jcb 3CX Service Manual
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jcb 3CX Service Manual

Backhoe loader
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Service Manual
Backhoe Loader
9803/3280
3CX, 4CX
930001 to 960000
214e, 214, 215, 217
903000 Onwards
Publication No.
S2-eng
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

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  • Page 1 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
  • Page 2 Brakes From M/c No. 930000 Onwards From M/c No. 903000 Onwards (USA) Steering PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, Engine WATERLOO PARK, UTTOXETER, ST14 5PA ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Servo Controls Publication No.
  • Page 3 Machine Nomenclature In this Service Manual, reference is made to machine models, e.g. 3CX, 4CX, these are European machine model names. North American machine models have different names, the table below shows the European and the equivalent North American nomenclature.
  • Page 4 Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications. Full Pressure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure.

  • Page 5: Table Of Contents

    - Body & Framework 4 - 1 - Electrics 4 - 4 - Hydraulics 4 - 6 - Transmission 4 - 10 - Engine 4 - 19* Sealing and Retaining Compounds 5 - 1 9803/3280 Issue 2* Find manuals at http://best-manuals.com/search?&s=JCB-9803-3280...

  • Page 6: Machine Identification Plate

    U.K. and R.O.W. Typical Engine Identification Number 50262 500405 A Engine Type AB = 4 cylinder turbo B Build Number C Country of Origin D Engine Sequence Number E Year of Manufacture A246740 North America 9803/3280 Issue 1 Find manuals at http://best-manuals.com/search?&s=JCB-9803-3280...

  • Page 7: Serial Plates

    A Front Axle (2WS machine) B Front Axle (4WS machine) C Rear Axle (2WS machine) D Rear Axle (4WS machine) E Synchro Shuttle Transmission F Powershift Transmission S259110 G Engine S257580 S259100 A401030 S156571 S260120 9803/3280 Issue 1 Find manuals at http://best-manuals.com/search?&s=JCB-9803-3280...

  • Page 8: Torque Settings

    0.12 10.0 24.0 18.0 (10) 48.0 35.5 (12) 82.0 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 Find manuals at http://best-manuals.com/search?&s=JCB-9803-3280...

  • Page 9: Service Tools Numerical List

    Hand Pump 4 - 7 4104/1310 Hand Cleaner 4 - 1 892/00224 Impulse Extractor 4 - 11 4104/1538 JCB Cleaner & Degreaser 5 - 1 892/00225 Adapter for Extractor 4 - 11 4104/1557 Cleaner/Degreaser (400 ml) 5 - 1 892/00252 Test Block for Loader Valve A.R.V...
  • Page 10 4 - 9 7213/0002 3 Way Pin Housing 4 - 5 892/01033 Electronic Service Tool Kit 4 - 18 7213/0003 3 Way Socket Retainer 4 - 5 7213/0004 3 Way Pin Retainer 4 - 5 9803/3280 Issue 6* Find manuals at http://best-manuals.com/search?&s=JCB-9803-3280...
  • Page 11 Section 1 General Information Section 1 3 - 3 3 - 3 Service Tools Numerical List Page No. 7213/0005 3 Way Socket Connector (DT) 4 - 5 The following parts are replacement items for kits and would 7213/0006 3 Way Pin Housing (DT) 4 - 5 normally be included in the kit numbers quoted on pages 7213/0007...

  • Page 12: Service Tools

    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;...
  • Page 13 '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.
  • Page 14 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) S186360...

  • Page 15: Electrics

    Section 1 General Information Section 1 4 - 4 4 - 4 Service Tools (cont'd) Section C - Electrics AVO Test Kit 892/00283 Tool Kit Case 892/00298 Fluke Meter 85 892/00286 Surface Temperature Probe 892/00284 Venture Microtach Digital Tachometer 892/00282 100 amp Shunt - open type 892/00285 Hydraulic Temperature Probe...
  • Page 16 Section 1 General Information Section 1 4 - 5 4 - 5 Service Tools (cont'd) Section C - Electrics Electrical Repair Kit 6A :7216/0002 6 Way Pin Housing 2A :7212/0002 2 Way Pin Housing 6B :7216/0004 6 Way Pin Retainer 2B :7212/0004 2 Way Pin Retainer 6C :7216/0003...

  • Page 17: Hydraulics

    Section 1 General Information Section 1 4 - 6 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/in :892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in :892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in :892/00254...
  • Page 18 Section 1 General Information Section 1 4 - 7 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 892/00309 A.R.V. Pressure Test Kit 892/00881 Valve Spool : 892/00340 Test Block Body Seal Fitting Tool...
  • Page 19 Section 1 General Information Section 1 4 - 8 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.
  • Page 20 Section 1 General Information Section 1 4 - 9 4 - 9 Service Tools (cont'd) Section E - Hydraulics 892/00252 Test Block for Loader Valve A.R.V. (214e Machines Only) 11 o 10mm 20mm S220840 110mm 175mm 892/01027 Piston Seal Assembly Tool 338500 S216250 892/00334...
  • Page 21 Section 1 General Information Section 1 4 - 10 4 - 10 Service Tools (cont'd) Section F - Transmission 892/00920 Flow Test Adapter 892/00301 Flow Test Adapter 892/00812 Drive Coupling Spanner for front 892/00302 Flow Test Adapter axle and gearbox yoke couplings S196720 S266880...
  • Page 22 Section 1 General Information Section 1 4 - 11 4 - 11 Service Tools (cont'd) Section F - Transmission 892/00224 Impulse Extractor Set for Hub Bearing Seals S216290 892/00817 17 mm A/F x 3/4in. square drive 892/00818 22 mm A/F x 3/4in. square drive 892/00819 15 mm A/F x 1/2in.
  • Page 23 Section 1 General Information Section 1 4 - 12 4 - 12 Service Tools (cont'd) Section F - Transmission 992/04800 Flange Spanner - for locking pinion flange while pinion nut is slackened or torque set S216310 892/00182 Bearing Pad Driver S197040 992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a...
  • Page 24 Section 1 General Information Section 1 4 - 13 4 - 13 Service Tools (cont'd) Section F - Transmission 892/01077 Synchro Shuttle Gearbox - Selector 892/01078 Synchro Shuttle Gearbox - Mainshaft Shaft Lock Screw Adjuster A395350 A396510 Synchro Shuttle Gearbox - Setting ring socket spanners Powershift Gearbox Flow Test Adaptor 892/01079...
  • Page 25 Section 1 General Information Section 1 4 - 14 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/in :892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in :892/00203...
  • Page 26 Section 1 General Information Section 1 4 - 15 4 - 15 Service Tools (cont'd) Section F - Transmission A396960 A396930 A396950 A396940 8, 9 A396580 9803/3280 Issue 3*...
  • Page 27 Section 1 General Information Section 1 4 - 16 4 - 16 Service Tools (cont'd) Section F - Transmission Solid Spacer Setting Kit 10 921/53400 Spacer Kit - Sychro Shuttle Gearbox, Synchro Shuttle Gearbox, SD70, SD80 SD70, SD80 Axles Axles, Powershift 2004 Gearbox Comprises of: 892/00918 Setting Tool Kit...

  • Page 28: Transmission

    Section 1 General Information Section 1 4 - 17 4 - 17 Service Tools (cont'd) Section F - Transmission 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.
  • Page 29 Section 1 General Information Section 1 4 - 18 4 - 18 Service Tools (cont'd) Section F - Transmission Powershift Gearbox - 6 Speed (ShiftMaster) Electronic Service Tool Kit 721/10885 - Interconnecting cable (Data Link Adaptor to machine ECU diagnostics socket). Note that this cable must be ordered separately in addition to the kit below.
  • Page 30 Section 1 General Information Section 1 4 - 19 4 - 19 Service Tools (cont’d) Section F - Transmission Wheel Hub Service Tool - Bearing Puller Bearing Press Hub Seal Dolly Item Description Part No. A, B & C Hub Service Kit 892/01092 comprises of: Puller Beam...
  • Page 31 Section 1 General Information Section 1 4 - 20 4 - 20 Service Tools (cont'd) Section H - Steering S216230 892/00180 Seal Fitting Tool for fitting 'O' ring and kin ring to Hydraulic Steer Unit 892/00181 Replacement Plastic Boss 9803/3280 Issue 1...

  • Page 32: Engine

    Section 1 General Information Section 1 4 - 21 4 - 21 Service Tools (cont'd) Section K - Engine 892/00836 Lifting Wire Assembly (for engine removal) S192390 892/00041 De-glazing Tool for Cylinder Bores (to S219080 assist bedding-in of new piston rings) A314530 892/00936 Timing pin for fuel injection pump...

  • Page 33: Sealing And Retaining Compounds

    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.
  • Page 34 Section 2 Care & Safety Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 9803/3280 Issue 1...
  • Page 35 Section 2 Care & Safety Section 2 1 - 1 1 - 1 Safety Notices In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. DANGER Denotes an extreme hazard exists.
  • Page 36 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.
  • Page 37 Section 2 Care & Safety Section 2 3 - 1 3 - 1 Operating Safety ! WARNING ! 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.
  • Page 38 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.
  • Page 39 Section 2 Care & Safety Section 2 4 - 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.
  • Page 40 ! WARNING loader arm safety strut. Fluoroelastomeric Materials 2-1-1-6 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.
  • Page 41 Section 3 Section 3 Routine Maintenance Contents Page No. Checking for Damage 1 - 1 Cleaning the Machine 1 - 2 Seat Belt Checking the Seat Belt Condition and Security 1 - 3 Fire Extinguisher (when fitted) Checking the Fire Extinguisher 1 - 3 ROPS/FOPS Structure Checking the ROPS/FOPS Structure...
  • Page 42 Section 3 Routine Maintenance Section 3 Contents Page No. Engine Air Filter Cleaning the pre-cleaner (if fitted) 3 - 9 Changing the Elements 3 - 10 Engine Oil and Filter Checking the Oil Level 3 - 11 Changing the Oil and Filter 3 - 12 Engine Cooling System Checking the Coolant...
  • Page 43 Section 3 Section 3 Routine Maintenance Contents Page No. Hydraulic System Checking the Fluid Level 3 - 37 Hydraulic Tank Cap 3 - 37 Changing the Filter Element 3 - 38 Changing the Suction Strainer 3 - 39 Hydraulic Oil Cooler Cleaning the Tubes/Fins 3 - 40 Windscreen Washer...

  • Page 44: Checking For Damage

    Section 3 Routine Maintenance Section 3 1 - 1 Checking for Damage 1 - 1 Inspect steelwork for damage. Note damaged paintwork for future repair. Make sure all pivot pins are correctly in place and secured by their locking devices. Ensure that the steps and handrails are undamaged and secure.

  • Page 45: Cleaning The Machine

    Section 3 Routine Maintenance Section 3 1 - 2 Cleaning the Machine 1 - 2 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.

  • Page 46: Seat Belt

    Section 3 Routine Maintenance Section 3 1 - 3 Seat Belt 1 - 3 Checking the Seat Belt Condition and Security ! WARNING When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.

  • Page 47: Rops/Fops Structure

    Section 3 Routine Maintenance Section 3 1 - 4 ROPS/FOPS Structure 1 - 4 Checking the ROPS/FOPS Structure The procedure for checking the ROPS/FOPS structure is described in the Body & Framework section. Refer to Section B Body & Framework, Service Procedures, Cab ROPS/FOPS Structure - Checks.

  • Page 48: Tyres And Wheels

    Section 3 Routine Maintenance Section 3 1 - 5 Tyres and Wheels 1 - 5 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.

  • Page 49: Lubricants - Health And Safety

    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.

  • Page 50: Service Schedules

    Section 3 Routine Maintenance Section 3 2 - 1 Service Schedules 2 - 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.
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