Content      ..      1      2      3      ..

JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 2

Section 3

Routine Maintenance

Section 3

9 - 7

Greasing

9 - 7

Power Sideshift

Kingpost

Total 4 Grease Points

9 Grease Points

Note: Release the kingpost clamps and lower the excavator

Note: Figure shows a centremount kingpost, greasing is

to the ground before greasing.

same for sideshift kingpost.

Note: It is recommended that grease points 2 and 3 are

lubricated using a hand grease gun. The use of a power

grease gun may result in the mounting plate being distorted.

2

1

9

1

2

3

4

3

4

5

7

8

6

S254690

A326770

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

9 - 8

Greasing

9 - 8

Knuckle (if fitted)

Backhoe Quickhitch (Hydraulic)

Refer to Backhoe greasing for the boom and dipper grease

! CAUTION

points.

Waxoyl contains turpentine substitute, which is

inflammable. Keep flames away when applying Waxoyl.

Total 2 Grease Points.

Waxoyl can take a few weeks to dry completely. Keep

flames away during the drying period.

Do not weld near the affected area during the drying

period. Take the same precautions as for oil to keep

Waxoyl off your skin. Do not breathe the fumes. Apply in

a well-ventilated area.

5-3-1-9

Coat the slide A with Waxoyl.

4 Grease Points

2

1

S256440

4

3

1

2

A

S211750

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

10 - 1

Tyres and Wheels

10 - 1

Tyre Inflation

Checking the Wheel Nut Torques

These instructions are for adding air to a tyre which is

On new machines, and whenever a wheel has been

already inflated. If the tyre has lost all its air pressure, call in

removed, check the wheel nut torques every two hours until

a qualified tyre mechanic. The tyre mechanic should use a

they stay correct.

tyre inflation cage and the correct equipment to do the job.

Every day, before starting work, check that the wheel nuts

! WARNING

are tight.

An exploding tyre can kill, inflated tyres can explode if

The correct torques are shown in the table below.

overheated. Do not cut or weld the rims. Use a

tyre/wheel specialist for all repair work.

2-3-2-7

Front - Nm

lbf ft

680

500

1

Prepare the Wheel

Before you add air to the tyre, make sure it is correctly

Rear - Nm

lbf ft

fitted on the machine or installed in a tyre inflation cage.

680

500

2

Prepare the Equipment

! WARNING

Use only an air supply system which includes a

If, for whatever reason, a wheel stud is renewed, all the

pressure regulator. Set the regulator no higher than

studs for that wheel must be changed as a set, since the

1.38 bar

(20 psi) above the recommended tyre

remaining studs may have been damaged.

pressure. See Section F, Technical Data for

2-3-2-8

recommended tyres and pressures for your machine.

Use an air hose fitted with a self-locking air chuck and

remote shut-off valve.

3

Add the Air

Make sure that the air hose is correctly connected to

the tyre valve. Clear other people from the area. Stand

behind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do not

over-inflate.

S089571

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

11 - 1

Brakes

11 - 1

Parking Brake Adjustment

Checking the Foot Brake Fluid Level

1

Disengage the parking brake (lever horizontal).

! WARNING

Faulty brakes can kill. If you have to add oil to the brake

2

Turn handle grip E clockwise, half a turn.

reservoir regularly get the brake system checked by your

JCB Dealer. Do not use the machine until the fault has

3

Test the parking brake, see Section G, Service

been put right.

Procedures.

2-3-2-5

4

If the brake fails the test, repeat steps 1, 2 and 3. If

1

Park the machine on firm level ground, engage the

there is no more adjustment and pin F is at the end of

parking brake and set the transmission to neutral. Raise

its travel get the brake checked by your JCB Dealer.

and block the loader arms. Lower the backhoe to the

ground and stop the engine.

2

Remove the reservoir cap A and check the level. The

MAX and MIN marks are marked on the side of the

reservoir B. If necessary, add fluid as in Step 3.

E

If the level has fallen below the MIN mark, get the

system checked by your JCB Dealer.

! WARNING

Using incorrect brake fluid could damage the system.

See Service Capacities and Lubricants in

MAINTENANCE Section. The fluid can harm your skin.

Wear rubber gloves. Cover cuts and grazes.

4-3-2-3

F

3

If required, carefully pour the recommended fluid (DO

NOT USE ORDINARY BRAKE FLUID) until it reaches

347581

the correct level.

4

Refit the reservoir cap. Wipe up any spillage.

A

B

399290

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

12 - 1

Engine Air Filter

12 - 1

Changing the Elements

4

Depress clips B and lift off cover C. Remove outer

! CAUTION

element D. Take care not to tap or knock the element. If

The outer element must be renewed immediately if the

the inner element is to be changed, lift up pulls E and

warning light on the instrument panel illuminates.

remove inner element F. On turbocharged engines,

2-3-3-1

remove pulsation ring L.

Note: Do not attempt to wash or clean the elements - they

5

Clean inside the canister H, pulsation ring L, cover C

must only be renewed.

and dust valve J.

Note: Do not run the engine with the dust valve J removed.

6

Insert the new elements into the canister, pushing them

firmly in so that seals G and K are fully seated. On

Note: A new inner element must be fitted at least every third

turbocharged engines, assemble the pulsation ring L

time the outer element is changed. As a reminder, mark the

into the cover, making sure that tongue M fits into slot

inner element with a felt tipped pen each time the outer

N. Fit cover C with dust valve J at the bottom. Push the

element is changed.

cover firmly into position and make sure it is secured by

clips B.

1

Stop the engine.

Note: Pulsation ring L is not fitted in this application.

2

Remove the engine side panel (left hand side).

7

Refit the induction hose to stub pipe A. Make sure that

3

If changing the inner element, cover the end of the hose

the wire is connected to the Air Filter Blocked switch.

to prevent rain and dirt from getting into the engine.

A

H

C

K

J

F

D

LN

G

M

N

C

B

E

J

M

S257910

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

13 - 1

Engine Oil and Filter

13 - 1

Checking the Oil Level

1

Make sure the park brake is engaged and the

2

Make sure the park brake is engaged and the

transmission set to neutral. Lower the loader arms and

transmission set to neutral. Lower the loader arms and

backhoe to the ground, switch OFF the engine and

backhoe to the ground, switch OFF the engine and

remove the starter key.

remove the starter key.

2

Open the bonnet, see Engine Panels, Opening and

3

Open the bonnet, see Engine Panels, Opening and

Closing the Bonnet.

Closing the Bonnet.

3

Check that the oil level is between the two marks on

4

Drain the oil:

the dipstick A.

! CAUTION

4

If necessary, remove the side panel and add oil through

Oil will gush from the hole when the drain plug is

filler B. Make sure that the dipstick and filler cap are

removed. Hot oil and engine components can burn you.

fully inserted and tightened.

Keep to one side when you remove the plug.

13-3-1-15

Changing the Oil and Filter

a Place a container of suitable size beneath the drain

plug.

1

Drain the oil when the engine is warm as contaminants

b Remove drain plug C and its 'O' ring. Let the oil

held in suspension will then be drained with the oil.

drain out, then clean and refit the drain plug with a

Park the machine on firm ground.

new 'O' ring. Tighten to 34 Nm (25 lbf ft).

! WARNING

5

Change the filter:

Make the machine safe before getting beneath it. Lower

a Unscrew the filter canister D. Remember that it will

the attachments to the ground; engage the parking

be full of oil.

brake; remove the starter key, disconnect the battery.

b Check that adapter G is secure.

2-3-2-2

c Clean the filter head F.

d Add clean engine lubricating oil to the new filter

canister. Allow enough time for the oil to pass

through the filter element.

e Smear the seal E on the new filter with oil. Screw in

the new filter canister - hand tight only.

B

6

Fill the engine to the max mark on the dipstick with new

oil through the filler. See Service Capacities and

Lubricants for recommended oil grades. Wipe off any

spilt oil. Check for leaks. Make sure the filler cap is

correctly refitted.

7

Make sure the engine will not start and turn the starter

399290

switch to operate the starter motor until the oil pressure

light is extinguished. (To make sure the engine will not

start, remove the engine shut-off solenoid fuse, housed

in the fuse box).

8

Insert the engine shut-off solenoid fuse and operate the

engine. Check for leaks. When the engine has cooled,

check the oil level.

A

B

D

F

C

E

G

S260260

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

14 - 1

Engine Cooling System

14 - 1

Checking the Coolant

1

Make sure the park brake is engaged and the

transmission set to neutral. Lower the loader arms and

backhoe to the ground, switch OFF the engine and

! WARNING

remove the starter key.

The cooling system is pressurised when the coolant is

hot. Hot coolant will burn you. Make sure the engine is

2

Open the bonnet, see Engine Panels, Opening and

cool before checking the coolant level or draining the

Closing the Bonnet.

system.

2-3-3-3

3

Carefully loosen cap A. Let any pressure escape.

Remove the cap.

1

Make sure the park brake is engaged and the

transmission set to neutral. Lower the loader arms and

! CAUTION

backhoe to the ground, switch OFF the engine and

remove the starter key.

Keep your face away from the drain hole when removing

the drain plug.

2

Open the bonnet, see Engine Panels, Opening and

2-3-3-4

Closing the Bonnet.

4

Remove drain plug C and let the coolant drain out.

Make sure the drain hole is not blocked.

3

The coolant level should be between the COLD/MIN

and the HOT/MAX marks on coolant reservoir B. Fill

5

Disconnect the radiator hose at D and allow the coolant

with pre-mixed water/antifreeze if necessary.

to drain. Flush the system using clean water.

Changing the Coolant

6

Clean and refit plug C. Make sure it is secure.

Reconnect the radiator hose

! WARNING

The cooling system is pressurised when the coolant is

7

Use the necessary mix of clean, soft water and

hot. Hot coolant will burn you. Make sure the engine is

antifreeze, see Coolant Mixtures. Fill to the COLD/MIN

cool before checking the coolant level or draining the

level on coolant reservoir B.

system.

2-3-3-3

8

Start the engine and run at idle to circulate the coolant,

top up with coolant as necessary.

9

Refit the filler cap. Make sure it is tight.

A

B

10

Run the engine for a while, to raise the coolant to

working temperature and pressure. Stop the engine.

Check for leaks.

Note: Make sure the cab heater control is in the hot

position. This will ensure the coolant mixture circulates

through the entire cooling system.

399290

C

D

S148060

S260270

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

14 - 2

Engine Cooling System

14 - 2

Adjusting the Fan Belt

Cleaning the Cab Heater Filter

1

Park the machine on firm level ground, engage the

! WARNING

parking brake and set the transmission to neutral.

Make sure the engine cannot be started. Disconnect the

Lower the attachments to the ground and stop the

battery before doing this job.

engine.

2-3-3-5

2

Remove the cover retaining screws (2 off) and then

1

Park the machine on firm level ground, engage the

remove the cover, item E.

parking brake and set the transmission to neutral. Raise

and block the loader arms. Lower the backhoe to the

3

Knock loose dust off the filter F. Carefully blow

ground and stop the engine.

compressed air through all the folds of the filter, blow in

the opposite direction to the arrows marked on the

2

Loosen pivot fastening bolts A and B. Loosen

filter.

adjustment link fastening bolts C and D.

Note: The compressed air must be set at a pressure no

3

Position the alternator so that there is 10 mm (3/8 in)

greater than 7 bar (100 lb/in²).

slack at point X.

4

Refit the cover E and secure with the retaining screws

4

Tighten bolts C and D, then bolts A and B.

(2 off).

Note: If a new belt is fitted, the belt tension must be

checked again after the first 20 hours of operation.

A

B

X

F

E

D

C

S254720

S209411

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

15 - 2

Fuel System

15 - 2

Filling the Tank

! WARNING

Lower the loader arms and switch off the engine before

refuelling. Do not permit operation of the machine

controls while refuelling.

2-3-3-9

At the end of every working day, fill the tank with the correct

type of fuel. This will prevent overnight condensation from

developing in the fuel.

The cap incorporates a side mounted barrel lock that is

operated by the ignition/door key.

A

Fit the Cap

B

Once the key has been removed, the cap will simply rotate

on the filler neck. To remove the cap from the filler neck, the

key must be reinserted and the cap unlocked.

Draining the Filter

1

Park the machine on firm level ground, engage the

399470

parking brake and set the transmission to neutral. Raise

and block the loader arms. Lower the backhoe to the

ground and stop the engine.

2

Drain off any water in the element A by turning tap B

Changing the Filter Element

1

Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.

Lower the loader arms and backhoe to the ground, stop

the engine.

2

Unscrew the filter element A. The element is hand tight

but may require a strap wrench to remove. The filter will

be full of fuel.

3

To assist with bleeding, fill the new filter element with

fuel before fitting. Install new element A hand tight only.

Check for leaks.

4

Bleed the System.

A

S233870

B

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

15 - 3

Fuel System

15 - 3

Draining the Sediment Bowl

Bleed the System

1

Park the machine on firm level ground, engage the

! CAUTION

parking brake and set the transmission to neutral.

Running the engine with air in the system could damage

Lower the loader arms and backhoe to the ground, stop

the fuel injection pump. After maintenance, remove air

the engine.

from the system as detailed below.

2-3-3-7

2

Look in bowl A. If it contains sediment, do Steps 3 to 6.

If there is water but no sediment, drain off the water by

1

Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.

opening tap B. Make sure tap B is turned off and

Lower the loader arms and backhoe to the ground and

secure.

stop the engine.

3

Support bowl A; unscrew nut C. Remove the bowl.

2

Set the starter key to the IGN position.

4

Wash the bowl. Use clean fuel.

! WARNING

5

Refit the bowl, make sure gasket is seated correctly.

Hot oil and engine components can burn you. Make sure

the engine is cool before doing this job.

6

Bleed the System.

2-3-3-2

3

Operate the fuel lift pump priming lever X slowly, for

approximately two minutes. The engine is now ready to

start. If the engine runs smoothly for a short time, and

then begins to run roughly or stops, check again for air

in the fuel system. Check all seals and connections,

especially in the low pressure side of the system.

Note: If no fuel is moved when the fuel lift pump priming

lever X is operated, then the pump diaphragm may have

rested in a 'maximum lift' position. To move the diaphragm,

use the starter key to turn the engine, then try the priming

lever again.

C

A

B

X

S148060

S260120

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

16 - 1

Synchro Shuttle Gearbox

16 - 1

Checking the Oil Level

Changing the Oil and Filter

1

Make sure the park brake is engaged and the

The transmission oil should be drained through the suction

transmission set to neutral. Lower the loader arms and

strainer aperture to flush out any particles which fall off the

backhoe to the ground, switch OFF the engine and

strainer during its removal.

remove the starter key.

! WARNING

2

Open the bonnet, see Engine Panels, Opening and

Make the machine safe before getting beneath it. Lower

Closing the Bonnet.

the attachments to the ground; engage the parking

brake; remove the starter key, disconnect the battery.

3

Switch OFF the engine and remove the starter key, fill

2-3-2-2

the transmission to maximum mark on dipstick/filler A.

Use only the recommended oil.

1

Park the machine on level ground. Engage the parking

brake. Lower the attachments to the ground. Stop the

4

Start and run the engine slowly for a period not

engine. Remove the starter key. Disconnect the battery.

exceeding five minutes. This allows the oil to fill filter,

pump, torque converter, oil cooler and hoses.

! CAUTION

When the strainer is removed, oil will gush out. Keep to

5

Switch OFF the engine and remove the starter key, wait

one side when you remove the strainer.

approximately 20 seconds. Check the oil level and if

2-3-4-1

required, fill to dipstick level.

2

Place a container, of suitable size beneath the drain

plug. Remove bolts D. Pull out the strainer E and its

gasket F. Allow the oil to drain into the container.

3

Clean the strainer with a suitable solvent. Follow the

solvent manufacturer's instructions on safety.

4

Fit the strainer E and a new gasket F. Apply JCB

Threadlocker and Sealer to bolts D before fitting and

tightening them. Torque tighten the bolts to 10 Nm (7

lbf ft).

5

Unscrew and remove the filter B. Fit the new filter:

5.1 Smear seal C with transmission oil.

5.2 Screw the filter on until it just contacts the filter

head.

5.3

Turn the filter at least another 3/4 of a turn.

6

Fill the system with new oil through the dipstick/filler A.

A

Do not fill past the top mark on the dipstick.

Note: Fit only a genuine supplied JCB filter, otherwise

damage to the system may be incurred through

contamination.

B

C

F D

E

399310

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

17 - 1

Powershift Gearbox

17 - 1

Checking the Oil Level

1

Make sure the park brake is engaged and the

transmission set to neutral. Lower the loader arms and

backhoe to the ground, switch OFF the engine and

remove the starter key.

2

Open the bonnet, see Engine Panels, Opening and

Closing the Bonnet.

3

Switch OFF the engine and remove the starter key, fill

the gearbox to maximum mark on dipstick/filler A. Use

only the recommended oil.

4

Start and run the engine slowly for a period not

exceeding five minutes. This allows the oil to fill filter,

pump, torque converter, oil cooler and hoses.

5

Switch OFF the engine and remove the starter key, wait

approximately 20 seconds. Check the oil level and if

required, fill to dipstick level.

A

A405230

9803/3280

Issue 2*

Section 3

Routine Maintenance

Section 3

17 - 2

Powershift Gearbox

17 - 2

Changing the Oil and Filter

When draining JCB 760 Series Powershift gearboxes it is

recommended that the oil is drained through the cover plate

A to make sure that the debris collected in the transmission

sump is flushed out. Draining oil through the sump plug will

filter oil through the strainer and not flush out the debris.

! WARNING

Make the machine safe before getting beneath it. Lower

the attachments to the ground; engage the parking

brake; remove the starter key, disconnect the battery.

2-3-2-2

F

1

Park the machine on firm level ground, apply the park

brake. Lower the loader arms, open the engine bonnet,

raise the loader arms and fit the safety strut. Lower the

excavator to the ground, switch OFF the engine and

remove the starter key.

2

Apply the parking brake and disconnect the battery,

A405230

remove the engine side panels.

3

Place a container of suitable size beneath the

transmission to catch the oil.

4

Remove bolts B. Pull off cover plate A and gasket C,

allow the oil to drain into the container. Be aware that

the oil may be hot.

E

Note: When the cover is removed oil will gush out. Keep to

one side when you remove the cover plate.

5

Fit cover plate A and a new gasket C. Apply JCB

C

Threadlocker and Sealer to bolts B before fitting them.

A

Torque tighten the bolts to 28 Nm (20.5 lbf ft.).

B

6

Unscrew and remove the filter D. Fit the new filter:

6.1 Smear seal E with transmission oil.

6.2 Screw the filter on until it just contacts the filter

head.

6.3 Turn the filter at least another 3/4 of a turn.

7

Fill the system with new oil through the dipstick/filler F.

Do not fill past the top mark on the dipstick.

8

On completion check for oil leaks.

Note: Fit only a genuine supplied JCB filter, otherwise

damage to the system may be incurred through

contamination.

D

A405170

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

18 - 1

Hydraulic System

18 - 1

Checking the Fluid Level

Hydraulic Tank Cap

! WARNING

The hydraulic tank breather (and filter) forms an integral part

of the hydraulic tank cap B. Replace the cap (and breather

Fine jets of hydraulic fluid at high pressure can penetrate

filter) with a new one at the recommended interval, see

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

Service Schedules.

fluid leaks. Do not put your face close to suspected

leaks. Hold a piece of cardboard close to suspected

The cap incorporates a side mounted barrel lock that is

leaks and then inspect the cardboard for signs of

operated by the ignition/door key. It is important to note that

hydraulic fluid. If hydraulic fluid penetrates your skin, get

seal C must be in good condition and correctly installed in

medical help immediately.

INT-3-1-10/1

the cap.

1

Position the machine on level ground. Set the loader

Fit the Cap

shovel on the ground. Retract the extending dipper if

fitted. Raise the boom, swing in the dipper and close

Insert the key and turn anticlockwise D, screw the cap on

the bucket. Stop the engine. Remove the starter key.

until resistance is felt then turn a further quarter of a turn,

turn the key clockwise E and remove the key. With the key

2

Look at the fluid level in the sight glass A. The level

removed the cap will rotate and can not be undone.

should be at the red mark (or above).

Remove the Cap

! CAUTION

Insert the key and turn anticlockwise D, unscrew the cap.

If the fluid in the tube appears cloudy, then water or air

has entered the system. The hydraulic pump could be

severely damaged if the machine is operated. Contact

your JCB distributor immediately.

2-3-4-3

B

3

If the oil level is low, remove filler cap B and replenish

with recommended hydraulic oil as required.

D

C

B

A

E

A329760

399330

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

18 - 2

Hydraulic System

18 - 2

Changing the Filter Element

! WARNING

3

Remove the element from its canister.

Fine jets of hydraulic fluid at high pressure can penetrate

a Hold canister F.

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

b Hold handle E and rotate the element G 90° anti-

fluid leaks. Do not put your face close to suspected

clockwise.

leaks. Hold a piece of cardboard close to suspected

c Pull on handle E, the element G should separate

leaks and then inspect the cardboard for signs of

from its canister F. Discard the old element.

hydraulic fluid. If hydraulic fluid penetrates your skin, get

medical help immediately.

d Remove and discard seal H.

INT-3-1-10/1

e Clean the inside of canister F.

1

Position the machine on level ground. Roll the loader

shovel forward and rest it on the ground. Retract the

New machines are fitted with a 5 micron filter element which

extending dipper if fitted. Close the backhoe bucket.

must be replaced at the first 100 hour service with a 10

Swing in the dipper. Lower the boom until the bucket

micron filter element.

rests on the ground. Lower the stabilisers to the

ground. Stop the engine. Remove the starter key.

4

Fit the new element.

a Fit a new seal H.

2

Remove the element assembly

b Make sure that seal J is fitted in the new element.

a Remove screws A. Remove the cover plate B and

c Push the element G into its canister F and rotate the

gasket C

element 90° to lock it into position. Check that the

* Note: If gasket C is a rubber type it can be reused provided

element has locked into position by pulling on

it is undamaged. If the gasket is a cork type it must be

handle E.

discarded and a new gasket fitted on assembly.

d Install the element assembly in the hydraulic tank.

b Remove spring D.

e Fit spring D and gasket C, (see ‘Note’ at step 2).

*

c Hold handle E and pull the element assembly from

f Fit cover plate B and tighten screws A to 21 Nm

the hydraulic tank.

(15.5 lbf ft).

g Check oil level and replenish as required through

filler. Fit and tighten the filler cap as described on

previous page.

E

J

G

A

H

B

C

D

F

399340

9803/3280

Issue 2*

Section 3

Routine Maintenance

Section 3

18 - 3

Hydraulic System

18 - 3

Changing the Suction Strainer

! WARNING

Make the machine safe before getting beneath it. Lower

the attachments to the ground; engage the parking

brake; remove the starter key, disconnect the battery.

2-3-2-2

1

Position the machine on level ground. Roll the loader

shovel forward and rest it on the ground. Retract the

extending dipper if fitted. Close the backhoe bucket.

B

Swing in the dipper. Lower the boom until the bucket

rests on the ground. Lower the stabilisers to the

ground. Stop the engine. Remove the starter key and

disconnect the battery.

2

Remove hydraulic tank filler cap.

3

Place a container beneath the hydraulic tank to catch

the oil, remove drain plug and drain the hydraulic tank.

Make sure the container is large enough to hold the

tank contents, see Service Capacities and

Lubricants.

A

A

4

Undo clips A and disconnect the hydraulic return pipe.

A334050

5

Using a 65mm A/F spanner unscrew suction strainer B

and discard.

6

Fit a new filter assembly B, torque tighten to 15-20 Nm

(11-15 lbf ft).

7

Reconnect suction hose. Make sure the clips A are

positioned 180° apart.

8

Refit drain plug, torque tighten to 100 Nm (74 lbf ft).

9

Refill hydraulic tank, fit and tighten the filler cap, see

Hydraulic Tank Cap.

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

19 - 1

Front and Rear Axle (All Wheel Steer Machines)

19 - 1

Checking the Differential Oil Level

Changing the Differential Oil

! WARNING

! WARNING

Make the machine safe before getting beneath it. Lower

Make the machine safe before getting beneath it. Lower

the attachments to the ground; engage the parking

the attachments to the ground; engage the parking

brake; remove the starter key, disconnect the battery.

brake; remove the starter key, disconnect the battery.

2-3-2-2

2-3-2-2

! CAUTION

1

Park the machine on level ground. Engage the parking

brake. Set the transmission to neutral. Lower the

The axle oil level must be checked with the machine

attachments to the ground. Stop the engine and

level, otherwise a false indication of the amount of oil in

remove the starter key.

the axle will be given.

16-3-5-3

2

Place a container of suitable size beneath plug B to

1

Park the machine on level ground. Engage the parking

catch the oil. Remove the drain plug B and its seal.

brake. Set the transmission to neutral. Lower the

Allow oil to drain out. The drain plug is magnetic. Wipe

attachments to the ground. Stop the engine and

it clean. (Metallic particles should be carefully

remove the starter key.

removed). Fit drain plug B and its washer. Tighten to

79 Nm (60 lbf ft).

2

Clean the area around fill/level plug A, then remove the

plug and its sealing washer. Oil should be level with the

3

Fill with recommended oil through fill/level hole A.

bottom of the hole. Add recommended oil if necessary.

Clean and refit plug A and its seal. Tighten to 79 Nm

(60 lbf ft).

3

Clean and refit the plug and its washer.

FRONT

REAR

S260420

A

A

B

B

S260430

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

19 - 2

Front and Rear Axle (All Wheel Steer Machines)

19 - 2

Checking the Hub Oil Levels

Changing the Hub Oil

Check each hub separately.

The axle oil is used to lubricate the brake components and

cool the brake plates.

1

Park the machine on level ground with the OIL LEVEL

mark horizontal. There is a tolerance of 5 mm (0.2 in)

It is important that the oil is changed regularly as specified in

above or below the horizontal.

the service schedule - the lubricating properties of the oil will

reduce as a result of brake wear.

2

Engage the parking brake. Set the transmission to

neutral. Lower the attachments to the ground. Stop the

Consult your JCB distributor for advice if necessary.

engine and remove the starter key.

Change the oil in each hub separately

3

Clean the area around the fill/level plug C. Remove the

plug. Oil should be level with the bottom of the hole. If

1

Set the machine level, with the tyres just clear of the

necessary, add the recommended oil. Clean the plug

ground. Manually rotate the wheels to bring the OIL

before refitting it.

LEVEL mark on the hubs to the vertical position, with

the fill/level plugs C at the bottom.

2

a Place a container of suitable size beneath plug C to

catch the oil.

b Remove fill/level plugs C. Allow time for the oil to

drain out.

3

a Set OIL LEVEL marks to the horizontal.

b Fill the hubs with recommended axle oil, through the

fill/level holes C. Oil should be level with the bottom

of the fill/level hole.

c Clean and refit fill/level plugs C.

OIL

LEVEL

C

C

356040

S209320

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

19 - 3

Front and Rear Axle (Two Wheel Steer Machines)

19 - 3

The front axle procedures are the same as described on the

1

Park the machine on level ground so that the 'OIL

previous pages (all wheel steer machines). Refer to the

LEVEL' mark on one hub is at the bottom, as shown in

following procedures for checking and changing the oil on

fig. 1. Engage the parking brake. Set the transmission

the rear axle.

to neutral. Lower the attachments to the ground. Stop

the engine and remove the starter key.

Checking the Oil Level

2

Place a container of suitable size beneath fill/level plug

C to catch the oil. Remove the fill/level plug C from the

! CAUTION

hub. Allow the oil to drain out. The drain plug is

The axle oil level must be checked with the machine

magnetic. Wipe it clean. (Metallic particles should be

level, otherwise a false indication of the amount of oil in

carefully removed). Clean and refit the hub fill/level plug

the axle will be given.

C.

16-3-5-3

3

Position the other wheel of the rear axle so that the

1

Park the machine on level ground. Engage the parking

'OIL LEVEL' mark on its hub is at the bottom. Repeat

brake. Set the transmission to neutral. Lower the

step 2.

attachments to the ground. Stop the engine and

remove the starter key.

4

Place a container of suitable size beneath the drain

plug B to catch the oil.

2

Clean the area around fill/level plug A, then remove the

plug and its sealing washer. Oil should be level with the

! CAUTION

bottom of the hole. Add recommended oil if necessary.

Oil will gush from the hole when the drain plug is

removed. Keep to one side when you remove the plug.

3

Clean and refit the plug and its washer.

2-3-4-2

Changing the Oil

Remove the drain plug B. Allow the oil to drain out. The

drain plug is magnetic. Wipe it clean. (Metallic particles

The axle oil is used to lubricate the brake components and

should be carefully removed). Clean and refit the drain

cool the brake plates.

plug B.

It is important that the oil is changed regularly as specified in

5

Remove fill/level plug A. Fill the axle with the specified

the service schedule - the lubricating properties of the oil will

quantity and recommended type of oil. Clean and refit

reduce as a result of brake wear.

fill/level plug A.

Consult your JCB distributor for advice if necessary.

1

A

C

B

S145210

S209320

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

21 - 1

Battery

21 - 1

Warning Symbols

! CAUTION

The following warning symbols may be found on the battery.

Do not disconnect the battery while the engine is

running, otherwise the electrical circuits may be

damaged.

Symbol

Meaning

INT- 3- 1-14

! WARNING

Understand the electrical circuit before connecting or

Keep away from children.

disconnecting an electrical component. A wrong

connection can cause injury and/or damage.

INT-3-1-4

A289230

! DANGER

Battery electrolyte is toxic and corrosive. Do not

Shield eyes.

breathe the gases given off by the battery. Keep the

electrolyte away from your clothes, skin, mouth and

eyes. Wear safety glasses.

INT-3-2-1/3

A289260

! CAUTION

No smoking, no naked flames,

Damaged or spent batteries and any residue from fires

no sparks.

or spillage should be put in a closed acid proof

receptacle and must be disposed of in accordance with

local environmental waste regulations.

A289280

INT-3-1-12

! WARNING

Explosive Gas.

Batteries give off explosive gases. Keep flames and

sparks away from the battery. Do not smoke close to

the battery. Make sure there is good ventilation in

closed areas where batteries are being used or

A289250

charged. Do not check the battery charge by shorting

the terminals with metal; use a hydrometer or voltmeter.

Battery acid.

INT-3-1-8

A289240

Note operating instructions.

A289270

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

21 - 2

Battery

21 - 2

! WARNING

Checking the Electrolyte Level

Batteries give off an explosive gas. Do not smoke when

handling or working on the battery. Keep the battery away

Maintenance free batteries used in normal temperate climate

from sparks and flames.

applications should not need topping up. However, in

certain conditions (such as prolonged operation at tropical

Battery electrolyte contains sulphuric acid. It can burn you if

temperatures or if the alternator overcharges) the electrolyte

it touches your skin or eyes. Wear goggles. Handle the

level should be checked as described below.

battery carefully to prevent spillage. Keep metallic items

! WARNING

(watches, rings, zips etc) away from the battery terminals.

Such items could short the terminals and burn you.

Do not top the battery up with acid. The electrolyte could

boil out and burn you.

2-3-4-6

Set all switches in the cab to OFF before disconnecting and

connecting the battery. When disconnecting the battery,

1

Park the machine on firm level ground, engage the

take off the earth (-) lead first.

parking brake and set the transmission to neutral.

Lower the backhoe to the ground, raise the loader arms

When reconnecting, fit the positive (+) lead first.

and fit the safety strut, see Loader Arm Safety Strut.

Switch OFF the engine and remove the starter key.

Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before

2

Remove the front grille A.

connecting or disconnecting the battery. When you have

installed the battery in the machine, wait five minutes before

3

Remove battery cell covers. Look at the level in each

connecting it up.

cell. The electrolyte should be 6 mm (1/4 in) above the

plates. Top up if necessary with distilled water or de-

First Aid - Electrolyte

ionised water.

Do the following if electrolyte:

GETS INTO YOUR EYES

Immediately flush with water for 15 minutes, always get

medical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable

A

oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with

a sterile dressing then get medical help.

5-3-4-3/1

399350

S260640

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

21 - 3

Battery

21 - 3

Battery Isolator

To disconnect the battery from the machine electrics a

battery isolator has been fitted.

! CAUTION

Except in an emergency, do not use the battery isolator

to switch OFF the engine. Failure to comply may result in

damage to the electrical circuits.

INT-3-2-13

At the end of a working cycle or if the machine is being left

unattended, provided the lights are not required, the battery

must be isolated. Before attempting to start the engine or

use the machine electrics the battery isolator key must be

fitted and switched on.

1

To isolate the battery turn the battery isolator key A in

an anti-clockwise direction B and remove. Keep the key

in a safe place and available for when the machine is

next required.

2

To connect the battery insert the key A and turn in a

clockwise direction C.

! CAUTION

Before carrying out arc welding on the machine

disconnect the battery and alternator to protect the

circuits and components.

The battery must still be disconnected even if the battery

isolator is fitted.

INT-3-1-13

B

C

A

A323611

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

23 - 1

Hydraulic Oil Cooler

23 - 1

Cleaning the Tubes/Fins

The hydraulic oil cooler is in front of the engine radiator. If

the hydraulic oil cooler tubes/fins get clogged (by dirt and

flies etc) the radiator and cooler will be less efficient.

A

1

Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral. Raise

and block the loader arms. Lower the backhoe to the

ground and stop the engine.

2

Unscrew bolts A. Lift off the radiator grille.

3

Brush off all debris from the cooler tubes and fins.

Make sure the loosened material is brushed out of the

cooler enclosure.

4

Refit the radiator grille. Tighten bolts A evenly.

399360

9803/3280

Issue 1

Section 3

Routine Maintenance

Section 3

25 - 1

Stabiliser Legs (Sideshift Machines only)

25 - 1

Wear Pads

Wear Pad Adjustment

The wear pads support and guide the inner leg section. They

Note: It is very important that the wear pads are adjusted

ensure that during extension and retraction the inner leg is

at the correct service intervals, as the inner leg could

kept central and has a minimum amount of ‘float’.

contact the outer leg and scoring could occur. Scoring

will dramatically reduce wear pad life.

Upper wear pads A (4 off) are fitted to the top of the inner

leg as shown. The upper pads are available in 3 sizes and

Remove and clean away all debris that may have built up in

are colour coded; 5mm (green); 6mm (red) and 7mm (blue).

stabiliser cavities.

Lower wear pads comprise adjustable pads B (2 off) and

fixed pads C (2 off).

As a guide, there should be approximately 1mm (0.039 in.)

float between the stabiliser inner and outer leg.

When pads A and C have worn to a minimum thickness of

0.5 mm (0.020 in.) they must be replaced with new ones. To

Before adjusting the clearance make sure that the leg is

replace the pads, the stabiliser inner leg must be removed

raised clear of the ground but not fully retracted.

(contact your JCB Distributor).

To adjust the clearance, screw pad B fully in until it just

It is important to note that lower pads C are designed to

touches the inner leg and then back the pad off by one

take most of the ‘loading’ during stabiliser leg operation, as

quarter of a turn.

a consequence these pads must be checked regularly for

wear.

Note: Over-tightening the adjustable pad B will lock the pad

in position, it will not be possible to back the pad off. If this

When replacing pads, it is recommended that the complete

should happen, operate the stabiliser leg as normal but be

lower set of pads are replaced (items B and C). The top

aware that pads B and C will wear more rapidly.

pads should be inspected and replaced as required.

A

C

B

S273120

9803/3280

Issue 1

Content      ..      1      2      3      ..