JCB 2CX, 2DX, 210, 212 Backhoe Loader Repair Service Manual

2CX, 2DX (S/N: 657001 to 763230) - 210, 212 (S/N: 481196 Onwards)
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This service manual PDF download for the 2CX, 2DX, 210, 212 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
2CX, 2DX, 210, 212 & VARIANTS
From M/c No. 657001 TO 763230
& 481196 Onwards

2CX, 2DX (S/N: 657001 to 763230)
210, 212 (S/N: 481196 Onwards)


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine 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 K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/7110
Total Pages : 381


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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Cover
Introduction

Section 1 - General Information
Machine Identification Plate
Typical Machine Identification Number
Typical Engine Identification Number
Unit Identification
Torque Settings
Service Tools
Numerical List
Body and Framework
Electrics
Hydraulics
Transmission
Engine
Sealing and Retainign Compounds

Section 2 - Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety
Safety Decals
2CX
210S
2CXU (212SU North America only)

Section 3 - Routine Maintenance
Lubricants and Capacities
2CX up to machine S/N 659598
2DX machines and 2CX machine from S/N 659599 - Including N.Am machines up to S/N 762079
N.Am. machines from S/N 762080
Service Schedules
Greasing
Loader Arms
6-in-1 Clamshovel
Hydraulic Backhoe Quickhitch
Backhoe Quickhitch
Backhoe (2CX Machines)
Backhoe (2DX Machines)
Front Axle
Propshaft
Extending Dipper
Stabiliser Legs (2DX Machines only)
Oiling
Control Levers
Loader Arm Safety strut
Installing and Removing
Boom and Slew Locks
Fitting and Removing Boom Lock
Fitting and Removing Slew Lock
Hydraulic Fluid
Check the Fluid Level
Hydraulic Filter
Changing the Filter Element
Syncro Shuttle Transmission
Checking the Oil Level
Changing the Oil and Filter
Axle Oil Level
Check Differential Oil Level
Change Differential Oil
Check Hub Oil Level
Change Hub Oil
Engine Oil and Filter
Check Level
Change Oil and Filter
Fuel Filter
Drain
Renew Element
Fuel System
Bleeding
Coolant System
Checking the Coolant System
Coolant Mixtures
Changing the Coolant
Fan Belt
Check Tension
Adjustment
Air Filter Pre-Cleaner
Empty
Air Filter
Renew Outer Element
Renew Inner Element
Brakes
Park Brake - Testing
Battery
First Aid
Checking the Electrolyte Level
Cleaning the Battery
Jump Starting - Safety
Jump Starting - Procedure
Road Wheels
Re-aligning
Fault Finding
Cleaning the Machine

Section A - Attachments
Hydraulic Tool Circuit (HTC)
Schematic Hydraulic Circuit
Circuit Description
Flow Diverter Valve
Removal and Replacement
Dismantling and Assembly
Flow Testing and Pressure Testing

Section B - Body and Framework
Backhoe
Kingpost & Carriage - Sideshift (2CX, 210S)
Dismantling and Assembly
Air Conditioning
R-134a Refrigerant
Operation
Control
Safety Procedures
Fault Finding
Checking Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
Blower Motor
Removal and Replacement
Thermostat
Removal and Replacement
Compressor Clutch Relay
Removal and Replacement
Pressure Switches
Testing
Removal and Replacement
Condenser Coil
Cleaning
Filters
Recirculation Filter - Change/Clean
Air Intake Filter - Clean
Adjusting the Compressor Belt Drive
Cab
Glazing - General
Rubber Seal Glazing
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Checking the ROPS/FOPS Structure
Stabiliser Leg
Removal and Replacement
Wear Pads - Removal and Replacement
2CX, 210S, 212S from Serial No. 489724
Kingpost and Carriage (2DX Machines)
Dismantling and Assembly
3 Point Hitch
Removal and Replacement

Section C - Electrics
Technical Data
Fuses and Relays 2CX from S/N 655030 to 656999
Fuses and Relays 2DX and 2CX from S/N 659600 to 761897
Fuses and Relays 2DX and 2CX from S/N 760841 to 763230 and 481196 to 489723
Fuses and Relays 2CXU, 212SU to 489723
Fuses and Relays 2CX, 2DX, 212SU from 489724
Fuse Link Box 2CX, 2DX, 212SU from 489724
Battery
Safety
First Aid
Maintenance
Testing - Specific Gravity
Testing
Engine Electrics
Alternator
General Description
Service Precautions
Charging Circuit Check
Alternator Charging Test
Removal and Replacement
Dismantling and Assembly
Starting Circuit Test
Starter Motor - Lucan M127
Removal and Replacement
Dismantling and Assembly
Servicing and Renewal
Circuit Diagrams and Component Lists
2CX Machines up to S/N 659598
2DX Machines from S/N 659249 to 760840
2CX Machines from S/N 659599 to 760849
Circuit Options and Variations
Electrical Pick-up Hitch Circuit
2CX, 2DX Machines from S/N 760841
2CXU (212SU North American only)
2CX, 2DX Machines from S/N 489724
212SU Machines from S/N 489724
Circuit Options - 2CX, 2DX, 212SU from S/N 489724
Worklights Circuit - German/Italisn Builds
Heater Circuit
Heater/Air Conditioning Circuit
Compressor Circuit 2Cx, 2DX
Radio Circuit
Hammer Circuit
Hand Held Hydraulic Tools Circuit
Hydraclamp Circuit
Wire Number Identification
Wire/Harness Numbers - Explanation of:
Mainframe Harness
Switch Console Harness
Instrument Console Harness
Cab Roof Harness
Park Brake Harness
Utility Solenoid Harness (210SU)
Trailer Socket Harness (m/c's with hydraulic pick-up hitch
Diverter Valve Harness (m/c's with hydraulic pick-up hitch)
Mainframe Harness (2DX)
Cab Panel Harness (2DX)
Cab Roof Harness (2DX)
Heater Harness (2DX)

Section D - Controls
Machine Controls
Loader Control Knob
Dismantling and Assembly
Steering Column
Dismantling and Assembly

Section E - Hydraulics
Technical Data
Hydraulics
2CX Machines to S/N 658960
2DX and 2CX Machines from 658961
2CXU & 212SU Machines N. Am Only
Steering
2CX Machines to S/N 658960
2DX and 2CX Machines from S/N 658961
Schematics
2CX Machines to S/N 658960
2CX & 2DX Machins from 658961 to 763230 and from 481196 on
2CXL, 210SL, 2CX Farm Master
2CXU (212SU N. Am. only)
Descriptions
Machine Neutral Circuit
2CX Machines to S/N 658960)
2CX and 2DX Machines from S/N 658961
Pump Operation
Loader Valve
Neutral Circuit
Load Hold Check Valves
Operation 1
Operation 2
Arms Lower
Float
ARV Operation
Main Relief Valve - Operation
Excavator Valve
Neutral Circuit - 2CX & 2DX Machines
Operation 1
Operation 2
Bi-Restrictor Operation (2CX Machines only)
Slew Operation
Slew Ram End Damping
Slew ARV and Anti-Cavitation Operation
ARV Operation
Pilot-Operated ARB Pressure Relief Operation
Steering Operation
1 - Neutral
2 - Turn Left
3 - Turn Right
4 - Right Turn, Unassisted
5 - Shock Valve
6 - Anti-cavitation Valve (if fitted)
Priority Valve Operation
1 - Neutral
2 - Turning
Charge/Priority Valve
Machines from S/N 658961 to 763230 & 481196 to 489723
Machines from 489724
Pump/Priority Valve (Machines up to S/N 658960
Pump Flow and Pressure Testing
Checking the Load Sensing Priority Valve
Removal and Replacement
Dismantling and Assembly (To machine S/N 657447)
Dismanting and Assembly (From machine S/N 657448)
Charge/Priority Valve (Machines from S/N 658961)
Pressure Testing
Removal and Replacement
Dismantlling and Assembly
Main Pump (machines from S/N 658961, including 2DX)
Pump Flow and Pressure Testing
Removal and Replacement
Dismantling and Assembly
Auxiliary Pump (2DX Machines)
Pump Flow and Pressure Testing
Removal and Replacement
Dismantling and assembly
Valves
3 Point Hitch Valve Block - 2CXU (212SU N.Am. only)
Removal and Replacement
Loader Valve
Dismantling and Assembly
Float Spool
Dismantling and Assembly
MRV and ARV's
Dismantling and Assembly
Electric Detent Spool
Dismantling and Assembly
Pressure Testing - Main Relief Valve - In Position
Pressure Testing ARV's - Using Hand Pump
Excavator Valve (2CX Machines)
Dismantling and Assembly
Check Valves
Spools
ARV - Dismantling and Assembly
Hydraclamp - Dismantling and Assembly
Excavator Valve (2DX Machines)
Dismantling and Assembly
ARV's - Dismantling and Assembly
Hydraclamp - Dismantling and Assembly
Hydraulic Steering Unit
Dismantling and Assembly
Steering System - Anti-Cavitation Valve
Removal and Replacement
Dismantling and Assembly
Steer Selector Valve - 2CXU (212SU N.Am. only)
Removal and Replacement
Dismantling and Assembly
Steer System Bleeding
Initial System Bleeding
Anti-cavitation Valve
2CXU (212SU N.Am. only)
3 Point Hitch
Rams
Removal and Replacement
Rams
Typical Ram (with dowelled piston head)
Dismantling and Assembly
Slew Ram
Dismantling and Assembly
JCB Ram Sealing Procedure

Section F - Transmission
Technical Data
Front Axle & Rear Axle (SD40) - used on 2CX, 210S
Front Axle & Rear Axle (SD55) - used on 2CXAM, 2CXL, 210FM, 210SL, 2DX, 212SU
Syncro Shuttle
Tyres
Product Changes
Towing Procedure
Synchromesh - Description
Fault Finding
Syncro Shuttle Gearbox - Hydraulic
Syncro Shuttle Gearbox - Mechanical
Parking Brake
Front Axle
Removal and Replacement
Rear Axle
Removal and Replacement
Front and Rear Axles
Drive Head
Dismantling and Assembly
Drive Head with Limited Slip Differential
SD40 Axles
Dismantling
Assembly
SD55 Axles
Dismantling
Assembly
Crown Wheel and Pinion - Adjustment
Renewing the Pinion Oil Seal
Axle Hub and Driveshaft
Dismantling
Assembly
SD55 Splined Hub and Drive Shaft
Dismantling
Assembly
Solid Spacer Installation
Propshafts
Removing and Replacing
Syncro Shuttle
Dismantling
Assembly
Reverser Unit
Dismantling
Assembly
Torque Converter
Replacing
Pressure and Flow Testing
Torque Converter Stall Test
Power Take Off Clutch
Description of Operation
Removal and Replacement
Dismantling and Assembly
Transfer Gearbox
Removal and Replacement
Dismantling and Assembly
Salvage/Repair
Drive Shaft Oil Seal (all JCB Axles)
Wear Sleeve Fitting
Axle and Gearbox Driveshaft Flange Seals (all JCB Axles)
Hub and Driveshaft - Fitting Bearing Carrier Combination Seal

Section G - Brakes
Tecnhical Data
Schematic Brakes Circuit
Machines to S/N 658960
Machines from S/N 658961 to 763230 and 481196 to 489723
2CX, 2CD & 212SU from S/N 489722
Brake Circuit Description
Untitled
2CX Machines to S/N 658960
Service Brakes
Brake Ssytem Venting
Residual Brake System Pressure
Brake System Pressure Testing
Brake Seal or Component Leakage
Bleeding Procedure
Dismantling and Assembly
Accumulator Charge Valve (Mc's to S/N 658960)
Removal and Replacement
Dismantling and Assembly
Foot Brake Valve
From S/N 657000 to 763230 and 481196 to 489723
Removal and Replacement
Dismantling and Assembly
2CX, 2DX, 212SU from S/N 489723
Removal and Replacement
Dismantling and Assembly
Parking Brake
Testing
Dismantling and Assembly

Section K - Engine
Technical Data
2CX Range of Machines
Inc. 210S & 210SU to S/N 762079
2DX Machines
Inc. 212S N. Am machines to S/N 762079
N. Am machines only from S/N 762080

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