JCB 3C Backhoe Loader Workshop Service Manual for Repair

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. World Class Customer Support 9803/3290-16 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 3 Maintenance Service Manual - 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 Section L - Servo Controls

Section 3 - Maintenance 3-0 3-0 9803/3290-16 Notes:

Page No. Contents Section 3 - Maintenance 3-i 3-i Routine Maintenance Health and Safety ...................................................................................... 3-1 Lubricants .............................................................................................. 3-1 Battery ................................................................................................... 3-3 Service Schedules ..................................................................................... 3-5 Introduction ............................................................................................ 3-5 Fuel System .......................................................................................... 3-5 How to Use the Service Schedules ....................................................... 3-5 Calendar Equivalents ............................................................................ 3-5 Pre-start Cold Checks, Service Points and Fluid Levels ....................... 3-6 Functional Test and Final Inspection ..................................................... 3-9 Lubricants and Capacities ....................................................................... 3-11 Coolant Mixtures ................................................................................. 3-13 Prepare the Machine for Maintenance .................................................... 3-14 Introduction .......................................................................................... 3-14 How to Make the Machine Safe (Loader Arms Lowered) .................... 3-14 How to Make the Machine Safe (Loader Arm Lifted) .......................... 3-14 Cleaning the Machine .............................................................................. 3-16 Introduction .......................................................................................... 3-16 Preparing the Machine for Cleaning .................................................... 3-16 Cleaning the Machine .......................................................................... 3-17 Checking for Damage .............................................................................. 3-20 Check the Machine Body and Structure .............................................. 3-20 Check the Tyres .................................................................................. 3-20 Check the Seat and Seat Belt ............................................................. 3-20 Check the Hydraulic Hoses and Fittings ............................................. 3-20 ROPS/FOPS Structure ............................................................................ 3-22 Checking The ROPS/FOPS Structure ................................................. 3-22 Greasing .................................................................................................. 3-23 Introduction .......................................................................................... 3-23 Preparing the Machine for Greasing ................................................... 3-23 Loader Arms ........................................................................................ 3-24 Backhoe and Quickhitch ...................................................................... 3-25 Front Axle (2 Wheel Drive Machines) .................................................. 3-26 Front Axle (4 Wheel Drive Machines) .................................................. 3-26 Front Axle (All Wheel Drive Machines) ................................................ 3-27 Rear Axle (All Wheel Drive Machines) ................................................ 3-27 Extending Dipper ................................................................................. 3-28 Driveshafts .......................................................................................... 3-28 6 - In - 1 Clamshovel ........................................................................... 3-29 Stabilisers (Centremount Machines) ................................................... 3-29 Loader Quickhitch ............................................................................... 3-29 Power Sideshift ................................................................................... 3-29 Kingpost .............................................................................................. 3-30 Knuckle (if fitted) .................................................................................. 3-30 Backhoe Quickhitch (Hydraulic) .......................................................... 3-31 Access Panels ......................................................................................... 3-32 Engine Cover ....................................................................................... 3-32 Front Grille ........................................................................................... 3-34 Heater and Air Conditioning .................................................................... 3-35 Cleaning the Cab Heater Fresh Air Filter ............................................ 3-35 Changing the Cab Heater Recirculation Filter(s) (if fitted) ................... 3-36 Brakes ..................................................................................................... 3-37 Park Brake ........................................................................................... 3-37 Foot Brake ........................................................................................... 3-39

Section 3 - Maintenance Contents 3-ii 3-ii Page No. Contents Electrical System ..................................................................................... 3-40 Battery ................................................................................................. 3-40 Jump Starting The Engine ................................................................... 3-42 Fuses ................................................................................................... 3-43 Link Box Fuses .................................................................................... 3-43 Relay Identification .............................................................................. 3-44 Engine ..................................................................................................... 3-45 Oil and Filter ........................................................................................ 3-45 Cooling System ................................................................................... 3-47 Front End Accessory Drive Belt .......................................................... 3-49 Air Filter ............................................................................................... 3-51 Fuel System ............................................................................................. 3-52 Fuel ..................................................................................................... 3-52 Filling the Tank .................................................................................... 3-52 Water Separator and Engine Fuel Filter .............................................. 3-53 Bleeding the System ........................................................................... 3-58 Hydraulic System ..................................................................................... 3-59 Introduction .......................................................................................... 3-59 Releasing the Hydraulic Pressure ....................................................... 3-59 Hydraulic Tank Filler Cap .................................................................... 3-60 Oil and Filter ........................................................................................ 3-61 Cooling Pack ....................................................................................... 3-65 Hose Burst Protection Valve (if fitted) ...................................................... 3-66 Checking Hose Burst Protection Valve ................................................ 3-66 Lowering a Load .................................................................................. 3-66 Transmission ........................................................................................... 3-68 Checking the Gearbox Oil Level .......................................................... 3-68 Changing the Oil and Filter .................................................................. 3-69 Axles ........................................................................................................ 3-71 Front and Rear Axle (All Wheel Steer Machines) ................................ 3-71 Front and Rear Axle (Two Wheel Steer Machines) ............................. 3-73 Tyres and Wheels .................................................................................... 3-75 Tyre Inflation ........................................................................................ 3-75 Wheel Nuts .......................................................................................... 3-76 Wheel Alignment ..................................................................................... 3-77 Introduction .......................................................................................... 3-77 Electronic Steer Mode Selector ........................................................... 3-77 Wear Pads ............................................................................................... 3-78 Extradig Dipper Wear Pads ................................................................. 3-78 Stabiliser Legs (Sideshift Machines Only) ........................................... 3-80 Windscreen Washer ................................................................................ 3-81 Checking the Level .............................................................................. 3-81 Fire Extinguisher (if fitted) ........................................................................ 3-82 Checking the Fire Extinguisher ........................................................... 3-82

Section 3 - Maintenance 3-1 3-1 9803/3290-16 Routine Maintenance Health and Safety Lubricants T3-060_2 Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too. Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following. Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers. Waste Disposal ! CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. INT-3-2-14 All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground. Handling ! WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3 New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices. Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1 Avoid prolonged, excessive or repeated skin contact with used oil. 2 Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin: a Wash your skin thoroughly with soap and water. b Using a nail brush will help.

JCB 3C Backhoe Loader Workshop Service Manual for Repair

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