.
• Tighten the exhaust manifold temperature sensor
  to the correct torque value.
• Table 138. Torque Values

N
Item Nm
N 45
9813/6950-3
15 - 289
21
15 - Engine 84 - Sensor 16 - Exhaust Manifold
Pressure
16 - Exhaust Manifold Pressure
Introduction
Introduction .....................................
............. 15-293
The exhaust manifold pressure sensor also known
Operation ..................................................... 15-294 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-294 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-295 (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
9813/6950-3
15 - 289
22
15 - Engine 84 - Sensor 16 - Exhaust Manifold
Pressure
Operation
Check (Operation)
1. For 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. The sensor
produces an analogue signal from 14.5V which
informs the ECM of the exhaust manifold
pressure. The voltage output proportional to
pressure is 0.54.5V.
9813/6950-3
15 - 289
23
15 - Engine 84 - Sensor 16 - Exhaust Manifold
Pressure
Remove and Install Special Tools
3. Use the special tool to tighten the exhaust
manifold pressure sensor to the correct torque
value.
Description Part No. Qty.
Deep Socket 892/12351 1
Table 139. Torque Values
Item Nm
1 22.5
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.
2
1

• P1
• Exhaust manifold pressure sensor
• Electrical connector
• P1 Sealing washer
• Remove
• Get access to the engine.
• Disconnect the electrical connector at the
  exhaust manifold pressure sensor.
• Use the special tool to remove the sensor from
  the exhaust manifold.
• Special Tool Deep Socket (Qty. 1)
• Discard the sealing washer.
• The exhaust manifold pressure sensor is a non-
  serviceable item. If the sensor is faulty or
  damaged it must be renewed.
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Renew the sealing washer.

9813/6950-3
15 - 289
24
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25
15 - Engine 84 - Sensor 17 - Temperature and
Manifold Air Pressure (TMAP)
17 - Temperature and Manifold Air Pressure (TMAP)
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.
Introduction .....................................
............. 15-296 Operation ...................
.................................. 15-297 Check
(Operation) ......................................
. 15-297 Remove and Install ......................
............... 15-298
Figure 371.
D
D
D TMAPsensor
15 - 296
9813/6950-3
15 - 296
26
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the link into your browser. The full manual is
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