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

2CX (S/N: 930000 Onwards) - 210, 212 (S/N: 903000 Onwards)
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This service manual PDF download for the 2CX, 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 (S/N: 930000 Onwards)
JCB Backhoe Loader 210 (S/N: 903000 Onwards)
JCB Backhoe Loader 212 (S/N: 903000 Onwards)


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3A - Maintenance
Section 3B - 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 - JCB Engine Variant


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/7130-07
Total Pages : 892


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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9803-7130

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 (Early Machines)
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
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 3A
Maintenance
Routine Maintenance
Introduction
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Loader Arm Lowered)
How to Make the Machine Safe (Loader Arms 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 - Standard
Loader Arms - High Specification
Backhoe
6-in-1 Clamshovel (if fitted)
Backhoe Quick-Hitch (Mechanical)
Backhoe Quick-Hitch (Hydraulic)
Axles
Propshafts
Airmaster Driveshaft
Stabiliser Legs
Extending Dipper
Lubrication
Engine Panels
Opening and Closing the Bonnet
Removing and Fitting a Side Panel
Removing and Fitting the Front Grille
Heater and Air Conditioning
Changing the Recirculation Filter
Adjusting the Compressor Drive Belt
Brakes
Park Brake Adjustment
Checking the Foot Brake Fluid Level
Electrical System
Battery
Jump Starting The Engine
Fuses and Relays
Engine
Checking the Oil Level
Changing the Oil and Filter
Cleaning the Pre-Cleaner (if fitted)
Changing the Air Filter Elements
Adjusting the Fan Belt
Checking the Coolant Level
Changing the Coolant
Fuel System
Fuel
Filling the Tank
Draining the Filter
Changing the Filter Element
Draining the Sediment Bowl
Cleaning the Fuel Lift Pump Strainer
Bleed the System
Fuel Pipes - Removal and Replacement
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Hydraulic Oil Cooler
Transmission
Checking the Gearbox Oil Level
Changing the Oil and Filter
Axles
Front and Rear Axle
Tyres and Wheels
Tyre Inflation
Wheel Nuts
Align Road Wheels
Wear Pads
Extradig Dipper Wear Pads
Stabiliser Legs (Sideshift Machines Only)
Windscreen Washer
AR Build Engines
RE Build Engines
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section 3B
Maintenance
Routine Maintenance
Introduction
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Loader Arm Lowered)
How to Make the Machine Safe (Loader Arms 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 - Standard
Loader Arms - High Specification
Backhoe
Front Axle
Rear Axle
Extending Dipper
Driveshafts
6 - In - 1 Clamshovel
Stabilisers
Backhoe Quickhitch (Mechanical)
Backhoe Quickhitch (Hydraulic)
Access Panels
Engine Cover
Front Grille
Heater and Air Conditioning
Cleaning the Cab Heater Filter
Brakes
Park Brake Adjustment
Checking the Foot Brake Fluid Level
Electrical System
Battery
Jump Starting The Engine
Fuses and Relays
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 Cap
Oil and Filters
Hydraulic Oil Cooler
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
Tyres and Wheels
Tyre Inflation
Wheel Nuts
Align Road Wheels
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
Service Tools
Numerical List
Tool Detail Reference
Hydraulic Tool Circuit (HTC)
Circuit Schematic
Hydraulic Operation
Flow and Pressure Testing
Flow Diverter Valve
Removal and Replacement
Dismantle and Assemble
Airmaster Compressor
Technical Data
Care and Safety
General Safety
Operating Safety
Maintenance Safety
Using the Compressor Unit and Site Safety
Unit Identification
Safety Labels
Routine Maintenance
Service Schedules
Compressor Approved Oils
Changing the Air Filter Elements
Draining the Air Receiver Condensate
Checking the Air Receiver Oil Level
Changing the Oil and Oil Filter
Drying the Air/Oil Separator Element
Checking Safety Valve Operation
Cleaning the Oil Cooler
Basic Operation
Compressor Unit
Compression Cycle
Lubrication System
Cooling System
Oil Separation and Recovery
Unloading and Speed Control System
Blow Down Valve
Transmission
Fault Finding
Fault Finding Tables
Commissioning the Compressor
Air/Oil Separator
Removal and Replacement
Pressure Regulator
Off-load Air Pressure Regulation
Checking Safety Valve Setting
Suction Unloader
Dismantle and Assemble
Compressor Unit
Dismantle and Assemble
3 Point Hitch
Control Valve
Removal and Replacement
Rams
Removal and Replacement
Transfer Gearbox
Removal and Replacement
Dismantle and Assemble
Service Procedures
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings

Section B
Body and Framework
Service Tools
Numerical List
Tool Detail Reference
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Cab Air Conditioning SYSTEM
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
System Operation
System Control
Safety Procedures
Service Checks
Off-Season Operation
Fault Finding
Fault Indications
Wiring Continuity Checks
System Diagnosis using Test Gauges
Test Procedures
Leak Testing
Tightening Leaking Hoses
Refrigerant Charge Level
Binary Pressure Switches
Refrigerant
Refrigerant Charging and Discharging
Filters - Changing and Cleaning
Recirculation Filter
Air Intake Filter
Compressor Drive Belt - Adjustment
Cab
Introduction
ROPS, FOPS Structure - Checks
Removal and Replacement
Direct Glazing
Air Conditioning Condenser
Introduction
Cleaning
Cab HVAC Unit
Introduction
Removal and Replacement
Blower Motor
Freeze Protection Thermostat
Compressor Clutch Relay
Fuel Tank
Introduction
Removal and Replacement
Fuel Level Sender
Hydraulic Tank
Introduction
Removal and Replacement
Fluid Level Sight Glass
Filter Cover Plate
Stabiliser Legs
Introduction
Sideshift
Wear Pads
Wear Pad - Adjustment
Removal and Replacement
Stabiliser Leg Alarm SYSTEM
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Leg Alarm Switch - Adjustment
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
Pressure Switch Renewal
Kingpost & Carriage
Introduction
Dismantle and Assemble

Section C
Electrics
Service Tools
Numerical List
Tool Detail Reference
Technical Data
General Electrical Data
Fuses and Relays (Early Machines)
Fuses
Link Box Fuses
Relays
Schematic Circuits
2CX
212SU Utility
2CX, 212SU Utility Options
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid - Electrolyte
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 and Replacement
Starter Motor
Removal and Replacement
Harness Data (Early Machines)
Drawings and Interconnection
Harnesses
Drawings

Section D
Controls
Steering Column
Removal and Replacement
Dismantle and Assemble
Loader Control Knob
Dismantle and Assemble
Shovel Reset (if fitted)
Operation and Adjustment

Section E
Hydraulics
Service Tools
Numerical List
Tool Detail Reference
Technical Data
Hydraulic Pump
Loader Valve (3 Spool)
Excavator Valve (7 Spool)
Smooth Ride System (SRS) - if fitted
Accumulator
Basic System Operation
Component Location and Neutral Circuit Descriptions
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
2CX, 210S Backhoe Loader
2CX Airmaster and 2CXL Loader
210SU, 212SU Utility (North America Only)
Circuit Descriptions
Hydraulic Pump Operation (Typical)
Loader Valve
Neutral Circuit
Load Hold Check Valves
Arms Lower
Float
Auxiliary Relief Valve (ARV) Operation
Main Relief Valve (MRV) Operation
Excavator Valve
Neutral Circuit
Load Hold Check Valves
Bi-Restrictor Operation
Slew Operation
Slew Ram End Damping
Slew A.R.V. and Anti-Cavitation Operation
A.R.V. Operation
Pilot-Operated Pressure Relief Valve Operation
Ram Operation and End Damping
Smooth Ride System (if fitted)
Fault Finding
Hydraulic System
Introduction
Fault Finding Tables
Smooth Ride System
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Flow and Pressure Testing
Main Pump
Pressure Testing - Main Relief Valve (M.R.V.)
Pressure Testing - Auxiliary Relief Valves (A.R.V's)
Quick Release Couplings
Connecting and Disconnecting
Smooth Ride System (SRS) Accumulator
Charging and Discharging
`Positional Type' Hydraulic Adaptors
Fitting Procedure
Main Pump
Removal and Replacement
Dismantle, Inspection and Assemble
Loader Valve
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
Hose Burst Protection Valves - if fitted
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
Removal and Replacement
Dismantle and Assemble
Boom HBPV
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Dismantle and Assemble
Typical Ram
Slew 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 Axle
Unit Identification
Designation
Specification
Rear Axle
Unit Identification
Designation
Specification
Synchro Shuttle Gearbox
Unit Identification
Designation
Specification
Engine Stall Speed Combinations
Basic Operation
Introduction
Front Axle - Steer Drive Type SD55
Component Identification
Rear Axle - Steer Drive Type SD55
Component Identification
Synchro Shuttle Gearbox
Component Identification
Principle of Operation
Power Take-Off Unit (if fitted)
Hydraulic and Electrical Operation
Torque Converter
Component Identification
Principle of Operation
Systems Description
Synchro Shuttle Gearbox
Synchromesh (Blocking Pin Type)
Synchromesh Operation
Forward and Reverser Clutch Operation
Electrical Connections
Synchro Shuttle Gearbox
Introduction
Quick Reference
Wires and Connectors
Fault Finding
Synchro Shuttle Gearbox
Introduction
Fault Finding Tables
Service Procedures
Front Axle SD55
Renewing the Pinion Oil Seal
Rear Axle SD55
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
Propshafts
Removal and Replacement
Front Axle SD55
Removal and Replacement
Dismantle and Assemble
Rear Axle SD55
Removal and Replacement
Dismantle and Assemble
Synchro Shuttle Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Torque Converter
Removal and Replacement
Oil Cooler Matrix
Removal and Replacement

Section G
Brakes
Service Tools
Numerical List
Tool Detail Reference
Technical Data
System Type
Basic System Operation
Compensating Master Cylinder
Pedals Locked - Normal Operation
Pedals Locked - Compensating Operation
Pedals Unlocked - Normal Operation
Fault Finding
Brake System
Service Procedures
Service Brakes
Bleeding
Brake Piston Seal Leakage Test
Brake Friction Plate Wear Check
Parking Brake
Testing
Adjustment
Switch Adjustment
Renewing the Brake Pads
Compensating Master Cylinder
Removal and Replacement
Dismantle and Assemble
Service Brakes
Dismantle and Assemble
Parking Brake
Torque Figures
Calliper
Removal and Replacement
Dismantle, Inspection and Assemble

Section H
Steering
Service Tools
Numerical List
Tool Detail Reference
Technical Data
System Type
Basic System Operation
All Wheel Steer Machines
Hydraulic Operation
Steer System Schematics
2/4 Wheel Steer Machines
Hydraulic Operation
Steer System Schematics
Circuit Descriptions
Steer Unit Operation
Neutral
Left Turn
Right Turn
Right Turn - Unassisted
Shock Valve
Priority Valve Operation
Neutral
Turning
Anti-Cavitation Valve (if fitted)
Fault Finding
Steering System
Fault Finding Tables
Service Procedures
Bleeding the System
All Wheel Steer Machines
2/4 Wheel Steer Machines
Testing the System Pressure
Re-phasing the Road Wheels
All Wheel Steer Machines
2/4 Wheel Steer Machines
Steer Rams
Removal and Replacement
Dismantle and Assemble
Priority Valve
Removal and Replacement
Dismantle and Assemble
Steer Mode Valve - Type 1
Removal and Replacement
Dismantle and Assemble
Steer Mode Valve - Type 2
Removal and Replacement
Dismantle and Assemble
Anti-Cavitation Valve (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
Technical Data
1000 Series
1100 Series
Service Procedures
Fuel Lift Pump (Mechanical Type)
Cleaning the Strainer

Section L
JCB Engine Variant
Introduction
Identifying the Machine
Note Regarding Machine Serial Numbers
Engine Identification Plate
Fuel
Types of Fuel
Service Tools
Numerical List
Tool Detail Reference
Electrics
Technical Data
Fuses and Relays
Fuses
Link Box Fuses
Relays
Schematic Circuits
2CX
210SU, 212SU Utility (North America Only)
Options
Alternator
Removal, Inspection and Replacement
Dismantle and Assemble
Starter Motor
Removal, Inspection and Replacement
Dismantle and Assemble
Harness Data
Drawings and Interconnection
Hydraulics
Technical Data
Hydraulic Pump
Schematic Circuits
2CX, 210S Backhoe Loader
2CX Airmaster, 2CXL Loader
210SU, 212SU Utility (North America Only)
Service Procedures
Checking Pump Flow
Testing Main Relief Valve (MRV)
Main Hydraulic Pump
Removal and Replacement
Dismantle, Inspection and Assemble
Transmission
Technical Data
Engine Stall Speed Combinations
Axle Specification (Airmaster Machines)
Steering
Technical Data
Hydraulic Steer Unit
Priority Valve
Service Procedures
Testing the Standby Pressure
Testing the System Pressure
Steer Priority Valve - Cleaning
Priority Valve
Removal and Replacement
444 Series Engine
Technical Data
Engine Specifications
Removal and Replacement
Cold Start Heater (if fitted)
Operation
Wires and Connectors
Fuel Injection Pump
Removal and Replacement

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