JCB 3CX 4CX 214 214E 215 217 Backhoe Loader Service Repair Manual on CD

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your JCB. Read and print pages directly from the CD, or copy the entire manual to your hard drive.

890 Pages

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MODELS:

From M/c No. 930000 Onwards
From M/c No. 903000 Onwards (USA) 

MANUAL COVERS:

Introduction

Section 1: General Information:

Machine Identification Plate/ Typical Vehicle Identification Number
Typical Engine Identification Number
Serial Plates
Torque Settings
Service Tools Numerical List
Service Tools
Body and Framework
Electrics
Hydraulics
Transmission
Engine
Sealing and Retaining Compunds

Section 2: Care and Safety:

Safety Notices
General Safety
Operating Safety
Maintenance Safety

Section 3: Routine Maintenance:

Lubricants - Heath and Safety
Service Schedules
Loader Arm Safety Strut
Checking for Damage
Cleaning the Machine
Engine Panels
Opening and Closing the Bonnet
Removing and Fitting a Side Panel
Seat Belt
Greasing
Loader Arms
Backhoe and Quickhitch
Front Axle - 2 Wheel Drive Machines
Front Axle - 4 Wheel Drive Machines
Front Axle - All Wheel Steer Machines
Rear Axle - All Wheel Steer Machines
Extending Dipper/Driveshafts
6-in-1 Clamshovel/Loader Quickhitch
Stabilisers (Centremount Machines)
Power Sideshift/Kingpost
Knuckle (if fitted)/Backhoe Quickhitch (Hydraulic)
Tires and Wheels
Tire Inflation/Checking the Wheel Nut Torques
Brakes
Parking Brake Adjustment/Checking the Foot Brake Fluid Level
Engine Air Filter
Changing the Elements
Engine Oil and Filter
Checking the Oil Level
Changing the Oil Filter
Engine Cooling System
Checking the Coolant
Changing the Coolant
Adjusting the Fan Belt
Cleaning the Cab Heater
Fuel System
Types of Fuel
Fuel Standards
Low Temperature Fuels
Filling the Tank
Draining the Filter
Changing the Filter Element
Draining the Sediment Bowl
Bleed the System
Synchro Shuttle Gearbox
Checking the Oil Level
Changing the Oil and Filter
Powershift Gearbox
Checking the Oil Level
Changing the Oil Filter
Hydraulic System
Checking the Fluid Level
Hydraulic Tank Cap
Changing the Filter Element
Changing the Suction Strainer
Front and Rear Axle (All Wheel Steer Machines)
Checking the Differential Oil Level
Changing the Differential Oil
Checking the Hub Oil Levels
Changing the Hub Oil
Checking the Oil Level
Changing the Oil
Battery
Warning Symbols
First Aid - Electrolyte
Checking the Electrolyte Level
Battery Isolator
Hydraulic Oil Cooler
Cleaning the Tubes/Fins
Stabiliser Legs (Sideshift Machines Only)
Wear Pads
Wear Pad Adjustment
Air Conditioning (if fitted)
Adjusting the Compressor Drive Belt
Hose Burst Protection Valve
Checking Hose Burst Protection Valve
Lowering a Load
Service Capacities and Lubricants
Coolant Mixtures
Section A: Attachments

Section B: Body and Framework:

Service Tools
Slide Hammer Kit Procedure
River Nut Tool Procedure
Technical Data
Air Conditioning (Option)
Basic Operation
Air Conditioning
R-134a Refrigerant
System Operation
System Control
Safety Procedures
Fault Finding
Air Conditioning
Air Conditioning System Diagnosis
Service Procedures
Air Conditioning
Leak Testing
Tightening Leaking Hoses
Checking Refrigerant Charge Level
Refrigerant Charging and Discharging
Binary Pressure Switch Testing
Condenser Matrix
Filters - Changing and Cleaning
Compressor Drive Belt - Adjusting
Glazing
Direct Glazing
Cab ROPS/FOPS Structure - Checks
Engine Panels - Removing and Fitting
Stabiliser Leg - Wear Pad Adjustment
Extending Dipper
Wear Pad Adjustment
Inspecting the Top Wear Pads
Adjusting the Bottom Wear Pads
Sideshift
Hydraclamp Clearance Setting
Power Sideshift - Wear Pad Removal
Power Sideshift - Chain Adjustment
Air Conditioning
HVAC/Air Conditioning Unit - Removal and Replacement
Blower Unit - Removal and Replacement
Freeze Protection Thermostat - Removal and Replacement
Evaporator Matrix - Removal and Replacement
Binary Pressure Switch - Removal and Replacement
Loader Arms
Removal and Replacement
Stabiliser Legs
Removal and Replacement - Centremount Machines
Removal and Replacement - Sideshift Machines
Kingpost
Removal and Replacement
Boom and Dipper
Boom - Removal and Replacement
Dipper - Removal and Replacement
Hydraulic Tank
Removal and Replacement
Power Sideshift Ram
Removal and Replacement
Cab Panels
Removal and Replacement
Side Console
Front/Steering Console

Section C: Electrics:

Service Tools
Technical Data
General Electric Data
Fuses and Relays
Basic System Operation
Circuit Schematic - Basic Operation
Circuit Schematic - Synchro Shuttle and Powershift
Circuit Schematic - Options
Circuit Schematic - Six Speed Powershift (Shiftmaster)
Circuit Schematic - 214e Machines
Service Procedures
Electrical Testing Methods - Using a Multimeter
Battery
Maintenance
Safety
First Aid - Electrolyte
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Test
Starter Motor
Starting Circuit Test
Wiring Harness
Introduction
Tools Required
Repair Procedure
Alternator
Removal and Replacement
Starter Motor
Removal and Replacement
Harness Data
Earth Points
Drawings
Contents
Harness Drawing - Front Console
Harness Drawing - Side Console
Harness Drawing - Cab Roof - USA
Harness Drawing - Cab Roof - Not USA
Harness Drawing - Steer Controls
Harness Drawing - Transmission
Harness Drawing - Engine Mainframe

Section D: Controls:

Steering Column
Removal and Replacement
Dismantling and Assembly
Shovel Reset
Return to Dig
Operation
Adjustment
Precision Control (Servo) - to S/N 931159
Basic System Operation
Component Location
Component Identification
Circuit Description
Electrical Operation
Hydraulic Operation
Electrical Connections
Fault Finding
Service Procedure
Testing the Pilot Pressure
Renewing the Pilot Supply Valve Oil Filter
Pilot Hose Removal and Replacement
Seat Arms Control Lever
Pilot Control Valves
Removal and Replacement
Dismantling, Inspection and Assembly
Electrical Switches
Removal and Replacement
Precision Control (Servo) - from Jan 2003
Basic System Operation
Hydraulic Operation
Electrical Operation - Joystick Controller
Pump Dump Controller
Joystick Controllers - Description
Servo Pressure Supply Valve
Fault Finding
Service Procedures
Joystick Controllers
Removal and Replacement
Dismantling and Assembly
Servo Pressure Supply Valve
Removal and Replacement
Dismantling and Assembly
Control Rods and Linkages
Dismantling and Assembly
Loader Valve Controls
Excavator Valve Controls (JCB + Pattern)
Control Cables
Removal and Replacement
Cab Heater Controls
Stabiliser Controls
Boom Lock Cable
Engine Throttle Cable
Auxiliary Footpedal Cable

Section E: Hydraulics:

Service Tools
Technical Data
Hydraulic Pumps - Fixed Flow
Hydraulic Pumps - Variable Flow
Relief Valve Pressures
Loader Valve - Fixed Flow
Loader Valve - Fixed Flow, Precision Control
Loader Valve - Variable Flow
Excavator Valve - Fixed Flow
Excavator Valve - Precision Control (Servo)
to S/N 931159
Auxiliary Valve - Fixed Flow
Smooth Ride System - System Type
Basic System Operation
Neutral Circuit Description
Fixed Flow - Single Pump
Fixed Flow - Double Pump
Servo Pilot Controlled
Variable Flow
Introduction to Hydraulic Schematic Symbols
Circuit Schematics
Fixed Flow
3CX, 4CX, 214, 215, 217 & 'S' Series Machines
3CX 'S' Series & 4CX Gear Pump Options
3CX 'S' Series Options
214e Machines
Variable Flow
4CXE, 4CX Super Machines - 7 Spool
4CXE. 4CX Super Machines - 6 Spool
4CX, 4CX - Hand Held Tools Option
Precision Control
Circuit Descriptions
Hydraulic Pump - Variable Flow
Operation
Pressure/Flow Regulator Valve
Loader Valve - Neutral Circuit
Loader Valve - Unloader CIrcuit
Loader Valve - Hydraulic Speed Control (HSC)
Loader Valve - Load Hold Check Valves
Loader Valve - Arms Lower
Loader Valve - Float
Loader Valve - A.R.V. Operation
Main Relief Valve (MRV) - Operation
Loader Valve - Variable Flow
Operation
Priority Inlet Section Operation
Auxiliary Spool
Loader Shovel Spool
Loader Lift Spool
Shuttle Valve Signal Network
Excavator Valve
Manual Control - Neutral Circuit
Load Hold Check Valves
Slew Ram End Damping
One Way restrictor Operation
Slew Operation
Slew A.R.V. and Anti-Cavitation Operation
A.R.V. Operation
Pilot Operated Pressure Relief Valve
Hydraclamp Valve Operation
Precision Control (Servo)
Smooth Ride System
Hose Burst Protection Valve
Boom and Dipper Operation
Loader Operation
Fault Finding
Hydraulic System
Fixed Flow
Variable Flow
Smooth Ride System
Service Procedures
Hydraulic Contamination
Fixed Flow Pumps
Flow and Pressure Testing
Variable Flow Pumps
Flow and Pressure Testing
Regulator Valve Adjustment
Renewing Drive Shaft Seal
Shuttle Valve Signal Network - Testing
Loader Valve - Pressure Testing
Main Relief Valve (M.R.V.)
Unloader Valve
Hydraulic Speed Control (HSC)
Auxiliary Relief Valves - Using Hand Pump
Excavator Valve - Pressure Testing
Auxiliary Relief Valves - Using Hand Pump
Excavator Valve Precision Control (Servo) - Pressure Testing
Pressure Compensator Network - Testing
Ram Creep Tests - All Services
Quick Release Couplings
Connecting and Disconnecting
Do's and Don'ts
Connecting Quick Release Couplings
Disconnecting Quick Release Couplings
Smooth Ride System
Charging/Discharging the Accumulator
Hose Burst Protection Valves
Checking
Lowering a Load - In a Failure Condition
Pressure Testing - Loader Lift Ram
Main Pump
Fixed Flow
Removal and Replacement
Dismantling and Assembly
Variable Flow
Dismantling and Assembly
Loader Valve - Fixed Flow
Removal and Replacement
Manual Control
Dismantling and Assembly
Main Relief Valve
Auxiliary Relief Valves and Load Hold Check Valves
Unloader Valve
Standard Spool - Manual
Float Spool - Manual
Electric Detent Spool - Manual
Bolt on Auxiliary Spool Selection
Body and Spool
Auxiliary Relief Valve (ARV)
Precision Control (Servo) from Jan 2003
Dismantling and Assembly
Standard Spool
Electric Detent Spool
Mechanical Detent Spool
Loader Valve - Variable Flow
Removal and Replacement
Dismantling and Assembly
Priority Inlet Section
Auxiliary Spool
Loader Shovel Spool
Loader Lift Spool
Fitting Spool Seal
Excavator Valve
Removal and Replacement
Manual Control
Variable Flow
Precision Control (Servo) to S/N 931159
Dismantling and Assembly
Manual Control
Auxiliary Relief Valves
Hydraclamp Valve (Sideshift Machines)
Hoses and Pipes (Sideshift Valve)
Hoses and Pipes (Centremount Valve)
Precision Control (Servo) to S/N 931159
Load Sense Drain Regulator and Relief Valve
Hydraclamp Valve
Precision Control (Servo) from Jan 2003
Flow Regulator Valve
Load Sense Relief Valve
Auxiliary Relief Valves (ARV's)
Anti-cavitation Valve
Auxiliary Valve
Servo Pilot Controlled
Removal and Replacement
Dismantling and Assembly
Hose Burst Protection Valves
Removal and Replcaement
Dismantling and Assembly
Loader Lift Ram
Boom and Dipper Rams
Hydraulic Rams
Removal and Replacement
Loader Lift Ram
Loader Shovel Ram
Slew Ram
Stabiliser Ram
Sideshift
Centermount
Dipper Ram
Bucket Crowd Ram
Boom Ram
Dismantling and Assembly
Loader Lift Ram
Loader Shovel Ram
Boom Ram
Bucket Ram
Stabiliser Ram
Dipper Ram
Slew Ram
Power Sideshift Ram
JCB Ram Sealing Procedure
Hydraulic Oil Cooler
Removal and Replacement
Smooth Ride System
Accumulator
Removal and Replacement
Dismantling and Assembly

Section F: Transmission:

Service Tools
Technical Data
Tyre Pressures
Front Wheels
Rear Wheels
Front Axle
Rear Axle
Synchro Shuttle Gearbox
Powershift Gearbox - 6 Speed
Powershift Gearbox - 4 Speed
Engine Stall Speed Combinations
Basic Operation
Front Axle - Steer Drive Type SD55, SD70
Rear Axle - Steer Drive Type SD80
Synchro Shuttle Gearbox
Component Identification
Principle of Operation
Hydraulic and Electrical Operation
Powershift Gearbox
Component Identification
Principle of Operation
Hydraulic and Electrical Operation
ShiftmasterOperation Characteristics
Drivepaths - 4 Speed
Drivepaths - 6 Speed
Torque Converter
Component Identification
Principles of Operation
Systems Description
Synchro Shuttle Gearbox
Synchromesh (Blocking Pin Type)
Forward/Reverse Clutch Operation
2/4 Wheel Drive Clutch Operation
Pressure ON/Spring OFF Type
Spring ON/Pressure OFF Type
Powershift Gearbox
Clutch Operation - Forward/Reverse
Clutch Operation - Mainshaft, Layshaft, 6 Speed
Clutch Operation - 2/4 Wheel Drive Clutch
Electrical Connections
Powershift Gearbox - 4 Speed
Quick Reference
Relay Actuation
Gearbox Solenoid Actuation
Powershift Gearbox - 6 Speed
Introduction
Component Identification
Quick Reference
Input Controls
Gearbox Solenoid Actuation
Fault Finding
Synchro Shuttle Gearbox
2/4 Wheel Drive Clutch
Powershift Gearbox
Service Procedures
Front Axle - SD55, SD70
Renewing the Pinion Oil Seal
Rear Axle
Renewing the Pinion Oil Seal
Brakes - Testing for Piston Seal Leakage
Synchro Shuttle Gearbox
Toruqe Converter Stall Test
Pressure and Flow Test
Forward/Reverse Solenoid Control Valve
Powershift Gearbox
Gearbox Hydraulic Pump
Suction Strainer
Torque Converter Stall Test
Pressure and Flow Test
Pressure Testing - Clutches
Speed Sensor
Powershift Gearbox - 6 Speed (Shiftmaster)
Electronic Control Unit
ShiftMaster Diagnostics
User Guide
Troubleshooting Guide
Propshafts
Removing and Replacing
Front Axle - SD55, SD70
Removal and Replacement
Hub and Driveshaft
Dismantling
Assembly
SD55
Drive Head
Dismantling
Assembly
Pinion Depth Setting
Crownwheel and Pinion Meshing
SD70
Drive Head
Dismantling
Assembly
Pinion Depth Setting
Crownwheel and Pinion Meshing
Front Axle
Removal and Replacement
Dismantling and Assembly
Rear Axle - PD70, SD80
Removal and Replacement
Brakes
Dismantling
Assembly
SD80
Hub
Dismantling
Assembly
PD70
Hub
Dismantling and Assembly
Drivehead
Dismantling
Assembly
Crownwheel and Pinion Meshing
Axles
Collapsible Spacer Assembly
Limited Slip Differential
Dismantling and Assembly
Synchro Shuttle Gearbox
Removal and Replacement
Dismantling
Inspection
Assembly
Reverser Unit
Dismantling
Assembly
Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON)
Dismantling and Assembly
Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON)
Dismantling and Assembly
Pressure Testing the 2/4 Wheel Drive Clutch
Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure
Powershift Gearbox
Removal and Replacement
Dismantling
Inspection
Assembly
PS760 - Forward/Input & Reverser Clutch
Dismantling
Assembly
PS760 - Layshaft Clutch
Dismantling
Assembly
PS760 - Mainshaft Clutch
Dismantling
Assembly
PS760 - 6 Speed Clutch
Dismantling
Assembly
PS760 - 2/4WD Clutch (Pressure ON)
Dismantling
Assembly
Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure
Torque Converter
Removal and Replacement

Section G: Brakes:

Technical Data
System Type
Basic System Operation
Compensating Master Cylinder
Description
Pedals Locked - Normal Operation
Pedals Locked - Compensating Operation
Pedals Unlocked - Normal Operation
Fault Finding
Service Procedures
Service Brakes
Brake Light Switch - Adjustment
Brake Piston Seal Leakage Test
Parking Brake
Testing
Adjustment
Switch Adjustment
Renewing the Brake Pads
Master Cylinder and Servo Unit
Removal and Replacement
Dismantling and Assembly
Service Brakes
Dismantling and Assembly
Bleeding
Parking Brake
Torque Figures
Calliper
Removal and Replacement
Dismantling and Assembly
Brake Disc - Removal and Replacement

Section H: Steering:

Service Tools
Technical Data
System Type
2 Wheel Steer Machines
4 Wheel Steer Machines
Basic System Operation
2 Wheel Steer Machines
Steer System Schematics
Hydraulic Operation
4 Wheel Steer Machines
Steer System Schematics
Hydraulic Operation
Electrical Operation
Circuit Descriptions
Steer Unit Operation
2 Wheel Steer Machines
4 Wheel Steer Machines
4 Wheel Steer Mode
Neutral
Left Turn
Right Turn
Right Turn, Unassisted
Shock Valve
2 Wheel Steer Mode
Right Turn
Crab Steer Mode
Right Turn
Priority Valve Operation
Fault Finding
Service Procedures
Steering System
Bleeding
Pressure Testing
Proximity Switch - Setting
Steer Mode Valve - Checking Solenoid Operation
Priority Valve
Cleaning
Standby Pressure Testing
Power Track Rod
Removal and Replacement
Link Arms - Removal and Replacement
Rams - Dismantling and Assembly
Priority Valve
Removal and Replacement
Dismantling and Assembly
Steer Mode Valve
Removal and Replacement
Dismantling and Assembly
Hydraulic Steer Unit
Removal and Replacement
Dismantling and Assembly

Section K: Engine:

Service Tools
Technical Data
Service Procedures
Fuel Lift Pump - Cleaning the Strainer
Engine
Removal and Replacement 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English 
Format: PDF - Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
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