3CX, 4CX (S/N: 930001 to 960000) - 214e, 214, 215, 217 (S/N: 903000 Onwards)
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This workshop repair service manual PDF download for the 3CX, 4CX, 214e, 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, 214e, 214, 215, 217 & VARIANTS
From M/c No. 930000 Onwards
From M/c No. 903000 Onwards (USA)
3CX, 4CX (S/N: 930001 to 960000)
214e, 214, 215, 217 (S/N: 903000 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
Section L: Servo Controls (Precision Control)
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3280 Issue 9
Total Pages : 1212
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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Introduction
Colour Coding
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
Steering
Engine
Sealing and Retaining Compunds
Section 2: Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety
Section 3: Routine Maintenance
Checking for Damage
Cleaning the Machine
Seat Belt
Cehcking the Seat Belt Condition and Security
Fire Extinguisher (when fitted)
Checking
ROPS/FOPS Structure
Checking
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Lubricants - Health and Safety
Hygiene
Storage
Waste Disposal
Handling
First Aid - Oil
Spillage
Fires
Service Schedules
Loader Arm Safety Strut
Installing
Removing
Engine Panels
Opening and Closing the Bonnet
Removing and Fitting a Side Panel
Removing and Fitting the Front Grille
Greasing
General
Loader Arms
Backhoe & 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)
Engine Air Filter
Cleaning the Pre-Cleaner (if fitted)
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
Adjusting the Fan Belt
Cleaning the Cab Heater Filter
Fuel System
Types of Fuel
Fuel Standards
Low Temperature Fuels
Filling the Tank
Draining the Filter
Changing the Filter Element
Draining the Sediment Bowl
Cleaning the Fuel Lift Pump Strainer
Bleed the System
Fuel Pipes - Removal and Replacement
Synchro Shuttle Gearbox
Checking the Oil Level
Changing the Oil and Filter
Powershift Gearbox
Checking the Oil Level
Changing the Oil and Filter
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
Front and Rear Axle (Two Wheel Steer Machines)
Checking the Oil Level
Changing the Oil
Brakes
Parking Brake Adjustment
Checking the Foot Brake Fluid Level
Hydraulic System
Checking the Fluid Level
Hydraulic Tank Cap
Changing the Filter Element
Changing the Suction Strainer
Hydraulic Oil Cooler
Cleaning the Tubes/Fins
Windscreen Washer
Electrical System
Fuses and Relays
Battery
Warning Symbols
First Aid - Electrolyte
Checking the Electrolyte Level
Battery Isolator (if fitted)
Stabiliser Legs (Sideshift Machines Only)
Wear Pad Adjustment
Extending Dipper Wear Pads
Inspecting the Top Wear Pads
Adjusting the Bottom Wear Pads
Air Conditioning (if fitted)
Adjusting the Compressor Drive Belt
Hose Burst Protection Valve (if fitted)
Checking Hose Burst Protection Valve
Lowering a Load - In a Failure Condition
Service Capacities and Lubricants
Coolant Mixtures
Section A: Attachments
Hi-Flow Rockbreaker Attachment
Hydraulic Schematic and Operation
Gearpump machines with extending dipper
Variflow machines with extending dipper
Precision Control (Servo) machines with extending dipper
NOT servo machines up to serial no. 941509
Electrical Connections
NOT servo machines from serial no. 941510
NOT servo machines from June 2004
Precision Control (Servo ) machines from serial no. 937516
Precision Control (Servo) machines from June 2004
Hydraulic Tool Circuit (HTC) Attachment
Hydraulic Schematic and Operation
Gearpump machines with extending dipper
Flow Diverter Valve
Removal and Replacement
Dismantling and Assembly
Flow and Pressure Testing
Electrical Connections
NOT Servo machines from serial no. 941510
Precision Control (Servo) machines from serial no. 937516
3 Point Hitch (214e Machines Only)
Control Valve
Removal and Replacement
Rams
Removal and Replacement
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 Cleaning
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
Condenser Matrix - 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
Machines up to serial no. 933756
Machines from serial no. 933757
Precision Control (Servo) Machines
Link Box Fuses
Relays
Fuses (214e Machines only)
Basic System Operation
Circuit Schematic
Basic Machine - 3CX, 4CX, 214, 215, 217 (Not 214e Machines)
Synchro Shuttle and Powershift
Options
Steer Mode - 4CX and 3CX Super (4x4x4)
2 Wheel Steer/Brake Mode
2 Wheel Steer/Brake Mode (Germany)
All Wheel Steer/Brake Mode
Auxiliary and Hydraclamp Hydraulics
Speedometer
Hand Held Tools
Dedicated Quickhitch
Poleplanter
Smooth Ride System (SRS)
Return to Dig (Shovel Reset)
Hydraulic Speed Control (HSC)
6 Speed Powershift (Shiftmaster)
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
Dismantling, Inspection and Assembly
Earth Points
Harness Data
Drawings
Harness Interconnection - Machines up to serial no. 941509
Harness Interconnection, not servo - Serial no 941510 on
Harness Interconnection - servo (Precision Control) - Serial no 937516 on
Harness Data (214e Machines Only)
Drawings
Harness Interconnection
Section D: Controls
Steering Column
Removal and Replacement
Dismantling and Assembly
Shovel Reset (214e Machines)
Return to Dig
Operation
Adjustment
Control Rods and Linkages
Dismantling and Assembly
Loader Valve Controls (Type 1)
Loader Valve Controls (Type 2)
Excavator Valve Controls
Side Console Mounted Stabiliser Levers
Tower Mounted Stabiliser Levers
Auxiliary Footpedal Control
Control Cables
Removal and Replacement
Cab Heater Controls
Stabiliser Controls
Boom Lock Cable
Boom Stop Setting
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 (214e Machines Only)
Loader Valve - Variable Flow
Excavator Valve - Fixed Flow
Auxiliary Valve - Fixed Flow
Smooth Ride System - System Type
Basic System Operation
Component Location and Neutral Circuit Descriptions
Fixed Flow - Double Pump
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 with High Flow Options
4CXE. 4CX Super Machines - 6 Spool with High/Low Flow Options
4CX, 4CX Super - Hand Held Tools Option
Circuit Descriptions
Hydraulic Pump - Fixed Flow
Double Pump - Operation
Hydraulic Pump - Variable Flow
Operation
Pressure/Flow Regulator Valve
Loader Valve
Manual Control
Neutral Circuit
Unloader Operation
Hydraulic Speed Control (HSC)
Load Hold Check Valves Operation
Arms Lower
Float
Auxiliary Relief Valve (A.R.V.) Operation
Main Relief Valve (MRV) - Operation
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
Auxiliary Relief Valve (A.R.V.) Operation
Pilot Operated Pressure Relief Valve Operation
Hydraclamp Valve Operation (Sideshift Machines)
Smooth Ride System (if fitted)
With Hose Burst Protection Valves (Option)
Hose Burst Protection Valve
Boom and Dipper Operation
Loader Operation
Electrical Connections
Hydraulic Speed Control (HSC)
Quick Reference
Wires and Connectors
Fault Finding
Hydraulic System
Fixed Flow
Variable Flow
Smooth Ride System
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
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 (214e Machines only)
Pressure Testing
Main Relief Valve
Auxiliary Relief Valves
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
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 (if fitted)
Checking
Lowering a Load - In a Failure Condition
Pressure Testing - Loader Lift Ram
Valve Block Spool Seals
Seal Fitting
‘Positional Type’ Hydraulic Adaptors
Main Pump
Fixed Flow
Removal and Replacement
Dismantling and Assembly
Variable Flow
Dismantling and Assembly
Loader Valve (214e Machines only)
Removal and Replacement
Dismantling and Assembly
Main Relief Valve (MRV)
Auxiliary Relief Valves (ARV's)
Standard Spool
Float Spool
Electric Detent Spool
Loader Valve - Fixed Flow
Removal and Replacement
Manual Control
Dismantling and Assembly
Main Relief Valve
Auxiliary Relief Valves (ARV's) and Load Hold Check Valves (LHCV)
Unloader Valve
Standard Spool - Manual
Float Spool - Manual
Electric Detent Spool - Manual
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
Dismantling and Assembly
Manual Control
Auxiliary Relief Valves
Hydraclamp Valve (Sideshift Machines)
Hoses and Pipes (Sideshift Valve)
Hoses and Pipes (Centremount Valve)
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
Centremount
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
Oil Cooler Matrix
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
Powershift Gearbox - 4 Speed - 2004
Engine Stall Speed Combinations
Basic Operation
Axles
Front Axle-Steer Drive Type SD55, SD80
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
Shiftmaster Operation 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
Powershift Gearbox
Clutch Operation - Forward/Reverse
Clutch Operation - Mainshaft, Layshaft, 6 Speed
Clutch Operation - 2/4 Wheel Drive Clutch
Electrical Connections
Synchro Shuttle Gearbox
Powershift Gearbox - 4 Speed
Powershift Gearbox - 6 Speed (ShiftMaster)
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 - SD80, PD70
Renewing the Pinion Oil Seal
Brakes - Testing for Piston Seal Leakage
Synchro Shuttle Gearbox
Torque Converter Stall Test
Pressure and Flow Test
Forward/Reverse Solenoid Control Valve
Dismantling and Assembly
Powershift Gearbox
Gearbox Hydraulic Pump
Removal and Replacement
Suction Strainer (Cone Type)
Removal and Replacement
Torque Converter Stall Test
Pressure and Flow Tests
Pressure and Flow Tests - Powershift - 2004
Speed Sensor - Testing
ShiftMaster
Electronic Control Unit
Diagnostics User Guide
Diagnostics Troubleshooting guide
Propshafts
Removing and Replacing
Front Axle - SD55, SD80
Removal and Replacement
Hub - SD55
Dismantling
Assembly
Hub Swivel and Driveshaft - SD55
Dismantling and Assembly
Hub - SD80
Dismantling
Assembly
Hub Swivel and Driveshaft - SD80
Dismantling and Assembly
Drivehead - SD55
Dismantling
Assembly
Pinion Depth Setting
Crownwheel and Pinion Meshing
Drivehead - SD80
Dismantling
Assembly
Pinion Depth Setting
Crownwheel and Pinion Meshing
Front Axle - 2 Wheel Drive Machines
Removal and Replacement
Dismantling and Assembly
Rear Axle - SD80, PD70
Removal and Replacement
Brakes
Dismantling
Assembly
Hub - SD80
Dismantling and Assembly
Hub Swivel and Driveshaft - SD80
Dismantling and Assembly
Hub - PD70
Dismantling and Assembly
Driveshaft - PD70
Removal and Replacement
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
Clutch Dismantling and Assembly Procedures
Forward/Reverse Clutch
Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON)
2/4 Wheel Drive Clutch Pressure Testing
Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure
Powershift Gearbox
Removal and Replacement
Dismantling
Inspection
Assembly
Powershift - 2004
Dismantling
Inspection
Assembly
Clutch Dismantling and Assembly Procedures
Forward/Input & Reverser Clutch
Layshaft Clutch
Mainshaft Clutch
6 Speed Clutch
2/4 Wheel Drive Clutch (4WD Pressure ON)
2/4 Wheel Drive Clutch (4WD Spring ON)
Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure
Torque Converter
Removal and Replacement
Oil Cooler Matrix
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
2/4 Wheel Braking Modes
Electrical Connections
2/4-Wheel Braking Modes
Quick Reference
2-Wheel Steer Machines, Synchro Shuttle and Powershift
4-Wheel Steer Machines, Synchro Shuttle and Powershift
2-Wheel Steer Machines, ShiftMaster
4-Wheel Steer Machines, ShiftMaster
2-Wheel Steer Machines, Synchro Shuttle and Powershift - German specification
4-Wheel Steer Machines, Synchro Shuttle and Powershift - German specification
Wires and Connectors to serial no. 941509
Machines up to serial no. 941509
Machines from serial no. 941510
Fault Finding
Brake System
Service Procedures
Service Brakes
Brake Light Switch - Adjustment
Brake Vacuum Test
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
Basic System Operation
2 Wheel Steer Machines
Steer System Schematics
Hydraulic Operation
4 Wheel Steer Machines
Steer System Schematics
Hydraulic Operation
Electrical Operation
Electrical Connections
Steer Mode
Machines up to serial no. 941509
Machines from serial no. 941510
Circuit Descriptions
Steer Unit Operation
2 Wheel Steer Machines
4 Wheel Steer Machines
4 Wheel Steer Mode
2 Wheel Steer Mode
Crab Steer Mode
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
Re-phasing the Steer System
Checking Components for Internal Hydraulic Leakage
Power Track Rod
Removal and Replacement
Link Arms - Removal and Replacement
Rams - Dismantling and Assembly
Priority Valve
Removal and Replacement
Dismantling and Assembly
Bleeding
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
Section L: Servo Controls (Precision Control)
Service Tools
Technical Data
Relief Valve Pressures
Loader Valve
Excavator Valve
Fuses and Felays
Basic System Operation
Component Location
System Description
Hydraulic Operation
Electrical Operation
Excavator Joystick Controls
Loader Joystick Controls
Stabiliser Controls
Servo Pressure Supply Valve
Inloader Valve
Loader Servo Pressure Isolation Valve
ISO/SAE Control Pattern Changeover Valve
Hydraulic Speed Control System (Unloader Valve Controller)
Circuit Schematics
Electrical Circuit Schematics
Mode Enable/Loader Lever Cut-out Circuit (Italian and German machines)
Hydraulic Circuit Schematics
Circuit Descriptions
Loader Valve Services
Excavator Valve Services
Load Sense - Pressure Compensator Valves Operation
Inloader Valve Operation
Fault Finding
Introduction
No Servo Controls (system fails to operate)
All Services Slow to Operate
ALL Services slow to operate - Particularly noticable when operating the loader arms
Lack of Power in All Services
One Service Fails or is Slow to Operate
Hydraulic Speed Control ECU Faults
Service Procedures
Engine Throttle Position Sensor - Adjustment
Testing the Servo Pressure
Testing the Main System Pressure
Adjusting the LS Relief Valve
Pressure Compensator Network - Testing
Testing the Pressure in the Load Sense Line
Testing the Inloader Valve
Joystick Controllers
Removal and Replacement
Dismantling and Assembly
Servo Pressure Supply Valve
Removal and Replacement
Dismantling and Assembly
Inloader Valve
Removal and Replacement
Loader Valve
Dismantling and Assembly
Excavator Valve
Dismantling and Assembly
Flow Regulator Valve
Load Sense Relief Valve
Auxiliary Relief Valves (ARV's)
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