JCB 3CX, 4CX Backhoe Loader Repair Service Manual

(S/N: 960001 to 985136 - S/N: 1327001 to 1349999)
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This service manual PDF download for the 3CX, 4CX JCB Backhoe Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Backhoe Loader 3CX, 4CX (with JCB 444 Engine)
S/N: 960001 to 985136
S/N: 1327001 to 1349999


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section L - Servo Controls


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/3290-16
Total Pages : 1912


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-3290

Section 1
General Information
Introduction
About this Publication
Using the Service Manual
Section Numbering
Units of Measurement
Left Side, Right Side
Cab/Canopy
Cross References
Machine Nomenclature
Identifying the Machine
Machine Identification Plate
Component Identification Plates
Fuel
Types of Fuel
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
`Quick-Connect' Pilot Hoses
Disconnecting
Connecting
Service Tools
Numerical List
Service Aids
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2
Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
Safety Label Identification

Section 3
Maintenance
Routine Maintenance
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
Fuel System
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Lubricants and Capacities
Coolant Mixtures
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Loader Arms Lowered)
How to Make the Machine Safe (Loader Arm Lifted)
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
ROPS/FOPS Structure
Checking The ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Loader Arms
Backhoe and Quickhitch
Front Axle (2 Wheel Drive Machines)
Front Axle (4 Wheel Drive Machines)
Front Axle (All Wheel Drive Machines)
Rear Axle (All Wheel Drive Machines)
Extending Dipper
Driveshafts
6 - In - 1 Clamshovel
Stabilisers (Centremount Machines)
Loader Quickhitch
Power Sideshift
Kingpost
Knuckle (if fitted)
Backhoe Quickhitch (Hydraulic)
Access Panels
Engine Cover
Front Grille
Heater and Air Conditioning
Cleaning the Cab Heater Fresh Air Filter
Changing the Cab Heater Recirculation Filter(s) (if fitted)
Brakes
Park Brake
Foot Brake
Electrical System
Battery
Jump Starting The Engine
Fuses
Link Box Fuses
Relay Identification
Engine
Oil and Filter
Cooling System
Front End Accessory Drive Belt
Air Filter
Fuel System
Fuel
Filling the Tank
Water Separator and Engine Fuel Filter
Bleeding the System
Hydraulic System
Introduction
Releasing the Hydraulic Pressure
Hydraulic Tank Filler Cap
Oil and Filter
Cooling Pack
Hose Burst Protection Valve (if fitted)
Checking Hose Burst Protection Valve
Lowering a Load
Transmission
Checking the Gearbox Oil Level
Changing the Oil and Filter
Axles
Front and Rear Axle (All Wheel Steer Machines)
Front and Rear Axle (Two Wheel Steer Machines)
Tyres and Wheels
Tyre Inflation
Wheel Nuts
Wheel Alignment
Introduction
Electronic Steer Mode Selector
Wear Pads
Extradig Dipper Wear Pads
Stabiliser Legs (Sideshift Machines Only)
Windscreen Washer
Checking the Level
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A
Attachments
Hi-Flow Rockbreaker Circuit
Operation Overview
Gearpump Machines
Gearpump Machines from September 2007
Variflow Machines
Precision Control (Servo) Machines
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings
Changing the Return Line Filter - if fitted
Hydraulic Tool Circuit (HTC)
Operation Overview
Gearpump Machines with Extending Dipper
Electrical Connections
NOT Servo Machines
Precision Control (Servo) Machines
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings
Flow Diverter Valve
Removal and Replacement
Dismantle and Assemble
Flow and Pressure Testing
3 Point Hitch (214e Landscaper)
Removal and Replacement
Control Valve
Operating Rams

Section B
Body and Framework
Service Tools
Numerical List
Tool Detail Reference
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Cab Air Conditioning (3CX, 4CX) SYSTEM
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
System Operation
System Control
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Safety Procedures
Service Checks
Off-Season Operation
Fault Finding
Fault Indications
System Diagnosis using Test Gauges
Test Procedures
Leak Testing
Tightening Leaking Hoses
Refrigerant Charge Level
Binary Pressure Switch
Refrigerant
Refrigerant Charging and Discharging
Cleaning the Cab Filter
Compressor Drive Belt - Adjustment
Cab Air Conditioning 3C-14 (214e), 3C SYSTEM
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
Cab
Introduction
ROPS, FOPS Structure - Checks
Removal and Replacement
Direct Glazing
Cab Mountings
Side Console
Front Steering Console
B Post Covers
Roof Lining
Cab Roof Moulding
Air Conditioning Condenser
Introduction
Cleaning
Removal and Replacement
Cab HVAC Unit (3CX, 4CX)
Introduction
Removal and Replacement
Air Conditioning Unit (HVAC)
Evaporator Matrix
Binary Pressure Switch
Blower Unit
Freeze Protection Thermostat
Cab HVAC Unit 3C-14 (214e), 3C
Introduction
Removal and Replacement
Blower Motor
Freeze Protection Thermostat
Compressor Clutch Relay
Heater Valve
Introduction
Removal and Replacement
Cab Seat (Not Servo)
Introduction
Removal and Replacement
Fuel Tank
Introduction
Removal and Replacement
Fuel Level Sender
Hydraulic Tank
Introduction
Removal and Replacement
Fluid Level Sight Glass
Filter Cover Plate
Engine Cover
Introduction
Removal and Replacement
Front Grille Housing
Introduction
Removal and Replacement
Loader Arms
Introduction
Removal and Replacement
Stabiliser Legs
Introduction
Sideshift
Wear Pads
Wear Pad - Adjustment
Removal and Replacement
Sideshift
Centremount
Stabiliser Leg Alarm SYSTEM
Related Topics
Operation Overview
Electrical Operation and Schematics - Early Machines
Electrical Description
Wires and Connectors
Electrical Operation and Schematics - Later Machines
Electrical Description
Wires and Connectors
Leg Alarm Switch - Adjustment (Sideshift)
Leg Alarm Switch - Adjustment (Centremount)
Boom and Dipper
Introduction
Extending Dipper
Wear Pad Adjustment
Removal and Replacement
Boom
Dipper
Overload Warning SYSTEM
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Description
Wires and Connectors - Early Machines
Wires and Connectors - Later Machines
Pressure Switch Renewal
Kingpost & Carriage
Introduction
Sideshift
Hydraclamp Clearance Setting
Powered Sideshift
Wear Pad Renewal
Chain Adjustment
Removal and Replacement
Power Sideshift Ram
Kingpost
Sideshift Carriage

Section C
Electrics
Service Tools
Numerical List
Tool Detail Reference
Technical Data
General Electrical Data
Fuses and Relays - 3CX & 4CX Machines
Fuses - NOT Servo Machines
Fuses - Joystick Controls (Servo) Machines
Link Box Fuses
Relays - NOT Servo (Early Machines)
Relays - NOT Servo (Later Machines to May 2009)
Relays - NOT Servo (From May 2009)
Relays - Joystick Controls (Servo) Machines
Relays - Gearbox/Steer Control
Fuses and Relays - 3C-14 (214e) & 3C Machines
Fuses
Link Box Fuses
Relays
Schematic Circuits - To May 2009 (Analog Instruments)
3CX & 4CX Machines
Gearbox Control
Synchro Shuttle Gearbox
Powershift Gearbox
Shiftmaster Gearbox
Options
Engine Cold Start Heater
Steer Mode (4x4x4) - PCB (Relay) Controlled
Steer Mode (4x4x4) - ECU Controlled
2 Wheel Steer - Brake Mode
2 Wheel Steer - Brake Mode (Germany)
All Wheel Steer - Brake Mode
Auxiliary & Hydraclamp Hydraulics
Auxiliary & Hydraclamp Hydraulics from S/No. 1332954
Speedometer
Hand Held Tools
Dedicated Quickhitch
Pole Planter
Smooth Ride System (SRS)
Return to Dig (Shovel Reset)
Hydraulic Speed Control (HSC)
Loader Hydraulic Quickhitch - Changeover
Schematic Circuits - From May 2009 (Digital Instruments)
3CX & 4CX Machines
Schematic Circuits - 3C-14 (214e) & 3C Machines
Basic Machine
Engine Cold Start Heater
Options
Return to Dig (Shovel Reset)
Smooth Ride System (SRS)
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Starter Motor
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Brush Gear
Renewing the Starter Solenoid
Earth Points
Location
Harness Data - 3CX & 4CX Machines
Drawings and Interconnection
Harnesses - NOT Servo Machines
Harnesses - Joystick Controls (Servo) Machines
Drawings
Harness Data - 3C-14 (214e) & 3C Machines
Drawings and Interconnection
Harnesses
Drawings

Section D
Controls
Steering Column
Removal and Replacement
Dismantle and Assemble
Column Switches
Removal and Replacement
Control Rods and Linkages
Dismantle and Assemble
Loader Valve Controls
Excavator Valve Controls
Auxiliary Footpedal Control
Control Cables
Removal and Replacement
Cab Heater Control Cables
Boom Lock Cable
Engine Throttle Cable
Park Brake Cable (Synchro Shuttle Machines)
Park Brake Cable (Powershift Machines)
Anti-Spill Mechanism 3C-14 (214e) & 3C Machines
Fitting and Adjustment
Shovel Reset
Operation and Adjustment
Shovel Reset 3C-14 (214e) & 3C Machines
Operation and Adjustment

Section E
Hydraulics
Service Tools
Numerical List
Tool Detail Reference
Technical Data
Gearpump - 3CX, 4CX Machines
Standard
High Pressure Type
Variable Flow Pump
Gearpump - 3C-14 (214e) Machines
Standard
High Pressure Type
Gearpump - 3C Machines (Sideshift)
Loader Valve - 3CX, 4CX Machines
Standard
High Pressure Type
Loader Valve - Variable Flow
Loader Valve - 3C-14 (214e) Machines
Standard
High Pressure Type
Loader Valve - 3C Machines (Sideshift)
Excavator Valve - 3CX, 4CX Machines
Standard
High Pressure Type
Excavator Valve - 3C-14 (214e) Machines
Excavator Valve - 3C Machines (Sideshift)
Auxiliary Valve - if fitted
Smooth Ride System (SRS) - if fitted
Accumulator
Basic System Operation
Component Location and Neutral Circuit Descriptions
Gearpump - Double Pump
Variable Flow Pump
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
3CX Gearpump Machines (up to September 2007)
3CX `S' Series Options
3CX `S' Series and 4CX Gearpump Options
3CX Gearpump Machines (from September 2007)
4CX Variable Flow Machines
7 Spool with High Flow Options
6 Spool with High and Low Flow Options
Hand Held Tools Option
3C-14 (214e) Backhoe
3C-14 (214e) Landscaper
3C Machines (Sideshift)
Circuit Descriptions
Gearpump - Operation
Double Pump
Variable Flow Pump - Operation
Pressure and Flow Regulator Valve
Loader Valve - Manual Control
Neutral Circuit
Unloader Operation
Hydraulic Speed Control (HSC)
Load Hold Check Valves
Arms Lower
Float
Auxiliary Relief Valve (ARV) Operation
Main Relief Valve (MRV) Operation
Loader Valve - Variable Flow
Operation
Priority Inlet Section Operation
Auxiliary Spool
Loader Shovel Spool
Loader Lift Spool
Shuttle Valve Signal Network
Excavator Valve - Manual Control
Neutral Circuit
Load Hold Check Valves
One Way Restrictor Operation
Slew Operation
Slew Ram End Damping
Slew A.R.V. and Anti-Cavitation Operation
A.R.V. Operation
Hydraclamp Valve Operation (Sideshift Machines)
Smooth Ride System (SRS) - if fitted
Smooth Ride System
SRS with Hose Burst Protection Valves (HBPV) Option
Electrical Connections
Hydraulic Speed Control (HSC)
Quick Reference
Circuit Descriptions
Wires and Connectors
Fault Finding
Hydraulic System
Gearpump Machines
Variable Flow Machines
Smooth Ride System (SRS) - if fitted
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Gearpump
Flow and Pressure Testing
Variable Flow Pump
Flow and Pressure Testing
Regulator Valve Adjustment
Renewing Drive Shaft Seal
Shuttle Valve Signal Network - Testing
Loader Valve - Pressure Testing
Main Relief Valve (MRV)
Unloader Valve
Hydraulic Speed Control (HSC)
Auxiliary Relief Valves - Using Hand Pump
Excavator Valve - Pressure Testing
Auxiliary Relief Valves - Using Hand Pump
Ram Creep Tests - All Services
Quick Release Couplings
Connecting and Disconnecting
Smooth Ride System (SRS) Accumulator
Charging and Discharging
Valve Block Spool Seals
Seal Fitting
`Positional Type' Hydraulic Adaptors
Fitting Procedure
3C-14 (214e) Machines
Checking Pump Flow
Loader Valve - Pressure Testing
3C Machines (Sideshift)
Checking Pump Flow
Loader Valve - Pressure Testing
Main Pump
Gearpump
Removal and Replacement
Dismantle, Inspection and Assemble
Variable Flow Pump
Removal and Replacement
Dismantle, Inspection and Assemble
Main Pump - 3C Machines (Sideshift)
Combined Gearpump/Priority Valve
Removal and Replacement
Dismantle, Inspection and Assemble
Loader Valve
Removal and Replacement
Dismantle and Assemble
Main Relief Valve (MRV)
Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV)
Unloader Valve
Standard Spool
Float Spool
Electric Detent Spool
Loader Valve - Variable Flow
Removal and Replacement
Dismantle and Assemble
Priority Inlet Section
Auxiliary Spool
Loader Shovel Spool
Loader Lift Spool
Fitting Spool Seal
Loader Valve - 3C-14 (214e) & 3C Machines
Removal and Replacement
Dismantle and Assemble
Main Relief Valve (MRV)
Auxiliary Relief Valves (ARV's)
Standard Spool
Float Spool
Electric Detent Spool
Excavator Valve
Removal and Replacement
Dismantle and Assemble
Valve Block
Auxiliary Relief Valves (ARV's)
Hydraclamp Valve (Sideshift Machines)
Hoses and Pipes (Sideshift Valve)
Hoses and Pipes (Centremount Valve)
Excavator Valve - Variable Flow
Removal and Replacement
Excavator Valve - 3C Machines (Sideshift)
Removal and Replacement
Dismantle and Assemble
Valve Block
Auxiliary Relief Valves (ARV's)
Hydraclamp Valve
Hose Burst Protection Valves - if fitted
Hydraulic Operation and Schematics - Loader HBPV
Load Raise
Load Lower
Relief Valve
Hose Burst
Smooth Ride System (SRS) - Option
Hydraulic Operation and Schematics - Boom HBPV
Load Raise
Load Lower
Relief Valve
Hose Burst
Hydraulic Operation and Schematics - Stabiliser HBPV
Twin Check Valves
Single Check Valve
Test Procedures
Checking Hose Burst Protection Valve
Lowering a Load
Pilot Valve Setting Procedure - Loader HBPV
Removal and Replacement
Dismantle and Assemble
Loader HBPV
Boom HBPV
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Loader Shovel Ram
Loader Lift Ram
Slew Ram
Stabiliser Ram (Sideshift)
Stabiliser Ram (Centremount)
Bucket Crowd Ram
Dipper Ram
Boom Ram
Dismantle and Assemble
Typical Ram
Slew Ram
Dipper Ram
Power Sideshift Ram
JCB Ram Sealing Procedure
Oil Cooler Matrix
Removal and Replacement
Smooth Ride System (SRS) - if fitted
Accumulator
Removal and Replacement

Section F
Transmission
Service Tools
Numerical List
Tool Detail Reference
Technical Data
Tyre Sizes and Pressures
Front Axles
All Wheel Steer Machines
2 Wheel Steer Machines (4 Wheel Drive)
2 Wheel Steer Machines (2 Wheel Drive)
Rear Axles
All Wheel Steer Machines
2 Wheel Steer Machines
Synchro Shuttle Gearbox
SS700 Manual Gearbox
Powershift Gearbox
PS764 4 Speed
PS766 6 Speed
Engine Stall Speed Combinations - SA, SB Type Engines
Engine Stall Speed Combinations - SD, SF Type Engines
Basic Operation
Introduction
Front Axle - Steer Drive Type SD55, SD80
Component Identification
Rear Axle - Steer Drive Type SD80
Component Identification
Synchro Shuttle Gearbox
Component Identification
Principle of Operation
Hydraulic and Electrical Operation
Forward and Reverser Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
Synchromesh (Blocking Pin Type)
Synchromesh Operation
Powershift Gearbox
Component Identification
Principle of Operation
Hydraulic and Electrical Operation
Forward and Reverser Clutch Operation
Mainshaft, Layshaft and 6 Speed Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
ShiftMaster Operation Characteristics
Drivepaths - 4 Speed
Drivepaths - 6 Speed
Torque Converter
Principle of Operation
Lock Up Torque Converter
Principle of Operation
Electrical Connections
Synchro Shuttle Gearbox
Introduction
Quick Reference
Wires and Connectors
Powershift Gearbox
Introduction
Quick Reference
Wires and Connectors
Powershift Gearbox (ShiftMaster)
Introduction
ECU Electrical Connections
Quick Reference
Wires and Connectors
Lock Up Torque Converter
Introduction
Quick Reference
Wires and Connectors
Service Procedures
Front Axles SD55 and SD80
Renewing the Pinion Oil Seal
Rear Axles PD70 and SD80
Renewing the Pinion Oil Seal
Testing for Brake Piston Seal Leakage
Synchro Shuttle Gearbox
Flushing the Transmission Oil
Torque Converter Stall Test
Pressure and Flow Tests
Forward and Reverse Solenoid Control Valve - Solenoid Coil
Forward and Reverse Solenoid Control Valve
Oil Pressure Switch
Oil Temperature Switch
Powershift Gearbox
Flushing the Transmission Oil
Torque Converter Stall Test
Pressure and Flow Tests
Clutch Leakage Tests
Solenoid Control Valve Cartridge - Solenoid Coil
Solenoid Control Valve Cartridge - Single Fixing Type
Solenoid Control Valve Cartridge - Twin Fixing Type
Oil Pressure Switch
Oil Temperature Switch - Non Lock Up Torque Converter Variants
Oil Temperature Switch - Lock Up Torque Converter Variants
Powershift Gearbox (ShiftMaster)
Speed Sensors
Electronic Control Unit
ShiftMaster Diagnostics 2.2 - User Guide
ShiftMaster Setup 2.2 - User Guide
ShiftMaster Flash Programmer - User Guide
Testing the Lock up Torque Converter
Speedometer - if fitted
Calibration Procedure
Fault Finding
Powershift Gearbox
Introduction
Fault Finding Tables
Synchro Shuttle Gearbox
Introduction
Fault Finding Tables
Propshafts
Removal and Replacement
Front Axle Dead Steer
Removal and Replacement
Dismantle and Assemble
Front Axles SD55 and SD80
Removal and Replacement
Dismantle and Assemble
Rear Axles PD70 and SD80
Removal and Replacement
Dismantle and Assemble
Synchro Shuttle Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Powershift Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Torque Converter
Removal and Replacement
Oil Cooler Matrix
Removal and Replacement

Section G
Brakes
Technical Data
Service Brakes
Service Brakes - 3C Machines
Park Brake
Basic System Operation
Compensating Master Cylinder
Pedals Locked - Normal Operation
Pedals Locked - Compensating Operation
Pedals Unlocked - Normal Operation
2 and 4 Wheel Braking Modes
2 Wheel Steer Machines
4 Wheel Steer Machines
Auto 2 and 4 Wheel Braking
Electrical Connections
2 and 4 Wheel Braking Modes
Quick Reference
Wires and Connectors
Fault Finding
Brake System
Service Procedures
Service Brakes
Brake Light Switch - Adjustment
Bleeding
Brake Vacuum Tests
Brake Piston Seal Leakage Test
Axle Breather (Braked Axles) - Inspection
Park Brake
Testing
Adjustment (Synchro Shuttle Machines)
Adjustment (Powershift Machines)
Park Brake Switch - Adjustment
Renewing the Brake Pads (Synchro Shuttle Machines)
Master Cylinder and Servo Unit
Removal and Replacement
Dismantle and Assemble
Remote Servo Unit - 3C Machines (Option)
Removal and Replacement
Servo Exhauster Unit
Removal and Replacement
Service Brakes
Dismantle and Assemble
Park Brake
Synchro Shuttle Machines
Torque Figures
Calliper - Removal and Replacement
Calliper - Dismantle, Inspection and Assemble
Disc - Removal and Replacement
Powershift Machines
Dismantle, Inspection and Assemble

Section H
Steering
Service Tools
Numerical List
Tool Detail Reference
Technical Data
Hydraulic Steer Unit
Priority Valve
Priority Valve - 3C Machines (Sideshift)
Basic Operation
General Description
2 Wheel Steer Machines
4 Wheel Steer Machines
Steer Circuit Schematics
2 Wheel Steer Machines
4 Wheel Steer Machines (Steer Mode Valve Type 1)
4 Wheel Steer Machines (Steer Mode Valve Type 2)
Circuit Descriptions
Steer Unit Operation
Neutral
Left Turn
Right Turn
Right turn, Unassisted
Shock Valve
2 Wheel Steer Mode - Right Turn
Crab Steer Mode - Right Turn
Priority Valve Operation
Neutral
Turning
Electrical System
PCB (Relay) Controlled Steer Mode
ECU Controlled Steer Mode
Wires and Connectors
Fault Finding
Steering System
Fault Finding Tables
Diagnostic `Blink' Codes - if applicable
Service Procedures
Hydraulic Pressure Tests
Standby Pressure
Steering Pressure
Steer Priority Valve - Cleaning
2 Wheel Steer Machines
Bleeding the System
4 Wheel Steer Machines
Re-phasing the Road Wheels
Bleeding the System
Proximity Switch - Setting
Steer Mode Valve - Checking Solenoid Operation
Checking Components for Internal Hydraulic Leakage
Service Procedures - 3C Machines (Sideshift)
Hydraulic Pressure Tests
Standby Pressure
Steering Pressure
Steer Priority Valve - Cleaning
Priority Valve
Removal and Replacement
Dismantle and Assemble
Priority Valve - 3C Machines (Sideshift)
Removal and Replacement
Power Track Rod
Removal and Replacement
Link Arms
Removal and Replacement
Rams
Dismantle and Assemble
Steer Mode Valve (Type 1) - if fitted
Removal and Replacement
Dismantle and Assemble
Steer Mode Valve (Type 2) - if fitted
Removal and Replacement
Dismantle and Assemble
Hydraulic Steer Unit
Removal and Replacement
Dismantle and Assemble
Dismantle
Assemble

Section K
Engine
Service Tools
Numerical List
Tool Detail Reference
Technical Data
JCB DieselMax
Engine Specifications
Electrical Connections
Cold Start Heater
Diagnostic `Blink' Codes
Wires and Connectors
Electrical Sensors and Solenoids
Removal and Replacement
Sensor Switches
Solenoids
Engine Bay Support Frame
Removal and Replacement
Cooling Fan Viscous Coupling
Principle of Operation
Removal and Replacement
Cooling Radiator
Removal and Replacement
Coolant Expansion Tank
Removal and Replacement
Low Coolant Level Sensor - if fitted
Fuel Injection Pump
Removal and Replacement
Removal and Replacement
JCB DieselMax
Component Identification
Removal
Replacement

Section L
Servo Controls
Introduction
Note Regarding Machine Types
Service Tools
Numerical List
Tool Detail Reference
Fuses and Relays
Precision Control Machines
Fuses
Relays - Early Machines
Relays - Later Machines
Advanced EasyControl Machines
Fuses
Relays - Early Machines
Relays - Later Machines to May 2009
Relays - From May 2009
EasyControl Machines
Fuses
Relays - Early Machines
Relays - Later Machines to May 2009
Relays - From May 2009
Schematic Circuits - Electrics
Precision Control Machines
Machines with Clam Shovel/Ext. Dipper Manual Isolator Switch
Machines with Clam Shovel/Ext. Dipper Isolator Relay
Advanced EasyControl Machines - To May 2009 (Analog Instruments)
Advanced EasyControl Machines - From May 2009 (Digital Instruments)
EasyControl Machines - To May 2009 (Analog Instruments)
EasyControl Machines - From May 2009 (Digital Instruments)
Schematic Circuits - Hydraulics
Precision Control Machines
Advanced EasyControl Machines
Variflow Pump Internal Circuit
EasyControl Machines
Precision Control SYSTEM
Related Topics
System Overview
Excavator Servo Controls
Load Sense and Pressure Compensator Function
Inloader Valve and Hydraulic Speed Control (HSC) Function
Grading Mode
Auxiliary Service Thumbwheel Controls
Joystick Enable and Seat Interlock Switches
Hydraulic Operation and Schematics
Unloader Valve Variant
Electrical Operation and Schematics
Joysticks Enable Circuit
Hydraulic Speed Control (HSC) Inloader Override Circuit
Clam Shovel and Extending Dipper Circuit
Fault Finding
Fault Finding Tables
Thumbwheel Diagnostic `Blink' Codes
Service Procedures
Checking the Servo Pressure
Checking the Main System Pressures
Checking for Internal Leakage Fault in Load Sense Line
Testing the Inloader Valve
Pressure Compensator Network - Testing
Bleeding the Auxiliary Service Pilot Hose
Advanced EasyControl SYSTEM
Related Topics
System Overview
Loader and Excavator Servo Controls
Variflow Pump
Load Sense and Pressure Compensator Function
Auxiliary Service Thumbwheel Controls
Joystick Enable and Seat Interlock Switches
Hydraulic Operation and Schematics
Electrical Operation and Schematics
Joysticks Enable Circuit
Excavator/Loader Changeover Circuit
Excavator/Loader Auxiliary Service Controls
Fault Finding
Fault Finding Tables
Thumbwheel Diagnostic `Blink' Codes
Service Procedures
Checking the Servo Pressure
Checking the Main System Pressures
Hydraulic Services Cycle Times
Checking for Internal Leakage Fault in Load Sense Line
Pressure Compensator Network - Testing
`Quick-Connect' Pilot Hoses
EasyControl SYSTEM
Related Topics
System Overview
Excavator Servo Controls
Unloader and Hydraulic Speed Control (HSC) Function
Auxiliary Service Thumbwheel Controls
Joystick Enable and Seat Interlock Switches
Excavator Bucket Thumb Ram - if fitted
Hydraulic Operation and Schematics
Electrical Operation and Schematics
Joysticks Enable Circuit
Hydraulic Speed Control (HSC)
Excavator/Loader Auxiliary Changeover Circuit
Excavator/Loader Auxiliary Service Controls
Fault Finding
Fault Finding Tables
Thumbwheel Diagnostic `Blink' Codes
Service Procedures
Checking the Servo Pressure
Checking the Main System Pressure
`Quick-Connect' Pilot Hoses
Joystick and Stabiliser Controls
Introduction
Descriptions
Joystick Controllers
Stabiliser Controls
ISO and SAE Control Pattern Changeover Valve - if fitted
Joystick/Auxiliary Control Changeover Valve - if fitted
Removal and Replacement
Dismantle and Assemble
Loader Lever Controls
Dismantle and Assemble
Servo Pressure Supply Valve
Introduction
Descriptions
Proportional Solenoid Valves Operation
PWM Controller Electronic Control Unit (ECU)
Removal and Replacement
Inloader Valve
Introduction
Specifications
Descriptions
Pump P2 Directed to Tank
Pump P2 in Circuit (Inloader Operation)
Inloader Operation Override
Graph of System Pressures
Removal and Replacement
Hydraulic Pump (Gearpumps)
Introduction
Specifications
Descriptions
Removal and Replacement
Dismantle and Assemble
Hydraulic Pump (Variflow)
Introduction
Specifications
Descriptions
Removal and Replacement
Dismantle and Assemble
Loader Valve (Sectional Type)
Introduction
Specifications
Descriptions
Loader Valve Services
Pressure Compensator Valves Operation
Removal and Replacement
Dismantle and Assemble
Valve Block Sections
Servo Operated Spool
Manually Operated - Electric Detent Spool
Manually Operated - Mechanical Detent Spool
Load Sense Relief Valve
External Auxiliary Relief Valves (ARV's)
Internal Auxiliary Relief Valves (ARV's) - if fitted
Flow Regulator Valve
Pressure Compensator Valves
Load Hold Check Valves
Loader Valve (Monoblock Type)
Introduction
Specifications
Descriptions
Loader Valve Services
Unloader Operation
Removal and Replacement
Dismantle and Assemble
Excavator Valve (Sectional Type)
Introduction
Specifications
Descriptions
Excavator Valve Services
Pressure Compensator Valves Operation
Removal and Replacement
Dismantle and Assemble
Valve Block Sections
Servo Operated Spool
External Auxiliary Relief Valves (ARV's)
Internal Auxiliary Relief Valves (ARV's) - if fitted
Pressure Compensator Valves
Load Hold Check Valves
Excavator Valve (Monoblock Type)
Introduction
Specifications
Descriptions
Excavator Valve Services
Hydraclamps Operation
Removal and Replacement
Dismantle and Assemble
Auxiliary Valve Block (Sectional Type)
Introduction
Specifications
Descriptions
Auxiliary Valve Block (Monoblock Type)
Introduction
Specifications
Descriptions
Cab Seat
Introduction
Service Procedures
Seat Position Sensors - Adjustment
Removal and Replacement

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