jcb 3CX User manual

SERVICE MANUAL
BACKHOE LOADER
3CX, 4CX, 5CX, 5CX Wastemaster Eco
EN - 9813/6900 - ISSUE 6 - 09/2018
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
Handling
06 - Body and Framework
09 - Operator Station
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

15 - Engine
12 - Crankshaft
00 - General
15 - 73 9813/6900-6 15 - 73
00 - General
Introduction .................................................... 15-73
Technical Data ............................................... 15-74
Component Identification ............................... 15-75
Operation ....................................................... 15-76
Check (Condition) .......................................... 15-77
Remove and Install ....................................... 15-78
Introduction
Figure 285.
B
A
ACrankcase
BCrankshaft

15 - Engine
12 - Crankshaft
00 - General
15 - 74 9813/6900-6 15 - 74
Technical Data
Table 100.
Main bearing journal diameter (x4)
- min 87.98mm
- max 88mm
Main rear bearing journal diameter (x1)
- min 99.98mm
- max 100mm
Connecting rod bearing journal diameter
- min 72.98mm
- max 73mm
Maximum wear and ovality on journals(1)
Crankshaft induction hardness 55 HRc min on surface
Thrust washer width
- min 2.44mm
- max 2.5mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
(1) No visible damage/wear or marks

15 - Engine
12 - Crankshaft
00 - General
15 - 75 9813/6900-6 15 - 75
Component Identification
Figure 286.
B
A
ACrankcase
BCrankshaft

15 - Engine
12 - Crankshaft
00 - General
15 - 76 9813/6900-6 15 - 76
Operation
Lubrication
Oil is fed from the main gallery via five drillings, one
to each of the main bearings. A groove around the
diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 287.
1Main gallery 2Drillings (x5)
3Main bearings 4Big end bearings
5Cross drillings 6Crankshaft gear
7Crankshaft oil seal 8Crankshaft oil seal

15 - Engine
12 - Crankshaft
00 - General
15 - 77 9813/6900-6 15 - 77
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 288.
A
AMain bearing shells
2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 289.
B
BCrankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
Figure 290.
D
C
CJ-jets
DFixing screws

15 - Engine
12 - Crankshaft
00 - General
15 - 78 9813/6900-6 15 - 78
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4 L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
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. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
25. Remove the bedplate, refer to (PIL 15-09).
Remove
1. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.

15 - Engine
12 - Crankshaft
00 - General
15 - 79 9813/6900-6 15 - 79
Figure 291.
C
B
A
A
AThrust Washers BCrankshaft
CRear main bearing
2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
4. Carefully lift out the bearing shells.
Figure 292.
D
DMain bearing shells
5. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
then install cooling J jets as follows:

15 - Engine
12 - Crankshaft
00 - General
15 - 80 9813/6900-6 15 - 80
Figure 293.
F
E
EJ jets (x4)
FFixing screws
3.1. Insert the cooling jets into the crankcase.
3.2. Note: There are different types of cooling
jets installed depending on the engine
application. The jets are colour coded.
3.3. Be sure to install the correct jets. Refer to
the relevant parts catalogue for the correct
cooling jet identification.
3.4. Tighten the retaining screws to the correct
torque value.
4. Install the upper bearing shells as follows:
Figure 294.
D
G
DMain bearing shells
GBearing location tab
4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
4.3. Important: Make sure that the oil-way holes
in the bearing saddles align with the holes
in the bearing shell. If the holes are even
partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:

15 - Engine
12 - Crankshaft
00 - General
15 - 81 9813/6900-6 15 - 81
Figure 295.
C
B
A
A
A
H
AThrust washers BCrankshaft
CRear main bearing HOil slot - thrust washers
6.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).
Table 101. Torque Values
Item Nm
F 24

15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 82 9813/6900-6 15 - 82
03 - Main Bearing
Introduction .................................................... 15-82
Check (Condition) .......................................... 15-83
Remove and Install ....................................... 15-83
Introduction
In a piston engine, the main bearings are the
bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 296.
A
B
AMain bearing
BCrankshaft

15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 83 9813/6900-6 15 - 83
Check (Condition)
1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
Refer to: PIL 15-12-00.
3. Renew any parts that are worn or not within the
specified tolerances.
Remove and Install
Refer to: PIL 15-12-00.

15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 84 9813/6900-6 15 - 84
06 - Front Oil Seal
Remove and Install
Special Tools
Description Part No. Qty.
Crankshaft Front Oil
Seal Installation Tool 892/01157 1
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
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.
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
Remove
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not
to scratch or damage the counterbore or the
crankshaft hub. Damaged or dirty sealing faces
will cause the oil seal to fail.
Figure 297.
C
A
B
ACrankshaft oil seal
BCrankcase
CCrankshaft hub
Install
1. Make sure that the counterbore and the
crankshaft hub are clean and free from damage
and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 298.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
298.

15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 85 9813/6900-6 15 - 85
Figure 298.
F
D
G
H
B
G
F
C
A
E
ACrankshaft oil seal BCrankcase
CCrankshaft hub DSeal installation tool
EFixing bolts (x3) FCentre body
GOuter sleeve HScrew
4. Turn the screw to push the seal squarely into
the counterbore until the outer sleeve comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore
within the specified tolerance. Refer to Figure
299.
Dimension: -0.5 -0/+0.5mm
Figure 299.
B
G
F
C
A
ACrankshaft oil seal
BCrankcase
CCrankshaft hub
FCentre body
GOuter sleeve
5. Remove the seal installation tool.

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