JCB 2CX/2DX/210/212 Backhoe Loader OEM Service & Repair Manual

Service Manual 2CX, 2DX, 210, 212 & VARIANTS Backhoe loader From M/c No. 657001 TO 763230 & 481196 Onwards PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, CHEADLE ROAD, UTTOXETER, ST14 7BS ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/7110 Open front screen 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

* 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: machine. 1 2 3 General Information -includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for all the The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A B Attachments 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. 2CX, 2DX, 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 2CX 2DX 9803/7110 North American 210S 213S Issue 2'

Section 1 9803/7110 General Information Contents Machine Identification Plate Typical Machine Identification Number Typical Engine Identification Number Unit Identification Torque Settings Service Tools Numerical List Service Tools Electrics Hydraulics Transmission Engine Sealing and Retaining Compounds Page No. 1 - 1 1 - 1 1 - 1 1 - 2 2 - 1 3 - 1 4 - 1 4- 2 4- 5 4- 7 5 - 1 Section 1 Issue 1

Section 1 General Information Section 1 1 - 1 Machine Identification Plate Your machine has an identification plate mounted on the right hand side of the machine just below the driver's cab door. 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. CE FRONT AXLE SERlAL NUMllER PEAR AXLE SERIAL ~lJMrlER ENC!NE POWER kW@ RPM S227230 9803/7110 * Typical Machine Identification Number SLP 2DX T S 0 e e e R E 8 G 0 World Manufacturer Identification C) Machine Model Q Steer Type (T = 2WS, F=4WS) 1 - 1 123456 e a Build Type (S=Sideshift, C=Centremount, L=Loader) * 4) Year of Manufacture: R = 1994 s = 1995 T = 1996 v = 1997 w = 1998 X= 1999 y = 2000 1 = 2001 2 = 2002 3 = 2003 4 = 2004 5 = 2005 6 = 2006 7 = 2007 G Manufacturer Location (E = England) 0 Machine Serial Number: Typical Engine Identification Number AB 50262 U 500405 P o e e a e 0 Engine Type AB = 4 cylinder turbo e Build Number e Country of Origin a Engine Sequence Number e Year of Manufacture Issue 3*

Section 1 General Information Section 1 1 - 2 Unit Identification The engine serial number is stamped on a plate mounted on the left hand side of the cylinder block (looking towards the front of the machine). The Syncro Shuttle serial number is stamped on a label which is mounted to the rear face of the unit. 9803/7110 1 - 2 The rear axle serial number is stamped on a plate mounted to the front face of the axle, as shown below. The front axle serial number is stamped on a plate mounted to the rear face of the axle, as shown below. Issue 1

Section 1 General Information Section 1 2- 1 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 kgfm 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 kgfm 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 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. 9803/7110 I ss ue 1

Section 1 General Information Section 1 3 - 1 3 - 1 Service Tools Numerical List Page No. Page No. 816/00189 Blanking Cap 4- 6 892/00301 Flow Test Adapter 4 - 7 816/00190 Blanking Ca 4- 6 892/00302 Flow Test Adapter 4 - 7 816/00193 Blanking Cap 4- 6 892/00304 Flow Test Adapter 4 - 7 816/00196 Blanking Cap 4- 6 * 892/00334 Ram Seal Fitting Tool 4- 6 816/00197 Blanking Cap 4- 6 892/00347 Gauge Connector 4 - 4 816/00294 Blanking Cap 4- 6 892/00706 Test Probe 4 - 5 816/15118 Pressure Test Adapter 4 - 4 892/00812 Drive Coupling Spanner 4 - 7 816/20008 Adapter 4 - 4 892/00822 Splined Bolt Socket 4- 8 816/50043 'T' Adapter 4- 6 892/00833 Annulus Removal Tool 4- 8 816/55038 Pressure Test 'T' Adapter 4 - 4 892/00843 Folding Stand 4 - 1 816/55040 Pressure Test 'T' Adapter 4 - 4 892/00844 Long Knife 4 - 2 816/60096 'T' Adapter 4- 6 892/00845 Cartridge Gun 4 - 1 892/00041 De-glazing Tool 4- 9 892/00846 Glass Extractor Handles 4 - 2 892/00047 'T' Adapter 4- 6 892/00847 Nylon Spatula 4 - 3 892/00048 'T' Adapter 4- 6 892/00848 Wire Starter 4 - 2 892/00055 Blanking Plug 4- 6 892/00849 Braided Cutting Wire 4 - 2 892/00056 Blanking Plug 4- 6 * 892/00956 Timing Pin 4- 9 892/00057 Blanking Plug 4- 6 * 892/01016 Ram Seal Protection Sleeve 25 mm 4- 6A 892/00059 Blanking Plug 4- 6 * 892/01017 Ram Seal Protection Sleeve 30 mm 4- 6A 892/00060 Blanking Plug 4- 6 * 892/01018 Ram Seal Protection Sleeve 40 mm 4- 6A 892/00074 Female Connector 4- 6 * 892/01019 Ram Seal Protection Sleeve 50 mm 4- 6A 892/00075 Female Connector 4- 6 * 892/01020 Ram Seal Protection Sleeve 50 mm 4- 6A 892/00077 Female Connector 4- 6 * 892/01021 Ram Seal Protection Sleeve 60 mm 4- 6A 892/00137 Hose 4 - 5 * 892/01022 Ram Seal Protection Sleeve 60 mm 4- 6A 892/00153 Test Block for Excavator A.R.V. 4 - 5 * 892/01023 Ram Seal Protection Sleeve 65 mm 4- 6A * 892/00167 Ram Seal Protection Sleeve 90mm 4- 6A * 892/01024 Ram Seal Protection Sleeve 70 mm 4- 6A 892/00174 Measuring Cup 4- 8 * 892/01025 Ram Seal Protection Sleeve 75 mm 4- 6A 892/00179 Bearing Press 4 - 7 * 892/01026 Ram Seal Protection Sleeve 80 mm 4- 6A 892/00180 Seal Fitting Tool 4- 6 * 892/01027 Piston Seal Assembly Tool 4- 6A 892/00223 Hand Pump 4 - 5 926/15500 Rubber Spacer Blocks 4 - 3 892/00224 Extractor 4- 8 992/00800 Extractor 4- 8 892/00225 Adapter - Impulse Extractor 4 - 7 992/01003 Plug 4 - 5 892/00252 Test Block 4 - 5 992/10200 Body for Hamworthy A.R.V. 4 - 5 892/00253 Pressure Test Kit 4 - 4 992/02400 Tee-piece 4 - 5 892/00255 Pressure Test Adapter 4 - 4 992/04000 Torque Multiplier 4- 8 892/00256 Pressure Test Adapter 4 - 4 992/07609 Bearing Adapter 4- 8 892/00257 Pressure Test Adapter 4 - 4 992/09300 Spanner 4 - 5 892/00258 Pressure Test Adapter 4 - 4 992/09400 Spanner 4 - 5 892/00259 Pressure Test Adapter 4 - 4 992/10800 Spanner 4 - 5 892/00260 Pressure Test Adapter 4 - 4 992/12300 12v Mobile Oven 4 - 1 892/00261 Pressure Test Adapter 4 - 4 992/12400 Static Oven - 2 Cartridge 4 - 1 892/00262 Pressure Test 'T' Adapter 4 - 4/4 - 5 992/12600 Static Oven - 6 Cartridge 4 - 1 892/00263 Pressure Test 'T' Adapter 4 - 4 992/12800 Cut-out Knife 4 - 2 892/00264 Pressure Test 'T' Adapter 4 - 4 992/12801 'L' Blades 4 - 2 892/00265 Pressure Test 'T' Adapter 4 - 4 993/59400 End Float Setting Tool 4- 8 892/00268 Flow Monitoring Unit 4 - 4 993/59500 Bearing Extractor 4 - 7 892/00269 Sensor Head 4 - 4 993/68100 Slide Hammer Kit 4- 2A 892/00270 Load Valve 4 - 4 993/85700 Battery Tester 4 - 3 892/00271 Adapter 4 - 4 1406/0011 Bonded Washer 4 - 5 892/00272 Adapter 4 - 4 1406/0018 Bonded Washer 4 - 5 892/00274 Adapter 4 - 5 1406/0021 Bonded Washer 4 - 5 892/00275 Adapter 4 - 4 1406/0029 Bonded Washer 4 - 5 892/00276 Adapter 4 - 4 1604/0003 Adapter 4 - 5 892/00277 Adapter 4 - 4 1604/0004 Adapter 4 - 5 892/00278 Gauge 4 - 5 1604/0006 Adapter 4 - 5 892/00279 Gauge 4 - 5 1606/0003 Adapter 4 - 5 892/00282 Shunt 4 - 3 1606/0004 Adapter 4 - 5 892/00283 Tool Kit Case 4 - 3 1606/0007 Adapter 4 - 5 892/00284 Tachometer 4 - 3 1606/0008 Adapter 4 - 5 892/00285 Hydraulic Oil Temperature Probe 4 - 3 1606/0009 Adapter 4 - 5 892/00286 Surface Temperature Probe 4 - 3 1612/0006 Adapter 4 - 4 892/00298 Fluke Meter 85 4 - 3 2401/0103 '0' Ring 4 - 5 9803/7110 Issue 7'

Section 1 General Information 3- 2 Service Tools Numerical List (cont'd) Page No. 41 04/1 310 Hand Cleaner 4 - 1 The following parts are replacement items for kits and would normally be included in the kit numbers quoted on page 1/3- 1. Replacement item for kit no. 892/00180 892/00181 Replacement Plastic Boss 4 - 6 Replacement items for kit no. 892/00253 892/00201 Replacement Gauge 4 - 4 892/00202 Replacement Gauge 4 - 4 892/00203 Replacement Gauge 4 - 4 892/00254 Replacement Hose 4 - 4 Replacement items for kit no. 993/59400 993/59401 Base Plate 4 - 8 993/59402 Setting Yoke 4 - 8 993/59403 Mainshaft Adapter (long) 4 - 8 993/59404 Mainshaft Adapter (short) 4 - 8 993/59405 Ouput Yoke Adapter Plate 4 - 8 * 993/59406 Setting Yoke Support Pillars 4 - 8 Replacement items for kit no. 993/68100 993/68101 Slide Hammer 4 - 2A 993/68102 End Stops 4 - 2A 993/68103 Adaptor- M20 x 5/8" UNF 4- 2A 993/68104 Adaptor- M20 x 1" UNF 4- 2A 993/68105 Adaptor - M20 x M20 4 - 2A 993/68106 Adaptor - M20 x M24 4 - 2A 993/68107 Bar- M20 x M20 X 800MM 4 - 2A 993/68108 Adaptor- M20 x 7/8" UNF 4 - 2A 993/68109 Adaptor - M20 x M12 4 - 2A 993/68110 Adaptor- M20 x 5/8" UNF (Shoulder) 4- 2A 993/68111 Adaptor- M20 x 1/2" UNF 4 - 2A 9803/7110 Section 1 3- 2 Issue 2'

Section 1 General Information Section 1 4- 1 Service Tools Section B - Body & Framework Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number- 4104/1310 (454g; 1 lb tub) S186240 12V Mobile Oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300). JCB part number- 992/12300 S186250 240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request- contact JCB Technical Service. JCB part number: 992/12400 - 2 Cartridge x 240V 992/12600 - 6 Cartridge x 240V 9803/7110 S186260 4- 1 Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB p 892/008~ Folding Stand for Holding Glass essential for preparing new glass prior to installation. JCB part number - 892/00843 S186280 Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. JCB part number- 892/00842 S186300 Iss ue 2

Section 1 General Information Section 1 4- 2 Service Tools (cont'd) Section B - Body & Framework Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. JCB part number- 892/00848 S186310 Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass. JCB part number- 892/00846 S186320 Braided Cutting Wire -consumable heavy duty cut-out wire used with the glass extraction tool (above). JCB part number- 892/00849 (approx 25 m length) 9803/7110 S186330 Cut-Out Knife - used to remove broken glass. JCB part number- 992/12800 4- 2 S186340 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number- 992/12801 (unit quantity= 5 off) S186350 Long Knife - used to give extended reach for normally inaccessible areas. JCB part number- 892/00844 Issue 2

JCB 2CX/2DX/210/212 Backhoe Loader OEM Service & Repair Manual

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