How to replace the hydraulic system of a JCB excavator loader and check the differential oil level.

 AWARNING
Make the machine safe before getting beneath it. Lower
the attachments to the ground; engage the parking
brake; remove the starter key, disconnect the battery.

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ACAUTION
The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil in
the axle will be given.

Park the machine on level ground. Engage the parking
brake.Set the transmission to neutral.Lower_the
attachments to the ground. Stop the engine and
remove the starter key.

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2
Clean the area around fill/level plug A, then remove the
plug and its sealing washer. Oil should be level with the
bottom of the hole. Add recommended oil if necessary.
3
Clean and refit the plug and its washer.

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How to replace the suction filter in the hydraulic system of a JCB backhoe loader

 AWARNING
Make the machine safe before getting beneath it. Lower
the attachments to the ground; engage the parking
brake; remove the starter key, disconnect the battery.

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 1
Position the machine on level ground. Roll the loader
shovel forward and rest it on the ground. Retract the
extending dipper if fitted. Close the backhoe bucket.
Swing in the dipper. Lower the boom until the bucket
rests on the ground.Lower the stabilisers to the
ground. Stop the engine. Remove the starter key and
disconnect the battery.

 2
Remove hydraulic tank filler cap.

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 3
Place a container beneath the hydraulic tank to catch
the oil, remove drain plug and drain the hydraulic tank.
Make sure the container is large enough to hold the
tank contents，see
eService Capacities and
Lubricants.

 

 4
Undo clips A and disconnect the hydraulic return pipe.

5
Using a 65mm A/F spanner unscrew suction strainer B
and discard.

6
Fit a new filter assembly B, torque tighten to 15-20 Nm
(11-15 Ibf ft).

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7 

Reconnect suction hose.Make sure the clips A are
positioned 180° apart.

 

 

 

How to replace the filter element in the hydraulic system of a JCB backhoe loader

 AWARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1

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1
Position the machine on level ground. Roll the loader
shovel forward and rest it on the ground. Retract the
extending dipper if fitted. Close the backhoe bucket.
Swing in the dipper. Lower the boom until the bucket
rests on the ground. Lower the stabilisers to the
ground. Stop the engine. Remove the starter key.

2
Remove the element assembly
a Remove screws A.Remove the cover plate B and
gasket C
* Note: If gasket C is a rubber type it can be reused provided
it is undamaged.If the gasket is a cork type it must be
discarded and a new gasket fitted on assembly.
bRemove spring D.
c Hold handle E and pull the element assembly from
the hydraulic tank. 

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 3
Remove the element from its canister.
a Hold canister F.
b Hold handle E and rotate the element G 90° anti-
clockwise.
c Pull on handle E, the element G should separate
from its canister F. Discard the old element.
d Remove and discard seal H.
eClean the inside of canister F.
New machines are fitted with a 5 micron filter element which
must be replaced at the first 1oo hour service with a 10
micron filter element.

Fit the new element.
aFit a new seal H.
b Make sure that seal J is fitted in the new element.
c Push the element G into its canister F and rotate the
element 90° to lock it into position. Check that the
element has locked into position by pulling on
handle E.
d Install the element assembly in the hydraulic tank.
* e Fit spring D and gasket C, (see 'Note' at step 2).
fFit cover plate B and tighten screws A to 21 Nm
(15.5 Ibf ft).
g Check oil level and replenish as required through
filler. Fit and tighten the filler cap as described on
previous page.

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Doosan engine emitting black and blue smoke, oil leaking from the turbocharger and oil dipstick - Solution

Doosan engine emitting black and blue smoke, oil leaking from the turbocharger and oil dipstick - Solution 

 

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Applicable Model: DH220LC-V Engine emitting black and blue smoke, oil leaking from the turbocharger and oil dipstick Symptom

 1. Inspection Guidelines: 1. Remove the intake manifold and muffler from the turbocharger and check the axial and radial clearances of the turbocharger spindle. Both are normal. 

2. Based on the symptoms, excessive pressure inside the crankcase is causing oil to leak from the oil dipstick and turbocharger. 

3. Removing the lower exhaust pipe and breather does not resolve the issue, indicating the cause is internal to the engine. 

4. Engine inspection revealed uneven wear on the fifth cylinder piston and worn connecting rod bearing. 

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 2. Cause:

 Due to the worn bearing, uneven piston wear allows the air-fuel mixture to enter the crankcase, causing oil to leak from the oil dipstick and turbocharger. 

 

 3. Solution: 

Replace the damaged part and it will be OK.

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How to disassemble the oil pressure regulator and viscosity sensor on a Cummins M11 series engine

 

(1) Removal of the main oil pressure regulator: See Figure 2-141 for disassembly of the main oil pressure regulator. Exercise extreme caution when removing the locating plug 1, as the pressure regulator spring 2 is compressed. 

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 (2) Removal of the viscosity sensor: Use a 7/16-inch sleeve.

 

Use a wrench, an extension rod, and a ratchet wrench to disassemble the viscosity sensor, as shown in Figure 2-142.

 

 

 Figure 2-139 Removing the crankshaft using a crane

 

 

 

 

 Figure 2-140 Marking on the surface of the upper bearing bush locating tongue

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Figure 2-141 Disassembly of the main engine oil pressure regulator

 

 

 Figure 2-142 Disassembly of the viscosity sensor

 

(3) Removal of the high oil pressure regulator. See Figure 2-143 for the removal of the high oil pressure regulator. During removal, use a light puller (part number 3375784) to remove the locating plug, regulator spring, washer, and valve disc. The valve seat will remain in the cylinder block. 

 

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How to disassemble the main bearing cap, bearing shell, and thrust bearing of the Cummins M11 series engine

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(1) Removal of the main bearing cap, lower bearing shell, and thrust bearing 

① Rotate the engine on the test bench so that the oil pan mounting flange faces upwards. The markings on the main bearing cap must match the numbers on the cylinder block oil pan flange, see Figure 2-134. During installation, the numbers on the main bearing cap and oil pan flange should match, and the locating tongue of the main bearing cap must be aligned with the locating tongue. 

 ②Use the ST-1178 main bearing cap puller to remove the main bearing cap, see Figure 2-135. The No. 4 main bearing cap is connected to the cylinder block by a locating pin, and the No. 4 main bearing shell is fitted with a thrust bearing. During disassembly, it is strictly forbidden to shake the main bearing cap; only the puller can be used to pull the main bearing cap vertically upwards.

 

 

 

 Figure 2-133 Marking the tongue plane for positioning the bearing shell on the connecting rod.

 

 

 

③ Remove the lower bearing shell from the main bearing cover and mark the journal number at the time of disassembly on the surface of the locating tongue, as shown in Figure 2-136. ④ Remove the lower thrust bearing from the No. 4 main bearing cover and mark it with the letters "L" and "front" or "rear", as shown in Figure 2-137.

 

 

 

 Figure 2-134 shows markings on the main bearing cap and oil pan flanges.

 

 

 

 

 Figure 2-135 Remove the main bearing cover using a puller

 

 

 

 

Figure 2-136 Marking on the surface of the bearing locating tongue

 

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Figure 2-137 Marking on the lower thrust bearing: “L” for front and “front” or “rear”.

 

 

 (2) 

① Crankshaft and Upper Bearing Removal Place nylon slings over connecting rod journals 3 and 4, and use a crane to remove the crankshaft, as shown in Figure 2-139. 

② Remove the upper bearing and mark the journal number at the time of removal on the surface of the bearing locating tongue, as shown in Figure 2-140.

 

 

 Figure 2-138 Mark "U" and "front" or "rear" on the upper thrust bearing.

 

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How to disassemble the Cummins M11 series engine: oil pump, camshaft, and gear housing.

  (1) Removal of the oil pump When removing the oil pump, it is strictly forbidden to pry the gear pump flange to avoid damaging the oil pump. Remove the three mounting bolts and two spacers, screw the two M8-1.25 bolts into the puller, and remove the oil pump from the engine, as shown in Figure 2-117.

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(2) Camshaft Removal Rotate the camshaft until the camshaft gear hole aligns with the thrust bracket bolt hole. Remove the two thrust bracket bolts, then remove the three bolts, rear cover plate, and gasket (see Figure 2-118). ② Install the camshaft installation guide tool (part number 3376388). Insert the expander (part number 3376923) through the opening in the rear cover plate into the camshaft. Rotate the bolt inside the expander clockwise to open the expansion plug (see Figure 2-119).

 

 Figure 2-117 Remove the bolts and use a puller to remove the oil pump.

 ③ Place the mandrel bushing onto the expander, and install the positioning guide extension rod on the expander, as shown in Figure 2-120. 

 ④ Slowly rotate the camshaft by hand to pull it out of the cylinder block, as shown in Figure 2-121. Support the removed camshaft with your other hand and remove the camshaft guide tool. 

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 (3) Removal of the gear housing: Remove all bolts from the gear housing and the gear housing itself, as shown in Figure 2-122, and remove the rear rectangular seal ring.

 

 Figure 2-118 Remove the camshaft thrust bracket bolts, rear cover plate, and gasket.

 

 Figure 2-119 Installing the expander into the camshaft 1 - Expander

 

 

 Figure 2-120 Insert the mandrel bushing onto the expander and install the extension rod. 2-Mandrel bushing 3-Extension rod  

 

Figure 2-121 The rotating camshaft pulls it out of the cylinder block. 

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