JCB 2CX 2CXU 210S 210SU BACKHOE Loader Full Service Manual

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/7130-08 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual Backhoe Loader 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

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/7130-08 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Service Manual - Backhoe Loader 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 1 - General Information 1-0 1-0 9803/7130-08 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Introduction About this Publication ................................................................................ 1-1 Using the Service Manual ..................................................................... 1-1 Section Numbering ................................................................................ 1-1 Left Side, Right Side .............................................................................. 1-1 Machine Nomenclature ......................................................................... 1-2 Machine Identification Machine Identification Plate ....................................................................... 1-3 Typical Vehicle Identification Number (VIN) .......................................... 1-3 Typical Product Identification Number (PIN) ......................................... 1-4 Component Identification Plates ................................................................ 1-5 Typical Engine Identification Number .................................................... 1-5 Transmission Identification Numbers .................................................... 1-6 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................ 1-7 Bolts and Screws ................................................................................... 1-7 Hydraulic Connections ............................................................................. 1-11 'O' Ring Face Seal System .................................................................. 1-11 'Torque Stop' Hose System ................................................................. 1-14 `Quick-Connect' Pilot Hoses .................................................................... 1-15 Disconnecting ...................................................................................... 1-15 Connecting .......................................................................................... 1-15 Service Tools Numerical List .......................................................................................... 1-17 Service Aids Sealing and Retaining Compounds ......................................................... 1-21 Terms and Definitions Colour Coding .......................................................................................... 1-23 Hydraulic Schematic Colour Codes ..................................................... 1-23

Page No. Contents Section 1 - General Information 1-ii 1-ii

Section 1 - General Information Introduction About this Publication 1-1 1-1 9803/7130-06 Introduction About this Publication Using the Service Manual T11-004 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. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. 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. 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. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first! Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. Left Side, Right Side In this manual, ‘left’ A and ‘right’ B mean your left and right when you are seated correctly in the machine. This is so whether you are facing the front or the rear. C003690 Fig 1. 1 General Information - includes torque settings and service tools. 2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Maintenance - includes service schedules and recommended lubricants for all the machine. A Attachments B Body and Framework, etc. A B A B

Section 1 - General Information Introduction About this Publication 1-2 1-2 9803/7130-06 Machine Nomenclature In this Service Manual, reference is made to machine models, e.g. 2CX, 2CXU, these are European machine model names. North American machine models have different names, the tables below show the European and the equivalent North American nomenclature. Table 1. European: North American: 2CX 210S 2CXU 210SU

Section 1 - General Information Machine Identification Machine Identification Plate 1-3 1-3 9803/7130-8 Machine Identification Machine Identification Plate The 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. Typical Vehicle Identification Number (VIN) 1 World Manufacturer Identification 2 Machine Model 3 Steer Type (T= 2WS, F= 4WS) 4 Build Type (S=Sideshift, C=Centremount, L=Loader) 5 Year of Manufacture: 4 = 2004 5 = 2005 6 = 2006 7 = 2007 6 Manufacturer Location (E = England) 7 Machine Serial Number T025210-1 Fig 1. U.K and R.O.W Fig 2. North America SLP 3CX T S 2 E 0960001 1 2 3 4 5 6 7

Section 1 - General Information Machine Identification Machine Identification Plate 1-4 1-4 9803/7130-8 Typical Product Identification Number (PIN) P2-1006 T016220-8 Fig 3. 1 World Manufacturer Identification (3 Digits) 2 Machine Model (5 Digits) 3 Check Letter (1 Digit) The Check Letter is used to verify the authenticity of a machine's PIN. 4 Machine Serial Number (8 Digits) Each machine has a unique serial number.

Section 1 - General Information Machine Identification Component Identification Plates 1-5 1-5 9803/7130-8 Component Identification Plates Typical Engine Identification Number Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). The data label contains important engine information and includes the engine identification number E. A typical engine identification number is explained as follows: 1 Engine Type SA = naturally aspirated. SB = turbocharged. SC = turbocharged and intercooled. SD = turbocharged. SE = electronic common rail fuel injection, turbocharged and intercooled. SF = turbocharged and intercooled. 2 Engine part number 3 Country of manufacture U = United Kingdom 4 Engine Serial Number 5 Year of Manufacture The last three parts of the engine identification number are stamped on the cylinder block at position B. Fig 4. Engine SA 320/40001 U 00001 04 1 2 3 4 5 U 00001 04 B C D B E

JCB 2CX 2CXU 210S 210SU BACKHOE Loader Full Service Manual

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