JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual

Section 1

General Information

Section 1

2 - 1

Torque Settings

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the

figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts

Bolt Size

Hexagon (A/F)

Torque Settings

(mm)

kgf m

lbf ft

1/4

(6.3)

7/16

1.4

5/16

(7.9)

1/2

2.8

3/8

(9.5)

9/16

5.0

7/16

(11.1)

5/8

8.0

1/2

(12.7)

3/4

117

12.0

9/16

(14.3)

13/16

170

17.3

125

5/8

(15.9)

15/16

238

24.3

175

3/4

(19.0)

11/8

407

41.5

300

7/8

(22.2)

15/16

650

66.3

480

(25.4)

11/2

970

99.0

715

11/4

(31.7)

17/8

1940

198.0

1430

11/2

(38.1)

21/4

3390

345.0

2500

Metric Grade 8.8 Bolts

Bolt Size

Hexagon (A/F)

Torque Settings

(mm)

kgf m

lbf ft

(5)

0.7

(6)

1.2

(8)

3.0

M10

(10)

5.7

M12

(12)

M16

(16)

244

180

M20

(20)

476

352

M24

(24)

822

607

M30

(30)

1633

166

1205

M36

(36)

2854

291

2105

Rivet Nut Bolts/Screws

Bolt Size

Torque Settings (for steel rivet nuts)

(mm)

kgf m

lbf ft

(3)

1.2

0.12

0.9

(4)

3.0

0.3

2.0

(5)

6.0

0.6

4.5

(6)

10.0

1.0

7.5

(8)

24.0

2.5

18.0

M10

(10)

48.0

4.9

35.5

M12

(12)

82.0

8.4

60.5

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/3280

Issue 1

Section 1

General Information

Section 1

3 - 1

Service Tools Numerical List

Page No.

460/15708

Flow Test Adapter

4 - 13

823/10420

Shim Kit - Powershift gearbox,

460/15707

Banjo Bolt

4 - 13

layshaft clutch

4 - 17

1406/0011

Bonded Washer

4 - 7

825/00410

Crowfoot Wrench

4 - 4

1406/0014

Bonded Washer

4 - 7

825/99833

Adapter for 825/00410

4 - 4

1406/0018

Bonded Washer

4 - 7, 13

826/01099

Rivet Nut

4 - 1

1406/0021

Bonded Washer

4 - 6, 4 - 7

826/01101

Rivet Nut

4 - 1

1406/0029

Bonded Washer

4 - 7

826/01102

Rivet Nut

4 - 1

1604/0003

Male Adapter

4 - 7

826/01103

Rivet Nut

4 - 1

1604/0004

Male Adapter

4 - 7, 13

826/01104

Rivet Nut

4 - 1

1604/0006

Male Adapter

4 - 6, 4 - 7

826/01105

Rivet Nut

4 - 1

1604/0008

Adapter

4 - 6

892/00011

Spool Clamp

4 - 8

1606/0003

Male Adapter

4 - 7

892/00041

De-glazing Tool

4 - 19

1606/0004

Male Adapter

4 - 7

892/00047

Adapter

4 - 8

1606/0007

Male Adapter

4 - 7

892/00048

Adapter

4 - 8

1606/0008

Male Adapter

4 - 7

892/00049

Adapter

4 - 8

1606/0009

Male Adapter

4 - 7

892/00051

Adapter

4 - 8

1606/0012

Male Adapter

4 - 6, 4 - 7

892/00055

Blanking Plug

4 - 8

1606/0014

Male Adapter

4 - 7

892/00056

Blanking Plug

4 - 8

1606/0015

Male Adapter

4 - 6, 4 - 7

892/00057

Blanking Plug

4 - 8

1606/0017

Male Adapter

4 - 7

892/00058

Blanking Plug

4 - 8

1612/0006

Adapter

4 - 6

892/00059

Blanking Plug

4 - 8

2401/0222

O-ring

4 - 13

892/00060

Blanking Plug

4 - 8

2403/0110

O-ring

4 - 13

892/00071

Male Adapter

4 - 7

2403/0108

O-ring

4 - 13

892/00074

Female Connector

4 - 8

4101/0651

Retainer (High Strength)

5 - 1

892/00075

Female Connector

4 - 8

4101/0250

Threadlocker and Sealer (10 ml)

5 - 1

892/00076

Female Connector

4 - 8

4101/0251

Threadlocker and Sealer (50 ml)

5 - 1

892/00077

Female Connector

4 - 8

4101/0451

Threadlocker

5 - 1

892/00078

Connector

4 - 6

4102/0502

High Strength Gasketing

5 - 1

892/00137

Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7

4102/0551

High Strength Threadlocker

5 - 1

892/00167

Ram Seal Protection Sleeve 90 mm

4 - 9

4102/0933

Clear Silicone Sealant

5 - 1

892/00174

Measuring Cup

4 - 11

4102/1212

Multi-Gasket

5 - 1

892/00179

Bearing Press

4 - 10

4102/1951

Threadseal

5 - 1

892/00180

Seal Fitting Tool

4 - 9

4102/2309

Black Polyurethane Sealant

5 - 1

892/00181

Replacement Plastic Boss

4 - 9

4103/2109

Ultra Fast Adhesive (310ml)

5 - 1

892/00182

Bearing Pad Driver

4 - 12

4104/0251

Activator (Aersol)

5 - 1

892/00223

Hand Pump

4 - 7

4104/0253

Activator (Bottle)

5 - 1

892/00224

Impulse Extractor

4 - 11

4104/1203

Active Wipe 205 (250g)

5 - 1

892/00225

Adapter for Extractor

4 - 11

4104/1206

Active Wipe 205 (30 ml)

5 - 1

892/00253

Pressure Test Kit

4 - 6

4104/1310

Hand Cleaner

4 - 1

892/00255

Pressure Test Adapter

4 - 6

4104/1538

JCB Cleaner & Degreaser

5 - 1

892/00256

Pressure Test Adapter

4 - 6

4104/1557

Cleaner/Degreaser (400 ml)

5 - 1

892/00257

Pressure Test Adapter

4 - 6

4201/4906

Black Primer 206J (30ml)

5 - 1

892/00258

Pressure Test Adapter

4 - 6

816/00017

Adapter

4 - 8

892/00259

Pressure Test Adapter

4 - 6

816/00189

Blanking Cap

4 - 8

892/00260

Pressure Test Adapter

4 - 6

816/00190

Blanking Cap

4 - 8

892/00261

Pressure Test Adapter

4 - 6

816/00193

Blanking Cap

4 - 8

892/00262

Pressure Test 'T' Adapter

4 - 6, 4 - 7

816/00196

Blanking Cap

4 - 8

892/00263

Pressure Test 'T' Adapter

4 - 6

816/00197

Blanking Cap

4 - 8

892/00264

Pressure Test 'T' Adapter

4 - 6

816/00294

Blanking Cap

4 - 8

892/00265

Pressure Test 'T' Adapter

4 - 6

816/00439

Male Adapter

4 - 7

892/00268

Flow Monitoring Unit

4 - 6

816/00440

Male Adapter

4 - 7

892/00269

Sensor Head

4 - 6

816/15007

Male Adapter

4 - 7

892/00270

Load Valve

4 - 6

816/15008

Male Adapter

4 - 7

892/00271

Adapter

4 - 6

816/15118

Pressure Test Adapter

4 - 6

892/00272

Adapter

4 - 6

816/20008

Adapter

4 - 6

892/00273

Sensor Head

4 - 6

816/20013

Adapter

4 - 6

892/00274

Adapter

4 - 7

816/50005

Adapter

4 - 8

892/00275

Adapter

4 - 6

816/50043

Adapter

4 - 8

892/00276

Adapter

4 - 6

816/55038

Pressure Test 'T' Adapter

4 - 6

892/00277

Adapter

4 - 6

816/55040

Pressure Test 'T' Adapter

4 - 6

892/00278

Gauge

4 - 7

816/60096

Adapter

4 - 8

892/00279

Gauge

4 - 7

9803/3280

Issue 2*

Section 1

General Information

Section 1

3 - 2

Service Tools Numerical List

Page No.

892/00282

Shunt

4 - 4

Shaft Lock Screw

4 - 13

892/00283

Tool Kit Case

4 - 4

892/00284

Tachometer

4 - 4

892/01078

Synchro Shuttle Gearbox

892/00285

Hydraulic Oil Temperature Probe

4 - 4

Mainshaft Adjuster

4 - 13

892/00286

Surface Temperature Probe

4 - 4

892/00293

Connector Pipe

4 - 6

892/01076

Synchro Shuttle Support Plate

892/00294

Connector Pipe

4 - 6

Transfer gear end float setting

4 - 13

892/00298

Fluke Meter

4 - 4

892/01082

Powershift - Assembly Cradle

4 - 17

892/00301

Flow Test Adapter

4 - 10

892/01083

Powershift - Assembly tool,

892/00302

Flow Test Adapter

4 - 10

transfer gear

4 - 17

892/00309

ARV Test Kit

4 - 7

892/01084

Powershift - Transfer gear, bearing

892/00333

Heavy Duty Socket

4 - 11

assembly

4 - 17

892/00334

Ram Seal Fitting Tool

4 - 9

892/01085

Powershift - Seal fitting tool

4 - 17

892/00335

ARV Cartridge Removal Tool

4 - 7

926/15500

Rubber Spacer Blocks

4 - 3

892/00706

Test Probe

4 - 6, 4 - 7

992/04000

Torque Multiplier

4 - 12

892/00812

Drive Coupling Spanner

4 - 10

992/04800

Flange Spanner

4 - 12

892/00817

Heavy Duty Socket

4 - 11

992/07608

Bearing Adapter

4 - 10

892/00818

Heavy Duty Socket

4 - 11

992/07609

Bearing Adapter

4 - 10

892/00819

Heavy Duty Socket

4 - 11

992/07610

Bearing Adapter

4 - 10

892/00822

Splined Bolt Socket

4 - 11

992/07611

Bearing Adapter

4 - 10

892/00836

Lifting Wire Assembly

4 - 19

992/07612

Bearing Adapter

4 - 10

892/00842

Glass Lifter

4 - 2

992/07613

Bearing Adapter

4 - 10

892/00843

Folding Stand

4 - 1

992/09100

Spool Clamp

4 - 8

892/00844

Long Knife

4 - 3

992/09200

Charging Tool

4 - 1

892/00845

Cartridge Gun

4 - 1

992/09300

Ram Spanner

4 - 8

892/00846

Glass Extractor (Handles)

4 - 2

992/09400

Ram Spanner

4 - 8

892/00847

Nylon Spatula

4 - 3

992/09500

Ram Spanner

4 - 8

892/00848

Wire Starter

4 - 2

992/09600

Ram Spanner

4 - 8

892/00849

Braided Cutting Wire

4 - 3

992/09700

Ram Spanner

4 - 8

892/00881

Spool Seal Fitting Tool

4 - 7

992/09900

Ram Spanner

4 - 8

892/00882

Alternator Pulley Socket

4 - 5

992/10000

Ram Spanner

4 - 8

892/00891

Wheel Hub Seal - Fitting Tool

4 - 10

992/12300

12V Mobile Oven

4 - 1

892/00918

Setting Tool Kit

4 - 16

992/12400

Static Oven - 2 Cartridge

4 - 2

892/00920

Flow Test Adapter

4 - 10

992/12600

Static Oven - 6 Cartridge

4 - 2

892/00922

12.2” T/C Alignment Tool

4 - 10

992/12800

Cut-Out Knife

4 - 2

892/00948

Charging Kit

4 - 9

992/12801

"L" Blades

4 - 2

892/00949

Pressure Gauge

4 - 9

993/55700

Direct Glazing Kit

5 - 1

892/00956

Timing Pin

4 - 19

993/59500

Impulse Extractor Adapter

4 - 11

892/00964

Test Point (1/8BSP)

4 - 12

993/68100

Slide Hammer Kit

4 - 3

892/00965

Test Point (3/8BSP)

4 - 12

993/69800

Seal Kit

4 - 6

892/00966

Test Point (1/4BSP

4 - 12

993/70111

Breakback Torque Wrench

4 - 15

892/01016

Ram Seal Protection Sleeve 25 mm

4 - 9

993/85700

Battery Tester

4 - 4

892/01017

Ram Seal Protection Sleeve 30 mm

4 - 9

7210/0001

Dummy Plug

4 - 5

892/01018

Ram Seal Protection Sleeve 40 mm

4 - 9

7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

4 - 5

892/01019

Ram Seal Protection Sleeve 50 mm

4 - 9

7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

4 - 5

892/01020

Ram Seal Protection Sleeve 50 mm

4 - 9

7212/0001

2 Way Socket Connector

4 - 5

(slew ram)

7212/0002

2 Way Pin Housing

4 - 5

892/01021

Ram Seal Protection Sleeve 60 mm

4 - 9

7212/0003

2 Way Socket Retainer

4 - 5

892/01022

Ram Seal Protection Sleeve 60 mm

4 - 9

7212/0004

2 Way Pin Retainer

4 - 5

(slew ram)

7213/0001

3 Way Socket Connector

4 - 5

892/01023

Ram Seal Protection Sleeve 65 mm

4 - 9

7213/0002

3 Way Pin Housing

4 - 5

892/01024

Ram Seal Protection Sleeve 70 mm

4 - 9

7213/0003

3 Way Socket Retainer

4 - 5

892/01025

Ram Seal Protection Sleeve 75 mm

4 - 9

7213/0004

3 Way Pin Retainer

4 - 5

892/01026

Ram Seal Protection Sleeve 80 mm

4 - 9

7213/0005

3 Way Socket Connector (DT)

4 - 5

892/01027

Piston Seal Assembly Tool

4 - 9

7213/0006

3 Way Pin Housing (DT)

4 - 5

892/01033

Electronic Service Tool Kit

4 - 18

7213/0007

3 Way Socket Retainer (DT)

4 - 5

892/01096

Speed Sensor Test Harness

4 - 17

7213/0008

3 Way Pin Retainer (DT)

4 - 5

892/01079

Ring Socket Spanner

7214/0001

4 Way Socket Connector

4 - 5

Mainshaft setting ring

4 - 13

7214/0002

4 Way Pin Housing

4 - 5

892/01080

Ring Socket Spanner

7214/0003

4 Way Socket Retainer

4 - 5

Layshaft setting ring

4 - 13

7214/0004

4 Way Pin Retainer

4 - 5

892/01077

Synchro Shuttle Gearbox Selector

7216/0001

6 Way Socket Connector

4 - 5

9803/3280

Issue 3*

Section 1

General Information

Section 1

3 - 3

Service Tools Numerical List

7216/0002

6 Way Pin Housing

4 - 5

The following parts are replacement items for kits and would

7216/0003

6 Way Socket Retainer

4 - 5

normally be included in the kit numbers quoted on pages

7216/0004

6 Way Pin Retainer

4 - 5

1/3-1 and 1/3-2.

7218/0001

8 Way Socket Connector

4 - 5

7218/0002

8 Way Pin Housing

4 - 5

Service Tools Numerical List

Page No.

7218/0003

8 Way Socket Retainer

4 - 5

Replacement item for kit no. 892/00180

7218/0004

8 Way Pin Retainer

4 - 5

892/00181

4 - 9

7219/0001

10 Way Socket Connector

4 - 5

7219/0002

10 Way Pin Housing

4 - 5

Replacement items for kit no. 892/00253

7219/0003

10 Way Socket Retainer

4 - 5

892/00201

Replacement Gauge

4 - 6

7219/0004

10 Way Pin Retainer

4 - 5

892/00202

Replacement Gauge

4 - 6

7219/0005

14 Way Socket Connector

4 - 5

892/00203

Replacement Gauge

4 - 6

7219/0006

14 Way Pin Housing

4 - 5

892/00254

Replacement Hose

4 - 6

7219/0007

14 Way Socket Retainer

4 - 5

7219/0008

14 Way Pin Retainer

4 - 5

Replacement items for kit no. 892/00309

892/00340

Test Block Body

4 - 7

892/00341

Setting Body

4 - 7

892/00343

Spanner

4 - 7

892/00345

Anti-Cavitation Lock Out Bung

4 - 7

993/68300

Adjusting Pin

4 - 7

Replacement items for kit no. 993/68100

993/68101

Slide Hammer

4 - 3

993/68102

End Stops

4 - 3

993/68103

Adaptor - M20 x 5/8" UNF

4 - 3

993/68104

Adaptor - M20 x 1" UNF

4 - 3

993/68105

Adaptor - M20 x M20

4 - 3

993/68106

Adaptor - M20 x M24

4 - 3

993/68107

Bar - M20 x M20 X 800MM

4 - 3

993/68108

Adaptor - M20 x 7/8" UNF

4 - 3

993/68109

Adaptor - M20 x M12

4 - 3

993/68110

Adaptor - M20 x 5/8" UNF (Shoulder)

4 - 3

993/68111

Adaptor - M20 x 1/2" UNF

4 - 3

9803/3280

Issue 2*

Section 1

General Information

Section 1

4 - 1

Service Tools (cont'd)

Section B - Body & Framework

826/01099

M6 x 16mm Rivet Nut

826/01101

M6 x 19mm Rivet Nut

826/01103

M8 x 18mm Rivet Nut

826/01102

M8 x 21mm Rivet Nut

826/01104

M10 x 23mm Rivet Nut

826/01105

M10 x 26mm Rivet Nut

Installation Tool Available from:

Bollhoff Fastenings Ltd.

Midacre

The Willenhall Estate

Rose Hill

Willenhall

West Midlands, WV13 2JW

S261210

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane materials etc.

JCB part number - 892/00845

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310

(454g; 1 lb tub)

S186240

S186270

Folding Stand for

Holding

Glass

essential for preparing

new glass prior to

installation.

12V Mobile Oven - 1 cartridge capacity - required to

JCB part number

pre-heat adhesive prior to use. It is fitted with a male

892/00843

plug (703/23201) which fits into a female socket

(715/04300).

JCB part number - 992/12300

S186250

S186280

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 2

Service Tools (cont'd)

Section B - Body & Framework

240V Static Oven - available with 2 or 6 cartridge

Glass Lifter - minimum 2 off - essential for glass

capacity - required to pre-heat adhesive prior to use.

installation, 2 required to handle large panes of glass.

No plug supplied. Note: 110V models available upon

Ensure suction cups are protected from damage

request - contact JCB Technical Service.

during storage.

JCB part number:

JCB part number - 892/00842

992/12400 - 2 Cartridge x 240V

992/12600 - 6 Cartridge x 240V

S186300

S186260

Wire Starter

- used to

access braided cutting wire

(below) through original

polyurethane seal.

Cut-Out Knife - used to

remove broken glass.

JCB part number - 992/12800

JCB part number - 892/00848

S186310

S186340

'L' Blades - 25 mm (1 in) cut - replacement blades for

cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting

wire (below) to cut out broken glass.

JCB part number - 892/00846

S186320

S186350

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 3

Service Tools (cont'd)

Section B - Body & Framework

Long Knife - used to give extended reach for normally

Braided Cutting Wire - consumable heavy duty cut-out

inaccessible areas.

wire used with the glass extraction tool (above).

JCB part number - 892/00844

JCB part number - 892/00849

(approx 25 m length)

S186330

S186360

Rubber Spacer Blocks - used to provide the correct

set clearance between glass edge

and cab frame.

JCB part number - 926/15500

Nylon Spatula

(unit quantity = 500 off)

general tool used for

smoothing sealants - also

used to re-install glass in

rubber glazing because metal tools

will chip the glass edge.

JCB part number - 892/00847

S186470

S186550

Slide Hammer Kit - 993/68100

:993/68101 Slide Hammer

:993/68106 Adaptor - M20 x M24

:993/68102 End Stops

:993/68107 Bar - M20 x M20 X 800MM

:993/68103 Adaptor - M20 x 5/8" UNF

:993/68108 Adaptor - M20 x 7/8" UNF

:993/68104 Adaptor - M20 x 1" UNF

:993/68109 Adaptor - M20 x M12

:993/68105 Adaptor - M20 x M20

:993/68110 Adaptor - M20 x 5/8" UNF (Shoulder)

:993/68111 Adaptor - M20 x 1/2" UNF

S196910

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 5

Service Tools (cont'd)

Section C - Electrics

Electrical Repair Kit

:7216/0002

6 Way Pin Housing

:7212/0002

2 Way Pin Housing

:7216/0004

6 Way Pin Retainer

:7212/0004

2 Way Pin Retainer

:7216/0003

6 Way Socket Retainer

:7212/0003

2 Way Socket Retainer

:7216/0001

6 Way Socket Connector

:7212/0001

2 Way Socket Connector

:7218/0002

8 Way Pin Housing

:7213/0002

3 Way Pin Housing

:7218/0004

8 Way Pin Retainer

:7213/0004

3 Way Pin Retainer

:7218/0003

8 Way Socket Retainer

:7213/0003

3 Way Socket Retainer

:7218/0001

8 Way Socket Connector

:7213/0001

3 Way Socket Connector

:7219/0002

10 Way Pin Housing

:7213/0006

3 Way Pin Housing (DT)

:7219/0004

10 Way Pin Retainer

:7213/0008

3 Way Pin Retainer (DT)

:7219/0003

10 Way Socket Retainer

:7213/0007

3 Way Socket Retainer (DT)

:7219/0001

10 Way Socket Connector

:7213/0005

3 Way Socket Connector (DT)

:7219/0006

14 Way Pin Housing

:7214/0002

4 Way Pin Housing

:7219/0008

14 Way Pin Retainer

:7214/0004

4 Way Pin Retainer

:7219/0007

14 Way Socket Retainer

:7214/0003

4 Way Socket Retainer

:7219/0005

14 Way Socket Connector

:7214/0001

4 Way Socket Connector

:7210/0001

Dummy Plug

:7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

:7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

S188380

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 6

Service Tools (cont'd)

Section E - Hydraulics

Hydraulic Circuit Pressure Test Kit

892/00253

Pressure Test Kit

:892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in²)

:892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in²)

:892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in²)

:892/00254

Replacement Hose

S267300

993/69800

Seal Kit for 892/00254 (can also be used with

probe 892/00706)

892/00706

Test Probe

S188121

S188131

Pressure Test Adapters

Pressure Test 'T' Adapters

892/00255

1/4 in BSP x Test Point

892/00256

3/8 in BSP x Test Point

S200141

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

892/00257

1/2 in BSP x Test Point

816/55038

3/8 in M BSP x 3/8 in F BSP x Test Point

892/00258

5/8 in BSP x Test Point

816/55040

1/2 in M BSP x 1/2 in F BSP x Test Point

816/15118

3/4 in BSP x Test Point

892/00263

5/8 in M BSP x 5/8 in F BSP x Test Point

892/00259

1 in BSP x Test Point

892/00264

3/4 in M BSP x 3/4 in F BSP x Test Point

892/00260

1.1/4 in BSP x Test Point

892/00265

1 in M BSP x 1 in F BSP x Test Point

892/00261

5/8 in UNF x Test Point

Flow Test Equipment

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006

Adapter 3/4 in M x 3/4 in M BSP

1612/0006

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

892/00273

Sensor Head 0 - 380 l/min

892/00294

Connector Pipe

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1606/0012

Adapter 1 in M x 3/4 in M BSP

S188151

816/20013

Adapter 3/4 in F x 1 in M BSP

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 7

Service Tools (cont'd)

Section E - Hydraulics

Components for Valve Block A.R.V. Testing

For 4CX Variable Flow machines use 25/201103

892/00881

Valve Spool

892/00309

A.R.V. Pressure Test Kit

Seal Fitting Tool

: 892/00340

Test Block Body

: 892/00341

Setting Body

: 993/68300

Adjusting Pin

: 892/00343

Spanner

: 892/00345

Anti-cavitation Lock Out Bung

892/00335

A.R.V. Cartridge Removal Tool

S261220

S196700

Hand Pump Equipment

892/00223

Hand Pump

Bonded Washers

892/00137

Micro-bore Hose 1/4 in BSP x 3 metres

892/00274

Adapter 1/4 in M BSP x 3/8 in M BSP Taper

1406/0011

1/4 in. BSP

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

1406/0018

1/2 in. BSP

892/00706

Test Probe

1406/0014

5/8 in. BSP

892/00278

Gauge 0 - 40 bar (0 - 600 lbf/in²)

1406/0021

3/4 in. BSP

892/00279

Gauge 0 - 400 bar (0 - 6000 lbf/in²)

1406/0029

1.1/4 in. BSP

S188140

S193850

Male Adapters - BSP x NPT (USA only)

Male Adapters - BSP x BSP

816/00439

3/8 in. x 1/4 in.

1606/0003

3/8 in. x 1/4 in.

816/00440

1/2 in. x 1/4 in.

1604/0003

3/8 in. x 3/8 in.

816/15007

3/8 in. x 3/8 in.

892/00071

3/8 in. x 3/8 in. taper

816/15008

1/2 in. x 3/8 in.

1606/0004

1/2 in. x 1/4 in.

1606/0007

1/2 in. x 3/8 in.

1604/0004

1/2 in. x 1/2 in.

1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

1606/0009

3/4 in. x 1/2 in.

1604/0006

3/4 in. x 3/4 in.

1606/0012

3/4 in. x 1 in.

1606/0014

3/4 in. x 1.1/4 in.

1606/0015

1 in. x 1.1/4 in.

S193860

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 8

Service Tools (cont'd)

Section E - Hydraulics

Female Cone Blanking Plug

892/00055

1/4 in. BSP

Male Cone Blanking Cap

892/00056

3/8 in. BSP

816/00294

1/4 in. BSP

892/00057

1/2 in. BSP

816/00189

3/8 in. BSP

892/00058

5/8 in. BSP

816/00190

1/2 in. BSP

892/00059

3/4 in. BSP

816/00197

5/8 in. BSP

892/00060

1 in. BSP

816/00196

3/4 in. BSP

816/00193

1 in. BSP

S193880

S193870

S193890

S193900

892/00047

3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048

1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049

5/8 in. BSP (A) x 1/4 in. BSP (B)

Female Connectors

816/50043

3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051

1 in. BSP (A) x 1/4 in. BSP (B)

892/00074

3/8 in. BSP x 3/8 in. BSP

816/50005

1/2 in. BSP (A) x 1/2 in. BSP (B)

892/00075

1/2 in. BSP x 1/2 in. BSP

816/60096

3/4 in. BSP (A) x 3/4 in. BSP (B)

892/00076

5/8 in. BSP x 5/8 in. BSP

816/00017

1 in. BSP (A) x 1 in. BSP (B)

892/00077

3/4 in. BSP x 3/4 in. BSP

992/09100

Excavator Spool Clamp

Hexagon Spanners for Ram Pistons and End Caps

892/00011

Spool Clamp

992/09300

55mm A/F

992/09400

65mm A/F

992/09500

75mm A/F

992/09600

85mm A/F

992/09700

95mm A/F

992/09900

115mm A/F

992/10000

125mm A/F

S216210

S193930

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 10

Service Tools (cont'd)

Section F - Transmission

892/00920 Flow Test Adapter

892/00812

Drive Coupling Spanner for front

892/00301 Flow Test Adapter

axle and gearbox yoke

892/00302 Flow Test Adapter

couplings

S196720

S266880

892/00922

12.2” Torque Converter Alignment Tool

892/00179

Bearing Press (use with

appropriate adapters)

S267260

S188200

992/07608

Bearing Adapter

992/07609

Bearing Adapter

992/07610

Bearing Adapter

992/07611

Bearing Adapter

992/07612

Bearing Adapter

992/07613

Bearing Adapter

S188160

S261230

Torque Measuring Tool for Wheel Hub Seals

Manufacture locally, procedures in this manual show

checking the wheel hub seal using a rolling force.

892/00891

However, the torque can be measured using above

locally manufactured tool.

Fitting Tool Assembly for

Wheel Hub Seals

Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft)

excluding seal drag. Maximum permissible including

seal drag is 40 Nm (29.5 lbf ft).

S227760

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 14

Service Tools (cont'd)

Section F - Transmission

Hydraulic Circuit Pressure Test Kit (also used for main hydraulic

system tests)

892/00253

Pressure Test Kit

:892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in²)

:892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in²)

:892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in²)

S267300

:892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with

probe 892/00706)

892/00706

Test Probe

S188121

Flow Test Equipment (also used for main hydraulic system

tests)

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006

Adapter 3/4 in M x 3/4 in M BSP

1612/0006

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

892/00273

Sensor Head 0 - 380 l/min

892/00294

Connector Pipe

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

S188151

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 16

Service Tools (cont'd)

Section F - Transmission

Solid Spacer Setting Kit

921/53400

Spacer Kit - Sychro Shuttle Gearbox,

Synchro Shuttle Gearbox, SD70, SD80

SD70, SD80 Axles

Axles

Comprises of:

892/00918

Setting Tool Kit

Spacer thickness mm

921/52627

Spacer 14.20 Service use

921/52628

12.600

993/70111

Breakback Torque Wrench

829/30405

12.625

892/01076

Support Bracket -

921/52629

12.650

829/30406

12.675

Synchro Shuttle Gearbox

921/52630

12.700

892/01075

Support Bracket

829/30407

12.725

PD70, SD80 Rear Axles

921/52601

12.750

997/11000

Support Bracket

829/30408

12.775

SD55, SD70 Front Axles

921/52602

12.800

998/10567

SD80 Pinion Shaft Adaptor

829/30409

12.825

921/52603

12.850

921/53300

Spacer Kit - SD55 Axles

829/30410

12.875

921/52604

12.900

Comprises of:

829/30411

12.925

Spacer thickness mm

921/52605

12.950

921/53322

13.550

829/30412

12.975

921/53323

13.575

921/52606

13.000

829/30413

13.025

921/53324

13.600

921/52607

13.050

921/53325

13.625

829/30414

13.075

921/53301

13.650

921/52608

13.100

921/53302

13.675

829/30415

13.125

921/53303

13.700

921/52609

13.150

921/53304

13.725

829/30416

13.175

921/53305

13.750

921/52610

13.200

921/53306

13.775

829/30417

13.225

921/53307

13.800

921/52611

13.250

921/53308

13.825

921/53424

13.275

921/53309

13.850

921/53425

13.300

921/53310

13.875

921/53426

13.325

921/53427

13.350

921/53311

13.900

921/53428

13.375

921/53312

13.925

921/53401

13.400

921/53313

13.950

921/53402

13.425

921/53314

13.975

921/53403

13.450

921/53315

14.000

921/53404

13.475

921/53316

14.025

921/53405

13.500

921/53317

14.050

921/53406

13.525

921/53318

14.075

921/53407

13.550

921/53319

14.100

921/53408

13.575

921/53320

14.125

921/53409

13.600

921/53321

14.150

921/53410

13.625

921/53411

13.650

921/53412

13.675

921/53413

13.700

921/53414

13.725

921/53415

13.750

921/53416

13.775

921/53417

13.800

921/53418

13.825

921/53419

13.850

921/53420

13.875

921/53421

13.900

921/53422

13.925

921/53423

13.950

921/52626

14.000

Note: After using a spacer, obtain a replacement to keep the

set complete.

9803/3280

Issue 1

Section 1

General Information

Section 1

4 - 17

Service Tools (cont'd)

Section F - Transmission

892/01083

Powershift - Assembly tool, transfer gear.

892/01084

Powershift - Transfer gear, bearing assembly.

892/01085

Powershift - Seal fitting tool

892/01094 Transmission Jack

When removing the Powershift gearbox use of a special

transmission jack is strongly recommended. This jack

can also be used when removing Synchro Shuttle

gearboxes.

Note that the jack must be used with special support

plates, see below.

A402680

* Powershift - Support plates, for use with transmission jack,

Manufacture locally, for details see Section F, Service

Tools.

892/01082 - Powershift - Assembly Cradle, for details see

Section F, Service Tools.

Powershift - Gearbox hydraulic pump removal tools, allow

pump to be removed with torque converter housing fitted to

gearbox. Manufacture locally, for details see Section F,

Service Tools.

823/10420

Thrust Washer Kit - Powershift

892/01096

Speed Sensor Test Harness -

gearbox - Layshaft clutch

Powershift Gearbox

Comprises of:

Washer thickness mm

823/10421

4.3

823/10422

4.4

823/10423

4.5

823/10424

4.6

823/10425

4.7

823/10426

4.8

298910

9803/3280

Issue 3*

Section 1

General Information

Section 1

5 - 1

Sealing and Retaining Compounds

JCB Multi-Gasket

A medium strength sealant suitable for all

sizes of gasket flanges, and for hydraulic fittings

of 25-65mm diameter.

4102/1212

50ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded

components. Gasketing for all sizes of flange where

the strength of the joint is important.

4102/0551

50ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be

dismantled.

4101/0651

50ml

JCB Threadlocker and Sealer

A high strength locking fluid for sealing

4101/0250

10ml

and retaining nuts, bolts, and screws up to

4101/0251

50ml

50mm diameter, and for hydraulic fittings up

to 25mm diameter.

Threadseal

A medium strength thread sealing compound.

4102/1951

50ml

Threadlocker

A locking fluid for use on threads larger than

50mm dia.

4101/0451

50ml

Activator

A cleaning primer which speeds the curing rate

4104/0251

(1ltr)

of anaerobic products.

4104/0253

Bottle (200ml)

Cleaner / Degreaser

For degreasing components prior to use of

anaerobic adhesives and sealants.

4104/1557

400ml

Direct Glazing Kit

For one pane of glass, comprises items

marked † below plus applicator nozzle etc.

993/55700

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1206

30 ml

4104/1203

250 g

† Black Primer 206J

For direct glazing

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass

4102/0933

Black Polyurethane Sealant

To finish exposed edges of laminated glass

4102/2309

310 ml

JCB Cleaner & Degreaser

For degreasing components prior to use of anaerobic

adhesives and sealants.

4104/1538

Aerosol

9803/3280

Issue 1

Section 2

Care & Safety

Section 2

2 - 1

All construction and agricultural equipment can be

hazardous. When a JCB machine is correctly operated and

properly maintained, it is a safe machine to work with. But

when it is carelessly operated or poorly maintained it can

become a danger to you (the operator) and others.

Do not work with the machine until you are sure that you can

control it.

Do not start any job until you are sure that you and those

around you will be safe.

If you are unsure of anything, about the machine or the job,

ask someone who knows. Do not assume anything.

Remember

BE CAREFUL

BE ALERT

BE SAFE

GEN-1-6

General Safety

! WARNING

Decals

Lifting Equipment

You can be injured if you do not obey the decal safety

You can be injured if you use faulty lifting equipment. Make

instructions. Keep decals clean. Replace unreadable or

sure that lifting equipment is in good condition. Make sure

missing decals with new ones before operating the machine.

that lifting tackle complies with all local regulations and is

Make sure replacement parts include warning decals where

suitable for the job. Make sure that lifting equipment is

necessary.

strong enough for the job.

INT-1-3-4

INT-1-3-7

! WARNING

Care and Alertness

Raised Attachments

All the time you are working with or on the machine, take

Raised attachments can fall and injure you. Do not walk or

care and stay alert. Always be careful. Always be alert for

work under raised attachments unless they are safely

hazards.

blocked.

INT-1-3-5

INT-1-3-8

! WARNING

Clothing

You can be injured if you do not wear the proper clothing.

Loose clothing can get caught in the machinery. Wear

protective clothing to suit the job. Examples of protective

clothing are: a hard hat, safety shoes, safety glasses, a well

fitting overall, ear-protectors and industrial gloves. Keep

cuffs fastened. Do not wear a necktie or scarf. Keep long

hair restrained.

INT-1-3-6

9803/3280

Issue 1

Section 2

Care & Safety

Section 2

3 - 1

Operating Safety

! WARNING

Machine Condition

ROPS/FOPS Structure

A defective machine can injure you or others. Do not operate

The machine is fitted with a Roll Over Protection Structure

a machine which is defective or has missing parts. Make

(ROPS) and a Falling Objects Protection Structure (FOPS).

sure the maintenance procedures in this handbook are

You could be killed or seriously injured if you operate the

completed before using the machine.

machine with a damaged or missing ROPS/FOPS. If the

INT-2-1-2

ROPS/FOPS has been in an accident, do not use the

machine until the structure has been renewed. Modifications

! WARNING

and repairs that are not approved by the manufacturer may

Controls

be dangerous and will invalidate the ROPS/FOPS

You or others can be killed or seriously injured if you operate

certification.

INT-2-1-9/3

the control levers from outside the cab. Operate the control

levers only when you are correctly seated inside the cab.

INT-2-1-3

! WARNING

Communications

! WARNING

Bad communications can cause accidents. Keep people

Machine Limits

around you informed of what you will be doing. If you will be

Operating the machine beyond its design limits can damage

working with other people, make sure any hand signals that

the machine, it can also be dangerous. Do not operate the

may be used are understood by everybody. Work sites can

machine outside its limits. Do not try to upgrade the

be noisy, do not rely on spoken commands.

INT-2-2-3

machine performance with unapproved modifications.

INT-2-1-4

! WARNING

Ramps and Trailers

Engine/Steering Failure

Water, mud, ice, grease and oil on ramps or trailers can

If the engine or steering fails, stop the machine as quickly as

cause serious accidents. Make sure ramps and trailers are

possible. Do not operate the machine until the fault has been

clean before driving onto them. Use extreme caution when

corrected.

driving onto ramps and trailers.

INT-2-1-5

INT-2-2-6

! WARNING

! DANGER

Engine

Sparks

The engine has exposed rotating parts. Do not open the

Explosions and fire can be caused by sparks from the

engine cover while the engine is running. Do not use the

exhaust or the electrical system. Do not use the machine in

machine with the cover open.

closed areas where there is flammable material, vapour or

INT-2-1-6/1

dust.

INT-2-2-10

! WARNING

Entering/Leaving

! WARNING

Always face the machine when entering and leaving the cab.

Powershift Transmission

Use the step(s) and handrails. Make sure the step(s),

Do not change from a high gear to a low gear (for instance,

handrails and your boot soles are clean and dry. Do not

4th to 1st) in one sudden movement whilst the machine is

jump from the machine. Do not use the machine controls as

moving. Otherwise the machine will rapidly decelerate, you

handholds, use the handrails.

or others could be killed or seriously injured. When selecting

INT-2-1-7

lower gears, allow the engine speed to drop before each

gear change.

! WARNING

2-1-1-9/1

Exhaust Gases

Breathing the machine exhaust gases can harm and

possibly kill you. Do not operate the machine in closed

spaces without making sure there is good ventilation. If

possible, fit an exhaust extension. If you begin to feel

drowsy, stop the machine at once. Get out of the cab into

fresh air.

INT-2-1-10

9803/3280

Issue 1

Section 2

Care & Safety

Section 2

4 - 1

Maintenance Safety

! WARNING

Battery

Repairs

A battery with frozen electrolyte can explode if it is used or

Do not try to do repairs or any other type of maintenance

charged. Do not use a machine with a frozen battery. To

work you do not understand. To avoid injury and/or damage

help prevent the battery from freezing, keep the battery fully

get the work done by a specialist engineer.

GEN-1-5

charged.

INT-3-1-7

! WARNING

Modifications and Welding

Battery Gases

Non-approved modifications can cause injury and damage.

Batteries give off explosive gases. Keep flames and sparks

Parts of the machine are made from cast iron; welds on cast

away from the battery. Do not smoke close to the battery.

iron can weaken the structure and break. Do not weld cast

Make sure there is good ventilation in closed areas where

iron. Contact your JCB distributor for advice before

batteries are being used or charged. Do not check the

modifying the machine.

INT-3-1-2/1

battery charge by shorting the terminals with metal; use a

hydrometer or voltmeter.

INT-3-1-8

! WARNING

Metal Splinters

! WARNING

You can be injured by flying metal splinters when driving

Battery Terminals

metal pins in or out. Use a soft faced hammer or drift to

The machine is negatively earthed. Always connect the

remove and fit metal pins. Always wear safety glasses.

INT-3-1-3

negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.

! WARNING

When disconnecting the battery, disconnect the earth (-)

Electrical Circuits

lead first.

Understand the electrical circuit before connecting or

INT-3-1-9

disconnecting an electrical component. A wrong connection

can cause injury and/or damage.

INT-3-1-4

! WARNING

Hydraulic Fluid

! WARNING

Fine jets of hydraulic fluid at high pressure can penetrate the

skin. Do not use your fingers to check for hydraulic fluid

Communications

leaks. Do not put your face close to suspected leaks. Hold a

Bad communications can cause accidents. If two or more

piece of cardboard close to suspected leaks and then

people are working on the machine, make sure each is

inspect the cardboard for signs of hydraulic fluid. If

aware of what the others are doing. Before starting the

hydraulic fluid penetrates your skin, get medical help

engine make sure the others are clear of the danger areas;

immediately.

examples of danger areas are: the rotating blades and belt

INT-3-1-10/1

on the engine, the attachments and linkages, and anywhere

beneath or behind the machine. People can be killed or

injured if these precautions are not taken.

INT-3-1-5

! DANGER

Hydraulic Pressure

Hydraulic fluid at system pressure can injure you. Before

! WARNING

disconnecting or connecting hydraulic hoses, stop the

Petrol

engine and operate the controls to release pressure trapped

Do not use petrol in this machine. Do not mix petrol with the

in the hoses. Make sure the engine cannot be started while

the hoses are open.

diesel fuel; in storage tanks the petrol will rise to the top and

INT-3-1-11/1

form flammable vapours.

INT-3-1-6

9803/3280

Issue 1

Section 2

Care & Safety

Section 2

4 - 2

Maintenance Safety (cont'd)

! CAUTION

! WARNING

Rams

Diesel Fuel

The efficiency of the rams will be affected if they are not

Diesel fuel is flammable; keep naked flames away from the

kept free of solidified dirt. Clean dirt from around the rams

machine. Do not smoke while refuelling the machine or

regularly. When leaving or parking the machine, close all

working on the engine. Do not refuel with the engine

rams if possible to reduce the risk of weather corrosion.

running. There could be a fire and injury if you do not follow

INT-3-2-10

these precautions.

INT-3-2-2

! CAUTION

! WARNING

Cleaning

Cleaning metal parts with incorrect solvents can cause

Oil

corrosion. Use only recommended cleaning agents and

Oil is toxic. If you swallow any oil, do not induce vomiting,

solvents.

seek medical advice. Used engine oil contains harmful

INT-3-2-11

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

! CAUTION

contaminated with oil thoroughly in warm soapy water. Do

not use petrol, diesel fuel or paraffin to clean your skin.

'O' rings, Seals and Gaskets

INT-3-2-3

Badly fitted, damaged or rotted 'O' rings, seals and gaskets

can cause leakages and possible accidents. Renew

whenever disturbed unless otherwise instructed. Do not use

! WARNING

Triochloroethane or paint thinners near 'O' rings and seals.

INT-3-2-12

Soft Ground

A machine can sink into soft ground. Never work under a

machine on soft ground.

! WARNING

INT-3-2-4

Fires

If your machine is equipped with a fire extinguisher, make

! WARNING

sure it is checked regularly. Keep it in the operator's cab

until you need to use it.

Tyres and Rims

Over-inflated or over-heated tyres can explode. Follow the

Do not use water to put out a machine fire, you could

instructions in this handbook for inflating the tyres. Do not

spread an oil fire or get a shock from an elecrical fire. Use

weld or cut rims. Get a tyre/wheel specialist to do any repair

carbon dioxide, dry chemical or foam extinguishers. Contact

work.

INT-3-2-6

your nearest fire department as quickly as possible.

Firefighters should use self-contained breathing apparatus.

INT-3-2-7/1

! WARNING

Hot Coolant

! WARNING

The cooling system is pressurised when the engine is hot.

Jacking

Hot coolant can spray out when you remove the radiator

A machine can roll off jacks and crush you unless the

cap. Let the system cool before removing the radiator cap.

wheels have been chocked. Always chock the wheels at the

To remove the cap; turn it to the first notch and let the

opposite end of the machine that is to be jacked. Do not

system pressure escape, then remove the cap.

INT-3-2-9

work underneath a machine supported only by jacks.

Always support a jacked-up machine on axle stands before

working underneath it.

INT-3-2-8

! WARNING

Always wear safety glasses when dismantling assemblies

containing components under pressure from springs. This

will protect against eye injury from components accidently

flying out.

GEN 6-2

9803/3280

Issue 1

Section 2

Care & Safety

Section 2

4 - 3

Maintenance Safety (cont'd)

! WARNING

To avoid burning, wear protective gloves when handling hot

Hydraulic Hoses

components. To protect your eyes, wear goggles when

Damaged hoses can cause fatal accidents. Inspect the

using a wire brush to clean components.

hoses regularly for:

HYD 1-3

Damaged end fittings

Chafed outer covers

Ballooned outer covers

! WARNING

Kinked or crushed hoses

Embedded armouring in outer covers

JCB Extradig Dipper Lubricant

Displaced end fittings.

JCB Extradig dipper lubricant contains 1.53% lead. The

INT-3-3-2

repeated swallowing of very small quantities can cause

chronic lead poisoning. Do not smoke or touch food while

handling this lubricant. Dispose of waste (rags etc.) in

! WARNING

accordance with local regulations.

2-1-1-8

Safety Strut

Raised loader arms can drop suddenly and cause serious

injury. Before working under raised loader arms, fit the

! WARNING

loader arm safety strut.

2-1-1-6

Fluoroelastomeric Materials

Certain seals and gaskets (e.g. crankshaft oil seal) on JCB

machines contain fluoroelastomeric materials such as Viton,

! WARNING

Fluorel and Technoflon. Fluoroelastomeric materials

subjected to high temperatures can produce highly

A raised and badly supported machine can fall on you.

corrosive hydrofluoric acid. THIS ACID CAN SEVERELY

Position the machine on a firm, level surface before raising

BURN.

one end. Ensure the other end is securely chocked. Do not

rely solely on the machine hydraulics or jacks to support the

New fluoroelastomeric components at ambient temperature

machine when working under it.

require no special safety precautions.

Disconnect the battery, to prevent the engine being started

Used fluoroelastomeric components whose temperatures

while you are beneath the machine.

GEN-1-1

have not exceeded

300°C require no special safety

precautions. If evidence of decomposition (e.g. charring) is

found, refer to the next paragraph for safety instructions DO

! WARNING

NOT TOUCH COMPONENT OR SURROUNDING AREA.

Waxoyl contains turpentine substitute, which is flammable.

Used fluoroelastomeric components subjected to

Keep flames away when applying Waxoyl. Waxoyl can take

temperatures greater than 300°C (e.g. engine fire) must be

a few weeks to dry completely. Keep flames away during the

treated using the following safety procedure. Make sure that

drying period.

heavy duty gloves and special safety glasses are worn:

Do not weld near the affected area during the drying period.

Ensure that components have cooled then remove and

Take the same precautions as for oil to keep Waxoyl off your

place material into plastic bags.

skin. Do not breathe the fumes. Apply in a well-ventilated

area.

5-3-1-9

Thoroughly wash contaminated area with 10% calcium

hydroxide or other suitable alkali solution, if necessary

use wire wool to remove burnt remains.

! WARNING

Thoroughly wash contaminated area with detergent

Make the machine safe before working underneath it. Park

and water.

the machine on level ground, lower the arms. Apply the

parking brake, put the transmission in neutral and stop the

Contain all removed material, gloves etc. used in this

engine. Chock both sides of all four wheels.

operation in sealed plastic bags and dispose of in

accordance with Local Authority Regulations.

Disconnect the battery, to prevent the engine being started

while you are beneath the machine.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

GEN-1-2

If contamination of skin or eyes occurs, wash the affected

area with a continuous supply of clean water or with calcium

hydroxide solution for 15-60 minutes. Get medical attention

immediately.

INT-3-3-5/1

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

Contents

Page No.

Lubricants - Health and Safety

Hygiene

2 - 1

Storage

2 - 1

Handling

2 - 1

First Aid - Oil

2 - 1

Spillage

2 - 1

Fires

2 - 1

Service Schedules

3 - 1

Loader Arm Safety Strut

Installing and Removing

4 - 1

Checking for Damage

5 - 1

Cleaning the Machine

6 - 1

Engine Panels

Opening and Closing the Bonnet

7 - 1

Removing and Fitting a Side Panel

7 - 1

Seat Belt

Checking the Seat Belt Condition and Security

8 - 1

Greasing

General

9 - 1

Loader Arms

9 - 1

Backhoe Quickhitch

9 - 2

Front Axle (2 Wheel Drive Machines)

9 - 3

Front Axle (4 Wheel Drive Machines)

9 - 3

Front Axle (All Wheel Steer Machines)

9 - 4

Rear Axle (All Wheel Steer Machines)

9 - 4

Extending Dipper

9 - 5

Driveshafts

9 - 5

6 - in - 1 Clamshovel

9 - 6

Stabilisers (Centremount Machines)

9 - 6

Loader Quickhitch

9 - 6

Power Sideshift

9 - 7

Kingpost

9 - 7

Knuckle (if fitted)

9 - 8

Backhoe Quickhitch (Hydraulic)

9 - 8

Tyres and Wheels

Tyre Inflation

10 - 1

Checking the Wheel Nut Torques

10 - 1

Brakes

Parking Brake Adjustment

11 - 1

Checking the Foot Brake Fluid Level

11 - 1

Engine Air Filter

Changing the Elements

12 - 1

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

Contents

Page No.

Engine Oil and Filter

Checking the Oil Level

13 - 1

Changing the Oil and Filter

13 - 1

Engine Cooling System

Checking the Coolant

14 - 1

Changing the Coolant

14 - 1

Adjusting the Fan Belt

14 - 2

Cleaning the Cab Heater Filter

14 - 2

Fuel System

Types of Fuel

15 - 1

Fuel Standards

15 - 1

Low Temperature Fuels

15 - 1

Fatty Acid Methyl Ester Fuels

15 - 1

Petrol

15 - 1

Advice

15 - 1

Filling the Tank

15 - 2

Draining the Filter

15 - 2

Changing the Filter Element

15 - 2

Draining the Sediment Bowl

15 - 3

Bleed the System

15 - 3

Synchro Shuttle Gearbox

Checking the Oil Level

16 - 1

Changing the Oil and Filter

16 - 1

Powershift Gearbox

Checking the Oil Level

17 - 1

Changing the Oil Filter

17 - 2

Hydraulic System

Checking the Fluid Level

18 - 1

Hydraulic Tank Cap

18 - 1

Changing the Filter Element

18 - 2

Changing the Suction Strainer

18 - 3

Front and Rear Axle (All Wheel Steer Machines)

Checking the Differential Oil Level

19 - 1

Changing the Differential Oil

19 - 1

Checking the Hub Oil Levels

19 - 2

Changing the Hub Oil

19 - 2

Front and Rear Axle (Two Wheel Steer Machines)

Checking the Oil Level

19 - 3

Changing the Oil

19 - 3

Battery

Warning Symbols

21 - 1

First Aid - Electrolyte

21 - 2

Checking the Electrolyte Level

21 - 2

Battery Isolator

21 - 3

9803/3280

Issue 2*

Section 3

Routine Maintenance

Section 3

2 - 1

Lubricants - Health and Safety

2 - 1

It is most important that you read and understand this

Apply a barrier cream to the skin before handling used

information and the publications referred to. Make sure

oil.

all your colleagues who are concerned with lubricants

read it too.

Note the following when removing engine oil from skin:

Hygiene

a Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

JCB lubricants are not a health risk when used properly for

their intended purposes.

c Use special hand cleansers to help clean dirty

hands.

However, excessive or prolonged skin contact can remove

the natural fats from your skin, causing dryness and

d Never use petrol, diesel fuel, or paraffin for washing.

irritation.

Avoid skin contact with oil soaked clothing.

Low viscosity oils are more likely to do this, so take special

care when handling used oils, which might be diluted with

Don't keep oily rags in pockets.

fuel contamination.

Wash dirty clothing before re-use.

Whenever you are handling oil products you should maintain

good standards of care and personal and plant hygiene. For

Throw away oil-soaked shoes.

details of these precautions we advise you to read the

relevant publications issued by your local health authority,

plus the following.

First Aid - Oil

Storage

Eyes.

In the case of eye contact, flush with water for 15 minutes. If

irritation persists, get medical attention.

Always keep lubricants out of the reach of children.

Swallowing.

Never store lubricants in open or unlabelled containers.

If oil is swallowed do not induce vomiting. Get medical

advice.

Waste Disposal

Skin.

All waste products should be disposed of in accordance

In the case of excessive skin contact, wash with soap and

with all the relevant regulations.

water.

The collection and disposal of used oil should be in

Spillage

accordance with any local regulations. Never pour used

engine oil into sewers, drains or on the ground.

Absorb on sand or a locally approved brand of absorbent

granules. Scrape up and remove to a chemical disposal

Handling

area.

New Oil.

Fires

There are no special precautions needed for the handling or

Extinguish with carbon dioxide, dry chemical or foam. Fire-

use of new oil, beside the normal care and hygiene

fighters should use self-contained breathing apparatus.

practices.

Used Oil.

Used engine crankcase lubricants contain harmful

contaminants.

Here are precautions to protect your health when handling

used engine oil:

Avoid prolonged, excessive or repeated skin contact

with used oil.

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

3 - 1

Service Schedules

3 - 1

A badly maintained machine is a danger to the operator and

Apart from the daily jobs, the schedules are based on

the people working around him. Make sure that the regular

machine running hours. Keep a regular check on the

maintenance and lubrication jobs listed in the service

hourmeter readings to correctly gauge service intervals. Do

schedules are done to keep the machine in a safe and

not use a machine which is due for a service. Make sure

efficient working condition.

any defects found during the regular maintenance checks

are rectified immediately.

! WARNING

Calendar equivalents:

Maintenance

10 Hours

Daily

Maintenance must be done by suitably qualified

50 Hours

Weekly

personnel. Before attempting any maintenance work,

500 Hours

Six Months

make sure the machine is safe. Park on level ground. If it

1000 Hours

Yearly

is necessary to work with the loader arms raised, then

2000 Hours

2 Years

the loader arm safety strut must be fitted as shown in

Loader Arm Safety Strut in MAINTENANCE section.

2-3-1-1

Pre-start Cold Checks

Operation

†100

500

1000

2000

Service Points and Fluid Levels

ENGINE

Oil level

- Check

Oil and Filter "

- Change

Air Cleaner Outer Element #

- Change

Air Cleaner Inner Element

- Change

Fuel Filter

- Change

Fuel Filter

- Drain

Coolant Quality/Level

- Check

Fuel Sedimenter

- Drain and Clean

Fan Belt Tension/Condition

- Check

Valve Clearances and Clean Breather Gauze (if fitted) $

- Check and Adjust

Engine Mounting Bolts for Tightness $

- Check

Radiator

- Clean

All Hoses - Condition

- Check

TRANSMISSION, AXLES

AND STEERING

Transmission Oil Level

- Check

Transmission Oil %

- Change

Transmission Filter

- Change

Axle Oil Level (incl. Hubs when applicable) &

- Check

Axle Oil (incl. Hubs when applicable) '

- Change

Axle Oil - Limited Slip Differential

- Change

Tyre Pressures/Condition

- Check

Front Hub Bearings $

- Check

Transmission Strainer

- Clean

Drive Shafts

- Security/Grease

Steer Axle Movement/Shimming $

- Check

Steer Axle Pivots and Linkages (

- Grease

Front Axle Main Pivot

- Grease

HYDRAULICS

Oil Level )

- Check

Oil $

- Sample/Change

Oil Filter

- Change

Rams - Chrome Condition

- Check

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

3 - 2

Service Schedules

3 - 2

Pre-start Cold Checks

Operation

†100

500

1000

2000

Service Points and Fluid Levels

Hydraulic Oil Cooler

- Clean

Hydraulic Oil Strainer

- Clean

Hydraulic Tank Filler Cap (with integral filter)

- Change

Hydraulic Pump Drive Shaft

- Examine/Grease

BRAKES

Brake System Fluid Level

- Check

Brake System Fluid $

- Change

Parking Brake

- Check and Adjust

ELECTRICS

Battery Electrolyte Level (if applicable)

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

BODYWORK AND CAB

All Pins and Bushes

- Check and Grease

Door/Window Hinges

- Lubricate

All Cables

- Lubricate

Cab Heater Filter #

- Clean/Change

Extending Dipper

- Adjust/Grease

Hydraclamp $

- Check and Adjust

Door - Fit and Catches

- Check

Cab Seat - Operation

- Check

Front Mudguards - Security (if fitted)

- Check

Windscreen Washer Fluid Level

- Check

Boom Lock Engagement

- Check

Condition of Paintwork

- Check

Stabiliser Legs (Sideshift)

- Check/Adjust

Machine Generally $

- Check and Clean

Power Sideshift Wear Pads

- Grease

Power Sideshift Wear Pads

- Check

Power Sideshift Chain

- Lubricate

Power Sideshift Chain Tension

- Check/Adjust

ATTACHMENTS

6-in-1 Clam Shovel

- Grease

Backhoe & Loader Quick Hitch

- Grease

Functional Test

Operation

†100

500

1000

2000

and Final Inspection

ENGINE

Idle Speed $

- Check and Adjust

Stall Speed $

- Check

Maximum No-Load Speed $

- Check and Adjust

Exhaust Smoke (excessive)

- Check

Exhaust System Security $

- Check

Air Inlet System Security

- Check

Throttle System and Control Cable $

- Check

TRANSMISSION, AXLES AND STEERING

Steer Modes - Operation/Phasing

- Check

2WD/4WD Selection

- Check

Wheel Nuts Torque

- Check

Forward/Reverse and Gear Change - Operation

- Check

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

3 - 3

Service Schedules

3 - 3

Functional Test

Operation

†100

500

1000

2000

and Final Inspection

Hydraulic Speed Control - Operation (if fitted)

- Check

Steer Circuit Pressure $

- Check

Transmission Main Line Pressure $

- Check

Transmission Dump Operation

- Check

Neutral Start Operation

- Check

Clutch Pack Pressures $

- Check

HYDRAULICS

MRV Pressure $

- Check and Adjust

Operation All Services

- Check

Hose Burst Protection Valves (if fitted)

- Check

Offloader Valve Pressure $

- Check and Adjust

Auxiliary Circuit & Pressures $

- Check and Adjust

BRAKES

Foot Brake - Operation

- Check

Parking Brake - Operation

- Check

Servo Operation (if fitted)

- Check

ELECTRICS

Starter Motor

- Check

Alternator - Output

- Check

All Electrical Equipment Operation, (e.g. warning lights, beacon,

- Check

alarms, horn, wipers etc)

Operation of Stop Control/E.S.O.S.

- Check

BODYWORK AND CAB

Teeth and Side Cutters

- Check

Doors and Windows - Fitment/Leaks

- Check

Seat/Seat Belts

- Check

† Note: First 100 Hours Service only, to be completed by your JCB Distributor.

& Note: Check for leaks every 50 hours, check level if leaking.

) Note: Check the hydraulic fluid level with the loader and backhoe in the travel position.

$ Note: Jobs which should only be done by a specialist are indicated by a † .

" Note: If operating under arduous conditions, change the engine oil and filter every 250 hours.

* Note: Check generally for leaks on ALL systems, for example, hydraulic, engine (coolant, fuel and oil), transmission,

brakes, axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with

the recommended fluid after repair. Examples of machine general damage are paintwork, toe plate, glazing rubbers etc.,

repair any damage as required. If any of the repair or top up procedures are not detailed in this handbook, then contact

your local JCB Distributor for advice.

# Note: If operating in dusty working environments, change more frequently.

( Note: The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is

used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice.

% Note: After a major transmission repair, the new oil should be run to operating temperature and changed again to remove

any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily

contaminated because of, or from the failure (eg. water contamination).

' Note: After a hub repair, the new oil should be run to operating temperature and changed again to remove any

contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in

wear. This is particularly important if new brake plates have been fitted.

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

4 - 1

Loader Arm Safety Strut

4 - 1

Installing

Install the loader arm safety strut as detailed below before

working underneath raised loader arms.

! WARNING

Raised loader arms can drop suddenly and cause

serious injury. Before working under raised loader arms,

fit the loader arm safety strut.

2-1-1-6

Empty the Shovel and Raise the Loader Arms fully.

Stop the Engine

Remove the starter key.

! WARNING

You could be killed or injured if the loader control is

accidentally operated. Make sure no-one comes near

the machine while you release the safety strut.

2-3-1-2

S215110

Release the Strut

a Release fastener A.

b Remove strut C from its stowage bracket.

Install the Strut

a Push strut C over the ram piston rod.

b Secure the strut in position with strap B.

Lower the Strut Onto the Cylinder

To prevent any chance of the loader arms creeping

down and trapping your fingers, the loader arms should

be carefully lowered onto the safety strut as shown.

Start the engine and slowly lower the loader arms onto

the safety strut, stop the movement immediately the

weight of the loader arms is supported by the safety

strut.

S161710

Note: When lowering the loader, operate the control lever

carefully. 'Feather' the lever to lower the loader very slowly.

Removing

Fully Raise the Loader Arms

To take the weight off the safety strut.

Stop the Engine

Remove the starter key.

! WARNING

You could be killed or injured if the loader control is

accidentally operated. Make sure no one comes near the

machine while you remove the safety strut.

2-3-1-3

Remove the Strut

a Undo the strap B.

b Remove the strut C from the ram piston rod.

Stow the Strut

Secure the strut in its stowage position with fastener A.

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

6 - 1

Cleaning the Machine

6 - 1

Park the machine on firm level ground, engage the parking

brake and set the transmission to neutral. Lower the

attachments to the ground and stop the engine.

Clean the machine using water and/or steam. Do not allow

mud, debris etc to build upon the machine, pay particular

attention to the following areas:

Backhoe hoses passing through mainframe.

Around twin slew rams.

Twin ram slew recess in chassis (centremount).

Kingpost slide rails (sideshift).

Kingpost hose tray and bottom ‘shelf’ (sideshift).

Recess between slew ram and kingpost casting

S272900

(sideshift).

Stabiliser cavities can become clogged when operating in

soft/wet ground conditions. Remove and clean away all

debris that may have built up.

Do not allow mud to build up on the engine and

transmission. Make sure the radiator grille is not clogged up.

! WARNING

Airborne particles of light combustible material such as

straw, grass, wood shavings, etc. must not be allowed to

S272880

accumulate within the engine compartment or in the

propshaft guards (when fitted). Please inspect these

areas frequently and clean at the beginning of each work

shift or more often if required. Before opening the engine

cover, ensure that the top is clear of debris.

5-3-1-12/2

Avoid using neat detergent - always dilute detergents as per

the manufacturer's recommendations, otherwise damage to

the paint finish may occur.

It is important to note that excessive power washing can

cause damage to the seals or bearings. Take care during

routine machine washing not to direct high power water jets

directly at oil seals or universal joints.

Note: The machine must always be greased after pressure

washing or steam cleaning.

Always adhere to local regulations regarding the disposal of

debris created from machine cleaning.

The illustrations show some of the areas that must be

thoroughly cleaned as required.

S272890

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

7 - 1

Engine Panels

7 - 1

Opening and Closing the Bonnet

Removing and Fitting a Side Panel

To release the bonnet, pull handle A, the bonnet will

! WARNING

automatically open and be supported on gas struts.

The loader arms must be raised and locked before you

remove an engine side panel. Keep the arms locked up

To close the bonnet, push the bonnet down, make sure it is

until the side panel is put back. If you do not lock the

locked in place and the side panels are located correctly.

loader arms, the shovel can fall and you could be

crushed. See Loader Arm Safety Strut in MAINTENANCE

section.

2-3-1-4/1

! WARNING

Do not remove the engine side panel while the engine is

running.

2-3-1-5

Raise the loader arms and fit the safety strut, see

Loader Arms Safety Strut.

Stop the engine, and remove the starter key.

Open the bonnet.

Remove the side panel B, lift the side upwards and

outwards.

Fit the side panel, carefully slot the side panel into

position. Lower and lock the bonnet.

399110

399380

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

9 - 1

Greasing

9 - 1

You must grease the machine regularly to keep it working

Greasing should be done with a grease gun. Normally, two

efficiently. Regular greasing will also lengthen the machine's

strokes of the gun should be sufficient. Stop greasing when

working life.

fresh grease appears at the joint.

The machine must always be greased after pressure

In the following illustrations, the grease points are

washing or steam cleaning.

numbered. Count off the grease points as you grease each

one. Refit the dust caps after greasing.

! WARNING

You will be working close into the machine for these

Loader Arms

jobs. Lower the attachments if possible. Remove the

starter key and disconnect the battery. This will prevent

For each grease point shown, there is another on the other

the engine being started. Make sure the parking brake is

side of the machine.

engaged.

Total 22 grease points.

Chock all four wheels before getting under the machine.

2-3-2-1

£$

()

¤⁄

S260190

9803/3280

Issue 1

JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 1