JCB 3CX, 4CX, 214, 215, 217 & Variants Backhoe Loader Service Manual – 9803/3270

3CX, 4CX (S/N: 460001 to 499999 & S/N: 920001 to 930000) – 214e, 214, 215, 217 (S/N: 900001 Onwards)
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This workshop repair service manual PDF download for the 3CX, 4CX, 214, 215, 217 & Variants JCB Backhoe Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Backhoe Loader
3CX, 4CX, 214, 215, 217 & VARIANTS
From M/c No. 460001 To 499999
920001 On
900001 On (N.Am only)

3CX, 4CX (S/N: 460001 to 499999 & S/N: 920001 to 930000)
214e, 214, 215, 217 (S/N: 900001 Onwards)

TABLE OF CONTENTS :

Section 1: General Information
Section 2: Care and Safety
Section 3: Routine 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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3270 & 9803/3270U
Total Pages : 711

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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More Info : http://www.sitelux.com

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Contents
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 Compounds

Section 2: Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Section 3: Routine Maintenance
Lubricants – Health and Safety
Lubricants and Capacities
Service Schedules
Loader Arm Safety Strut
Fitting and Removing
Engine Panels
Removing and Fitting a Side Panel
Removing and Fitting the Access Panel
Removing and Fitting the Engine Cover
Greasing
Loader Arms
Backhoe/Kingpost
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/Backhoe Quickhitch
Stabilisers (Centremount Machines)/Loader Quickhitch
Hydraulic Pump Driveshaft
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Brakes
Checking the Foot Brake Fluid Level
Engine Air Filter
Changing the Elements
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Engine Cooling System
Checking the Coolant
Changing the Coolant
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
Syncro Shuttle Transmission
Checking the Oil Level/Changing the Oil and Filter
Powershift Transmission
Checking the Oil Level
Changing the Oil and Filter
Hydraulic System
Checking the Fluid Level/Hydraulic Tank Cap
Changing the Filter Element
Front and Rear Axle (All Wheel Steer Machine)
Checking the DIfferential Oil Level
Changing the Differential Oil
Checking the Hub Oil Levels
Changing the Hub Oil
Front and Rear Axle (Two Wheel Steer Machine)
Checking the Oil Level
Changing the Oil

Section A: Attachments
Extradig Dipper Wear Pads – Upper/Lower
Inspecting the Top Wear Pads
Adjusting the Bottom Wear Pads

Section B: Body and Framework
Engine Panels
Removing and Fitting a Side Panel
Removing and Fitting the Access Panel
Removing and Fitting the Engine Cover
Rivet Nuts
Fiting Procedure
Slide Hammer Kit
Procedures
Cab
ROPS/FOPS Structure
Checking
Glazing
General
Direct Glazing
Loader Front End
Loader Arms
Removal and Replacement
Stabiliser Legs (Centremount Machines)
Removal and Replacement
Stabiliser Legs (Sideshift Machines)
Wear Pads
Wear Pad Adjustment
Removal and Replacement
Kingpost
Removal and Replacement
Boom and Dipper
Dipper Removal and Replacement
Boom Removal and Replacement
Sideshift
Setting Clearance – Carriage/Hydraclamp
Power Sideshift Wear Pad
Power Sideshift Chains
Power Sideshift Ram
Rear Electric Window
Open/Close the Window
Manual Operation
Reset Procedure
Fault Finding
Air Conditioning
Technical Data
Safety Procedures
Operation
Control
Fault Finding
Checking Refrigerant Charge Level
Refrigerant Charging and Discharging
Leak Testing
Tightening Leaking Hoses
Blower Motor
Removal and Replacement
Pressure Switches
Testing
Removal and Replacement
Condenser Coil – Cleaning
Adjusting the Air Conditioning Compressor Drive Belt
Hydraulic Tank
Removal and Replacement

Section C: Electrics
Technical Data
General Electric Data
Fuse Identification (Except 3CXE, 214E)
Relay Identification (Except 3CXE, 214E)
Fuse Identification – 3CXE, 214E
Relay Identification – 3CXE, 214E
Fuse Identification – Servo Command
Relay Identification – Servo Command
Fuse Identification 214Se
Relay Identification 214Se
Fuse Identification – From Serial No. 495455
Relay Identification – From Serial No. 495455
Relay Identification – Autoshift Only
Relay Identification – Powershift Transmission From Serial No. 495455
Relay Identification – Syncro Shuttle Transmission From Serial No. 495455
Link Box Fuses
Bulbs
Test Methods
Use of Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
How to Test a Diode or Wire
Psion Workabout
Introduction of Autoshift Transmission
Loading JCB-supplied Psion Software onto the Workabout
Downloading Psion Programs to the Workabout
Starting Link from the Psion Command Processor
Disabling Link
Psion Connection to the Information Display Centre (IDC)
Powershift Auto Diagnostic and Fault Finding
Fault Finding
Servo Command Fault Finding
Brake Light Switch
Adjustment
Parking Brake Switch
Adjustment
Speed Sensor
Testing
Servo Command
Fuse and Relay Panel
Removal and Replacement
Circuit Diagrams and Component Lists
Circuit Options and Variations
Basic Machine (2WS)
Powershift (PS700) Transmission and Steer Circuit – AWS Machines Only
Powershift Transmission (PS700) – 2WS Only
Steer Circuit for 3CX 4x4x4 Machines
3CXE (214E Series 3) Machines Only
214e Series 4 Machines Only
Autoshift Transmission – 2WS Machines Only
Autoshift Tranmission – AWS Machines Only
Powershift Transmission (PS750) & Steer Circuit – AWS Machines Only
Powershift Transmission (PS750) – 2WS Machines
Steer Circuit for 3CX 4x4x4 Machines
Auxiliary Electrical Options
Handheld Tools
Dedicated Quickhitch
Pole Planter
Smooth Ride System (SRS)
Hammer
Hand Held Tools (Variable Flow Pump)
Powershift (PS750) 2/4WD Powered On 2WD (Germany)
Power Sideshift with Hammer Circuit
Servo Command Up To Serial No. 495454
Basic Machine from Serial No. 495455 To 499999 And From 920000
Transmission and Steering From Serial No. 495455
Options From Serial No. 495455
Autoshift Transmission from S/N: 495455
Auxiliary Electrical Options
Servo Command Pilot Circuit From Serial No. 495455
Batteries
Safety
Specific Gravity
Battery Testing
Wiring Harness Repair
Harness Repair Introduction
Tools Required
Procedure
Starter Motor
Starting Circuit Test
Removal and Replacement
Dismantling
Servicing and Renewal
Assembly
Alternator
General Description
Service Precuations
Charging Test
Removal and Replacement
Dismantling and Assembly
Dismantling and Assembly – Magneti Marelli Type
Harness Location
Cab and Chasis
Servo Command
Cab and Chasis – All Later Machines

Section D: Controls
Backhoe
Boom Lock – Removal and Replacement
Steering Column
Dismantling and Assembly
Control Rods and Linkages
Loader Valve
Backhoe Valve
Return to Dig
Description/Operation/Adjustment
Servo Command
Joystick Control Lever
Shovel Reset – 214e Machines Only

Section E: Hydraulics
Technical Data
Hydraulic Pumps
Loader Valve
Backhoe Valve
Auxiliary Valve
Ancillary Equipment
Stabiliser Check Relief Valve
Hydraulic Filter Element
Manifold Block (Servo Command)
Quick Release Couplings
Hydraulic Contamination
Fault Finding
Standard Machines
Servo Command
Variable Flow Hydraulics
Introduction to Hydraulic Schematic Symbols
Schematics
3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines
3CX ‘S’ Series & 4CX Gear Pump Options
3CX ‘S’ Series Options
Servo Command Pilot Circuit
3CXE (214E Series 3) Machines Only
214 Series 4 Machines
214Se Series 4 Machines Only
Variable Flow Hydraulics
4CXE, 4CX Super Machines (7 Spool with High Flow Options)
4CXE, 4CX Super Machines (6 Spool with High Flow Options)
4CX, 4CX Super Machines Hand Held Tools Option
Machine Neutral Circuit Description
3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines
3CX (214E) Machines
Servo Pilot Circuit
Variable Flow Hydraulics
4CX, 4CX Super Machines
Hydraulic Pumps
Pump Description
Pump Flow Testing
Removal and Replacement
Dismantling and Assembly
Dismantling and Assembly – 3CXE (214E & 214e) Machines – Model No. 6197C
Dismantling and Assembly – 3CXE (214E & 214e) Machines – Model No. J101702
Dismantling and Assembly – 214Se Machines – Model No. J101701
Variable Flow Hydraulics
Pump Operation
Pump Pressure/Flow Regulator Valve Operation
Removal and Replacement
Renewing Drive Shaft Seal
Dismantling and Assembly
Flow and Pressure Testing
Regulator Valve Adjustment
Loader Valve
Manual Description
Servo Description
Manual – Removal and Replacement
Servo – Removal and Replacement
Main Relief Valve
Description
Dismantling and Assembly
Auxiliary Relief Valve and Load Hold Check Valves
Description
Dismantling and Assembly
Unloader Valve Assembly
Description
Dismantling and Assembly
Standard Spool Manual
Dismantling and Assembly
Float Spool Manual
Dismantling and Assembly
Electric Detent Spool Manual
Dismantling and Assembly
Standard Spool Servo
Dismantling and Assembly
Float Spool Servo
Dismantling and Assembly
Electric Spool Servo
Dismantling and Assembly
Loader Valve – Variable Flow Hydraulics
Description
Removal and Replacement
Priority Inlet Selection
Decription of Operation
Dismantling and Assembly
Auxiliary Service
Description of Operation
Dismantling and Assembly
Loader Shovel Service
Description of Operation
Dismantling and Assembly
Loader Lift Service
Description of Operation
Dismantling and Assembly
Valve Section – Spool Seal Assembly
Loader Valve – 3CXE, 214E Machines Only
Description
Removal and Replacement
Main Relief Valve
Description
Dismantling and Assembly
Auxiliary Relief Valve and Load Hold Check Valves
Description
Dismantling and Assembly
Standard Spool
Dismantling and Assembly
Float Spool
Dismantling and Assembly
Loader Valve – Pressure Testing
Main Relief Valve (M.R.V.)
Unloader Valve
Hydraulic Speed Control
Auxiliary Relief Valves
Backhoe Valve
Manual Description
Servo Description
Backhoe Valve Manual – Removal and Replacement
Backhoe Valve Servo – Removal and Replacement
Manual – Dismantling and Assembly
Servo – Dismantling and Assembly
Auxiliary Relief Valves
Description
Dismantling and Assembly
Hydraclamp Valve (Sideshift Machines)
Operation
Dismantling and Assembly
Hoses and Pipes
Sideshift Valve
Centremount Valve
Backhoe Valve – Pressure Testing
Auxiliary Relief Valves – Using Hand Pump
Auxiliary Valve Servo
Description
Removal and Replacement
Dismantling and Assembly
Variable Flow Hydraulics
Description
Testing
Backhoe Valve – Removal and Replacement
Hose Burst Protection Valve
Boom and Dipper Priciple of Operation
Loader Principle of Operation
Checking Hose Burst Protection Valve
Lowering a Load
Removal and Replacement
Dismantling and Assembly
Pressure Testing – Loader Arms Lift Ram
Servo Command
Lowering the Loader Arms and Boom
Pilot Hose – Removal and Replacement
Pilot Pressure – Testing
Rams
Removal and Replacement
Loader Lift Ram
Loader Shovel
Slew
Stabiliser (Centremount)
Stabiliser (Sideshift)
Dipper
Bucket Crowd
Boom
Dismantling and Assembly
Loader Lift
Loader Shovel
Boom
Bucket
Stabilisers
Dipper
Slew Ram
Power Sideshift Ram
JCB Ram Sealing Procedure
Hydraulic Oil Cooler
Removal and Replacement
Smooth Ride System
Technical Data
Description
Fault Finding
Accumulator
Charging/Discharging
Removal and Replacement
Dismantling and Assembly

Section F: Transmission
Technical Data
Front Axle
All Wheel Steer Machines
2 Wheel Steer Machines
2 Wheel Steer (2 Wheel Drive) Machines
Rear Axle
All Wheel Steer Machines
2 Wheel Steer Machines
Tyre Pressures
Front Wheels
Rear Wheels
Syncro Shuttle Transmission
Powershift Transmission
Pump/Transmission Stall Speed Combinations
2 Wheel Steer Machines, Gear Pump
All Wheel Steer Machines, Gear Pump
All Wheel Steer Machines, Variable Pump
Low Emission Engine, 2 Wheel Steer Machines
Low Emisison Engine, All Wheel Steer Machines
Towing Procedure
Syncro Shuttle and Powershift Gearbox
Summary of Changes
Propshafts
Removal and Replacement
Front Axle – SD55/SD70
Torque Figures and Cut-Away of Front Axle
Removal and Replacement
Renewing the Pinion Oil Seal
Hub and Driveshaft
Dismantling
Assembly
Drivehead (4WS Machines)
Dismantling
Assembly
Drivehead (2WS Machines)
Dismantling
Assembly
Removal and Replacement (2 Wheel Drive Machines)
Dismantling and Assembly (2 Wheel Drive Machines)
Rear Axle
Torque Figures and Cut-Away of Rear Axle
Removal and Replacement
Renewing the Pinion Oil Seal
Brakes (without controlled back off)
Dismantling
Assembly
Brakes (with controlled back off)
Dismantling
Assembly
Hub and Driveshaft SD70
Doweled Hub – Dismantling
Doweled Hub – Assembly
Splined Hub – Dismantling
Splined Hub – Assembly
Hub and Driveshaft PD70
Dismantling and Assembly
Drivehead
Dismantling
Assembly
Limited Slip Differential
Dismantling and Assembly
Syncro Shuttle Tranmission
General Description and Operation
Syncromesh Operation
Clutch Operation
2/4 Wheel Drive Operation
Fault Finding
Syncro Shuttle Gearbox
2/4 Wheel Drive Clutch
Removal and Replacement
Sectional Views and Torque Figures
Gearbox
Dismantling
Assembly
Polytetrafluoroethylene (PTFE) Piston Ring Seals
Fitting Procedure
Solenoid Valve Unit
Dismantling and 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
Torque Converter
Removal and Replacement
Stall Test
Pressure and Flow Test
Collapsible Spacer – Assembly
Output Shaft (Larger Diameter Gear)
Powershift Transmissions
General Descriptions
Hydraulic Operation
Drivepaths
Clutch Operation
2/4 Wheel Drive Operation
Fault Finding
Transmission
2/4 Wheel Drive Clutch
Removal and Replacment
PS700 Sectional Views and Torque Figures
Dismantling (See Summary of Changes)
Assembly (See Summary of Changes)
Polytetrafluoroethene (PTFE) Piston Ring Seals
Fitting Procedure
Solenoid Valve
Dismantling and Assembly
PS700 Input Clutch and Reverser Clutch
Dismantling
Assembly
PS750 Input Clutch and Reverser Clutch
Dismantling
Assembly
PS700 Mainshaft
Dismantling
Assembly
PS750 Mainshaft
Dismantling
Assembly
PS700 Layshaft
Dismantling
Assembly
PS750 Layshaft
Dismantling
Assembly
Hydraulic 2/4 Wheel Drive Unit
Dismantling and Assembly
Torque Converter
Dismantling and Assembly
Torque Converter Stall Test
Testing For Clutch Leakage
Pressure and Flow Testing
Flushing the Transmission Oil
Powershift (With Reverser Shaft Sealing Plug & PS750) (See Summary of Changes)
PS750 Section Views and Torque Figures
Dismantling
Assembly

Section G: Brakes
Technical Data
Descriptions
Compensating Master Cylinder
Pedals Locked – Normal Operation
Pedals Locked – Compensating Operation
Pedals Unlocked – Normal Operation
Fault Finding
Brake System
Brake Piston Seal Leakage Test
Brake System
Bleeding
Parking Brake Caliper
Testing the Parking Brake
Parking Brake Adjustment
Dismantling and Assembly Type 1
Removal and Replacement Type 2
Dismantling and Assembly Type 2
Torque Figures
Service Brakes
Dismantling and Assembly
Master Cylinder and Servo unit
Removal and Replacement
Dismantling and Assembly

Section H: Steering
Technical Data
Steer Hydraulics (4WS Machines)
Steer Hydraulics (2WS Machines
Schematics
2WS Machines
4WS Machines
Fault Finding
Machine Steer Circuit Description
2WS Machines
4WS Machines
Priority Valve
Removal and Replacement
Dismantling and Assembly
Hydraulic Steer Unit
Removal and Replacment
Dismantling and Assembly
Steer Mode Valve
Removal and Replacement
Dismantling and Assembly
Steer System Pressure Testing
Steer System Bleed Procedure
Power Track Rod
Removal and Replacment
Link Arms – Removal and Replacement
Rams – Dismantling and Assembly
Proximity Switches
Setting Procedure

Section K: Engine
Technical Data
Engine
Removal and Replacement
Fuel Lift Pump

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