jcb 215 Manuals

Manuals and User Guides for jcb 215. We have 5 jcb 215 manuals available for free PDF download: Service Manual, Operator's Manual, Quick Reference Manual

jcb 215 Service Manual (891 pages)

Backhoe Loader

Brand: jcb | Category: Other | Size: 39.2 MB

Machine Nomenclature
2
Colour Coding
3
Table of Contents
4
Machine Identification Plate
5
Typical Vehicle Identification Number (VIN)
5
Serial Plates
6
Torque Settings
7
Service Tools Numerical List
8
- 12V Mobile Oven
  11
- Body & Framework
  11
  - Cartridge Gun
    11
  - Hand Cleaner
    11
  - Service Tools - Body and Framework
    11
  - 240V Static Oven
    12
  - Glass Extractor (Handles)
    12
  - Glass Lifter
    12
  - Wire Starter
    12
  - Braided Cutting Wire
    13
  - Long Knife
    13
  - Nylon Spatula
    13
  - Rubber Spacer Blocks
    13
  - AVO Test Kit
    14
  - Battery Tester
    14
  - Service Tools - Electrics
    14
  - Socket for Alternator Pulley Nut
    14
  - Electrical Repair Kit
    15
  - Flow Test Equipment
    16
  - Hydraulic Circuit Pressure Test Kit
    16
  - Pressure Test Adapters
    16
  - Service Tools - Hydraulics
    16
  - Bonded Washers
    17
  - Hand Pump Equipment
    17
  - Male Adapters
    17
  - Valve Spool
    17
  - Female Cone Blanking Plug
    18
  - Female Connectors
    18
  - Male Cone Blanking Cap
    18
  - Piston Seal Assembly Tool
    19
  - Ram Seal Protection Sleeves
    19
  - Replacement Plastic Boss
    19
  - Seal Fitting Tool
    19
  - Bearing Press
    20
  - Drive Coupling Spanner
    20
  - Fitting Tool Assembly
    20
  - Torque Measuring Tool for Wheel Hub Seals
    20
- Transmission
  20
  - Adapter - Impulse Extractor
    21
  - Impulse Extractor Set for Hub Bearing Seals
    21
  - Measuring Cup
    21
  - Splined Bolt Socket for Driveshafts
    21
  - Bearing Pad Driver
    22
  - Flange Spanner
    22
  - Service Tools - Transmission
    22
  - Torque Multiplier
    22
  - Powershift Gearbox Flow Test Adaptor
    23
  - Synchro Shuttle Gearbox
    23
  - Flow Test Equipment List
    24
  - Hydraulic Circuit Pressure Test Kit - List
    24
  - Solid Spacer Setting Kit
    26
  - Spacer Kit
    26
  - Powershift
    27
  - Speed Sensor Test Harness
    27
  - Thrust Washer Kit
    27
  - Transmission Jack
    27
  - Powershift Gearbox - 6 Speed (Shiftmaster) Electronic Service Tool Kit
    28
  - Adaptor for Compression Testing (AK, AM, AR)
    29
  - De-Glazing Tool for Cylinder Bores
    29
- Issue
  29
  - Lifting Wire Assembly
    29
  - Service Tools - Engine
    29
  - Sealing and Retaining Compounds
    30
  - Care & Safety
    31
  - Safety Notices
    32
  - General Safety
    33
  - Operating Safety
    34
  - Maintenance Safety
    35
  - Routine Maintenance
    38
  - First Aid - Oil
    41
- Hygiene
  41
  - Lubricants - Health and Safety
    41
  - Spillage
    41
  - Waste Disposal
    41
  - Pre-Start Cold Checks
    42
- Service Schedules
  42
- Checking for Damage
  46
- Cleaning the Machine
  47
  - Engine Panels
    48
  - Opening and Closing the Bonnet
    48
- Removing and Fitting a Side Panel
  48
- Loader Arms
  50
- Backhoe & Quickhitch
  51
- Front Axle (2 Wheel Drive Machines)
  52
- Front Axle (4 Wheel Drive Machines)
  52
- Front Axle (All Wheel Steer Machines)
  53
  - Rear Axle (All Wheel Steer Machines)
    53
  - Driveshafts
    54
- Extending Dipper
  54
  - 6 - in - 1 Clamshovel
    55
  - Loader Quickhitch
    55
  - Stabilisers (Centremount Machines)
    55
  - Kingpost
    56
- Power Sideshift
  56
- Backhoe Quickhitch (Hydraulic)
  57
- Knuckle (if Fitted)
  57
- Checking the Wheel Nut Torques
  58
  - Tyre Inflation
    58
  - Tyres and Wheels Maintenance
    58
  - Brakes Maintenance
    59
- Checking the Foot Brake Fluid Level
  59
- Changing the Oil and Filter
  61
- Checking the Oil Level
  61
- Engine Oil and Filter Maintenance
  61
- Changing the Coolant
  62
- Checking the Coolant
  62
- Engine Cooling System Maintenance
  62
- Adjusting the Fan Belt
  63
- Cleaning the Cab Heater Filter
  63
- Advice
  64
- Fuel Standards
  64
- Fuel System Maintenance
  64
- Low Temperature Fuels
  64
- Petrol
  64
- Types of Fuel
  64
- Changing the Filter Element
  65
- Draining the Filter
  65
- Filling the Tank
  65
- Bleed the System
  66
- Draining the Sediment Bowl
  66
- Checking the Fluid Level
  70
- Hydraulic System Maintenance
  70
- Hydraulic Tank Cap
  70
- Changing the Filter Element (Hydraulic System)
  71
- Changing the Suction Strainer
  72
- Checking the Differential Oil Level
  73
- Front and Rear Axle (All Wheel Steer Machines) Maintenance
  73
- Changing the Hub Oil
  74
- Checking the Hub Oil Levels
  74
- Changing the Oil
  75
- Checking the Oil Level
  75
- Front and Rear Axle (Two Wheel Steer Machines)
  75
  - Battery Maintenance
    76
  - Battery: Warning Symbols
    76
- Checking the Electrolyte Level
  77
- First Aid - Electrolyte
  77
- Battery Isolator
  78
- Cleaning the Tubes/Fins
  79
- Hydraulic Oil Cooler
  79
- Stabiliser Legs (Sideshift Machines Only)
  80
- Wear Pad Adjustment
  80
- Adjusting the Compressor Drive Belt
  81
- Air Conditioning Maintenance
  81
- Checking Hose Burst Protection Valve
  82
- Hose Burst Protection Valve (if Fitted)
  82
- Lowering a Load
  82
- Service Capacities and Lubricants
  83
- Coolant Mixtures
  84
  - Body & Framework
    86
  - Body & Framework: Service Tools
    88
- Slide Hammer Kit Procedure
  91
- Rivet Nut Tool Procedure
  92
  - Air Conditioning Data
    93
  - Body and Framework: Technical Data
    93
  - Body & Framework - Basic Operation
    94
  - Air Conditioning
    95
  - R-134A Refrigerant
    95
  - System Operation
    95
- Air Conditioning
  96
- Basic Operation
  96
- System Control
  96
- System Operation
  96
- Technical Data Air Conditioning (Option)
  96
- Safety Procedures (Air Conditioning System)
  97
- Fault Finding
  98
  - General Fault Indications (Air Conditioning)
    98
  - Sight Glass Indications
    98
  - Fault Finding (Air Conditioning)
    99
  - No Air Conditioning
    99
  - Air Conditioning - System Diagnosis
    100
  - Normally Functioning A/C System
    100
  - Low R-134A Charge
    101
  - Poor Refrigerant Circulation
    101
- System Diagnosis
  101
- Wiring Continuity Checks
  105
- Air Conditioning: Service Procedures
  106
- Checking Refrigerant Charge Level
  106
- Leak Testing
  106
- Tightening Leaking Hoses
  106
- Refrigerant Charging and Discharging
  107
  - Refrigerant Recovery
    107
  - Evacuating (Vacuuming)
    108
  - Electronic Vacuum Gauge
    109
  - Relubricating
    110
  - Refrigerant Charging
    111
- Binary Pressure Switch Testing
  112
- Condenser Matrix Cleaning
  113
- Filters - Changing and Cleaning
  114
- Compressor Drive Belt - Adjusting
  115
- Glazing
  116
- Removing Broken Glass and Old Sealant
  116
  - Preparing the Cab Frame Aperture
    118
  - Preparing the New Glass
    119
  - Installing the New Glass
    120
- Cab ROPS/FOPS Structure - Checks
  122
- Engine Panels - Removing and Fitting
  123
- Stabiliser Leg - Wear Pad Adjustment
  124
- Stabiliser Legs Wear Pads
  124
- Extending Dipper - Wear Pad Adjustment
  125
  - Inspecting the Top Wear Pads
    125
  - Adjusting the Bottom Wear Pads
    126
- Sideshift - Hydraclamp Clearance Setting
  127
- Power Sideshift - Wear Pad Renewal
  128
- Power Sideshift - Chain Adjustment
  129
- Air Conditioning Hvac*/Air Conditioning Unit - Removal and Replacement
  131
- Freeze Protection Thermostat
  131
- Alternator
  155
- Electrics: General Electrical Data
  155
- System Type
  155
- Technical Data
  155
  - Fuses and Relays
    156
  - Link Box Fuses
    158
  - Relays
    158
  - Circuit Schematic - Basic Machine
    159
- Basic System Operation
  160
  - Circuit Schematic - Powershift
    163
  - Circuit Schematic - Synchro Shuttle
    163
  - 2 Wheel Steer/Brake Mode
    165
  - 2 Wheel Steer/Brake Mode (Germany)
    165
  - Circuit Schematics - Options
    165
  - Steer Mode - 4CX and 3CX Super (4X4X4)
    165
  - S Mode Schematics
    166
  - Steermode 3CX Super (4X4X4) Schematics
    166
  - All Wheel Steer/Brake Mode Schematics
    167
  - Auxiliary and Hydraclamp Hydraulics Schematics
    167
  - Speedometer Schematics
    167
- All Wheel Steer/Brake Mode
  168
- Auxiliary and Hydraclamp Hydraulics
  168
- Speedometer
  168
- Dedicated Quickhitch
  169
- Hand Held Tools
  169
- Hydraulic Speed Control (HSC)
  169
- Pole Planter
  169
- Return to Dig (Shovel Reset)
  169
- Smooth Ride System (SRS)
  169
  - Autoshift Transmission Schematics
    171
  - Circuit Schematics - 6 Speed Powershift (Shiftmaster)
    171
- Speed Powershift (Shiftmaster)
  172
- Measuring Continuity
  179
- Measuring DC Voltage
  179
- Measuring Resistance
  179
  - Testing a Diode or a Diode Wire
    181
  - Battery - Maintenance
    182
  - Battery Safety
    182
  - Battery Testing
    183
- Specific Gravity Testing
  183
  - Alternator - Charging Test
    184
  - Alternator - General Description
    184
  - Alternator - Service Precautions
    184
- Starter Motor
  185
- Starting Circuit Test
  185
- Repair Procedure
  187
- Wiring Harness
  187
  - Alternator Removal and Replacement
    190
  - Starter Motor Diagram
    191
  - Starter Motor Inspection
    192
  - Starter Motor Removal and Replacement
    192
- Earth Points
  193
- Harness Data Drawings
  193
- Removal and Replacement
  232
- Shovel Reset (214E Machines)
  235
  - Shovel Reset Diagrams
    235
  - Shovel Reset (214E Machines Only)
    236
  - Return to Dig Diagram
    237
  - Return to Dig Adjustment
    238
  - Return to Dig Operation
    238
  - Precision Control (Servo) - Basic System Operation
    239
  - Precision Control (Servo) - Component Location
    239
- Circuit Description
  240
- Electrical Connections
  244
- Renewing the Pilot Supply Valve Oil Filter
  250
- Testing the Pilot Pressure
  250
- Pilot Hose Removal and Replacement
  252
- Seat Arms Control Lever - Adjustment
  253
- Basic System Operation
  260
- Component Location
  260
- Circuit Description
  261
- Component Identification
  261
- Hydraulic Operation
  262
- Pump Dump Controller (Power Management ECU)
  265
- Joystick Controllers - Description
  266
- Servo Pressure Supply Valve - Description
  267
  - Precision Control (Servo) Fault Finding
    268
  - Chart A: no Servo Controls (System Fails to Operate)
    269
- Dismantling and Assembly
  269
- Service Procedures - Testing the Servo Pressure
  276
- Loader Valve Controls
  279
- Excavator Valve Controls (JCB + Pattern)
  281
- Cab Heater Controls
  283
- Control Cables Removal and Replacement
  283
- Stabiliser Controls
  285
- Boom Lock Cable
  287
- Boom Stop Setting
  288
- Engine Throttle Cable
  289
- Auxiliary Footpedal Cable
  291
  - Hydraulics
    292
  - Hydraulics Service Tools
    297
- Service Tools
  300
- Fixed Flow
  301
  - Hydraulic Pumps
    301
  - Hydraulics Technical Data
    301
- Variable Flow
  303
- Loader Valve - Fixed Flow
  304
- Relief Valve Pressures
  304
- Loader Valve - Precision Control (Servo)
  305
- Machines up to Serial No. 931159
  305
- Loader Valve - Variable Flow
  307
- Excavator Valve - Fixed Flow
  308
- Excavator Valve - Precision Control (Servo)
  309
- Auxiliary Valve - Fixed Flow
  311
- Smooth Ride System
  312
- Basic System Operation
  319
- Introduction to Hydraulic Schematic Symbols
  319
- Circuit Schematics Fixed Flow
  325
- Machines from January 2003
  339
- Double Pump - Operation
  342
- Hydraulic Pump - Fixed Flow
  342
  - Hydraulics - Circuit Descriptions
    342
  - Single Pump - Operation
    342
- Hydraulic Pump - Variable Flow
  344
- Operation
  344
- Pressure/Flow Regulator Valve
  346
- Arms Lower
  358
- Float
  358
  - Loader Valve - A.R.V. Operation
    359
  - Main Relief Valve (MRV) - Operation
    362
  - Pilot Valve Opens
    362
  - Valve at Rest
    362
  - Valve Moves off Its Seat
    362
  - Loader Valve - Variable Flow Operation
    363
  - Priority Inlet Section Operation
    364
  - Auxiliary Spool
    366
  - Loader Shovel Spool
    367
  - Loader Lift Spool
    368
  - Shuttle Valve Signal Network
    369
- Excavator Valve
  370
  - Manual Control - Neutral Circuit
    370
  - Excavator Valve - Load Hold Check Valves
    373
  - Excavator Valve - One Way Restrictor Operation
    374
  - Excavator Valve - Slew Operation
    374
  - Excavator Valve - A.R.V. Operation
    377
  - Excavator Valve - Slew A.R.V. and Anti-Cavitation Operation
    377
  - Pilot - Operated Pressure Relief Valve Operation
    378
  - Excavator Valve - Manual Control
    380
  - Hydraclamp Valve Operation (Sideshift Machines)
    380
  - Excavator Valve - Precision Control (Servo) (Machines up to Serial No. 931159)
    381
  - Load Sense (Isolator Compensator) Valve Operation
    384
  - No Service Is Selected (All Spools in Neutral)
    384
  - Spool at Point of Operating a Service
    384
  - Spool Fully Operating a Service
    384
  - Clamps Locked up
    385
  - Clamps Pressurised
    385
  - Clamps Released
    385
  - Hydraclamp Valve Operation
    385
  - Excavator Valve - Precision Control (Servo (Machines from January 2003)
    386
  - No Service Selected
    386
  - Servo Spool Actuation
    386
  - When a Service Is Selected
    386
  - Load Sense - Pressure Compensator Valves Operation
    387
  - Operating an Individual Service
    390
  - Operating Multiple Services
    390
  - Smooth Ride System Diagram
    391
  - Boom & Dipper Operation
    393
  - Hose Burst Protection Valve
    393
  - Operation 1 - Load Raise
    393
  - Operation 2 - Load Lower
    393
  - Operation 3 - Relief Valve
    396
  - Operation 4 - Hose Burst Condition
    396
  - Hose Burst Protection Valve - Loader Operation
    397
  - Hydraulic System - Fixed Flow
    401
  - Hydraulics: Fault Finding
    401
  - Lack of Power in All Hydraulic Functions
    401
  - All Hydraulic Rams Slow to Operate
    402
  - One Hydraulic Service Fails to Operate or Is Slow to Operate
    402
  - The Engine Tends to Stall When Hydraulics Are under Load
    402
  - A Spool Is Sticking
    403
  - Leaking Oil Seal (Control Valves)
    403
  - Ram Creep
    403
  - Hydraulic Oil Becomes too Hot
    404
  - Hydraulic System - Variable Flow
    405
  - Smooth Ride System Fault Finding
    407
  - Contaminant Standards
    408
  - Hydraulic Contamination
    408
  - Hydraulic Fluid Quality
    408
  - Hydraulics - Service Procedures
    408
  - Checking Flow
    410
  - Fitting/Removing a Flow Meter and Load Valve
    410
  - Fixed Flow Pumps
    410
  - Flow and Pressure Testing
    410
  - Variable Flow Pumps - Flow and Pressure Testing
    411
  - Load Sensing Pressure
    412
  - Stand-By Pressure
    412
  - Maximum Hydraulic Stall
    413
  - Load Sense Line Flow
    414
  - Pump Flow
    414
  - Flow Regulator Spool
    415
  - Pressure Regulator Spool
    415
  - Regulator Valve Adjustment
    415
  - Renewing Drive Shaft Seal
    417
  - Shuttle Valve Signal Network - Testing
    418
  - Loader Valve - Pressure Testing
    419
  - Main Relief Valve (M.R.V.)
    419
  - Unloader Valve
    420
  - Hydraulic Speed Control (HSC)
    421
  - Auxiliary Relief Valves - Using Hand Pump
    422
  - Excavator Valve - Precision Control (Servo (Machines up to Serial No. 931159) - Pressure Testing
    427
  - Load Sense Drain Regulator and Relief Valve
    427
- Precision Control (Servo)
  427
- Manual Control
  447
- Machines from January 2003
  501
- Precision Control (Servo)
  501
- Flow Regulator Valve
  502
- JCB Ram Sealing Procedure
  536
- System Type
  813
- Basic System Operation
  814
- Pedals Locked - Compensating Operation
  814
- Pedals Locked - Normal Operation
  814
- Pedals Unlocked - Normal Operation
  814
- Brake System Fault Finding
  815
- Brake Light Switch - Adjustment
  818
- Brakes - Service Procedures
  818
- Brake Piston Seal Leakage Test
  819
- Parking Brake - Testing
  820
  - Cable Adjustment
    821
  - Lever Adjustment
    821
  - Parking Brake - Adjustment
    821
  - Renewing a Worn or Damaged Cable
    821
  - Parking Brake - Switch Adjustment
    822
  - Pad Inspection
    823
  - Pad Removal
    823
  - Pad Replacement
    823
  - Parking Brake - Renewing the Brake Pads
    823
  - Master Cylinder and Servo Unit Removal and Replacement
    825
  - Master Cylinder and Servo Unit Dismantling and Assembly
    826
  - Service Brakes Dismantling and Assembly
    827
  - Service Brakes Bleeding
    828
  - Parking Brake - Torque Figures
    829
  - Parking Brake - Calliper Removal and Replacement
    830
  - Parking Brake Diagram
    831
- Calliper Dismantling and Assembly
  832
- Parking Brake Assembly
  834
- Brake Disc - Removal and Replacement
  835
  - Steering
    836
  - Steering - Service Tools
    837
  - Steering Technical Data
    838
- System Type
  838
- Wheel Steer Machines
  838
- 2 Wheel Steer Machines
  839
- Steer System Schematics
  839
- Proximity Switch - Setting
  868
- Steer Mode Valve - Checking Solenoid Operation
  869
- Priority Valve - Cleaning
  870
  - Priority Valve - Standby Pressure Testing
    871
  - Power Track Rod Removal and Replacement
    872
- Link Arms - Removal and Replacement
  873
- Rams Dismantling and Assembly
  875
- Rams - Dismantling and Assembly
  876
  - Priority Valve Bleeding
    877
  - Priority Valve Dismantling and Assembly
    877
  - Priority Valve Removal and Replacement
    877
  - Steer Mode Valve Removal and Replacement
    878
  - Steer Mode Valve Dismantling and Assembly
    879
  - Hydraulic Steer Unit Removal and Replacement
    880
  - Hydraulic Steer Unit Diagram
    881
  - Hydraulic Steer Unit Dismantling and Assembly
    882
  - Pressure Relief Valve Cartridge
    883
  - Shock Valves
    883
  - Engine
    884
  - Engine - Service Tools
    885
  - Engine Technical Data
    886
  - Engine Service Procedures
    887
  - Fuel Lift Pump - Cleaning the Strainer
    887
  - Engine Removal
    889
  - Engine Replacement
    890

jcb 215 Service Manual (51 pages)

Backhoe Loader

Brand: jcb | Category: Compact Loader | Size: 1.32 MB

General Information

5
- Table of Contents
  5
- Machine Identification Plate
  6
- Typical Vehicle Identification Number (VIN)
  6
- Typical Engine Identification Number
  6
- Serial Plates
  7
- Torque Settings
  8
- Service Tools Numerical List
  9
- Service Tools
  12
  - Body & Framework
    12
  - Electrics
    15
  - Hydraulics
    17
  - Transmission
    28
  - Engine
    32
- Sealing and Retaining Compounds
  33
Section 3 Section 3 Routine Maintenance

41
- Checking for Damage
  
  44
- Cleaning the Machine
  
  45
- Seat Belt
  
  46
  - Checking the Seat Belt Condition and Security
    46
- Fire Extinguisher (When Fitted)
  
  46
  - Checking the Fire Extinguisher
    46
- ROPS/FOPS Structure
  
  47
  - Checking the ROPS/FOPS Structure
    47
- Tyres and Wheels
  
  48
  - Tyre Inflation
    48
  - Checking the Wheel Nut Torques
    48
- Lubricants - Health and Safety
  
  49
  - Hygiene
    49
  - Storage
    49
  - Waste Disposal
    49
  - Handling
    49
  - First Aid - Oil
    49
  - Spillage
    49
  - Fires
    49
- Service Schedules
  
  50

jcb 215 Operator's Manual (31 pages)

SKIDSTEER LOADER

Brand: jcb | Category: Compact Loader | Size: 2.48 MB

Table of Contents
4
Acronyms Glossary
10
Introduction
12
About this Manual
12
Model and Serial Number
12
Using the Manual
12
Left-Hand Side, Right-Hand Side
12
Cross References
13
Location of Manual
13
Safety
14
Safety - Yours and Others
14
Safety Warnings
14
General Safety
15
Clothing and Personal Protective Equipment (PPE)
16
About the Product
18
Introduction
18
General
18
Name and Address of the Manufacturer
18
Product Compliance
18
Description
19
General
19
Intended Use
19
Log Moving/Object Handling
19
Optional Equipment and Attachments
19
Danger Zone
19
Main Component Locations
20
Product and Component Identification
21
Machine
21
Engine
21
Operator Protective Structure
22
Safety Labels
24
General
24
Safety Label Identification
24
Operator Station
27
Component Locations
27
Interior Switches
28
Ignition Switch
28
Cab Interior Light
29
Console Switches
30
Window Wipers
30

jcb 215 Service Manual (16 pages)

SKIDSTEER LOADER

Brand: jcb | Category: Multi Terrain Loaders | Size: 5.92 MB

jcb 215 Quick Reference Manual (2 pages)

Brand: jcb | Category: Compact Loader | Size: 0.69 MB

jcb Categories

Excavators Compact Loader Power Tool Construction Equipment Drill

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jcb 215 Manuals

jcb 215 Service Manual (891 pages)

Table of Contents

jcb 215 Service Manual (51 pages)

Table of Contents

General Information

Section 3 Section 3 Routine Maintenance

Checking for Damage

Cleaning the Machine

Seat Belt

Fire Extinguisher (When Fitted)

ROPS/FOPS Structure

Tyres and Wheels

Lubricants - Health and Safety

Service Schedules

jcb 215 Operator's Manual (31 pages)

Table of Contents

jcb 215 Service Manual (16 pages)

Table of Contents

jcb 215 Quick Reference Manual (2 pages)

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