JCB 2CX, 2CXU, 210S, 210SU Backhoe Loader Service Manual
965 pages · Publication 9803-7130-08
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What's inside
From the manual's own table of contents: 8 sections, 465 entries. See sample pages (PDF, 382 KB)
General79 topics
- About this Publication
- Using the Service Manual
- Section Numbering
- Left Side, Right Side
- Machine Nomenclature
- Machine Identification Plate
- Typical Vehicle Identification Number (VIN)
- Typical Product Identification Number (PIN)
- Component Identification Plates
- Typical Engine Identification Number
- Transmission Identification Numbers
- 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
- Numerical List
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Important Information
- The Operator Manual
- Safety Warnings
- Safety Check List
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Safety Labels
- Safety Label Identification
- Health and Safety
- Lubricants
- Battery
- Service Schedules
- 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
- Cleaning the Machine
- Preparing the Machine for Cleaning
- Checking for Damage
- Check the Machine Body and Structure
- Check the Seat and Seat Belt
- Check the Tyres
- ROPS/FOPS Structure
- Checking The ROPS/FOPS Structure
- Prepare the Machine for Maintenance
- How to Make the Machine Safe (Loader Arm Lowered)
- How to Make the Machine Safe (Loader Arms Lifted)
- Greasing
- 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
- Brakes
- Park Brake Adjustment
- Checking the Foot Brake Fluid Level
- Electrical System
- Jump Starting The Engine
- Fuses and Relays
Section 3A - Maintenance61 topics
- 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
- Types of 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
- Hydraulic Oil Cooler
- Transmission
- Checking the Gearbox Oil Level
- Tyres and Wheels
- Tyre Inflation
- Align Road Wheels
- Front and Rear Axle
- Wear Pads
- Extending Dipper Wear Pads
- Stabiliser Legs (Sideshift Machines Only)
- Windscreen Washer
- AR Build Engines
- RE Build Engines
- Cab Heater Filter
- Changing the Recirculation Filter
- Air Conditioning (if fitted)
- Adjusting the Compressor Drive Belt
- Fire Extinguisher (if fitted)
- Checking the Fire Extinguisher
- Service Requirements
- Owner/Operator Support
- Service/Maintenance Agreements
- Initial Service and Inspection
- Fit for Purpose Tests for Lifting Equipment
- Obtaining Replacement Parts
- Fuels
- Tools
- Toolbox (If fitted)
- Carrying Tools onto the Machine
- How to Make the Machine Safe (Loader Arm Lifted)
- Check the Hydraulic Hoses and Fittings
- Check the Electrical Circuits
- Loader Arms
- Front Axle
- Rear Axle
- Driveshafts
- 6-in-1 Clam bucket
- Stabilisers
- Backhoe Quickhitch (Mechanical)
- Access Panels
- Engine Cover
- Front Grille
Section 3B - Maintenance65 topics
- Heating and Air Conditioning
- Cleaning the Cab Heater Fresh Air Filter
- Airmaster
- Compressor Oil and Filter (Airmaster machines)
- Compressor Air Filter (Airmaster machines)
- Oil Cooler
- Park Brake
- Foot Brake
- Fuses
- Link Box Fuses
- Relays
- Oil and Filter
- Cooling System
- Front End Accessory Drive Belt
- Air Filter
- Water Separator and Engine Fuel Filter
- Bleeding the System
- Releasing the Hydraulic Pressure
- Hydraulic Tank Filler Cap
- Oil and Filters
- Hose Burst Protection Valves (If fitted)
- Steering
- Checking the Emergency Steer System
- Gearbox
- Wheel Nuts
- Wheel Alignment
- Re-phasing the Steer System
- Checking the Level
- Tool Detail Reference
- Circuit Schematic
- Hydraulic Operation
- Flow and Pressure Testing
- Flow Diverter Valve
- Removal and Replacement
- Dismantle and Assemble
- Technical Data
- Care and Safety
- Using the Compressor Unit and Site Safety
- Basic Hot Tests
- Compressor
- Pneumatic Test
- Electrical Test
- Unit Identification
- Routine Maintenance
- Compressor Approved Oils
- 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
- Oil Separation and Recovery
- Unloading and Speed Control System
- Blow Down Valve
- Fault Finding
- Fault Finding Tables
- Commissioning the Compressor
- Air/Oil Separator
- Pressure Regulator
- Off-load Air Pressure Regulation
- Checking Safety Valve Setting
Section A - Attachments41 topics
- Suction Unloader
- Control Valve
- Rams
- Transfer Gearbox
- Connecting/Disconnecting Hydraulic Hoses
- Connecting the Hydraulic Hoses
- Disconnecting the Hydraulic Hoses
- Quick Release Couplings
- Rivet Nuts
- Fitting Procedure
- Slide Hammer Kit
- Related Topics
- Specifications
- R134a Refrigerant
- PAG Type Refrigerant Oil
- Operation Overview
- System Operation
- System Control
- Safety Procedures
- Service Checks
- Off-Season Operation
- 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
- ROPS, FOPS Structure - Checks
- Direct Glazing
- Cleaning
- Blower Motor
- Freeze Protection Thermostat
- Compressor Clutch Relay
Section B - Body & Framework45 topics
- Fuel Level Sender
- Fluid Level Sight Glass
- Filter Cover Plate
- Sideshift
- Wear Pad - Adjustment
- Electrical Operation and Schematics
- Electrical Description
- Wires and Connectors
- Leg Alarm Switch - Adjustment
- Wear Pad Adjustment
- Boom
- Dipper
- Pressure Switch Renewal
- Perkins Engine
- JCB Dieselmax Engine
- Fuses and Relays (Perkins Engines)
- Fuses and Relays (JCB Dieselmax Engine)
- Schematic Circuits (Perkins Engines)
- 212SU Utility
- 2CX, 212SU Utility Options
- Schematic Circuits (JCB Dieselmax Engines)
- 210SU, 212SU Utility (North America Only)
- Options
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- 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
- Wire Numbers and Functions
- Wiring Harness Repair
- Repair Procedure
- Alternator (Perkins Engines)
Section C - Electrics43 topics
- Alternator (JCB Dieselmax Engines)
- Removal, Inspection and Replacement
- Starter Motor (Perkins Engines)
- Starter Motor (JCB Dieselmax Engines)
- Harness Data (Perkins Engines)
- Harnesses
- Drawings
- Harness Data (JCB Dieselmax Engines)
- Drawings and Interconnection
- Operation and Adjustment
- Technical Data (Perkins Engines)
- Hydraulic Pump
- Technical Data (JCB Dieselmax Engines)
- Loader Valve (3 Spool)
- Excavator Valve (7 Spool)
- Smooth Ride System (SRS) - if fitted
- Accumulator
- Component Location and Neutral Circuit Descriptions
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Schematic Circuits (JCB Perkins Engines)
- 2CX, 210S Backhoe Loader
- 2CX Airmaster and 2CXL Loader
- 2CX Airmaster, 2CXL Loader
- 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
- 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)
Section E - Hydraulics64 topics
- Smooth Ride System
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Filters
- Flow and Pressure Testing (Perkins Engines)
- Main Pump
- Pressure Testing - Main Relief Valve (M.R.V.)
- Pressure Testing - Auxiliary Relief Valves (A.R.V's)
- Flow and Pressure Testing (JCB Dieselmax Engines)
- Checking Pump Flow
- Testing Main Relief Valve (MRV)
- Smooth Ride System (SRS) Accumulator
- Charging and Discharging
- `Positional Type' Hydraulic Adaptors
- Main Hydraulic Pump (Perkins Engines)
- Dismantle, Inspection and Assemble
- Main Hydraulic Pump (JCB Dieselmax Engines)
- Main Relief Valve (MRV)
- Auxiliary Relief Valves (ARV's)
- Standard Spool
- Float Spool
- Electric Detent Spool
- Valve Block
- Hydraclamp Valve
- 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
- Checking Hose Burst Protection Valve
- Lowering a Load
- Boom HBPV
- Precautions During Use
- Installation
- Caution During Use
- Maintenance, Inspection Points
- Typical Ram
- Slew Ram
- JCB Ram Sealing Procedure
- Tyre Sizes and Pressures
- Designation
- Specification
- Synchro Shuttle Gearbox
- Engine Stall Speed Combinations (Perkins Engines)
- Engine Stall Speed Combinations (JCB Dieselmax Engines)
- Engine Stall Speed Combinations
- Axle Specification (Airmaster Machines)
- Front Axle - Steer Drive Type SD55
- Component Identification
- Rear Axle - Steer Drive Type SD55
- Principle of Operation
- Power Take-Off Unit (if fitted)
- Hydraulic and Electrical Operation
- Torque Converter
- Synchromesh (Blocking Pin Type)
- Synchromesh Operation
- Forward and Reverser Clutch Operation
- Quick Reference
Section F - Transmission48 topics
- Front Axle SD55
- Renewing the Pinion Oil Seal
- Rear Axle SD55
- Testing for Brake Piston Seal Leakage
- Flushing the Transmission Oil
- Torque Converter Stall Test
- Pressure and Flow Tests
- Forward and Reverse Solenoid Control Valve
- Dismantle, Inspection and Assembly
- System Type
- Compensating Master Cylinder
- Pedals Locked - Normal Operation
- Pedals Locked - Compensating Operation
- Pedals Unlocked - Normal Operation
- Brake System
- Service Brakes
- Bleeding
- Brake Piston Seal Leakage Test
- Brake Friction Plate Wear Check
- Parking Brake
- Adjustment
- Switch Adjustment
- Renewing the Brake Pads
- Torque Figures
- Calliper
- Hydraulic Steer Unit
- Priority Valve
- All Wheel Steer Machines
- Steer System Schematics
- 2/4 Wheel Steer Machines
- Steer Unit Operation
- Neutral
- Left Turn
- Right Turn
- Right Turn - Unassisted
- Shock Valve
- Priority Valve Operation
- Turning
- Anti-Cavitation Valve (if fitted)
- Steering System
- Service Procedures (Perkins Engines)
- Testing the System Pressure
- Re-phasing the Road Wheels
- Service Procedures (JCB Dieselmax Engines)
- Testing the Standby Pressure
- Priority Valve (Perkins Engines)
- Priority Valve (JCB Dieselmax Engines)
- Steer Priority Valve - Cleaning
Section H - Steering11 topics
- Dismantle
- Assemble
- Series
- Fuel Lift Pump (Mechanical Type)
- Cleaning the Strainer
- Engine Specifications
- Removal
- Replacement
- Cold Start Heater (if fitted)
- Operation
- Fuel Injection Pump
Inside this manual
Real pages from this service manual (965 pages). Open the sample pages (PDF, 382 KB)
- Diagram, page 615: Section E - Hydraulics
- Troubleshooting, page 783: Section F - Transmission
- Specifications, page 867: Section H - Steering
- Color page, page 252: Section A - Attachments
- Color page, page 398: Section B - Body & Framework
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 965 pages
Quantity one is the manual described above.
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