JCB 215 Backhoe Loader (& Variants) Service & Repair Manual

General Information 1 Care & Safety 2 Routine Maintenance 3 Attachments A Body & Framework B Electrics C Controls D Hydraulics E Transmission F Brakes G Steering H Engine K Service Manual 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader From M/c No. 930000 Onwards From M/c No. 903000 Onwards (USA) PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, WATERLOO PARK, UTTOXETER, ST14 5PA ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/3280 Issue 4 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 = General Information - includes torque settings and service tools. 2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 = Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A = Attachments B = Body & Framework ...etc. The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. 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. European North American 3CX = 214 4CX = 214S, 215S, 217S 9803/3280 Issue 1 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications. 9803/3280 Issue 1 A390940 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. Pressure Pressure that is above neutral circuit pressure but lower than that denoted by red. Servo Oil pressure used in controlling a device (servo). Neutral Neutral circuit pressure. Exhaust Cavitation Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Lock Up Oil trapped within a chamber or line, preventing movement of components (lock up). Red Pink Orange Blue Green Light Green Yellow www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

i Section 1 General Information 9803/3280 Section 1 i Issue 2* Contents Page No. Machine Identification Plate 1 - 1 Typical Vehicle Identification Number (VIN) 1 - 1 Typical Engine Identification Number 1 - 1 Serial Plates 1 - 2 Torque Settings 2 - 1 Service Tools Numerical List 3 - 1 Service Tools - Body & Framework 4 - 1 - Electrics 4 - 4 - Hydraulics 4 - 6 - Transmission 4 - 10 - Engine 4 - 19* Sealing and Retaining Compounds 5 - 1 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

Machine Identification Plate Your machine has an identification plate mounted on the loader tower. The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. 1 - 1 Typical Vehicle Identification Number (VIN) SLP 3CX T S V E 930000 A B C D E F G A World Manufacturer Identification B Machine Model C Steer Type (T= 2WS, F=4WS) D Build Type (S=Sideshift, C=Centremount, L=Loader) E Year of Manufacture: 2 = 2002 3 = 2003 4 = 2004 5 = 2005 6 = 2006 7 = 2007 8 = 2008 F Manufacturer Location (E = England) G Product Identification Number (PIN) Typical Engine Identification Number AB 50262 U 500405 P A B C D E A Engine Type AB = 4 cylinder turbo B Build Number C Country of Origin D Engine Sequence Number E Year of Manufacture Section 1 General Information 9803/3280 Section 1 1 - 1 Issue 1 S218131 U.K. and R.O.W. North America A246740 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

1 - 2 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 G Engine Section 1 General Information 9803/3280 Section 1 1 - 2 Issue 1 E F G A S257580 A401030 S260120 B C S259100 S156571 S259110 D www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

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 in (mm) in Nm kgf m lbf ft 1/4 (6.3) 7/16 14 1.4 10 5/16 (7.9) 1/2 28 2.8 20 3/8 (9.5) 9/16 49 5.0 36 7/16 (11.1) 5/8 78 8.0 58 1/2 (12.7) 3/4 117 12.0 87 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 1 (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) mm Nm kgf m lbf ft M5 (5) 8 7 0.7 5 M6 (6) 10 12 1.2 9 M8 (8) 13 28 3.0 21 M10 (10) 17 56 5.7 42 M12 (12) 19 98 10 72 M16 (16) 24 244 25 180 M20 (20) 30 476 48 352 M24 (24) 36 822 84 607 M30 (30) 46 1633 166 1205 M36 (36) 55 2854 291 2105 Rivet Nut Bolts/Screws Bolt Size Torque Settings (for steel rivet nuts) (mm) Nm kgf m lbf ft M3 (3) 1.2 0.12 0.9 M4 (4) 3.0 0.3 2.0 M5 (5) 6.0 0.6 4.5 M6 (6) 10.0 1.0 7.5 M8 (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. Section 1 General Information 9803/3280 Section 1 2 - 1 Issue 1 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

3 - 1 460/15708 Flow Test Adapter 4 - 13 460/15707 Banjo Bolt 4 - 13 1406/0011 Bonded Washer 4 - 7 1406/0014 Bonded Washer 4 - 7 1406/0018 Bonded Washer 4 - 7, 13 1406/0021 Bonded Washer 4 - 6, 4 - 7 1406/0029 Bonded Washer 4 - 7 1604/0003 Male Adapter 4 - 7 1604/0004 Male Adapter 4 - 7, 13 1604/0006 Male Adapter 4 - 6, 4 - 7 1604/0008 Adapter 4 - 6 1606/0003 Male Adapter 4 - 7 1606/0004 Male Adapter 4 - 7 1606/0007 Male Adapter 4 - 7 1606/0008 Male Adapter 4 - 7 1606/0009 Male Adapter 4 - 7 1606/0012 Male Adapter 4 - 6, 4 - 7 1606/0014 Male Adapter 4 - 7 1606/0015 Male Adapter 4 - 6, 4 - 7 1606/0017 Male Adapter 4 - 7 1612/0006 Adapter 4 - 6 2401/0222 O-ring 4 - 13 2403/0110 O-ring 4 - 13 2403/0108 O-ring 4 - 13 4101/0651 Retainer (High Strength) 5 - 1 4101/0250 Threadlocker and Sealer (10 ml) 5 - 1 4101/0251 Threadlocker and Sealer (50 ml) 5 - 1 4101/0451 Threadlocker 5 - 1 4102/0502 High Strength Gasketing 5 - 1 4102/0551 High Strength Threadlocker 5 - 1 4102/0933 Clear Silicone Sealant 5 - 1 4102/1212 Multi-Gasket 5 - 1 4102/1951 Threadseal 5 - 1 4102/2309 Black Polyurethane Sealant 5 - 1 4103/2109 Ultra Fast Adhesive (310ml) 5 - 1 4104/0251 Activator (Aersol) 5 - 1 4104/0253 Activator (Bottle) 5 - 1 4104/1203 Active Wipe 205 (250g) 5 - 1 4104/1206 Active Wipe 205 (30 ml) 5 - 1 4104/1310 Hand Cleaner 4 - 1 4104/1538 JCB Cleaner & Degreaser 5 - 1 4104/1557 Cleaner/Degreaser (400 ml) 5 - 1 4201/4906 Black Primer 206J (30ml) 5 - 1 816/00017 Adapter 4 - 8 816/00189 Blanking Cap 4 - 8 816/00190 Blanking Cap 4 - 8 816/00193 Blanking Cap 4 - 8 816/00196 Blanking Cap 4 - 8 816/00197 Blanking Cap 4 - 8 816/00294 Blanking Cap 4 - 8 816/00439 Male Adapter 4 - 7 816/00440 Male Adapter 4 - 7 816/15007 Male Adapter 4 - 7 816/15008 Male Adapter 4 - 7 816/15118 Pressure Test Adapter 4 - 6 816/20008 Adapter 4 - 6 816/20013 Adapter 4 - 6 816/50005 Adapter 4 - 8 816/50043 Adapter 4 - 8 816/55038 Pressure Test 'T' Adapter 4 - 6 816/55040 Pressure Test 'T' Adapter 4 - 6 816/60096 Adapter 4 - 8 823/10420 Shim Kit - Powershift gearbox, layshaft clutch 4 - 17 825/00410 Crowfoot Wrench 4 - 4 825/99833 Adapter for 825/00410 4 - 4 826/01099 Rivet Nut 4 - 1 826/01101 Rivet Nut 4 - 1 826/01102 Rivet Nut 4 - 1 826/01103 Rivet Nut 4 - 1 826/01104 Rivet Nut 4 - 1 826/01105 Rivet Nut 4 - 1 892/00011 Spool Clamp 4 - 8 892/00041 De-glazing Tool 4 - 19 892/00047 Adapter 4 - 8 892/00048 Adapter 4 - 8 892/00049 Adapter 4 - 8 892/00051 Adapter 4 - 8 892/00055 Blanking Plug 4 - 8 892/00056 Blanking Plug 4 - 8 892/00057 Blanking Plug 4 - 8 892/00058 Blanking Plug 4 - 8 892/00059 Blanking Plug 4 - 8 892/00060 Blanking Plug 4 - 8 892/00071 Male Adapter 4 - 7 892/00074 Female Connector 4 - 8 892/00075 Female Connector 4 - 8 892/00076 Female Connector 4 - 8 892/00077 Female Connector 4 - 8 892/00078 Connector 4 - 6 892/00137 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7 892/00167 Ram Seal Protection Sleeve 90 mm 4 - 9 892/00174 Measuring Cup 4 - 11 892/00179 Bearing Press 4 - 10 892/00180 Seal Fitting Tool 4 - 9 892/00181 Replacement Plastic Boss 4 - 9 892/00182 Bearing Pad Driver 4 - 12 892/00223 Hand Pump 4 - 7 892/00224 Impulse Extractor 4 - 11 892/00225 Adapter for Extractor 4 - 11 892/00253 Pressure Test Kit 4 - 6 892/00255 Pressure Test Adapter 4 - 6 892/00256 Pressure Test Adapter 4 - 6 892/00257 Pressure Test Adapter 4 - 6 892/00258 Pressure Test Adapter 4 - 6 892/00259 Pressure Test Adapter 4 - 6 892/00260 Pressure Test Adapter 4 - 6 892/00261 Pressure Test Adapter 4 - 6 892/00262 Pressure Test 'T' Adapter 4 - 6, 4 - 7 892/00263 Pressure Test 'T' Adapter 4 - 6 892/00264 Pressure Test 'T' Adapter 4 - 6 892/00265 Pressure Test 'T' Adapter 4 - 6 892/00268 Flow Monitoring Unit 4 - 6 892/00269 Sensor Head 4 - 6 892/00270 Load Valve 4 - 6 892/00271 Adapter 4 - 6 892/00272 Adapter 4 - 6 892/00273 Sensor Head 4 - 6 892/00274 Adapter 4 - 7 892/00275 Adapter 4 - 6 892/00276 Adapter 4 - 6 892/00277 Adapter 4 - 6 892/00278 Gauge 4 - 7 892/00279 Gauge 4 - 7 Section 1 General Information 9803/3280 Section 1 3 - 1 Issue 2* Service Tools Numerical List Page No. Page No. * www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

3 - 2 892/00282 Shunt 4 - 4 892/00283 Tool Kit Case 4 - 4 892/00284 Tachometer 4 - 4 892/00285 Hydraulic Oil Temperature Probe 4 - 4 892/00286 Surface Temperature Probe 4 - 4 892/00293 Connector Pipe 4 - 6 892/00294 Connector Pipe 4 - 6 892/00298 Fluke Meter 4 - 4 892/00301 Flow Test Adapter 4 - 10 892/00302 Flow Test Adapter 4 - 10 892/00309 ARV Test Kit 4 - 7 892/00333 Heavy Duty Socket 4 - 11 892/00334 Ram Seal Fitting Tool 4 - 9 892/00335 ARV Cartridge Removal Tool 4 - 7 892/00706 Test Probe 4 - 6, 4 - 7 892/00812 Drive Coupling Spanner 4 - 10 892/00817 Heavy Duty Socket 4 - 11 892/00818 Heavy Duty Socket 4 - 11 892/00819 Heavy Duty Socket 4 - 11 892/00822 Splined Bolt Socket 4 - 11 892/00836 Lifting Wire Assembly 4 - 19 892/00842 Glass Lifter 4 - 2 892/00843 Folding Stand 4 - 1 892/00844 Long Knife 4 - 3 892/00845 Cartridge Gun 4 - 1 892/00846 Glass Extractor (Handles) 4 - 2 892/00847 Nylon Spatula 4 - 3 892/00848 Wire Starter 4 - 2 892/00849 Braided Cutting Wire 4 - 3 892/00881 Spool Seal Fitting Tool 4 - 7 892/00882 Alternator Pulley Socket 4 - 5 892/00891 Wheel Hub Seal - Fitting Tool 4 - 10 892/00918 Setting Tool Kit 4 - 16 892/00920 Flow Test Adapter 4 - 10 892/00922 12.2” T/C Alignment Tool 4 - 10 892/00948 Charging Kit 4 - 9 892/00949 Pressure Gauge 4 - 9 892/00956 Timing Pin 4 - 19 892/00964 Test Point (1/8BSP) 4 - 12 892/00965 Test Point (3/8BSP) 4 - 12 892/00966 Test Point (1/4BSP 4 - 12 892/01016 Ram Seal Protection Sleeve 25 mm 4 - 9 892/01017 Ram Seal Protection Sleeve 30 mm 4 - 9 892/01018 Ram Seal Protection Sleeve 40 mm 4 - 9 892/01019 Ram Seal Protection Sleeve 50 mm 4 - 9 892/01020 Ram Seal Protection Sleeve 50 mm 4 - 9 (slew ram) 892/01021 Ram Seal Protection Sleeve 60 mm 4 - 9 892/01022 Ram Seal Protection Sleeve 60 mm 4 - 9 (slew ram) 892/01023 Ram Seal Protection Sleeve 65 mm 4 - 9 892/01024 Ram Seal Protection Sleeve 70 mm 4 - 9 892/01025 Ram Seal Protection Sleeve 75 mm 4 - 9 892/01026 Ram Seal Protection Sleeve 80 mm 4 - 9 892/01027 Piston Seal Assembly Tool 4 - 9 892/01033 Electronic Service Tool Kit 4 - 18 892/01096 Speed Sensor Test Harness 4 - 17 892/01079 Ring Socket Spanner Mainshaft setting ring 4 - 13 892/01080 Ring Socket Spanner Layshaft setting ring 4 - 13 892/01077 Synchro Shuttle Gearbox Selector Shaft Lock Screw 4 - 13 892/01078 Synchro Shuttle Gearbox Mainshaft Adjuster 4 - 13 892/01076 Synchro Shuttle Support Plate Transfer gear end float setting 4 - 13 892/01082 Powershift - Assembly Cradle 4 - 17 892/01083 Powershift - Assembly tool, transfer gear 4 - 17 892/01084 Powershift - Transfer gear, bearing assembly 4 - 17 892/01085 Powershift - Seal fitting tool 4 - 17 926/15500 Rubber Spacer Blocks 4 - 3 992/04000 Torque Multiplier 4 - 12 992/04800 Flange Spanner 4 - 12 992/07608 Bearing Adapter 4 - 10 992/07609 Bearing Adapter 4 - 10 992/07610 Bearing Adapter 4 - 10 992/07611 Bearing Adapter 4 - 10 992/07612 Bearing Adapter 4 - 10 992/07613 Bearing Adapter 4 - 10 992/09100 Spool Clamp 4 - 8 992/09200 Charging Tool 4 - 1 992/09300 Ram Spanner 4 - 8 992/09400 Ram Spanner 4 - 8 992/09500 Ram Spanner 4 - 8 992/09600 Ram Spanner 4 - 8 992/09700 Ram Spanner 4 - 8 992/09900 Ram Spanner 4 - 8 992/10000 Ram Spanner 4 - 8 992/12300 12V Mobile Oven 4 - 1 992/12400 Static Oven - 2 Cartridge 4 - 2 992/12600 Static Oven - 6 Cartridge 4 - 2 992/12800 Cut-Out Knife 4 - 2 992/12801 "L" Blades 4 - 2 993/55700 Direct Glazing Kit 5 - 1 993/59500 Impulse Extractor Adapter 4 - 11 993/68100 Slide Hammer Kit 4 - 3 993/69800 Seal Kit 4 - 6 993/70111 Breakback Torque Wrench 4 - 15 993/85700 Battery Tester 4 - 4 7210/0001 Dummy Plug 4 - 5 7210/0002 Wire Seal (1.4 - 2.2 mm dia.) 4 - 5 7210/0003 Wire Seal (2.2 - 2.9 mm dia.) 4 - 5 7212/0001 2 Way Socket Connector 4 - 5 7212/0002 2 Way Pin Housing 4 - 5 7212/0003 2 Way Socket Retainer 4 - 5 7212/0004 2 Way Pin Retainer 4 - 5 7213/0001 3 Way Socket Connector 4 - 5 7213/0002 3 Way Pin Housing 4 - 5 7213/0003 3 Way Socket Retainer 4 - 5 7213/0004 3 Way Pin Retainer 4 - 5 7213/0005 3 Way Socket Connector (DT) 4 - 5 7213/0006 3 Way Pin Housing (DT) 4 - 5 7213/0007 3 Way Socket Retainer (DT) 4 - 5 7213/0008 3 Way Pin Retainer (DT) 4 - 5 7214/0001 4 Way Socket Connector 4 - 5 7214/0002 4 Way Pin Housing 4 - 5 7214/0003 4 Way Socket Retainer 4 - 5 7214/0004 4 Way Pin Retainer 4 - 5 7216/0001 6 Way Socket Connector 4 - 5 Section 1 General Information 9803/3280 Section 1 3 - 2 Issue 3* Service Tools Numerical List Page No. Page No. * * * * www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

3 - 3 The following parts are replacement items for kits and would normally be included in the kit numbers quoted on pages 1/3-1 and 1/3-2. Service Tools Numerical List Page No. Replacement item for kit no. 892/00180 892/00181 4 - 9 Replacement items for kit no. 892/00253 892/00201 Replacement Gauge 4 - 6 892/00202 Replacement Gauge 4 - 6 892/00203 Replacement Gauge 4 - 6 892/00254 Replacement Hose 4 - 6 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 Section 1 General Information 9803/3280 Section 1 3 - 3 Issue 2* Service Tools Numerical List 7216/0002 6 Way Pin Housing 4 - 5 7216/0003 6 Way Socket Retainer 4 - 5 7216/0004 6 Way Pin Retainer 4 - 5 7218/0001 8 Way Socket Connector 4 - 5 7218/0002 8 Way Pin Housing 4 - 5 7218/0003 8 Way Socket Retainer 4 - 5 7218/0004 8 Way Pin Retainer 4 - 5 7219/0001 10 Way Socket Connector 4 - 5 7219/0002 10 Way Pin Housing 4 - 5 7219/0003 10 Way Socket Retainer 4 - 5 7219/0004 10 Way Pin Retainer 4 - 5 7219/0005 14 Way Socket Connector 4 - 5 7219/0006 14 Way Pin Housing 4 - 5 7219/0007 14 Way Socket Retainer 4 - 5 7219/0008 14 Way Pin Retainer 4 - 5 * * * * * www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk

JCB 215 Backhoe Loader (& Variants) Service & Repair Manual

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